U.S. patent application number 09/741073 was filed with the patent office on 2002-09-12 for hydrophobic, anti-microbial insulation products and a hydrophobic, anti-microbial coating composition for preparing the same.
This patent application is currently assigned to Certainteed Corporation. Invention is credited to Mankell, Kurt O., Noone, Michael J., Tessari, Domenic J..
Application Number | 20020127399 09/741073 |
Document ID | / |
Family ID | 24979263 |
Filed Date | 2002-09-12 |
United States Patent
Application |
20020127399 |
Kind Code |
A1 |
Mankell, Kurt O. ; et
al. |
September 12, 2002 |
Hydrophobic, anti-microbial insulation products and a hydrophobic,
anti-microbial coating composition for preparing the same
Abstract
A coating composition is provided for obtaining a hydrophobic,
antimicrobial product, particularly fiberglass products, wherein
the coating composition contains a compound having at least one
hydrophobic group and at least one group capable of interacting
with a group on the surface of the product substrate, particularly
with Si or OH groups on the glass fibers of the fiberglass product,
and the coated products obtained thereby.
Inventors: |
Mankell, Kurt O.; (Blue
Bell, PA) ; Noone, Michael J.; (Wayne, PA) ;
Tessari, Domenic J.; (Berwyn, PA) |
Correspondence
Address: |
OBLON SPIVAK MCCLELLAND MAIER & NEUSTADT PC
FOURTH FLOOR
1755 JEFFERSON DAVIS HIGHWAY
ARLINGTON
VA
22202
US
|
Assignee: |
Certainteed Corporation
750 E. Swedesford Road P.O. Box 860
Valley Forge
PA
19482
|
Family ID: |
24979263 |
Appl. No.: |
09/741073 |
Filed: |
December 21, 2000 |
Current U.S.
Class: |
428/375 |
Current CPC
Class: |
C03C 25/25 20180101;
Y10T 428/2933 20150115; C03C 25/40 20130101 |
Class at
Publication: |
428/375 |
International
Class: |
D02G 003/00 |
Claims
1. A coated fiberglass product, comprising: glass fibers having
thereon a coating obtained by application of a coating composition
comprising a compound having at least one hydrophobic group and at
least one group capable of interacting with Si or OH groups present
on the glass fibers.
2. The coated fiberglass product of claim 1, wherein said at least
one hydrophobic group is a long chain organic group having from
14-22 carbon atoms.
3. The coated fiberglass product of claim 2, wherein said at least
one hydrophobic group is an alkyl group having from 16-20 carbon
atoms.
4. The coated fiberglass product of claim 3, wherein said at least
one hydrophobic group is a C-18 alkyl group.
5. The coated fiberglass product of claim 1, wherein said at least
one group capable of interacting with Si or OH groups of the glass
fibers is a member selected from the group consisting of halides,
amino groups, hydroxy, and C1-4 alkoxy groups.
6. The coated fiberglass product of claim 5, wherein said at least
one group capable of interacting with Si or OH groups of the glass
fibers is a halide group.
7. The coated fiberglass product of claim 1, wherein said compound
is a member selected from the group consisting of monoalkyl silyl
trihalides, dialkyl silyl dihalides and trialkyl silyl
monohalides.
8. The coated fiberglass product of claim 1, wherein said compound
is a member selected from the group consisting of octadecyl silyl
trichloride, dimethyl silyl dichloride and octadecanoic acid.
9. The coated fiberglass product of claim 1, wherein said glass
fibers are in a form selected from the group consisting of
fiberglass batts, fiberglass boards and fiberglass duct liners.
10. The coated fiberglass product of claim 1, wherein said coating
is present in an amount of from 1 to 20 mg/m.sup.2.
11. The coated fiberglass product of claim 10, wherein said coating
is present in an amount of from 2 to 10 mg/m.sup.2.
12. The coated fiberglass product of claim 11, wherein said coating
is present in an amount of about 5 mg/m.sup.2.
13. A method for preparation of an antimicrobial product,
comprising: applying to a surface of a substrate a coating
composition comprising a compound having at least one hydrophobic
group and at least one group capable of interacting with a group on
said surface of said substrate.
