Development and manufacturing of innovative, low-cost, mass-produced, environmentally friendly filters and masks protecting against COVID-19
Lead Research Organisation:
University of Surrey
Department Name: Mechanical Engineering Sciences
Abstract
Given the surge in demand for masks to protect against CONVID-19, there is huge investment for new mask manufacturing plants in UK. A shortage of specialised mask materials points to the need to also manufacture these materials in UK. Enlisted in this herculean effort, we have assembled a team of industrial partners, including mask manufacturers, an equipment manufacturer, and testing companies. Our project aims at bringing manufacturing of filters and masks to the UK, lowering the cost and developing a roll-to-roll process of additive manufacturing using low-cost, abundant and environmentally-friendly materials. The principal idea of this project is to select, after testing, a range of natural-fibre cloths, to be used as substrate for additive manufacturing. Such substrates will be coated with a novel porous layer with functional groups trapping the COVID-19 and other high-risk viruses. Electrospinning is proposed as our additive manufacturing technique, where the assembly of coating layer(s) and cloth substrate will protect against the virus by filtering it, depending on porosity, pore size, fibre orientation, coating layer thickness and functional groups of coating and cloth. The proposed project includes the following tasks: (a) molecular simulations to screen materials and functional groups in terms of their binding energy with the virus spike; (b) continuum infiltration mechanics simulations to investigate the virus migration through the porous material assembly, as well as the air flow for breathing in the case of masks or air flow filters; (c) development of the electrospinning to a continuous roll-to-roll process; (d) material and product testing.
Organisations
Description | Molecular simulations were carried and according to the results we selected two biopolymers as best candidate materials for filter layers, so that these biopolymers best "bind" with the spike protein of covid-19 virus. Continuum level simulations resulted in a best design of our filter layer from the selected biopolymers, to fabricate by electrospinning. |
Exploitation Route | At present the findings are only revealed in our group and consortium. As soon as we make the designed layers and test them successfully, we shall proceed with the next step regarding impact. |
Sectors | Healthcare,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology |
Title | Construction of apparatus for the measurement of air permeability through filters |
Description | In-house construction of apparatus for the measurement of air permeability through filters, fabrics, etc. by designing the housing and fabricating it in our mechanical workshop. Purchasing other accessories: pump, flowmeter, pressure gauge, etc, and assemble the rig. |
Type Of Material | Improvements to research infrastructure |
Year Produced | 2021 |
Provided To Others? | Yes |
Impact | The paper has not been prepared yet, but we are going to publish it. The method has been used to measure permeability of masks of our industrial partners and is available to other researchers if requested. |
Description | Collaboration with NPL North |
Organisation | National Physical Laboratory |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Presentation of our findings at project meeetings |
Collaborator Contribution | Advice and feedback at project meetings. Advice at separate meeting about measurement methods. |
Impact | No outcomes just yet |
Start Year | 2021 |
Description | Meetings with Industrial Partners |
Form Of Engagement Activity | A formal working group, expert panel or dialogue |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | Meetings with industrial manufacturers of masks and NPL North. |
Year(s) Of Engagement Activity | 2022 |