Since the emergence of the COVID-19 pandemic outbreak, the increasing demand and disposal of surgical masks has resulted in significant economic costs and environmental impacts. Here, we applied a dual-channel spray-assisted nanocoating hybrid of shellac/copper nanoparticles (CuNPs) to a nonwoven surgical mask, thereby increasing the hydrophobicity of the surface and repelling aqueous droplets. The resulting surface showed outstanding photoactivity (combined photocatalytic and photothermal properties) for antimicrobial action, conferring reusability and self-sterilizing ability to the masks. Under solar illumination, the temperature of this photoactive antiviral mask (PAM) rapidly increased to >70 °C, generating a high level of free radicals that disrupted the membrane of nanosized (∼100 nm) virus-like particles and made the masks self-cleaning and reusable. This PAM design can provide significant protection against the transmission of viral aerosols in the fight against the COVID-19 pandemic.

The outbreak of coronavirus disease (COVID-19) has transformed the daily lifestyles of people worldwide. COVID-19 was characterized as a pandemic owing to its global spread, and technologies based on engineered materials that help to reduce the spread of infections have been reported. Nanotechnology present in materials with enhanced physicochemical properties and versatile chemical functionalization offer numerous ways to combat the disease. Facemasks are a reliable preventive measure, although they are not 100% effective against viral infections. Nonwoven materials, which are the key components of masks, act as barriers to the virus through filtration. However, there is a high chance of cross-infection because the used mask lacks virucidal properties and can become an additional source of infection. The combination of antiviral and filtration properties enhances the durability and reliability of masks, thereby reducing the likelihood of cross-infection. In this review, we focus on masks, from the manufacturing stage to practical applications, and their abilities to combat COVID-19. Herein, we discuss the impacts of masks on the environment, while considering safe industrial production in the future. Furthermore, we discuss available options for future research directions that do not negatively impact the environment.

Coronavirus has affected the entire global community owing to its transmission through respiratory droplets. This has led to the mandatory usage of surgical masks for protection against this lethal virus in many countries. However, the currently available disposable surgical masks have limitations in terms of their hydrophobicity and reusability. Here, we report a single-step spray-coating technique for the formation of a superhydrophobic layer of single-walled carbon nanotubes (SWCNTs) on a meltblown polypropylene (PP) surgical mask. The sprayed SWCNTs form a nanospike-like architecture on the PP surface, increasing the static contact angle for water from 113.6°± 3.0°to 156.2°± 1.8°a nd showing superhydrophobicity for various body fluids such as urine, tears, blood, sweat, and saliva. The CNT-coated surgical masks also display an outstanding photothermal response with an increase in their surface temperature to more than 90 °C within 30 s of 1 sun solar illumination, confirming its self-sterilization ability. Owing to the cumulative effect of the superhydrophobicity and photothermal performance of the SWCNTs, the CNT-coated masks show 99.99% higher bactericidal performance toward Escherichia coli than pristine masks. Further, the virucidal ability of the SWCNT-coated mask, tested by using virus-like particles, was found to be almost 99% under solar illumination. As the spray-coating method is easily scalable, the nanotube-coated mask provides cost-effective personal protection against respiratory diseases.