GB2632875A

GB2632875A - Compostable, bio-degradable breathable personal protective equipment (PPE)

Info

Publication number: GB2632875A
Application number: GB2313033.9A
Authority: GB
Inventors: O'riordan Mary; O'riordan Lisa; O'Riordan David; Shine Robert
Original assignee: Bawnmore Lightworkers Ltd
Current assignee: Bawnmore Lightworkers Ltd
Priority date: 2023-08-25
Filing date: 2023-08-25
Publication date: 2025-02-26
Also published as: GB202313033D0

Abstract

The present invention accordingly provides compostable Personal Protective Equipment (PPE) comprising a compostable plant-based material. The compostable plant- based material may comprises a compostable starch-based polymer. The compostable plant-based material may comprise a compostable base material and a compostable sealer material. The PPE may be a medical apron, a medical head covering, or a medical footwear covering. The formed medical footwear may comprise a compostable drawstring configured to be tied around the user’s leg or tightened around the user’s leg when pulled. The medical footwear cover may be roughed. Also provided is a method for manufacturing compostable PPE comprising a compostable plant-based material. The compostable PPE may be formed by blow-moulding. The compostable PPE may be integrally formed from a single piece of compostable material. The compostable PPE is preferably, formed by roller cutting process.

Description

COMPOSTABLE, BIO-DEGRADABLE BREATHABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) The present invention relates to compostable, bio-degradable breathable Personal Protective Equipment (PPE), such as is typically used in a healthcare environment for example, a hospital, or nursing care/nursing home settings.

BACKGROUND

Single-use disposable medical clothing such as aprons (known as "splash aprons"), gowns, footwear-covers and head/hair-covers are commonly used in healthcare environments, in particular, hospitals and nursing care settings. Known single-use disposable medical clothing is made from plastics material, typically, Low density polyethylene (LDPE). The known plastics material was chosen because this material is resistant to liquids which is a required property of PPE.

The material used must be light and thin (typically, 12-16 microns for an apron and up to microns for footwear cover (also known as "bootie")) so that it makes it easier for the wearer to carry out essential activities when wearing the PPE such as a disposable apron, footwear-cover or head/hair cover. The PPE must be used only for a single-use in the healthcare setting and to ensure avoidance of carrying infection between patients, and therefore, the PPE must be disposed of after that single-use.

All healthcare environments and indeed other environments such as in medtech, electronics industry clean rooms, food industry e.g. food processing plants, all require the use of the plastics material PPE. Such single-use PPE made of plastics material is responsible for, substantial amount of plastics material waste, leading to significant environmental and monetary costs in its disposal. For instance, 100 million plastics apron result in 1,000 tons of plastics material waste.

The present invention seeks to alleviate the disadvantages of the prior art.

BRIEF SUMMARY OF THE PRESENT INVENTION

For years, the above referenced single-use PPE apron has been in use in healthcare settings and other environments as referred to above. In what can be considered to be a significant technical improvement relative to the status-quo, the inventors have surprisingly invented compostable single-use Personal Protective Equipment (PPE) including aprons, footwear-covers and head/hair covers that is biodegradable but also meets the requirements of a Class 1 medical device as classified according to the Medical Device Regulation (EU) 2017/745 (MDR).

The present invention accordingly provides compostable Personal Protective Equipment (PPE) comprising a compostable plant-based material. Ideally, the PPE according to the invention also meets the requirements of a Class 1 medical device as classified according to the Medical Device Regulation (EU) 2017/745 and therefore, can be referred to as "medical grade Personal Protective Equipment (PPE)." Preferably, the compostable plant-based material comprises a compostable starch-based polymer.

The compostable plant-based material comprises a compostable base material and a compostable additive material comprising compostable sealer material.

The compostable PPE of the present invention preferably comprises 95-97 w/w% base compostable material and 3-5 w/w % compostable additive material comprising compostable sealer material.

The compostable material of the present invention has a water repellence of 948 g/m2/day at a temperature of 38 °C.

The compostable material of the present invention has a gravimetric thickness of 12-35 microns.

The compostable material of the present invention has an impact strength sufficient to resist 30g dropped from 660 mm.

The compostable material of the present invention has a tear resistance of 70.06 mN. The compostable PPE article of the present invention can be in the form of a single-use medical apron.

The compostable PPE article of the present invention can further be in the form of a single-use medical footwear-cover.

The compostable PPE article of the present invention can be in the form of a single-use medical head cover.

In certain aspects, the compostable single-use medical footwear-cover of the present invention includes a strip portion that is configured to be tied around the wearer's leg to hold the footwear-cover securely around footwear worn by the wearer.

Further, the single-use medical footwear-cover includes a compostable drawstring that is configured to be pulled so as to tighten the footwear-cover around the wearer's leg to hold the footwear-cover securely around footwear worn by the user.

