Copper-Nanoparticle-Coated Melt-Blown Facemask Filter with Antibacterial and SARS-CoV-2 Antiviral Ability

Personal protective equipment, particularly facemasks, has an essential role in reducing the transmission risk of airborne infections from person to person. Thus, this study aimed to develop a hydrophobic facemask filter with antiviral and antibacterial effects to prevent the transmission of SARS-CoV-2 or other infectious pathogens that spread through the respiratory system. In this study, the melt-blown surface was modified with poly(acrylic acid) (PAA) by photoactivated graft polymerization and copper nanoparticles (CuNPs) were immobilized on the PAA-grafted melt-blown surface. The surface morphology and composition of the coated melt-blown surface were characterized by scanning electron microscopy, energy-dispersive spectrometry, X-ray diffraction, and Fourier transform infrared spectroscopy. CuNPs-coated melt-blown surfaces with hydrophobic nature showed inherent antiviral and antibiofilm formation activities against SARS-CoV-2 and Staphylococcus aureus and Escherichia coli, respectively. A more than 98% bacterial reduction and a significant decrease in the N and RdRp RNA titer were achieved following direct contact with the coated melt-blown surface. The standard sterilization processes, including autoclaving and UV irradiation, did not affect the antibacterial efficacy or the biocompatibility of the coated mask with dermal fibroblasts. The incorporation of CuNPs onto a melt-blown surface was not detrimental to the textile structure, although it caused a slight decrease in the air permeability, breathability, and tensile strength. The coated sample showed less than 4 ppm copper ion release during each of the 10 laundry cycles, and more than 50% of the initial copper content remained after the 10th laundry cycle, demonstrating the strong adhesion of CuNPs to the melt-blown surface. The facile processability of the CuNPs-coated hydrophobic mask filter with virus inactivation ability and reusability ensure its role in preventing the widespread transmission of viral infections through respiratory aerosols.