Screen-printing of chitosan and cationised cellulose nanofibril coatings for integration into functional face masks with potential antiviral activity

Masks proved to be necessary protective measure during the COVID-19 pandemic, but they provided a physical barrier rather than inactivating viruses, increasing the risk of cross-infection. In this study, high-molecular weight chitosan and cationised cellulose nanofibrils were screen-printed individually or as a mixture onto the inner surface of the first polypropylene (PP) layer. First, biopolymers were evaluated by various physicochemical methods for their suitability for screen-printing and antiviral activity. Second, the effect of the coatings was evaluated by analysing the morphology, surface chemistry, charge of the modified PP layer, air permeability, water-vapour retention, add-on, contact angle, antiviral activity against the model virus phi6 and cytotoxicity. Finally, the functional PP layers were integrated into face masks, and resulting masks were tested for wettability, air permeability, and viral filtration efficiency (VFE). Air permeability was reduced for modified PP layers (43 % reduction for kat-CNF) and face masks (52 % reduction of kat-CNF layer). The antiviral potential of the modified PP layers against phi6 showed inhibition of 0.08 to 0.97 log (pH 7.5) and cytotoxicity assay showed cell viability above 70 %. VFE of the masks remained the same (~99.9 %), even after applying the biopolymers, confirming that these masks provided high level of protection against viruses. Chitosan and cationized cellulose nanofibril formulations (individually or as a mixture) were screen-printed onto a polypropylene mask layer, and a biopolymer-modified functional layer was incorporated into a three-layer face mask to provide antiviral properties. [Display omitted] •First PP mask layers surface was modified with biopolymers using screen-printing.•Functional PP layers provided moderate antiviral activity at neutral pH.•phi6 inactivation was influenced by various surface properties of modified PP layers.•Biopolymer-modified PP layers were integrated into a three-layer masks.•The biopolymer-modified masks can provide a high level of protection against viruses.