In some aspects of the invention, the outer surface area of the single-use medical footwear-cover is roughened or dimpled.

In other aspects of the invention, the surface area of the bottom of the single-use medical footwear-cover is roughened or dimpled.

The single-use medical head cover includes a compostable drawstring that is configured to be pulled so as to tighten the footwear-cover around the wearer's head to hold the head cover securely around the head of the wearer.

Additionally, it is envisioned that the compostable PPE article according to any one of embodiments above comprises the compostable plant-based material which comprises a compostable thistle starch-based polymer.

Also provided by the present disclosure is a method to manufacture the compostable PPE comprising a compostable plant-based material. In some aspects, the compostable plant-based material comprises a compostable base material and a compostable additive material comprising compostable sealer material.

The method of manufacture comprises blow-moulding and is achieved with the following steps: 1) the compostable base material and the compostable additive material comprising compostable sealer material are mixed in ratios of between 95:5 to 97:3 of base material to additive material; 2) the resulting mixture of compostable materials is heated to between at least 71 °C and °C until molten; 3) the molten mixture is pushed through a longitudinal shaping mould to form a thin air tube, wherein air is brought through a hole in the centre of the mould to inflate the tube and the material is cooled by a high-speed air ring arranged above; 4) the inflated tube of resin is shaped into a sheet of resin; 5) the resulting sheet of resin is cut using a cutting machine to form a compostable PPE article.

In some aspects of the present invention, the compostable base material and the compostable additive material comprising compostable sealer material are in the form of pellets.

In some aspects of the present disclosure, the compostable PPE article manufactured according to the method above is a single-use medical apron.

In other aspects of the present disclosure, the compostable PPE article manufactured according to the method above is a single-use medical footwear-cover.

In yet other aspects of the present disclosure, the compostable PPE article manufactured according to the method above is a single-use medical head-cover.

In the method described above, the compostable PPE material may be integrally formed off from a single piece of compostable material.

The compostable material can further be formed by roller cutting process.

Thistle-based resin is preferred due to its starch content and tensile strength properties but also because it is not competing with a food source and is a sustainable source.

The PPE of the present invention has several advantages and breathability was one key advantage that the PPE of the present invention provides. This is achieved because of the inherent properties of the bio-resin source material that has inherent natural breathability over and above the traditional PPE material that is formed of low density poly-ethyene (LDPE). The PPE of the present invention, in particular, the compostable apron has been designed to have the optimised combination of enough fluid repellent properties to meet the standards required to perform the function as a splash apron but also has a natural fibre that allows for breathability and evaporation of water vapour through the PPE material to provide the desired wearer comfort since PPE is, typically worn in an often challenging, hot, environment such as is typical in a healthcare setting, for instance.

The PPE of the present invention also provides an appropriate gravimetric thickness of the material from which the PPE is formed. Parameters must be no thicker than 16 micron with a 20% margin either side. To achieve this, the manufacturing process of the present invention comprises a step of blow-moulding the bio-resins in an even manner to achieve a consistent gravimetric thickness. The bio-resins achieved the optimum impact strength and also tear resistance at the lower gravimetric thickness of 12 microns which reduced the amount of resin needed.

In addition, due to the difference in bio-resin properties over low density polyethylene, it was discovered that specific apron cutting machinery was needed due to the heat sensitive nature of the bio-resins.

Roller cutting mechanisms rather than the routine punch cutting technique gave a cleaner cut and thereby reducing waste of product due to an efficient pull off from the dani-centre. The PPE of the present invention has properties that meet the requirements of the Medical Device Regulation (EU) 2017/745 (MDR), including but are not limited to: water repellence, density and tensile strength.

Furthermore, the PPE according to the present invention has the advantage of meeting composting standards including the following composting standards: EN 13430 (recycling) EN 13431 (energy recovery) EN 13432 (organic recovery) and ASTM 6400 (American Society for Testing and Materials (ASTM)) standard specification for solid material biodegradation (by composting) required for the labelling of plastics designed to be aerobically composted in municipal or industrial facilities.

Accordingly, the PPE according to the present invention has the impact of revolutionising the traditional thinking that PPE for single-use demands that plastics material such as LDPE be used to provide the required properties of PPE, including all the properties of a class 1 medical device.

In addition, it is to be noted that known Studies have shown that approx 80% of healthcare waste (HCVV) is non-risk waste, and therefore, the inventors have surprisingly discovered that the PPE according to the present invention has the further advantage that, as a plant-based product, after use, the PPE can be combined with the food waste cycle of a healthcare setting such as a hospital and can be processed using anaerobic digestion (AD).

