U.S. patent application number 17/560056 was filed with the patent office on 2022-04-14 for household goods with antimicrobial coatings and methods of making thereof.
The applicant listed for this patent is Simplehuman, LLC. Invention is credited to Di-Fong Chang, Hon-Lun Chen, Frank Yang.
Application Number | 20220112029 17/560056 |
Document ID | / |
Family ID | |
Filed Date | 2022-04-14 |
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United States Patent
Application |
20220112029 |
Kind Code |
A1 |
Yang; Frank ; et
al. |
April 14, 2022 |
HOUSEHOLD GOODS WITH ANTIMICROBIAL COATINGS AND METHODS OF MAKING
THEREOF
Abstract
Various trashcans, their coatings, and coatings for other
household goods are disclosed. In certain implementations, the
disclosed coatings are antimicrobial. Various methods for forming
antimicrobial coatings for household goods are also disclosed. In
some embodiments, the antimicrobial coating comprises a substrate
and an antimicrobial agent. In certain implementations the coating
can be applied to a household good where the coating leaves a
substantially streak-free finish. Some embodiments pertain to
protective films that can be removed from a coated household good
without leaving residue.
Inventors: |
Yang; Frank; (Rancho Palos
Verdes, CA) ; Chang; Di-Fong; (Torrance, CA) ;
Chen; Hon-Lun; (Irvine, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Simplehuman, LLC |
Torrance |
CA |
US |
|
|
Appl. No.: |
17/560056 |
Filed: |
December 22, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15343899 |
Nov 4, 2016 |
11242198 |
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17560056 |
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62253612 |
Nov 10, 2015 |
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International
Class: |
B65F 1/02 20060101
B65F001/02; A01N 59/16 20060101 A01N059/16; B05D 1/28 20060101
B05D001/28; B32B 1/02 20060101 B32B001/02; B65D 25/14 20060101
B65D025/14; B32B 15/08 20060101 B32B015/08 |
Claims
1. A trashcan comprising: a metal body shaped to provide at least a
portion of a container that is configured to receive refuse;
wherein a surface of the metal body comprises a coating, the
coating comprising a substrate with an antimicrobial agent
dispersed within the substrate; wherein the coating is applied
directly to a metal sheet used to form the metal body by applying a
slurry comprising a solvent, a substrate material, and the
antimicrobial agent to the metal sheet using a reverse-rolling
device; wherein at least a portion of the antimicrobial agent is
exposed on an outside surface of the coating and is available to
directly contact microbes on the surface of the coating after
application of the coating to the metal sheet; and wherein the
coating is substantially streak-free.
2. The trashcan of claim 1, wherein the coating comprises a
fingerprint resistant material.
3. The trashcan of claim 2, wherein the fingerprint resistant
material allows fingerprints to be removed by wiping without using
a liquid solution.
4. The trashcan of claim 1, wherein the coating is substantially
resistant to water-based material transfer.
5. The trashcan of claim 1, wherein the substantially streak-free
coating appears substantially flat.
6. The trashcan of claim 1, wherein the substrate comprises
polyethylene.
7. The trashcan of claim 1, wherein the antimicrobial agent
comprises a zeolite.
8. The trashcan of claim 1, wherein the antimicrobial agent
comprises ionic silver, ionic copper, and ammonium.
9. The trashcan of claim 1, wherein the antimicrobial agent is
supported on a nanoparticle.
10. The trash can of claim 1, wherein the metal sheet is a
stainless steel metal sheet.
11. The trashcan of claim 1, wherein 24 hours after an initial
bacterial exposure to the coating, an amount of bacteria remaining
on the coating is at least about 95% less than at the initial
bacterial exposure.
12. The trashcan of claim 1, wherein the coating reduces an amount
of E. coli from about 2.3.times.10.sup.5 colony forming units (CFU)
per 50 mm.times.50 mm carrier to less than about 5 CFU/carrier over
a period of about 24 hours.
13. The trashcan of claim 1, wherein the coating reduces an amount
of S. aureus from about 3.85.times.10.sup.5 CFU per 50 mm.times.50
mm carrier to less than about 5 CFU/carrier over a period of about
24 hours.
14. A trashcan comprising: a stainless steel metal body shaped to
provide at least a portion of a container that is configured to
receive refuse; wherein a surface of the stainless steel metal body
comprises a coating, the coating comprising a substrate with an
antimicrobial agent dispersed within the substrate; wherein the
coating is applied directly to a stainless steel metal sheet used
to form the stainless steel metal body by applying a slurry
comprising a solvent, a substrate material, and the antimicrobial
agent directly to the stainless steel metal sheet using a
reverse-rolling device; wherein at least a portion of the
antimicrobial agent is exposed on an outside surface of the coating
and is available to directly contact microbes on the surface of the
coating after application of the coating to the stainless steel
metal sheet; wherein the coating is substantially streak-free; and
wherein the coating comprises a fingerprint resistant material.
15. The trashcan of claim 14, wherein the fingerprint resistant
material allows fingerprints to be removed by wiping without using
a liquid solution.
16. The trashcan of claim 14, wherein the coating is substantially
resistant to water-based material transfer.
17. The trashcan of claim 14, wherein the substantially streak-free
coating appears substantially flat.
18. The trashcan of claim 14, wherein the substrate comprises
polyethylene.
19. The trashcan of claim 14, wherein the antimicrobial agent
comprises a zeolite.
20. The trashcan of claim 14, wherein the antimicrobial agent
comprises ionic silver, ionic copper, and ammonium.
21. The trashcan of claim 14, wherein the antimicrobial agent is
supported on a nanoparticle.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of U.S.
application Ser. No. 15/343,899, filed Nov. 4, 2016, which claims
the benefit of priority to U.S. Provisional Application No.
62/253,612, filed Nov. 10, 2015. Each of the foregoing applications
is fully incorporated herein by reference in its entirety for all
purposes.