14. The method of claim 13, wherein said substrate comprises a
member selected from the group consisting of metal, glass and
plastic.
15. The method of claim 14, wherein said substrate comprises
glass.
16. The method of claim 15, wherein said glass is a member selected
from the group consisting of fiberglass batts, fiberglass duct
liners and fiberglass boards.
17. The method of claim 15, wherein said coating composition
comprises a compound having at least one hydrophobic group and at
least one group capable of interacting with Si or OH groups present
on the glass.
18. The method of claim 13, wherein said coating composition
further comprises a suitable carrier.
19. The method of claim 13, wherein said at least one hydrophobic
group is a long chain saturated or unsaturated organic group having
from 14-22 carbon atoms.
20. The method of claim 19, wherein said at least one hydrophobic
group is an alkyl group having from 16-20 carbon atoms.
21. The method of claim 20, wherein said at least one hydrophobic
group is a C-18 alkyl group.
22. The method of claim 17, wherein said at least one group capable
of interacting with Si or OH groups present on the glass is a
member selected from the group consisting of halides, amino groups,
hydroxy, and C1-4 alkoxy groups.
23. The method of claim 22, wherein said at least one group capable
of interacting with Si or OH groups present on the glass is a
halide group.
24. The method of claim 13, wherein said compound is a member
selected from the group consisting of monoalkyl silyl trihalides,
dialkyl silyl dihalides and trialkyl silyl monohalides.
25. The method of claim 13, wherein said compound is a member
selected from the group consisting of octadecyl silyl trichloride,
dimethyl silyl dichloride and octadecanoic acid.
26. The method of claim 13, wherein said coating is applied in an
amount of from 1 to 20 mg/m.sup.2.
27. The method of claim 23, wherein said coating is applied in an
amount of from 2 to 10 mg/M.sup.2.
28. The method of claim 24, wherein said coating is applied in an
amount of about 5 mg/m.sup.2.
29. A method for improving air quality, comprising: coating a
fiberglass duct liner with a coating composition comprising a
compound having at least one hydrophobic group and at least one
group capable of interacting with Si or OH groups present on the
glass fibers.
30. The method of claim 29, wherein said coating composition
further comprises a suitable carrier.
31. The method of claim 29, wherein said at least one hydrophobic
group is a long chain saturated or unsaturated organic group having
from 14-22 carbon atoms.
32. The method of claim 31, wherein said at least one hydrophobic
group is an alkyl group having from 16-20 carbon atoms.
33. The method of claim 32, wherein said at least one hydrophobic
group is a C-18 alkyl group.
34. The method of claim 29, wherein said at least one group capable
of interacting with Si or OH groups present on the glass fibers is
a member selected from the group consisting of halides, amino
groups, hydroxy, and C1-4 alkoxy groups.
35. The method of claim 34, wherein said at least one group capable
of interacting with Si or OH groups present on the glass fibers is
a halide group.
36. The method of claim 29, wherein said compound is a member
selected from the group consisting of monoalkyl silyl trihalides,
dialkyl silyl dihalides and trialkyl silyl monohalides.
37. The method of claim 29, wherein said compound is a member
selected from the group consisting of octadecyl silyl trichloride,
dimethyl silyl dichloride and octadecanoic acid.
38. The method of claim 29, wherein said coating composition is
applied in an amount of from 1 to 20 mg/m.sup.2.
39. The method of claim 38, wherein said coating composition is
applied in an amount of from 2 to 10 mg/m.sup.2.
40. The method of claim 39, wherein said coating composition is
applied in an amount of about 5 mg/m.sup.2.
41. The method of claim 29, wherein said coating step is performed
prior to installation of said fiberglass duct liner in a HVAC
system.
42. The method of claim 29, wherein said coating step is performed
on a fiberglass duct liner previously installed in a HVAC system.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to insulation products having
easy-release, hydrophobic and anti-microbial properties by virtue
of a coating placed on the insulation material, particularly
fiberglass products.