Therefore, the inventors have found that, irrespective of which waste stream, the PPE of the present invention is disposed in, the PPE of the present invention has the advantage that it will decompose in an environmentally friendly manner. The PPE of the present invention therefore facilitates the introduction of a composting waste disposal cycle for medical waste, enabling the transition of the healthcare cycle to a circular economy.

Accordingly, the PPE of the present invention has positive environmental impact and has the positive impact of a significant reduction of the carbon footprint of healthcare.

The PPE of the present invention, can be provided in various embodiments including as a medical apron, as footwear-covers; and/or as head/hair covers. The PPE of the present invention is configured to be comfortable as well as being adapted to be worn properly by the wearer. The PPE of the present invention has the function, in the Healthcare environment, of minimizing the risk of being contaminated by microbes and dangerous liquids. Additionally, the PPE of the present invention has the advantage that it increases comfort for the wearer, in particular, by providing a PPE material that is breathable while simultaneously providing the appropriate protection properties.

There is also the benefit of "guilt-free" usage of the PPE as well as human comfort level from the fact that the healthcare worker is not contributing to the environmental damage that is associated with single-use plastics items.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which: Figure 1A is a plan view of a first aspect of the PPE of the present invention in the form of a compostable medical single-use apron; Fig. 1B is a plan view of the medical apron of the first aspect of the PPE of the present invention during use; Fig. 2A is a side view of a second aspect of the PPE of the present invention in the form of a compostable medical single-use footwear-cover; Fig. 2B is a side view of the footwear-cover in use with a shoe inside the cover with the fastening strips perpendicular to the longitudinal plane of the footwear-cover; Fig. 2C is a perspective view of the footwear-cover in use with a shoe inside the cover with the fastening strips perpendicular to the longitudinal plane of the footwear-cover; Fig. 2D is a perspective view of the footwear-cover in use with a shoe inside the cover with fastening strips parallel to and oriented towards the front of the longitudinal plane of the footwear-cover; Fig. 3A is a side view of a further embodiment of the second aspect of the PPE of the present invention in the form of an alternative compostable medical single-use footwear-cover with the fastening strips parallel to the longitudinal plane of the footwear-cover; Fig. 3B is a side view of the footwear-cover in use with a shoe inside the cover with the fastening strips parallel to the longitudinal plane of the footwear-cover; Fig. 3C is a perspective view of the footwear-cover in use with a shoe inside the cover with the fastening strips parallel to the longitudinal plane of the footwear-cover; Fig. 3D is a perspective view of the footwear-cover in use with a shoe inside the cover with the fastening strips parallel to and oriented towards the front of the longitudinal plane of the footwear-cover; Fig. 4A is a side view of a further embodiment of the second aspect of the PPE of the present invention in the form of a further alternative compostable medical single-use footwear-cover with drawstrings; Fig. 4B is a side view of the footwear-cover in use with a shoe inside the cover with drawstrings loose; Fig. 4C is an perspective view of the footwear-cover in use with a shoe inside the cover with drawstrings loose; Fig 4.D is a perspective view of the footwear-cover in use with a shoe inside the cover with drawstrings fastened; and Fig. 5 is a side view of a third aspect of the PPE of the present invention in the form of a further alternative compostable medical single-use head-cover.

DETAILED DESCRIPTION

The PPE of the present invention is compostable and is formed of a compostable starch-based polymer resin having properties including but are not limited to water repellence, density and tensile strength. The starch-based polymer resin also meets WHO standards for biodegradable PPE option and matches on all equivalency profiles as outlined below.

The method of manufacture of the compostable starch-based biopolymer resin is comprises the steps of processing of a base ingredient, preferably, a thistle based ingredient such as a Base Ingredient available under the trade mark, Novamont TM, into the film sheet. Then at least one plant based additive is added, which is preferably, a fluid repellent additive and most preferably, the additive that is commercially available under the trade mark, Novamont Mater-bi fluid repellent additive. The fluid repellant additive is included to reduce the fluid, (the term, fluid includes water, alcohol and detergent vapor) transmission of the film. The additives, which are within the Base Ingredients, comprise a range of waxes and organic oils. In general, the following formula applies: 95-96% of base compostable material, 3-5% of compostable additive material which comprising compostable sealer material.

The PPE of the present invention is preferably formed from a combination of 97% thistle-based resin combined with 3% compostable fluid repellent additive was derived to ensure technical adherence to appropriate water, chlorine and ethanol repellence -this combination was tested to ensure the optimum balance of protection with dissolvability under appropriate bio-digestion processes.

The thistle-based resin is preferred due to its starch content and tensile strength properties but also because it is not competing with a food source and is a sustainable source. The specific combination of resins was chosen to adhere to the international composting standards.