BACKGROUND
Field
[0002] The disclosure relates generally to the field of household
goods with antimicrobial coatings and methods of making the
same.
Description of the Related Art
[0003] Household goods and/or their components comprise surfaces
that can be exposed to contaminants during use. For example,
trashcans are often exposed to raw meat, food stuffs, and other
forms of garbage. Soap dispensers are exposed to users' soiled
hands. This exposure to contaminants can lead to bacterial and
other microbial build-up and growth.
SUMMARY
[0004] Certain embodiments disclosed herein pertain to a coating
for a household good. In some embodiments, the coating comprises a
polymeric substrate configured to adhere to a surface of the
household good. In some embodiments, the coating comprises an
antimicrobial agent dispersed on or within the substrate.
[0005] Any of the embodiments described above, or described
elsewhere herein, can include one or more of the following
features.
[0006] In some embodiments, the antimicrobial agent comprises a
zeolite. In some embodiments, the antimicrobial agent comprises
ionic silver. In some embodiments, the antimicrobial agent
comprises ionic copper. In some embodiments, the antimicrobial
agent comprises ammonium.
[0007] In some embodiments, the antimicrobial agent comprises at
least about 2% and/or less than or equal to about 5% weight percent
of the substrate. In some embodiments, the antimicrobial agent
comprises equal to or at least about 2% and/or less than or equal
to about 5% ionic silver by weight. In some embodiments,
antimicrobial agent comprises equal to or at least about 4.0%
and/or less than or equal to about 7.0% ionic copper by weight. In
some embodiments, the antimicrobial agent comprises equal to or at
least about 0.1% and/or less than or equal to about 2.0% ammonium
by weight. In some embodiments, the antimicrobial agent comprises a
zeolite having antimicrobial ions adhered to, deposited on, or
diffused therein. In some embodiments, the antimicrobial agent
comprises AGION.RTM.. In some embodiments, the antimicrobial agent
is present in an amount of about 1.25 wt % relative to the
substrate.
[0008] In some embodiments, the polymeric substrate comprises
polyethylene. In some embodiments, the polymeric substrate
comprises a material that resists or makes it easier to wipe away
fingerprints and smudges.
[0009] In some embodiments, the coating is sufficiently durable so
that it can withstand repeated cleanings or washings without losing
its antimicrobial properties.
[0010] Some embodiments pertain to a coating for a household good
comprising a polymeric substrate configured to adhere to a surface
of the household good and an antimicrobial agent or a combination
of antimicrobial agents dispersed on or within the substrate, such
as wherein the one or more antimicrobial agents comprise one or
more of a zeolite, ionic silver, ionic copper, or ammonium. In some
embodiments, the coating is the antimicrobial agent.
[0011] In some embodiments, the polymeric substrate comprises
polyethylene.
[0012] In some embodiments, the coating comprises equal to or
greater than about 0.1% and/or less than or equal to about 1.5%
antimicrobial agent by weight.
[0013] In some embodiments, the antimicrobial agent comprises equal
to or greater than about 68% and/or less than or equal to about 94%
zeolite by weight. In some embodiments, the antimicrobial agent
comprises equal to or greater than about 2% and/or less than or
equal to about 5% ionic silver by weight. In some embodiments, the
antimicrobial agent comprises equal to or greater than about 4.0%
and/or less than or equal to about 7.0% ionic copper by weight. In
some embodiments, the antimicrobial agent comprises equal to or
greater than about 0.1% and/or less than or equal to about 2.0% an
ammonium ion (or ammonium salt) by weight. In some embodiments, the
antimicrobial agent comprises AGION.RTM.. In some embodiments, the
antimicrobial agent is present in an amount of about 1.25 wt %
relative to the substrate.
[0014] In some embodiments, the polymeric substrate comprises a
material that resists or makes it easier to wipe away fingerprints
and smudges. In some embodiments, the coating is sufficiently
durable so that it can withstand repeated cleanings or washings
without losing its antimicrobial properties.
[0015] Some embodiments pertain to a metal sheet comprising a
coating that includes any one or more of the features described
above.
[0016] Some embodiments pertain to a household product, such as a
trashcan comprising a coating that includes any one or more of the
features described in this specification. In some embodiments, the
coating is located to the outside surface of the trashcan. In some
embodiments, the trashcan comprises a metal body, the coating being
located on the metal body.
[0017] Some embodiments pertain to a trashcan comprising a metal
body, a lid coupled to the body and configured to move between open
and closed positions, and a base on which the metal body is
configured to rest. In some embodiments, an outside surface of the
metal body comprises a coating, the coating comprising a substrate
with an antimicrobial agent dispersed on or within the substrate,
the antimicrobial agent comprising silver ions. In some
embodiments, the coating is substantially even or homogeneous in
thickness and/or composition and/or reflectivity across the surface
of the substrate. For example, the coating can be substantially
streak-free.
[0018] In some embodiments, the antimicrobial agent comprises a
zeolite. In some embodiments, the substrate comprises polyethylene.
In some embodiments, the antimicrobial agent comprises ionic
copper. In some embodiments, the antimicrobial agent comprises
ammonium. In some embodiments, the coating reduces an amount of
bacteria of about 9.5.times.10.sup.6 colony forming units
(CFU)/carrier on the coating to less than about 5 CFU/carrier on
the coating over a period of about 24 hours. In some embodiments,
the coating reduces an amount of E. coli from about
2.3.times.10.sup.5 CFU/carrier to less than about 5 CFU/carrier on
the coating over a period of about 24 hours.
[0019] Some embodiments pertain to a trashcan comprising a metal
body forming at least a portion of a container configured to
receive refuse. In some embodiments, an outside surface of the
metal body comprises a coating. In some embodiments, the coating
comprises a substrate with an antimicrobial agent dispersed on or
within the substrate. In some embodiments, the coating is
substantially even or homogeneous in thickness and/or composition
and/or reflectivity across the surface of the substrate. For
example, the coating can be substantially streak-free.