[0003] 2. Discussion of the Background
[0004] Recent studies have shown that it is possible to disinfect
air by photocatalytic techniques similar to those proven successful
in killing microorganisms in water. Goswandi et al, J. Solar Energy
Eng., 119, 92-96 (1997); Jacoby et al, Environ. Sci. Technol., 32,
2650-2653 (1998). These studies are described, particularly with
respect to the reaction chemistry of titanium dioxides, in a 1997
review article by Mills et al, J. Photochem. Photobiol. A:Chem.,
108, 1-35 (1997).
[0005] Many indoor air quality problems have been associated with
bioaerosols of more than 60 different types, including bacteria,
viruses and fungi causing a host of diseases and conditions, such
as tuberculosis, Legionnaires' disease, influenza, mumps, measles,
pneumonia and meningitis. These types of bioaerosols are also
implicated in increasing incidence of asthma, upper respiratory
distress syndromes and the common cold. One factor in this increase
is that conventional insulation materials, filter materials, or
duct liner materials are thought to provide a medium for growth of
these microorganisms, thus providing a means for the bioaerosols to
generate and spread throughout the HVAC system of a building.
Additionally, even when the duct surfaces are disinfected, the dead
or destroyed microbes are not easily removed due to adherence to
the duct liner surfaces.
[0006] Unfortunately, the use of the titanium dioxide based
coatings described above in insulation materials, duct liner
materials or filter materials cannot readily take advantage of the
photocatalytic properties of the titanium dioxide described in the
papers, since most insulation materials, duct liners and filter
materials are enclosed in areas away from any suitable UV light
source. Accordingly, there is a need for coatings that provide
antimicrobial properties to such materials in the absence or
presence of light, and which also provide the material with an easy
release, hydrophobic surface to prevent adherence of the
microorganisms to the surface of the material.
SUMMARY OF THE INVENTION
[0007] Accordingly, one object of the present invention is to
provide a coating for insulation materials, duct liners or filter
materials that reduces or prevents adherence of microorganisms to
the material surface and that provides anti-microbial properties to
the material surface.
[0008] A further object of the present invention is to provide a
fiberglass batt having an anti-microbial coating that gives the
fiberglass batt easy release and hydrophobic characteristics.
[0009] A further object of the present invention is to provide a
fiberglass duct board having easy-release, hydrophobic and
anti-microbial properties.
[0010] Another object of the present invention is to provide a
fiberglass duct liner that prevents or reduces adherence of
microorganisms onto the duct liner surface and provides
anti-microbial properties.
[0011] Another object of the present invention is to provide a
method for improving indoor air quality by use of the fiberglass
batts, fiberglass duct boards, or fiberglass duct liners of the
present invention.
[0012] These and other objects of the present invention have been
satisfied by the discovery of a coated fiberglass product
comprising:
[0013] a fiberglass substrate having coated at least partially
thereon a coating comprising an organic silane group or long chain
organic acid
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The present invention relates to a coating composition for
application to insulation materials, duct liner materials or filter
materials, which provides the materials with easy-release,
hydrophobic and anti-microbial properties, and the materials
obtained by application of the coating.
[0015] The coating composition of the present invention comprises a
compound having at least one hydrophobic group and at least one
group having functionality capable of interacting with a group
present on the surface of the substrate being coated. Suitable
substrates include glass, metal or plastics, with glass substrates
being preferred, and fiberglass being most preferred. Metal
substrates include, but are not limited to, surfaces of metal HVAC
systems, metal fiber media, etc. Glass substrates include, but are
not limited to, windows, glass containers, car windows, fiberglass
batts, duct board, duct liners and fiberglass filtering media.
Other filtering media include the above noted metal filtering
media, such as steel fiber media. When the substrate is fiberglass,
the at least one group having functionality capable of interacting
with a group present on the surface of the fiberglass is preferably
capable of interacting with the Si or OH groups on the fiberglass
substrate. Preferably, the hydrophobic group is a long chain
organic group having from 14-22 carbon atoms which can be saturated
or unsaturated, more preferably an alkyl group having from 16-20
carbon atoms, most preferably a C-18 alkyl group (octadecyl).