The compostable resin has been designed to match the specifications of the harmonised conformity standards based on current EU standards and WHO medical PPE guidelines. Table 1 below shows the parameters that were tested:

Parameters Specifications

Protection. y of end user PolyethyleneLLDPEsihgle-usehyg,eneapronMeetsviostanqarqsfor biodegradable r,E0:tionendmatchesonalIequivalenc;Prefileeesoutlin:d below.

Meets international and Europeanbiodegradable andcompostable standaras.

Eco-friendly Adheres to water repellencedensityendtensiIe strength f current-ow -D e n s i t o.

EuroO--n stendarduNiENl3432,AmericanstandardAsTm640o Excelient948glmscuaredperdayg8degreesu Breathability Excellent 30g drop from 660nirn corfirmdBsBNIs( 7765 -1:2004) Water parameters for grev etrc thickness repellence Gravimetric 12 microneehewsequivalentprotectionontesting and in line with current thickness Impact Strength Tear 70 06 niN (BS EN ISO 6383-2 2004) resistance Wearability As per current standards and pattern The PPE of the present invention has the advantage that it meets medical technical specification requirements, while also having bio resin properties, as well as being suitable for blow-moulding and cutting techniques. The challenges of manufacturing PPE manufactured from bio resin materials are significant in terms of difficulties in cutting the material to the appropriate outline and having the required properties eg clean edges that will not cause friction against the skin of the wearer. The manufacturing process of the present invention has addressed these problems.

Throughout the description and claims of this specification, the words "comprise" and "contain" and variations of them mean "including but not limited to", and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

In one embodiment, the compostable starch-based biopolymer resin comprises 95% base compostable material, 5% compostable additive material comprising compostable sealer material.

In another embodiment, the compostable starch-based biopolymer resin comprises 96% base compostable material, 4% compostable additive material comprising compostable sealer material.

In another embodiment, the compostable starch-based biopolymer resin comprises 97% base compostable material, 3% compostable additive material comprising compostable sealer material.

In another embodiment, the compostable starch-based biopolymer resin is formed into a medical apron intended to protect the wearer from exposure to contaminants/hazardous substances, such that it is classified as Personal Protective Equipment and regulated under Regulation (EU) 2016/425.

In another embodiment, the compostable starch-based biopolymer resin is formed into medical foot-covers with a resin thickness of 40 micron, ranging from shoe size 14-16" and embossed to prevent slippage. The foot-covers also adhere to European PPE Equipment Directive 89/686/EEC and the 4.0 AQL level II sampling plan per MIL-std-150E for the following defect criteria for sterile options.

In another embodiment, the compostable starch-based biopolymer resin is formed into medical head-covers with a reason thickness of 30 micron with a width of 380-400 mm and a height of 140 mm. The head-cover is provided with an internal fold of 40 mm from the bottom edge of the head-cover.

DETAILED DESCRIPTION OF THE DRAWINGS

A number of aspects of the compostable Personal Protective Equipment (PPE) of the present invention will now be described more particularly, with reference to the drawings. Like reference numerals refer to like features.

First aspect of the present invention -compostable apron Referring firstly to Figure 1, FIG. 1 is a plan view of a first aspect of the PPE of the present invention in which the PPE is in the form of a compostable medical single-use apron 100. The compostable medical single-use apron 100 comprises a main body 102, a plurality of flexible thin strips extending from the main body 104 and a aperture 106 positioned in the top of the main body 100. The compostable single-use apron 100 is formed of compostable plant-based material comprising a compostable starch-based polymer. The compostable single-use apron 100 is integrally formed from a single piece of compostable material.

The compostable PPE of the present invention is formed of plant-based material comprising a compostable base material and a compostable sealer material. The compostable single-use apron 100 is ideally, formed by roller cutting process.

Referring now to Figure 1B, Fig. 1B is a plan view of the first aspect of the compostable medical single-use apron 100 during use. The head of the user is positioned in aperture 106, and the fastening strips 104 are positioned and tied behind the back of the user.

Second aspect of the present invention -compostable Footwear-cover Referring now to FIG. 2A, there is shown a side view of a first embodiment of a second aspect of the PPE of the present invention in which the PPE is the form of a compostable single-use footwear-cover 200. The single-use footwear-cover 200 comprises a main body 202, an interior seal/fold 204 configured to expand when tensioned along the transverse axis to form an expanded space for receiving the footwear of the user, in the compostable single-use footwear-cover 200. The single-use footwear-cover 200 also comprises a fastening strip 206 comprising two flexible separable portions extending from the main body 202. The fastening strips 206 are configured to be tied at or towards the front of each of the wearer's lower leg/upper ankle to secure the single-use footwear-cover around the leg of the wearer and thereby hold it securely in place and prevent it from slipping off when the wearer is moving. The boundaries of the compostable single-use footwear-cover 200 are defined by a plurality of open and sealed portions. The sealed portions 208, 210, 212, 214 and 218 prevent the footwear of the user from slipping out of the footwear-cover. Additionally, an interior seal/fold 216 configured to expand when tensioned along the transverse axis to form an expanded space for receiving the head of the user. In certain aspects of the present invention, some or all of the exterior surface area of the single-use footwear-cover 200 is dimpled and/or roughened to reduce slippage while the footwear-cover 200 is in use.