[0020] In some embodiments, the antimicrobial agent comprises one
or more of a zeolite, ionic silver, ionic copper, or ammonium. In
some embodiments, the antimicrobial agent comprises a zeolite
having antimicrobial ions adhered to, deposited on, or diffused
therein. In some embodiments, the antimicrobial agent comprises
AGION.RTM..
[0021] In some embodiments, the substrate comprises
polyethylene.
[0022] In some embodiments, the coating is applied to a metal sheet
used to prepare the metal body by applying a slurry comprising a
solvent, a substrate material, and the antimicrobial agent to the
metal sheet using a reverse-rolling device.
[0023] In some embodiments, the coating comprises a fingerprint
resistant material or a material that allows fingerprints to be
easily removed, such as by wiping without requiring a solution or
excessive or forceful rubbing of the surface where the fingerprint
is made.
[0024] In some embodiments, about 24 hours after bacterial exposure
on the coating, an amount of bacteria remaining on the coating is
at least about 95% less than upon initial exposure. In some
embodiments, about 24 hours after bacterial exposure on the
coating, an amount of bacteria remaining on the coating is at least
about 99.99% less than upon initial exposure. In some embodiments,
about 24 hours after bacterial exposure on the coating, an amount
of bacteria remaining on the coating is reduced by about 95% to
about 100%. In some embodiments, the coating reduces an amount of
E. coli from about 2.3.times.10.sup.5 CFU/50 mm.times.50 mm carrier
to less than or equal to about 5 CFU/carrier over a period of about
24 hours. In some embodiments, the coating reduces an amount of S.
aureus from about 3.85.times.10.sup.5 CFU/50 mm.times.50 mm carrier
to less than or equal to about 5 CFU/carrier over a period of about
24 hours.
[0025] Some embodiments pertain to methods of coating a metal
surface. In some embodiments, the method of coating a metal surface
comprises obtaining a solution of a polymer substrate in solvent.
In some embodiments, the method comprises dispersing an
antimicrobial agent on or within the solution forming a mixture. In
some embodiments, the method comprises agitating the mixture to
form a substantially uniform slurry. In some embodiments, the
method comprises obtaining a sheet of material. In some
embodiments, the method comprises applying the slurry onto the
sheet of material as a layer. In some embodiments, the method
comprises curing the slurry on the sheet to provide a coated sheet.
In some embodiments, the resultant coated metal sheet is
substantially streak-free. Some embodiments pertain to a method of
manufacturing a metallic sheet having an antimicrobial coating. In
some embodiments, the method comprises providing a metallic sheet.
In some embodiments, the method comprises applying a slurry
comprising an antimicrobial agent and a solvent onto the metallic
sheet. In some embodiments, the method comprises drying the slurry
on the metallic sheet to provide the antimicrobial coating. In some
embodiments, the metallic sheet is shaped to provide a portion of a
surface of a household good. In some embodiments, the slurry is
applied to the metallic sheet using a reverse-rolling device.
[0026] In some embodiments, the method comprises applying an
acrylic and/or silicone and/or silicone rubber adhesive over the
coated portion of the coated metal sheet and thereafter applying a
protective film over such adhesive on the coated metal sheet.
[0027] In some embodiments, the antibacterial agent used in the
method comprises a zeolite (and/or any one of ionic silver, ionic
copper, or ammonium).
[0028] Some embodiments pertain to a metal sheet comprising a
coating, layer, and/or sheet. In some embodiments, the coating
comprises a polymeric substrate configured to adhere to a surface
of the household good. In some embodiments, the coating comprises
an antimicrobial agent dispersed on or within the substrate. In
some embodiments, the coating is an antimicrobial agent. In some
embodiments, the coating comprises a protective film that protects
the coating from abrasions during shipment of the metal sheet. In
some embodiments, the coating comprises an acrylic and/or silicone
and/or silicone rubber adhesive that adheres the protective film to
the coating. In some embodiments, the adhesive leaves substantially
no residue on the coating after removal of the protective film.
[0029] Some embodiments pertain to a coating for a household good
comprising a coating comprising an antimicrobial agent. In some
embodiments, the coating further comprises a fingerprint resistant
agent, such as an agent that resists the formation of visible
fingerprints and/or that an agent that allows fingerprints to be
easily removed. In some embodiments, the coating is applied to a
surface of a household good. Any feature, structure, component, or
step that is described and/or illustrated in any embodiment in this
specification can be used with or instead of any feature,
structure, component, or step that is described and/or illustrated
in any other embodiment in this specification. Everything disclosed
and/or illustrated in this specification is intended to be
interchangeable and combinable.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 illustrates a trashcan having an antimicrobial
coating.
[0031] FIG. 2 is front view of the trashcan of the FIG. 1 and a
close-up, cross-sectional view of a portion of the trashcan.
[0032] FIGS. 3A-B are photographs of sheets of material comprising
one or more coatings containing an antimicrobial agent.
[0033] FIGS. 4A-B are close-up views of portions of the photographs
of FIGS. 3A-B.
[0034] FIG. 5 is a graph showing Escherichia coli growth on
uncoated versus coated metal sheets.
[0035] FIG. 6 is a graph showing Staphylococcus aureus growth on
uncoated versus coated metal sheets.
[0036] FIG. 7 is a flow chart showing a process of preparing an
antimicrobial coating on a metal sheet.
[0037] FIG. 8 illustrates diagram of a sheet being coated using a
reverse-rolling process.
[0038] FIG. 9 is a flow chart showing a process of protecting an
antimicrobial coating on a metal sheet.
[0039] FIGS. 10A-B are photographs of partially removed protective
films applied to sheets of material comprising coatings containing
an antimicrobial agent.
