Diamond-Like Carbon Coated Copper Virus Filter

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Solution Overview

Problem

Current face masks have short lifetimes, are prone to clogging, and lack breathability, necessitating a solution for improved filtration efficiency and reusability while minimizing environmental impact.

Innovation Solution

A mask assembly with a filter comprising a hydrophobic and lipophobic layer, a diamond-like carbon-coated copper layer, and non-woven fabric layers, which enhances virus filtration and inactivation, and offers better breathability and longer usage without compromising filtration efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional masks (KN95, disposable) are used for virus filtration, then filtration efficiency is improved (up to 95% for KN95), but breathability deteriorates due to high air resistance and multiple thick layers

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidbreathability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent employs a composite material structure consisting of a hydrophobic outer layer, a copper layer with diamond-like carbon coating, and a non-woven fabric layer. This composite structure achieves both high filtration efficiency (90% for particles ≥0.3μm) and improved breathability by combining materials with complementary properties: the hydrophobic layer repels viruses, the copper layer provides antimicrobial action, and the non-woven fabric ensures air permeability.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional masks are used, then initial filtration efficiency is achieved, but service life deteriorates due to short lifetime and easy clogging from dust

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent changes the physical and chemical parameters of the filter material by applying diamond-like carbon coating to the copper layer. This coating modifies surface properties to reduce clogging from dust particles while maintaining antimicrobial effectiveness. The hydrophobic outer layer also prevents liquid penetration that would otherwise saturate and disable the filter, thereby extending service life.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The copper layer with diamond-like carbon coating provides self-cleaning and self-disinfection properties. The copper ions continuously exert antimicrobial action on captured viruses and bacteria, while the hydrophobic surface repels liquids and prevents dust accumulation that would clog the filter. This self-maintaining capability allows the mask to retain filtration efficiency throughout its extended service life.

Inventive Principle:

Principle #25Self-service

3Reliability

If conventional masks are used, then virus filtration is achieved, but environmental impact worsens due to need for regular replacement and stable virus persistence on masks

Engineering Contradiction:

Improvevirus filtrationVSAvoidenvironmental impact

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the potentially harmful trapped viruses into harmless substances through the antimicrobial action of the copper layer. The copper ions continuously inactivate and decompose captured viruses and bacteria on the mask surface, preventing virus persistence and transformation into environmental contaminants. This active decomposition capability transforms the mask from a potential source of viral persistence into a safe, self-decontaminating barrier that protects both the wearer and the environment.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The proposed filter achieves 90% virus filtration efficiency and 99% virus inactivation within 2 hours, with lower air resistance compared to conventional masks, making it a more sustainable and effective option for prolonged use.

Implementation Method 1

a porous hydrophobic and lipophobic layer

Methodology Applied

Scientific EffectHydrophobic: Hydrophobe

Implementation Method 2

a porous hydrophobic and lipophobic layer

Methodology Applied

Scientific EffectLipophobic: Hydrophobe

Implementation Method 3

a diamond - like carbon coated copper layer

Methodology Applied

Scientific EffectDiamond-like carbon coating: Diamond-like Carbon

Data Source

PatentUS20230158343A1Filters for virus filtration and inactivation and mask assemblies containing the same

Publication Date: 2023.05.25 PURDUE RES FOUND

AI summary

A mask assembly comprising a face covering portion, a pocket connected to the face portion and positioned to cover a wearer’s nose and mouth, where in a filter is removably inserted into the pocket, the filter comprising a porous hydrophobic and lipophobic layer, a diamond - like carbon coated copper layer, and a non- woven fabric layer. A filter containing at least one porous hydrophobic and lipophobic layer, at least one diamond like carbon coated copper layer interposed between two non-woven fabric layers, and at least one additional non- woven fabric layer. A filter comprising at least one porous hydrophobic and lipophobic layer, at least one diamond - like carbon coated copper layer, and at least one non - woven fabric layer, the at least diamond-like carbon coated layer is between the at least one porous hydrophobic and lipophobic layer and at least one non - woven fabric layer.