Referring now to FIG. 2B, there is shown a side view of the first embodiment of the second aspect in use with a shoe inside the footwear-cover 200. The fastening strips 206 are arranged perpendicular to the longitudinal axis of the footwear-cover, and are intended to be brought down to and fastened around the lower leg/upper ankle of the operator to ensure that the footwear-cover 200 does not disengage from the shoe while in use.

Referring now to FIG. 2C, there is shown a perspective view of the first embodiment of the second aspect in use with a shoe inside the footwear-cover 200. The fastening strips 206 are arranged perpendicular to the longitudinal axis of the footwear-cover, and are intended to be brought down to and fastened around the lower leg/upper ankle of the operator to ensure that the footwear-cover 200 does not disengage from the shoe while in use. FIG. 2C shows the interior seal/fold 216 in its expanded configuration to receive the shoe of the user.

Referring now to FIG. 2D, there is shown a perspective view of the first embodiment of the second aspect in use with a shoe inside the footwear-cover 200. The fastening strips 206 are arranged parallel to and angled towards the front of the longitudinal axis of the footwear-cover. In use, they are fastened around the lower leg/upper ankle of the user to ensure that the footwear-cover 200 does not disengage from the shoe while in use. FIG. 2D shows the interior seal/fold 216 in its expanded configuration to receive the shoe of the user.

Referring now to FIG. 3A, there is shown a second embodiment of the second aspect of the PPE of the present invention in the form of a compostable single-use footwear-cover 300. The footwear-cover 300 comprises a main body 302, an interior seal/fold 304 configured to expand when tensioned along the transverse axis to form an expanded space for receiving the footwear of the user. The single-use footwear-cover 300 also comprises a strip portion 306 comprising two flexible separable portions 306 extending from the main body 302. The strip portions 306 are configured to be tied around each of the wearer's legs to secure the single-use footwear-cover around the leg of the wearer and thereby hold it securely in place and prevent it from slipping off when the wearer is moving.

Referring now to FIG 3B, there is shown a side view of the second embodiment of the second aspect in use with a shoe inside the footwear-cover 300. The fastening strips 306 are arranged parallel to the longitudinal axis of the footwear-cover, and are intended to be brought down to and fastened around the lower leg/upper ankle of the operator to ensure that the footwear-cover 300 does not disengage from the shoe while in use.

Referring now to FIG. 3C, there is shown a perspective view of the second embodiment of the second aspect in use with a shoe inside the footwear-cover 300. The fastening strips 306 are arranged parallel to the longitudinal axis of the footwear-cover, and are intended to be fastened around the lower leg/upper ankle of the operator to ensure that the footwear-cover 300 does not disengage from the shoe while in use. FIG. 3C shows the interior seal/fold 316 in its expanded configuration to receive the shoe of the user.

Referring now to FIG. 3D, there is shown a perspective view of the second embodiment of the second aspect in use with a shoe inside the footwear-cover 300. The fastening strips 306 are arranged parallel to and angled towards the front of the longitudinal axis of the footwear-cover. In use, they are fastened around the lower leg/upper ankle of the user to ensure that the footwear-cover 300 does not disengage from the shoe while in use. FIG. 3D shows the interior seal/fold 316 in its expanded configuration to receive the shoe of the user.

FIG. 4A is a side view of a third embodiment of the second aspect of the PPE of the present invention in the form of a compostable medical single-use footwear-cover 400, comprising a main body 402, a track 404 provided around the perimeter of the footwear-cover 400, the track being defined by an interior space 404 formed about the upper edges of the footwear-cover 400 in which a compostable drawstring 406 is provided with the drawstring 406 configured such that that tensioning of the compostable drawstring 406 causes a contraction of the track 404 of the footwear-cover 400 around the perimeter of the footwear-cover 400 thereby securing it around the wearer's leg; and thereby hold it securely in place and prevent it from slipping off when the wearer is moving. The boundaries of the compostable single-use footwear-cover 400 are defined by a plurality of open and sealed portions. The sealed portions 408, 410 and 412, prevent the footwear of the user from slipping out of the footwear-cover. Additionally, an interior seal/fold 414 configured to expand when tensioned along the transverse axis to form an expanded space for receiving the footwear of the user.

FIG. 4B is a side view of a third embodiment of the second aspect of the PPE of the present invention in the form of a compostable medical single-use footwear-cover in use, with a shoe inside the footwear-cover 400. The drawstring 406 is not tensioned.