DETAILED DESCRIPTION OF SOME EMBODIMENTS
[0040] A variety of antimicrobial coatings and methods of forming
and using the same are described below to illustrate various
examples that may be employed to achieve one or more desired
improvements. These examples are only illustrative and not intended
in any way to restrict the general inventions presented and the
various aspects and features of these inventions. Furthermore, the
phraseology and terminology used herein is for the purpose of
description and should not be regarded as limiting. No features,
structure, or step disclosed herein is essential or
indispensable.
Overview
[0041] Some embodiments disclosed herein pertain to a coating for a
household good. In certain implementations, the coating is
antimicrobial. As used herein, the term "antimicrobial," and its
derivatives, describes the property of killing microbes and/or
preventing or slowing microbial growth. As used herein, the term
"microbe," and its derivatives, means an organism that is too small
to be seen by the unaided eye, such as various bacteria, archaea,
fungi, and protists.
[0042] As will be described in more detail below, in some
embodiments, the coating comprises a substrate and an antimicrobial
agent distributed in that substrate. In certain embodiments, the
coating is applied to a metal (e.g., stainless steel or aluminum),
which is formed into a portion of a household product (e.g., a
trashcan). In some variants, the coating comprises the
antimicrobial agent, substrate, and a compound that facilitates
avoiding or wiping-off fingerprints. Such a combined coating can be
applied to a surface (e.g., a metal sheet), which can be formed
into a portion of a household product.
[0043] As shown in FIGS. 1 and 2, certain embodiments are disclosed
herein in the context of a coating 120 for a trashcan 100
comprising sheet metal 110, as the coating may have particular
utility in this context. However, the various aspects of the
present disclosure can be used on sheet goods generally and for
other household goods having metal or non-metal components. For
example, some illustrative household goods are: soap dispensers,
mirrors (e.g. metal trim on mirrors, stands, etc.), soap dishes,
grocery bag dispensers, shower/sink caddies, utensil holders,
organizers (e.g., for drawers or countertops), paper towel holders,
dishracks, wall mount liquid pumps (e.g., for soap, shampoo, etc.),
toilet plunger handles, appliance handles (e.g., for microwaves,
refrigerators, dishwashers, ovens, coffee makers, etc.), appliances
(e.g., refrigerators, microwaves, dishwashers, ovens, blenders,
coffee makers, trash compactors, BBQ grills, etc.), sink
accessories (e.g., handles, faucets, etc.), liquid dispensers
(e.g., for drinkables), washers, driers, components for the same,
and the like. In some variants, the coating is applied to the
handles, trim, or removable inner buckets of trashcans (e.g.,
removable inserts that fit within a larger trashcan body). In some
embodiments, the coatings described herein can be applied to
handheld devices or touchscreens.
[0044] In some embodiments, the household good is broadly a metal
good. In some variants, the household good comprises stainless
steel. In some embodiments, the metal of the household good
comprises one or more of stainless steel, brass, copper, steel,
aluminum, iron, platinum, gold, silver, zinc, other metals, metal
alloys of the same, and the like. In certain embodiments, the
household good is made of a nonmetal material (e.g., plastic,
glass, etc.) and/or a composite material.
[0045] In certain variants, the coating is configured to adhere to
one or more surfaces of the household good. In some
implementations, the coating is applied to a material sheet surface
used to make a household good. For example, as discussed in more
detail below, the coating can be applied to a sheet of metal that
is subsequently formed into a portion of the household good, such
as the body and/or lid of a trashcan. In some variants, for
example, the coating can be applied to the inside and outside
surfaces of the household good (e.g., both sides of a stainless
steel sheet used to prepare a trashcan). In certain variants, the
coating is applied to only select surfaces of the household good.
For example, in some implementations, the coating is applied only
to the outside of the household good, (e.g., trashcan, etc.). In
other variants, the coating is applied only to the inside of the
household good (e.g., trashcan, etc.). In some embodiments, the
coating is applied to one or more of the inside, outside, lid,
handle, or pedal of the household good (e.g., trashcan, etc.).
[0046] In some variants, the coatings and methods of coating
materials described herein increase and/or maximize antimicrobial
effects of an antimicrobial agent in the coating without
substantially affecting the appearance of the household good. For
example, in some embodiments, the antimicrobial coating is smooth
and uniform without visible streaking and/or is clear (or
substantially clear). In some embodiments, the antimicrobial
coating is substantially smooth and/or substantially uniform and/or
substantially even or consistent in reflectivity across a
particular surface of the coating or a particular portion of a
surface of the coating, without substantial visible streaking
and/or is clear (or substantially clear). FIGS. 3A-B and 4A-B shows
side-by-side examples of an antimicrobial coating that are streaked
or smooth and uniform without visible streaking. For instance, the
coatings of FIGS. 3B and 4B are substantially streak-free, while
those of FIGS. 3A and 4A are not. In certain implementations, the
antimicrobial coating shows unobstructed views of the surfaces
underneath the coating, such as the top of the surface to which the
coating is applied. In certain implementations, the coating is
colorless or substantially colorless. In some implementations, the
coating has a blue tint.
[0047] In certain implementations, the coating is generally planar
and/or substantially flat. In some embodiments, the coating is
substantially uniform and/or smooth. In some variants, the coating
is generally contiguous. In some embodiments, the aforementioned
properties of the coating make it appear substantially streak-free
where streaks are not generally visible upon casual visual
observation.
Certain Substrates
[0048] In certain implementations, as disclosed above, the coating
comprises a substrate and one or more antimicrobial agents. In
certain implementations, the antimicrobial is dispersed under,
within (e.g., homogenously throughout the substrate or as a
gradient), or on the substrate (e.g., adhered and/or functionalized
to the substrate surface). In some embodiments, the substrate is
any material that provides a support for the antimicrobial agent
while allowing access to the antimicrobial agent by bacteria or
other microbes that come into contact with the coating. In some
implementations, the substrate is substantially clear (e.g.,
selected to be substantially optically transparent to the naked
eye).