Preferably, the group having functionality capable of interacting
with the Si or OH groups on the fiberglass substrate is a member
selected from the group consisting of halides, amino groups,
hydroxy, and alkoxy. More preferably, the functional group is a
halide group, most preferably chloro. The compound of the coating
composition is more preferably an alkyl silyl halide, most
preferably a compound selected from alkyl trihalosilanes, dialkyl
dihalosilanes and trialkyl halosilanes.
[0016] In preferred embodiments, the coating composition comprises
octadecyl trichlorosilane (C.sub.18H.sub.37SiCl.sub.3),
dimethyldichlorosilane Si(CH.sub.3).sub.2Cl.sub.2 or octadecyl acid
C.sub.18H.sub.37COOH, either neat or in a suitable carrier.
[0017] The coating composition of the present invention is applied
to the surface of the substrate material. While the substrate
material can be any suitable material needing antimicrobial
protection, including but not limited to glass, metal and plastics,
the present invention will be further described referring to
fiberglass materials as the substrate. However, it is to be
understood that this is exemplary only and not intended to
limiting.
[0018] The coating composition is applied to the surface of the
fiberglass material by any conventional application method,
including, but not limited to, spraying, dipping, applicator (or
kiss) roller. As noted above, the compound of the coating
composition can be applied either neat or as a solution in a
suitable carrier. Suitable carriers include, but are not limited
to, water, organic solvents or binder compositions conventionally
used in the fiberglass industry. The application of the coating
composition to the fiberglass material can be performed at any
stage along the fiberglass production line, so long as there are no
later steps that would adversely affect the coating. The coating
composition of the present invention can be added prior to the
addition of binder to the fiberglass, at the same time as the
binder composition, post binder addition or after curing of the
binder. Preferably, the coating composition is added at the same
time as the binder during the formation of fiberglass batts,
between spinning of the fiberglass fibers and formation of the
batts. Additionally, depending on the end use, the coating
composition can be applied in the field, for example by spraying,
particularly when applied to fiberglass duct liners or duct boards.
The present coating composition can also be periodically reapplied
in the field if desired.
[0019] The coating composition of the present invention helps
prevent the attachment of microbes to the surface of the substrate,
such as fiberglass fibers, duct liners or duct boards, by lowering
the bio-adhesion ability of the microbe. Additionally, the
hydrophobicity of the coating helps prevent the entry of water into
the substrate material. This provides an additional reduction in
the ability of the microbes to grow, since the microbes generally
need a moist environment for growth.
[0020] The coating composition is applied to the fiberglass
materials in an amount sufficient to prevent microbial attachment
or growth and reduce moisture entry into the material. Preferably,
the coating is applied in amount sufficient to provide the coating
compound in an amount of from 1 to 20 mg/M.sup.2, more preferably
from 2 to 10 mg/m.sup.2, most preferably about 5 mg/M.sup.2. While
it is most preferred that the coating composition cover the entire
surface of the glass fibers, the present invention coating can also
be effective in preventing microbial growth by covering a
substantial portion of the exposed exterior surface of the fibers,
preferably at least 50% of the fiber surface area, more preferably
at least 75%, most preferably between 90 and 100%.
[0021] Application of the coating composition of the present
invention to fiberglass materials such as fiberglass batts,
fiberglass duct board or fiberglass duct liner inhibits the growth
of microbes compared to uncoated fiberglass products. Accordingly,
the use of the coated fiberglass products prepared with the coating
of the present invention provides a method for improving indoor air
quality by reducing the proliferation of microbes in HVAC systems,
thereby providing safer indoor environments. This is a particular
advantage in new construction, where the buildings are more well
insulated and airtight.
[0022] The present invention also relates to the coated fiberglass
products produced with the coating composition of the present
invention. These products are preferably fiberglass, in any desired
form, such as fiberglass batts, duct board, duct liners, as well as
other fiberglass structures, such as filtering media, as noted
above. Most preferably, the products are coated fiberglass
insulation batts, duct boards or duct liners.
[0023] Obviously, additional modifications and variations of the
present invention are possible in light of the above teachings. It
is therefore to be understood that within the scope of the appended
claims, the invention may be practiced otherwise than as
specifically described herein.
* * * * *