FIG. 4B is a perspective view of a third embodiment of the second aspect of the PPE of the present invention in the form of a compostable medical single-use footwear-cover in use, with a shoe inside the footwear-cover 400. The interior seal/fold 414 has been expanded by tensioning along the transverse axis to form an expanded space that received the footwear of the user. The drawstring 406 is not tensioned.

FIG. 4B is a perspective view of a third embodiment of the second aspect of the PPE of the present invention in the form of a compostable medical single-use footwear-cover in use, with a shoe inside the footwear-cover 400. The interior seal/fold 414 has been expanded by tensioning along the transverse axis to form an expanded space that received the footwear of the user. The drawstring 406 is has been tensioned, leading to contraction of the track 404 of the footwear-cover 400 around the perimeter of the footwear-cover 400 thereby securing it around the wearer's leg; and thereby hold it securely in place and prevent it from slipping off when the wearer is moving. The drawstring 406 has been tied into a knot to secure it in place.

Third aspect of the present invention -compostable head cover In a third aspect of the present invention, we refer now to FIG. 5 which shows a plan view of a third embodiment of the PPE of the present invention in the form of a compostable medical single-use head cover 500. The compostable single-use head cover 500 comprising a main body 502, a track 504 provided around the perimeter of the headwear cover 500, the track being defined by an interior space 404 formed about the upper edges of the head cover 500 in which a compostable drawstring 506 is provided with the drawstring 506 configured such that that tensioning of the compostable drawstring 506 causes a contraction of the track 404 of the head cover 500 around the perimeter of the head cover 500 thereby securing it around the wearer's head; securing it and preventing it from accidentally being removed. Additionally, an internal fold 508 is configured to fold under the main body 502 of the single-use head cover 500.

EXAMPLES

Exemplary Compositions will now be set out in the following examples.

EXAMPLE 1

In this example, the method of manufacture for the compostable PPE article comprises the following: 95% base compostable material; and 5% compostable additive materials including compostable sealer material.

Method: The base compostable material and the compostable material including additives are combined and heated to at least 71 °C until melted; The combined melted material is then pushed through longitudinal shaping moulds to form a thin tube; Air is brought in through a hole in the centre of the mould to inflate the tube. Above is arranged a high-speed air ring to cool the finished product; The inflated tube of resin is formed into a sheet of resin.

To ensure a clean cut, the roller cutting machine (or retrofitting of punch cutting machines) is required to achieve an appropriate compostable PPE article.

The heat that a punch cutter generates softens the bio-resin during the cutting process and leaves poor lines that risks in complete tearing from Dani centres -increasing wastage on tear. Some embodiments of the invention, in particular the compostable medical apron as manufactured according to Example 1 above (shown in Figures 1A-1 D), comprise a compostable starch-based biopolymer resin comprising 95% base compostable material and 5% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

TESTS AND TESTING PROCEDURES

Tensile Strength Tensile testing was conducted on Lloyd TA1 Texture Analyzer after conditioning for a minimum of 24 hours at 23+/-2oC. The Tensometer was fitted with a 20N loadcell and large, vice-type grips suitable for thin plastic specimens. A test speed of 100 mm/minute and a distance between the grips of 25mm was used. The test temperature was measured as 23.3oC. The tensile specimen used conformed to the ISO 527 Type 5.

Six specimens were tested and the dimensions determined using digital callipers (serial number 500-196-20). The tensile strength was measured in accordance with ISO 527 as the mean of the six specimens tested. Each test material was tested in the Transverse and the machine direction.

Trouser Tear Testing Trouser Tear testing was conducted on Lloyd TA1 after conditioning for a minimum of 24 hours at 23+/-2oC. Samples were clamped with a distance between the jaws of 25mm.

The test speed of 100 mm/min was set until a deflection of 150mm was reached.

The Tensometer was fitted with a 20N load-cell. The test temperature was measured as 23.3oC. The machine recorded the force taken for each of the tests to tear the specimens under analysis. Each test material was tested in the Transverse and the machine direction.

Puncture Testing Puncture Testing was conducted on Lloyd TA1 Tensometer after conditioning for a minimum of 24 hours at 23.5oC. The test was carried out according to ISO 6603-2 specifications. The diameter of the puncture apparatus was 4.26mm.

The test speed of 50mm/min was set until a deflection of 20mm was reached. Each test material was tested in the Transverse and the machine direction.

FTIR Analysis FTIR Testing was conducted using a Perkin Elmer Spectrum One FTIR. Fourier transform infrared spectroscopy was carried out using the ATR mode of the FTIR with a 4 scan per sample cycle and a resolution of 8. The sample was scanned from 650cm-1 to 4000cm-1

EXAMPLE 2

In this example, the method of manufacture for the compostable apron comprises the following: 96% base compostable material; and 4% compostable additive materials including compostable sealer material.