[0049] In certain implementations, the substrate comprises a
polymeric material. For example, the substrate can comprises
polyethylene. In some variants, the substrate comprises a mixture
of more than one polymeric material.
[0050] While polymeric substrates are described here, any other
matrices could be used, keeping in mind that the goal of the
substrate (i.e., the matrix, the support, etc.) is, in some
embodiments, to provide a material that is capable of supporting an
antimicrobial agent while adhering to a household good in a manner
that does not substantially distort the appearance of that good.
For example, in some embodiments, the substrate comprises a
crosslinkable polymer matrix or copolymer matrix.
[0051] In some embodiments, the substrate itself is formulated
using one or more polymers that themselves have antimicrobial
effects. For example, in certain implementations, the substrate
comprises a polymeric material comprising one or more polymeric
antimicrobial materials, such as polyethyleneimine, NIPAM, or other
cationic or polycationic polymers.
Certain Antimicrobial Agents
[0052] Some embodiments pertain to an antimicrobial agent bound to
a surface (e.g., a metal portion) of a household good. In some
embodiments, the antimicrobial is adhered to the surface of a
household good via a substrate as described elsewhere herein. In
some embodiments, the substrate and antimicrobial agent form a
coating. In certain embodiments, the antimicrobial agent itself
provides a coating and/or is the coating on the household good. In
certain implementations, as described above and as shown in FIG. 2,
the coating comprises an antimicrobial agent 220 dispersed within a
substrate 210. In certain implementations, as shown in the expanded
cross-sectional view of FIG. 2, at least a portion of the
antimicrobial agent 220 is exposed on the outside surface of the
coating 120. In some variants, the antimicrobial agent 220 is able
to directly contact microbes that are on the surface of the coating
120 because the antimicrobial agent 220 escapes and/or protrudes
from (e.g., is sticking out of) the substrate 210. In some
embodiments, the antimicrobial agent can diffuse over time to the
surface of the coating to interact directly with microbes on the
surface of the household good.
[0053] In some embodiments, the antimicrobial agent comprises an
antimicrobial zeolite. In some embodiments, the antimicrobial
zeolite comprises one or more antimicrobial metal ions,
antimicrobial metals, or antimicrobial organic ions. In some
embodiments, the antimicrobial agent and/or antimicrobial zeolite
comprises water. For instance, in some embodiments, where the
antimicrobial agent comprises a zeolite, some portion of water can
be trapped in or adhered to the zeolite. In some embodiments, the
antimicrobial zeolite or antimicrobial agent comprises one or more
of ionic silver, ionic copper or copper metal, or ammonium. In some
embodiments, the antimicrobial zeolite and/or the antimicrobial
agent comprises each of silver ions, copper (ionic or metallic),
and ammonium. In some embodiments, the antimicrobial agent
comprises AGION.RTM., available from Sciessent LLC of Wakefield,
Mass. In some embodiments, the weight percent of zeolite (e.g., an
aluminosilicate portion of the zeolite without water, antimicrobial
anions, or antimicrobial organic cations) in the antimicrobial
zeolite and/or the antimicrobial agent is equal to or greater than
about 68% and/or less than or equal to about 94%. In some
embodiments, the weight percent of zeolite in the antimicrobial
agent and/or antimicrobial zeolite is equal to or at least: about
60%, about 65%, about 70%, about 80%, about 90%, about 95%, about
99%, values between the aforementioned values, ranges spanning
those values, or otherwise. In some embodiments, the weight percent
of zeolite in the antimicrobial agent and/or antimicrobial zeolite
is less than or equal to: about 99%, about 95%, about 90%, about
85%, about 80%, about 75%, about 70%, about 65%, about 60%, values
between the aforementioned values, ranges spanning those values, or
otherwise. In some embodiments, the antimicrobial agent comprises
one or more antimicrobial zeolites and/or other antimicrobial
entities (e.g., silver ions, ionic copper, ammonium, etc.).
[0054] In some embodiments, ionic silver can be present in an
amount equal to or greater than about 2% and/or less than or equal
to about 5% by weight of the antimicrobial zeolite and/or by weight
of the antimicrobial agent. In some embodiments, the weight percent
of ionic silver in the antimicrobial zeolite (and/or in the
antimicrobial agent) is equal to or greater than at least: about
0.5%, about 1.0%, about 2.0%, about 3.0%, about 4.0%, about 5.0%,
about 6.0%, about 7.0%, about 8.0%, about 9.0%, about 10.0%, values
between the aforementioned values, ranges spanning those values, or
otherwise. In some embodiments, the weight percent of ionic silver
in the antimicrobial zeolite (and/or in the antimicrobial agent) is
less than or equal to: about 0.5%, about 1.0%, about 2.0%, about
3.0%, about 4.0%, about 5.0%, about 6.0%, about 7.0%, about 8.0%,
about 9.0%, about 10.0%, values between the aforementioned values,
ranges spanning those values, or otherwise.
[0055] In some variants, ionic copper or copper metal can be
present in an amount equal to or greater than about 4% and/or less
than or equal to about 7% by weight of the antimicrobial zeolite
(and/or by weight of the antimicrobial agent). In some embodiments,
the weight percent of ionic copper or copper metal in the
antimicrobial zeolite (and/or in the antimicrobial agent) is equal
to or at least: about 0.5%, about 1.0%, about 2.0%, about 3.0%,
about 4.0%, about 5.0%, about 6.0%, about 7.0%, about 8.0%, about
9.0%, about 10.0%, values between the aforementioned values, ranges
spanning those values, or otherwise. In some embodiments, the
weight percent of ionic copper or copper metal in the antimicrobial
zeolite (and/or in the antimicrobial agent) is less than or equal
to: about 0.5%, about 1.0%, about 2.0%, about 3.0%, about 4.0%,
about 5.0%, about 6.0%, about 7.0%, about 8.0%, about 9.0%, about
10.0%, values between the aforementioned values, ranges spanning
those values, or otherwise.
