Use of Polycaprolactone Electrospun Nanofiber Mesh in a Face Mask

Electrospun nanofiber mesh has previously been used as an air filtration device. However, the qualification of polycaprolactone (PCL) nanofiber mesh cloth in face masks to protect individuals against airborne particles carrying microorganisms has yet to be investigated. The long-term goal of this study is to develop methods to use PCL nanofiber mesh to provide better protection against microorganisms. To achieve this goal, we observed the morphology, water droplet absorption, thermal (differential scanning calorimetry), mechanical, and airborne particle filtering capabilities, and also the microbial activities of a PCL cloth, to evaluate whether it is suitable to act as a filter in a face mask. We have produced a polycaprolactone (PCL) nanofiber cloth after electrospinning it onto a drum for 3 and 10 min, referred to hereafter as PCL-3 and PCL-10, respectively. Our study found that the middle protection layer (control) of the Henry Schein Earloop Procedure Mask contains pores (average diameter = 5.72 ± 0.62 µm) which are 48 times larger than the diameter of a microorganism an average diameter of ~120 nanometers. However, PCL-10 nanofiber membranes show pores with an average diameter of 1.42 ± 0.34 µm. Our contact angle measurement tests found that all the samples were very hydrophobic (contact angle values varied between 120 and 150 degrees). However, both PCL cloths’ contact angle values were lower compared to the control. The produced PCL cloths showed a lower water droplet absorption compared to the control. Thermal studies found that PCL is stable in extreme conditions and no plasticizing effect occurs due to the presence of a solvent. Mechanical tests showed that PCL-10 cloth had higher strength and modulus compared to the control and PCL-3 under tension loading conditions. A vacuum experiment found that the PCL-10 fiber cloth could withstand a negative pressure of 18 Psi without any signs of breakage, and the mask was able to capture airborne particles and microorganisms. The feasibility of immobilizing anti-bacterial nanoparticles with PCL during electrospinning creates the future potential of producing an anti-bacterial face mask using PCL.