Method: The base compostable material and the compostable material including additives are combined and heated to at least 71 °C until melted.

The combined melted material is then pushed through longitudinal shaping moulds to form a thin tube.

Air is brought in through a hole in the centre of the mould to inflate the tube. Above is arranged a high-speed air ring to cool the finished product.

The inflated tube of resin is formed into a sheet of resin.

To ensure a clean cut, a roller cutting machine (or retrofitting of punch cutting machines) is required to achieve an appropriate compostable PPE article.

Some embodiments of the invention, in particular the compostable medical apron as manufactured according to Example 2 (shown in Figures 1A-D), comprise a compostable starch-based biopolymer resin comprising 96% base compostable material and 4% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 2 are the same as described for Example 1 25 above.

EXAMPLE 3

In this example, the method of manufacture for the compostable apron comprises the following: 97% base compostable material; and 3% compostable additive materials including compostable sealer material.

Method The base compostable material and the compostable material including additives are combined and heated to at least 71 'C until melted.

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable medical apron manufactured according to Example 3 (and shown in Figures 1A-D), comprise a compostable starch-based biopolymer resin comprising 97% base compostable material and 3% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 3 are the same as described for Example 1 25 above.

EXAMPLE 4

In this example, the method of manufacture for the compostable footwear-cover comprises the following: 95% base compostable material; and 5% compostable additive materials including compostable sealer material.

Method: The base compostable material and the compostable material including additives are combined and heated to at least 71 t until melted.

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable footwear-cover manufactured according to Example 4 (and shown in Figures 2 and 3), comprise a compostable starch-based biopolymer resin comprising 95% base compostable material and 5% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 4 are the same as described for Example 1 25 above.

EXAMPLE 5

In this example, the method of manufacture for the compostable footwear-cover comprises the following: 96% base compostable material; and 4% compostable additive materials including compostable sealer material.

Method: The base compostable material and the compostable material including additives are combined and heated to at least 71 'C until melted.

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable foot-cover manufactured according to Example 5 (and shown in Figures 2 and 3), comprise a compostable starch-based biopolymer resin comprising 96% base compostable material and 4% compostable additive material including compostable sealer material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These rolled sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 5 are the same as described for Example 1 above.

EXAMPLE 6

In this example, the method of manufacture for the compostable foot-cover comprises the following: 97% base compostable material; and 3% compostable additive materials including compostable sealer material.

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable foot-cover manufactured according to Example 6 above (and shown in Figures 2 and 3), comprise a compostable starch-based biopolymer resin comprising 97% base compostable material and 3% compostable additive material including compostable sealer material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These rolled sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 6 are the same as described for Example 1 above.

EXAMPLE 7

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable footwear-cover manufactured according to Example 7 above (and shown in Figure 4), comprise a compostable starch-based biopolymer resin comprising 95% base compostable material and 5% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 7 are the same as described for Example 1 above.

EXAMPLE 8

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable footwear-cover manufactured according to Example 8 above (and shown in Figures 4A-C), comprise a compostable starch-based biopolymer resin comprising 96% base compostable material and 4% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 8 are the same as described for Example 1 above.

EXAMPLE 9

In this example, the method of manufacture for the compostable footwear-cover comprises the following: 97% base compostable material; and 3% compostable additive materials including compostable sealer material.

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable footwear-cover manufactured according to Figure 9 above (and shown in Figure 4A-C), comprise a compostable starch-based biopolymer resin comprising 97% base compostable material and 3% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 9 are the same as described for Example 1 above.

EXAMPLE 10

In this example, the method of manufacture for the compostable head-cover comprises the following: 95% base compostable material; and 5% compostable additive materials including compostable sealer material.

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable head-cover manufactured according to Example 10 above (and shown in Figure 5), comprise a compostable starch-based biopolymer resin comprising 95% base compostable material and 5% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 10 are the same as described for Example 1 above.

EXAMPLE 11

In this example, the method of manufacture for the compostable head-cover comprises the following: 96% base compostable material; and 4% compostable additive materials including compostable sealer material.

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable head-cover manufactured according to Example 11 above (and shown in Figure 5), comprise a compostable starch-based biopolymer resin comprising 96% base compostable material and 4% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 11 are the same as described for Example 1 above.

EXAMPLE 12

In this example, the method of manufacture for the compostable head-cover comprises the following: 97% base compostable material.

3% compostable additive materials including compostable sealer material.

The inflated tube of resin is formed into a sheet of resin.

