Exploring Reusability of Disposable Face Masks: Effects of Disinfection Methods on Filtration Efficiency, Breathability, and Fluid Resistance

Sterilization and Filter Performance of Nano- and Microfibrous Facemask Filters - Electrospinning and Restoration of Charges for Competitive Sustainable Alternatives

Facemask materials have been under constant development to optimize filtration performance, wear comfort, and general resilience to chemical and mechanical stress. While single-use polypropylene meltblown membranes are the established go-to material for high-performing mask filters, they are neither sustainable nor particularly resistant to sterilization methods. Herein an in-depth analysis is provided of the sterilization efficiency, filtration efficiency, and breathing resistance of selected aerosol filters commonly implemented in facemasks, with a particular focus on the benefits of nanofibrous filters. After establishing a general overview over face mask filters and machine washing parameters required for successful decontamination, respective changes in filter performance and structure are presented. Sustainably manufactured, highly efficient, but also more fragile electrospun membranes not only offer competitive performance as well as a more environment-friendly production and degradation process, but also support a subsequent sterilization and recharging approach via alcohol exposition and drying in an electric field. It is further elaborated on the prospective sustainability of each material to offer a clear outlook on electrospun membranes as the most promising filter membranes of the future.

Unraveling the impact of operational parameters and environmental conditions on the quality of viable bacterial aerosols

Viable pathogen-laden droplets of consistent quality are essential for reliably assessing the protection offered by facemasks against airborne infections. We identified a significant gap in guidance within standardized tests for evaluating the filtration efficiencies of facemask materials using viable bacteria-laden aerosol droplets. An aerosol platform, built according to the American Society for Testing and Materials standard F2101-19, was used to validate and standardize facemask filtration test procedures. We utilized this platform to investigate the impact of varying five operating parameters, namely suspension media composition, relative humidity, pathogen concentration, and atomizer airflow and feed flow rates, on the aerosol quality of viable bacteria-laden aerosols. We achieved consistent generation of 1,700 to 3,000 viable bacteria-laden droplets sized between 2.7 and 3.3 µm under the following optimized test conditions: 1.5% w/v peptone water concentration, ≥80% relative humidity at 24 ± 2 °C, 1 × 105 CFU/mL bacterial concentration, 1.5 L/min atomizer airflow rate, and 170 μL/min feed flow rate. We also explored the consequence of deviating from these optimized test parameters on viable bacteria-laden aerosol quality. These results highlight the importance of controlling these parameters when studying airborne transmission and control.

Enhanced and copper concentration dependent virucidal effect against SARS-CoV-2 of electrospun poly(vinylidene difluoride) filter materials

Virucidal filter materials were prepared by electrospinning a solution of 28 wt % poly(vinylidene difluoride) in N,N-dimethylacetamide without and with the addition of 0.25 wt %, 0.75 wt %, 2.0 wt %, or 3.5 wt % Cu(NO3)2 · 2.5H2O as virucidal agent. The fabricated materials had a uniform and defect free fibrous structure and even distribution of copper nanoclusters. X-ray diffraction analysis showed that during the electrospinning process, Cu(NO3)2 · 2.5H2O changed into Cu2(NO3)(OH)3. Electrospun filter materials obtained by electrospinning were essentially macroporous. Smaller pores of copper nanoclusters containing materials resulted in higher particle filtration than those without copper nanoclusters. Electrospun filter material fabricated with the addition of 2.0 wt % and 3.5 wt % of Cu(NO3)2 · 2.5H2O in a spinning solution showed significant virucidal activity, and there was 2.5 ± 0.35 and 3.2 ± 0.30 logarithmic reduction in the concentration of infectious SARS-CoV-2 within 12 h, respectively. The electrospun filter materials were stable as they retained virucidal activity for three months.