[0056] In various embodiments, ammonium can be present in an amount
equal to or greater than about 0% and/or less than or equal to
about 2% by weight of the antimicrobial zeolite (and/or in the
antimicrobial agent). In some embodiments, the weight percent of
ammonium in the antimicrobial zeolite (and/or in the antimicrobial
agent) is equal to or at least: about 0.5%, about 1.0%, about 2.0%,
about 3.0%, about 4.0%, about 5.0%, about 6.0%, about 7.0%, about
8.0%, about 9.0%, about 10.0%, values between the aforementioned
values, ranges spanning those values, or otherwise. In some
embodiments, weight percent of ammonium in the antimicrobial
zeolite (and/or in the antimicrobial agent) is less than or equal
to: about 0.5%, about 1.0%, about 2.0%, about 3.0%, about 4.0%,
about 5.0%, about 6.0%, about 7.0%, about 8.0%, about 9.0%, about
10.0%, values between the aforementioned values, ranges spanning
those values, or otherwise.
[0057] In some embodiments, the antimicrobial agent comprises
water. For instance, zeolites can also be hygroscopic and can
naturally absorb water from the environment. In some embodiments,
water can be present in an amount equal to or greater than about 0%
to less than or equal to about 18% by weight of the antimicrobial
zeolite (and/or of the antimicrobial agent). In some embodiments,
the weight percent of water in the antimicrobial zeolite (and/or
the antimicrobial agent) is equal to or at least: about 0.5%, about
1.0%, about 2.0%, about 3.0%, about 4.0%, about 5.0%, about 6.0%,
about 7.0%, about 8.0%, about 9.0%, about 10.0%, about 15.0%, about
20.0%, values between the aforementioned values, ranges spanning
those values, or otherwise. In some embodiments, the weight percent
of water in the antimicrobial zeolite (and/or in the antimicrobial
agent) is less than or equal to: about 0.5%, about 1.0%, about
2.0%, about 3.0%, about 4.0%, about 5.0%, about 6.0%, about 7.0%,
about 8.0%, about 9.0%, about 10.0%, about 15.0%, about 20.0%,
values between the aforementioned values, ranges spanning those
values, or otherwise. In certain implementations, the antimicrobial
zeolite comprises about 18% water by weight ("AC10N"), about 5%
water by weight ("AC10D"), or about 2% water by weight
("AC10H").
[0058] In some embodiments, one or more antimicrobial agents are
supported by a sub-support structure that, by itself, may or may
not be antimicrobial. For instance, in some embodiments, one or
more antimicrobial agents are supported on a nanoparticle (e.g., a
particle with an average particle sizes ranging from equal to or
greater than about 10 nm to less than or equal to about 1000 nm) or
microparticle (e.g., a particle with an average particle sizes
ranging from equal to or greater than about 1 .mu.m to less than or
equal to about 1000 .mu.m). In some embodiments, the sub-support
comprises a zeolite. In some embodiments, the sub-support structure
can comprise any one of ionic silver, ionic copper, ammonium,
and/or water in any of the weight percentages described elsewhere
herein. In some embodiments, as described above, the antimicrobial
agent comprises a zeolite sub-support with one or more
antimicrobial ions adhered to it (or diffused within it). In some
embodiments, the average particle size of the zeolite (or other
sub-support structure) is equal to or less than: about 100 .mu.m,
about 10 .mu.m, about 1 .mu.m, values ranging between the
aforementioned values, values between the aforementioned values or
otherwise. In some embodiments, the average particle size of the
zeolites (and/or other sub-support structure) is less than about 6
.mu.m.
[0059] In some variants, the antimicrobial agent lacks a zeolite
(e.g., a zeolite sub-support structure) or other sub-support
structure and instead comprises one or more of free silver (e.g.,
silver ions, a silver salt, metallic, etc.), copper (copper ions, a
copper salt, or metallic copper, etc.), organosilanes, ammonium, or
cationic materials (e.g.,
3-(trimethoxysilyl)-propyldimethyloctadecyl ammonium chloride,
etc.) that provide antimicrobial effect. For instance, in some
embodiments, the coating comprises silver ions.
[0060] In some embodiments, the substrate that supports the
antimicrobial agent comprises the bulk dry weight of the coating.
In some embodiments, the antimicrobial agent makes up equal to or
less than about 1.25 wt % (i.e., weight percent) of the total
coating weight. In some embodiments, the coating comprises equal to
or greater than about 0.1% and/or less than or equal to about 1.5%
antimicrobial agent by weight. In some embodiments, the coating
comprises equal to or greater than about 1.1% and/or less than or
equal to about 1.3% antimicrobial agent by weight. In some
embodiments, the coating comprises equal to or greater than about
1.1% and/or less than or equal to about 1.2% antimicrobial agent by
weight. In some embodiments, the weight percent of antimicrobial
agent in the coating is at least: about 0.0001%, about 0.001%,
about 0.01%, about 0.1%, about 0.5%, about 1.0%, about 1.25, about
1.5%, about 2.0%, values between the aforementioned values, values
greater than the aforementioned values, values less than the
aforementioned, or otherwise. In some embodiments, the weight
percent of the antimicrobial agent in the sub-support is less than
or equal to: about 0.0001%, about 0.001%, about 0.01%, about 0.1%,
about 0.5%, about 1.0%, about 1.25, about 1.5%, about 2.0%, values
between the aforementioned values, ranges spanning those values, or
otherwise.