Some embodiments of the invention, in particular the compostable head-cover manufactured according to Example 12 above (and shown in Figure 5), comprise a compostable starch-based biopolymer resin comprising 97% base compostable material and 3% compostable additive material including compostable sealer material. The additives serve to reduce the penetration of fluids, including water, alcohol and detergent fluids, from penetrating through the product compostable material. The additives further serve to reduce the penetration of vapours, including water, alcohol and detergent vapours, from penetrating through the product compostable material. The separate components are combined in the appropriate ratios defined above and mixed before being formed into large sheets via rolling or pressing. These sheets have a thickness of 10-50 pm, and preferably have a thickness of 30 pm.

The tests and testing procedures for Example 12 are the same as described for Example 1 above.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

CLAIMS1. A compostable Personal Protective Equipment (PPE) article comprising a compostable plant-based material.
2. A compostable Personal Protective Equipment (PPE) article as claimed in claim 1 wherein the compostable plant-based material comprises a compostable starch-based polymer.
3. A compostable Personal Protective Equipment (PPE) article as claimed in claim 1 or claim 2 wherein the compostable plant-based material comprises a compostable base material and a compostable additive material comprising compostable sealer material.
4. A compostable Personal Protective Equipment (PPE) article as claimed in any preceding claim wherein the compostable material comprises 95-97 w/w% base compostable material and 3-5w/w % compostable additive material comprising compostable sealer material.
5. A compostable PPE article as claimed in any of the preceding claims wherein the compostable material has a water repellence of 948 g/m2/day at a temperature of 38 °C
6. A compostable PPE article as claimed in any of the preceding claims wherein the compostable material has a gravimetric thickness of 12-35 microns.
7. A compostable PPE article as claimed in any of the preceding claims wherein the compostable material has an impact strength sufficient to resist 30g dropped from 660 mm.
8. A compostable PPE article as claimed in any of the preceding claims wherein the compostable material has a tear resistance of 70.06 mN.
9. A compostable PPE article according to any preceding claim wherein the PPE article is in the form of a single-use medical apron.
10. A compostable PPE article according to any of claims 1-8 wherein the PPE article is in the form of a single-use medical footwear-cover.
11. A compostable PPE article according to any of claims 1-8 wherein the PPE article is in the form of a single-use medical head cover.
12. A compostable PPE article according to claim 10 wherein the single-use medical footwear-cover includes a strip portion that is configured to be tied around the wearer's leg to hold the footwear-cover securely around footwear worn by the wearer.
13. A compostable PPE article according to claim 10 wherein the single-use medical footwear-cover includes a compostable drawstring that is configured to be pulled so as to tighten the footwear-cover around the wearer's leg to hold the footwear-cover securely around footwear worn by the wearer.
14. A compostable PPE article according to claim 10 wherein the outer surface area of the single-use medical footwear-cover is roughened or dimpled.
15. A compostable PPE article according to claim 10 wherein the surface area of the bottom of the single-use medical footwear-cover is roughened or dimpled.
16. A compostable PPE article according to claim 11 wherein the single-use medical head cover includes a compostable drawstring that is configured to be pulled so as to tighten the footwear-cover around the wearer's head to hold the head cover securely around the head of the wearer.
17. A compostable PPE article according to any one of claims 2-16 wherein the compostable plant-based material comprises a compostable thistle starch-based polymer.
18. A method for manufacturing compostable Personal Protective Equipment (PPE) comprising a compostable plant-based material.
19. A method as claimed in claim 19 wherein the compostable plant-based material comprises a compostable base material and a compostable additive material comprising compostable sealer material.
20. A method as claimed in claim 18 wherein the method of manufacture comprises blow-moulding and is achieved with the following steps: 1) the compostable base material and the compostable additive material comprising compostable sealer material are mixed in ratios of between 95:5 to 97:3 of base material to additive material; 2) the resulting mixture of compostable materials is heated to between at least 71 °C and 100 °C until molten; 3) the molten mixture is pushed through a longitudinal shaping mould to form a thin air tube, wherein air is brought through a hole in the centre of the mould to inflate the tube and the material is cooled by a high-speed air ring arranged above; 4) the inflated tube of resin is shaped into a sheet of resin; 5) the resulting sheet of resin is cut using a cutting machine to form a compostable PPE article.
21. The method of claim 20 wherein in step 1) the compostable base material and the compostable additive material comprising compostable sealer material are in the form of pellets.
22. The method of claim 20 wherein the compostable PPE article is a single-use medical apron.
23. The method of claim 20 wherein the compostable PPE article is a single-use medical footwear-cover.
24. The method of claim 20 wherein the compostable PPE article is a single-use medical head cover.
25. A method as claimed in claim 18-20 wherein the compostable PPE may be integrally formed from a single piece of compostable material.
26. A method as claimed in any one of claims 18--20 wherein the compostable PPE is formed by roller cutting process.