Antipathogenic Applications of Copper Nanoparticles in Air Filtration Systems

The COVID-19 pandemic has underscored the critical need for effective air filtration systems in healthcare environments to mitigate the spread of viral and bacterial pathogens. This study explores the utilization of copper nanoparticle-coated materials for air filtration, offering both antiviral and antimicrobial properties. Highly uniform spherical copper oxide nanoparticles (~10 nm) were synthesized via a spinning disc reactor and subsequently functionalized with carboxylated ligands to ensure colloidal stability in aqueous solutions. The functionalized copper oxide nanoparticles were applied as antipathogenic coatings on extruded polyethylene and melt-blown polypropylene fibers to assess their efficacy in air filtration applications. Notably, Type IIR medical facemasks incorporating the copper nanoparticle-coated polyethylene fibers demonstrated a >90% reduction in influenza virus and SARS-CoV-2 within 2 h of exposure. Similarly, heating, ventilation, and air conditioning (HVAC) filtration pre- (polyester) and post (polypropylene)-filtration media were functionalised with the copper nanoparticles and exhibited a 99% reduction in various viral and bacterial strains, including SARS-CoV-2, Pseudomonas aeruginosa, Acinetobacter baumannii, Salmonella enterica, and Escherichia coli. In both cases, this mitigates not only the immediate threat from these pathogens but also the risk of biofouling and secondary risk factors. The assessment of leaching properties confirmed that the copper nanoparticle coatings remained intact on the polymeric fiber surfaces without releasing nanoparticles into the solution or airflow. These findings highlight the potential of nanoparticle-coated materials in developing biocompatible and environmentally friendly air filtration systems for healthcare settings, crucial in combating current and future pandemic threats.

Environmental Decay of Single Use Surgical Face Masks as an Agent of Plastic Micro-Fiber Pollution

Large numbers of Single Use Surgical-type Face Masks, used by the public as personal protective equipment during the 2020–2022 COVID-19 pandemic, have been lost or intentionally discarded and have entered the environment rather than the waste management stream. These masks, made from non-woven polypropylene fibers, will undergo environmental decay which will release fiber fragments as microplastics into the environment. While the photochemical process of the decay of polypropylene polymers (photo-oxidation) is well understood, and while there are numerous studies that investigate mask decay and micro-fiber shedding in laboratory settings, there are no observational data that describe the progress and speed of decay on polypropylene face masks in real-life environmental settings. This paper examines the breakdown of single use surgical-type face masks under natural conditions. Masks from three manufacturers were exposed to natural sunlight over a ten-week period and their state of decay was photographically recorded in situ at weekly intervals. Visible decay accelerated after three weeks, with masks made from thinner spunbond fabric decaying more rapidly. Among same-weight fabric, photo-oxidation affected fabric dyed light blue more than undyed fabric, leading to a total breakdown after six weeks. The results are novel as they demonstrate a differential decay between the spunbonded and the melt-blown fabric, which cracks and breaks down much faster due to thinner fibers of shorter length and the lack of thermal bonding points. The resultant extensive micro-fiber generation was accelerated by external physical forces such as wind. This experiment highlights the fact that municipal agencies have only a narrow window of time to remove stray face masks from the urban environment if micro-fiber pollution is to be prevented.

Face Mask Wastes as Cementitious Materials: A Possible Solution to a Big Concern

After more than two years wearing surgical masks due to the COVID-19 pandemic, used masks have become a significant risk for ecosystems, as they are producing wastes in huge amounts. They are a potential source of disturbance by themselves and as microplastic contamination in the water system. As 5500 tons of face masks are estimated to be used each year, there is an urgent need to manage them according to the circular economy principles and avoid their inadequate disposal. In this paper, surgical wear masks (WM), without any further pretreatment, have been introduced as addition to mortars up to 5% in the weight of cement. Mechanical and microstructural characterization have been carried out. The results indicate that adding MW to the cement supposes a decrease in the properties of the material, concerning both strength and durability behavior. However, even adding a 5% of WM in weight of cement, the aspect of the mortars is quite good, the flexural strength is not significantly affected, and the strength and durability parameters are maintained at levels that-even lower than the reference-are quite reasonable for use. Provided that the worldwide production of cement is around 4.1 Bt/year, the introduction of a 5% of WM in less than 1% of the cement produced, would make it possible to get rid of the mask waste being produced.