[0061] As described below in Examples 2 and 3, and as shown in
FIGS. 5 and 6, the antimicrobial coating kills substantially all of
the bacteria present on the coating after a period of about 24
hours of exposure to the coating. As shown in the Escherichia coli
(E. coli) results from Example 2 (and FIG. 5), both coatings
comprising about 1.25 wt % AGION.RTM. or about 1.5 wt % AGION.RTM.
kill substantially all of the E. coli present on the coating after
a period of about 24 hours of exposure to the coating. As shown in
the Staphylococcus aureus ("S. aureus") results from Example 2 (and
as shown in FIG. 6), the coating comprising about 1.25 wt %
AGION.RTM. kills this form of bacteria slightly more effectively
than the about 1.5 wt % AGION.RTM. coating after a period of about
24 hours of exposure to the coating. This result surprisingly shows
that a lower amount of AGION.RTM. can be used to achieve a nearly
100% kill rate relatively to larger doses. Without being bound to
any particular mechanism, it is thought that the lower dose of
AGION.RTM. (e.g., 1.25 wt % or less) allows it to be better
distributed within the coating layer (e.g., by preventing
aggregation) giving it a more efficient and effective antibacterial
effect.
[0062] In embodiments, where the antimicrobial agent is provided
without a sub-support structure (e.g., free of the zeolite), the
weight % of antimicrobial agent in the coating can be reduced to
account for the lack of this sub-support.
[0063] In some embodiments, about 24 hours after bacterial exposure
on the coating, an amount of bacteria remaining on the coating is
reduced by equal to or at least about 95% to about 100%. In some
embodiments, 24 hours after bacterial exposure on the antibacterial
coating, the amount of bacteria present is reduced by equal to or
at least: about 75%, about 85%, about 95%, about 98%, about 99%,
about 99.9%, about 99.99%, about 99.999%, about 99.9999%, or about
99.99999%. In some embodiments, the coating reduces the amount of
E. coli from about 2.3.times.10.sup.5 CFU/carrier to about 0
CFU/carrier and/or less than or equal to about 5 CFU/carrier (with
a limit of detection of about 5 CFU/carrier) over a period of about
24 hours. In some embodiments, as shown in Table 1, relative to a
control, the coating reduces the amount of bacteria from about
2.35.times.10.sup.7 colony forming units (CFU)/carrier (on a
control surface) to about 0 CFU/carrier and/or less than or equal
to about 5 CFU/carrier (with a limit of detection of about 5
CFU/carrier) over a period of about 24 hours. In some embodiments,
the coating reduces the amount of S. aureus from about
3.85.times.10.sup.5 CFU/carrier to about 0 CFU/carrier and/or less
than or equal to about 5 CFU/carrier (with a limit of detection of
about 5 CFU/carrier) over a period of about 24 hours. In some
embodiments, as shown in Table 2, relative to a control, the
coating reduces the amount of bacteria from about
9.5.times.10.sup.6 colony forming units (CFU)/carrier (on a control
surface) to about 0 CFU/carrier and/or less than or equal to about
5 CFU/carrier (with a limit of detection of about 5 CFU/carrier)
over a period of about 24 hours. In some embodiments, the coating
has the above described antimicrobial effects on one or more
bacteria selected from Streptococcus pneumoniae, Haemophilus
influenzae, Moraxella catarrhalis, S. aureus, E. coli, or the like.
In some embodiments, the coating has antimicrobial effects on gram
positive and/or gram negative bacteria.
Features of Certain Antimicrobial Coatings
[0064] As described above, the antimicrobial coating can be applied
to household goods. In some embodiments, the coating is
sufficiently durable for long-term use (e.g., is able to maintain
integrity and substantially unreduced efficacy over a period of at
least one year with regular and normal usage). In some variants,
the look of the household good remains substantially unchanged
and/or the antimicrobial properties remain substantially unchanged
during long term use (e.g., for periods of one, two, three, four or
more years as could be measured over time or with accelerated
stress conditions).
[0065] In some embodiments, the coating is sufficiently durable to
withstand repeated cleanings or washings. For instance, because
household goods such as trashcans and sink accessories are
typically washed repeatedly over their lifetimes, in certain
variants, the coating is configured to maintain its antimicrobial
properties after repeated cleanings that include scrubbing and
washing with soapy water. In some embodiments, a durable coating
maintains its antimicrobial properties after at least about 25, at
least about 50, at least about 100, or more washes with a standard
wash cloth and soapy water. In certain variants, the coating
maintains its antimicrobial activity after at least about 25, at
least about 50, at least about 100, or more washes with a paper
towel and a household cleaner (e.g., bleach, an ammonia-based
cleaner (e.g., WINDEX.RTM. cleaner), etc.).
[0066] In some variants, the coating maintains its antimicrobial
properties under accelerated wear conditions (e.g., under heat
stress, increased humidity, exposure simulated sunlight, etc.)
intended to simulate the lifetime of the good. In some embodiments,
the coating maintains its antimicrobial properties after being
abraded (e.g., abrasions or scratches caused by steel wool or other
abrading agents). In some variants, the coating maintains its
antimicrobial properties after about 1000 wipes using a dry
kimwipe. In some embodiments, a product that maintains its
antimicrobial properties includes products that retain at least
about 75%, at least about 85%, at least about 90%, at least about
95%, at least about 99%, or more of its initial antimicrobial
property before use.
[0067] In some embodiments, the durability of the coating can be
measured using the contact angle of a droplet of water or oil on
the coating surface. In certain variants, the contact angle of a
droplet of water on the coating changes less than about 10% under
one or more of the washing and wear conditions described above. In
some embodiments, the contact angle of a droplet of water on the
coating changes less than about 20% and/or less than about 40%
under one or more of the washing and wear conditions described
above. In some embodiments, the contact angle of a droplet of oil
on the coating changes less than about 10% under one or more of the
washing and wear conditions described above. In some embodiments,
the contact angle of a droplet of oil on the coating changes less
than about 20% or less than about 40% under one or more of the
washing and wear conditions described above.
[0068] In some embodiments, the coating maintains its antimicrobial
activity even after polishing and/or drawing. Polishing can include
abrasion with a cloth and a polishing agent under typical polishing
conditions. In certain implementations, the coatings provided
herein advantageously protect the appearance of metal goods, making
polishing of the surfaces of the household good unnecessary. In
some embodiments, this property can advantageously give products
even longer lasting antimicrobial properties.
