Ultrasonic Processing of Graphene Nanoplatelet–Silver Nanoparticle Composite Coatings for Enhanced Mechanical and Antiviral Properties in Medical Textiles

Respiratory protective textiles increasingly require multifunctional surface treatments that enhance durability and provide active antiviral performance without compromising filtration. In this context, this study develops graphene nanoplatelet–silver nanoparticle (GNP–Ag) and super activated carbon–silver nanoparticle (SAC–Ag) composite coatings for PPE-grade nonwoven fabrics using a room-temperature ultrasonic atomization process. The coatings enhanced mechanical integrity while maintaining baseline filtration efficiency. GNP–Ag increased spunbond grab strength by 54% and, when combined with polyurethane and UV cross-linking, improved meltblown strength by 47%. Surface wettability shifted from hydrophilic to hydrophobic, with meltblown contact angle increasing from 88° to 121°, and wash fastness improved following heat and UV curing. Cytotoxicity assays showed a dose-dependent response, with GNP–Ag exhibiting lower cytotoxicity compared with SAC–Ag. Antiviral testing against human coronavirus OC43 demonstrated a 1.93-log reduction (98.8%) after 10 min for unwashed GNP–Ag fabrics and a 1.43-log reduction (96.3%) after washing. Filtration performance remained unchanged for GNP–Ag and slightly increased for SAC–Ag. These results demonstrate a stable, mechanically reinforcing, and antiviral coating that enhances the protective function of PPE-grade nonwoven fabrics.