Copper ‘foam’ could be used as filters for COVID-19 masks

The lightweight new material is washable and recyclable

Face masks have become a vital tool in slowing the spread of the virus that causes COVID-19. They help filter or block spit or mucus droplets that carry infectious particles. Even homemade fabric masks can do a good job. But many are not very durable. Now, researchers have come up with a new sort of filter for use in masks. Made of copper, it’s sturdy and lightweight. The sponge-like material also is easy to clean and can be recycled. In tests, it performed as well in filtering as a standard N95 mask. It might even trap and kill bacteria, its developers say.

Masks to guard against viruses can be made of many different materials. Some fabric ones even use extra layers — often cotton, silk or some synthetic — to boost their filtering prowess. Others use paper similar to coffee filters. With so many people now being asked to wear masks during the pandemic, researchers began scrambling to identify new and better filters. Kai Liu was among them.

This materials scientist thought his team at Georgetown University in Washington, D.C., had a head start. They already had been testing materials to filter small particles out of polluted air.

Recalls Liu, “We saw that small droplets carrying viruses were the same size as some atmospheric pollutants.” Right away, he says, “we thought we should check our materials to see if they might make good filters for face masks.”

Liu’s team soon began cranking out new batches of a material they call copper foam.

They started with templates to make copper nanowires. The diameter of each wire was typically about 200 nanometers, says Liu — or less than one ten-millionth of an inch. After dumping those wires into ultrapure water, they flash-froze the mix in liquid nitrogen. Afterward, they put the copper-filled ice in a vacuum chamber. It drove off the ice to freeze dry the now loosely packed mass of tiny copper wires. Finally, they heated the mass of wires to 300° Celsius (572° Fahrenheit). This fostered chemical reactions that helped bind them into a mesh.

Unfortunately, that mesh was super flimsy, says Liu. Tests showed it would collapse if someone breathed on it. Obviously, that would not work well in masks. So, the researchers kept tweaking the process.

They bathed the weak mesh in a liquid that included copper ions. Then they sent an electric current through this chemical bath. That deposited more copper onto the nanowires, thickening them. Liu says it also helped weld the wires at points where they touched. In tests, some samples of this material could now support about 10,000 times their own weight without collapsing. That was true even when the material was 85 percent air.

More importantly, this 85-percent-air foam filtered out tiny particles. A sample 2.5 millimeters (0.1 inch) thick captured 97 percent of particles between 0.1 to 0.4 micrometers in diameter. Such super-small particles not only are the hardest to trap but also the size of the smallest aerosol droplets that can carry virus particles. These particles don’t just get trapped by the material’s tiny pores, Liu explains. The particles are particularly attracted to the enormous surface area that the nanowires provide. They get stuck there on it as they try to move through the wire maze between the outer and inner edges of the filter. Liu and his colleagues described their innovative new foam April 14 in Nano Letters.

 

Chemists win Nobel Prize for faster, cleaner way of making molecules

Making molecules is hard work. Atoms must be bonded together in specific arrangements through a series of chemical reactions. Those reactions often are slow and far from straightforward. They also can waste resources. The 2021 Nobel Prize in chemistry goes to two scientists who developed a tool some 20 years ago that revolutionized how chemists create new molecules. Their process is not only faster but also friendlier to the environment.

“This is a fitting recognition of very important work,” says H.N. Cheng. He’s president of the American Chemical Society, based in Washington, D.C. “We can think of chemists as magicians having magic wands in the lab,” Cheng says. “We wave the wand and a reaction goes on.” These Nobel laureates gave chemists “a new wand,” that’s drastically more efficient and less wasteful, he says.

That wand is a new way to speed the reactions that build specific molecules. It’s a process known as asymmetric organocatalysis (AY-sih-MEH-trik Or-gan-oh-kah-TAL-ih-sis). This year’s winners came up with the idea for it independently. One of the chemists, Benjamin List, works at the Max Planck Institute for Coal Research. It’s in Mülheim an der Ruhr, Germany. The other is David MacMillan. He works at Princeton University in New Jersey.

List’s and MacMillan’s work prompted others to seek out more organic catalysts and to study how they might be used. These catalysts tend to be small carbon-and-hydrogen molecules which might also include oxygen, nitrogen, sulfur and/or phosphorus.

Catalysis is a big deal. Roughly one-third of the world’s collective income depends on it, notes Peter Somfai. He’s a chemist at Lund University in Sweden and another member of the Nobel Committee for Chemistry. At an October 6 news conference announcing the new winners, he noted “We now have a new powerful tool available for making organic molecules.” He said it’s one that can be drastically more efficient and “greener” than previous methods.

And because this process eliminates use of toxic chemicals, it’s also a far more environmentally friendly process.

If building new molecules is like playing chess, asymmetric organocatalysis has “completely changed the game,” Somfai said. “It’s like adding a new chess piece that can move in different ways.”

For their achievements, List and MacMillan will each get a medal and share 10 million Swedish kroner (more than $1.1 million).

Molecule

 

Molecule (noun, “MOLL-eh-kewl”)

A molecule is usually two or more atoms held together with chemical bonds.

Molecules can be homonuclear. That means they contain atoms of only one element. The oxygen we breathe, for example, is a molecule of two oxygen atoms — O2. Other molecules are heteronuclear — made of more than one element. A molecule of water — H2O — is made of two hydrogen atoms bonded to one oxygen atom.

Molecules make up your own body, the air we breathe, everything living around us. A molecule is the smallest particle of a substance that still has all the chemical properties of that substance. For example, a single molecule of water — H2O — has all the properties of water. But split it apart into its atoms, and it will not be water anymore.

Smaller molecules can join together to make up large ones. A single strand of DNA, for instance, is one large molecule. That one molecule of DNA is made from many smaller molecules, including sugars and phosphates. Take apart a DNA molecule and it will not be able to do what DNA does — provide the instructions cells need to survive.

Put together, the atoms in most molecules have a neutral electrical charge — neither positive nor negative. But some atoms — such as helium — don’t have any electrical charge, even by themselves. Some people count these single atoms as molecules too. And some molecules do have an electrical charge. These charged molecules are called ions.