[0069] In some embodiments, the antimicrobial properties of the
coatings are accomplished without leaching of copper from the
coating. In some embodiments, the antimicrobial properties of the
coatings are accomplished without leaching of silver from the
coating. In some embodiments, the antimicrobial properties of the
coatings are accomplished without leaching of copper and/or
ammonium from the coating.
[0070] In some embodiments, the coating is fingerprint or smudge
resistant. The terms "fingerprint resistant," or "smudge resistant"
refer to the ability of a surface to resist the visible transfer of
residue from physical interactions with a user, the minimization,
hiding, or obscuring of tactilely-transferable residue on a
surface, and/or combinations thereof. In certain implementations, a
fingerprint-resistant surface is substantially resistant to both
water-based material and oil-based material transfer when contacted
by a user. In some embodiments, a fingerprint-resistant surface is
substantially resistant to one or more of inorganic-based material
and organic-based material transfer when contacted by a user. In
some embodiments, fingerprint resistance is measured using the
amount of transferred residue after a user makes physical contact
with the household good. For instance, after physical contact
(e.g., from the skin of a user), some amount of residue can
transfer to the household good. The mass of the residue on the
coated household good after each interaction can be quantified, for
example, by weighing the mass (or by weighing the mass of a
representative test sheet of that material). In some embodiments,
the mass transferred from a user to the coated household good is
less than or equal to: about 1 mg, about 0.02 mg, or 0.001 mg per
instance of physical contact (for instance by dragging a hand
across the test surface) to a portion of the household good that is
sized 4''.times.4''. In some embodiments, the fingerprint
resistance is qualitatively measured using the human eye and a
fingerprint/smudge resistant material shows less visible residue
after physical contact than a non-resistant surface. In some
embodiments, the fingerprint resistance of a material is measured
by determining the reflectivity before contact (e.g., when clean)
or after one or more instances of physical contact (as described
above). In some implementations, when the fingerprint resistant
material is coated on a mirrored-surface (or a chromed-surface,
stainless steel, or another otherwise reflective surface of a
household good), the fingerprint resistant material maintains at
least about 75%, at least about 95%, or at least about 99% of the
reflectance of the surface compared to that before an instance of
physical contact. In some embodiments, coatings that are
fingerprint or smudge resistant are advantageously more desirable
to consumers for aesthetic reasons.
[0071] In certain implementations, the antimicrobial agent is
deposited directly into a fingerprint mitigating (fingerprint
resistant) material to form the coating material and the two are
added to any surface of the household good together. In some
embodiments, the fingerprint resistant material (e.g., compound) is
applied separately (before or after) the antimicrobial compound. In
some embodiments, antimicrobial coatings and fingerprint resisting
coatings are added as separate layers that can be sandwiched on top
of one another. A plurality of layers can be added by exposing
sheets of, for example, metal to antimicrobial coating and
fingerprint proof coating conditions repetitively. In certain
implementations, the antimicrobial agent and the fingerprint
resistant material are added in patterns on a surface (e.g.,
patches, stripes, etc.) that give the household good both
antimicrobial and fingerprint resistant properties on substantially
the entire coated surface.
Certain Methods Related to the Antimicrobial Coating
[0072] Some embodiments pertain to methods of preparing a coated
household good. A flow chart describing an embodiment of a method
700 is provided in FIG. 7. As shown, in certain variants, the
antimicrobial agent is dispersed within a solution, such as a
solution of polymer and solvent 701. This mixture is agitated to
form a substantially uniform slurry 702. After the slurry is
formed, a sheet of material is obtained 703 and the slurry it is
layered onto a sheet of material to form a coated sheet 704. For
example, the slurry can be applied to a sheet of metal, such as
stainless steel 704. In some embodiments, the sheet can be cured
for a period of time to afford a coated sheet 705. In certain
implementations, the dried coated sheet can then be cut and shaped
in appropriate ways to form walls, lids, foot pedals, and handles
for metal household goods including trashcans.
[0073] In some embodiments, prior to application to the sheet, the
antimicrobial agent is slurried with the polymer in a solvent to
form a mixture. In some variants, the slurry is agitated
continuously prior to application to the metal sheet in order to
maintain a homogenous dispersion. In some embodiments, the
dispersion is distributed into a coating device that spreads an
even layer of the slurry onto the sheet. The solvent can then be
evaporated from the slurry, leaving an antimicrobial surface on the
sheet that comprises a smooth layer of polymer with the
antimicrobial agent dispersed within it. In some embodiments, the
evaporation of the solvent cures the polymer/antimicrobial agent.
In certain implementations, after curing, at least a portion of the
antimicrobial agent protrudes from the substrate and is available
to directly interact with microbes on the surface of a coated
household good. In some embodiments, the antimicrobial agent can
diffuse over time to the surface of the coating to interact
directly with microbes on the surface of the household good. In
certain implementations, the antimicrobial agent is consumed during
the killing of microbes, while in other embodiments it is not. In
some embodiments, direct contact with the microbe and the
antibacterial agent is not necessary.
[0074] It has been found that several coating techniques for
surfaces are not amenable to distributing streak-free antimicrobial
coatings. For instance, coatings applied using a metered-rolling
process result in streaked coatings (see FIG. 3A and 4A). In a
metered-rolling process, a rolling element rolls in the direction
of a sheet that passes over the rolling element. In a
metered-rolling device, the rolling element is at least partially
submerged in a reservoir of a coating agent. As the rolling element
rolls, it draws coating agent from this reservoir and deposits it
on a sheet as the sheet moves by. This process coats the sheet as
the sheet travels along in the direction of rolling.
[0075] In contrast, in various embodiments described herein, the
coating device uses a non-metered-rolling process (e.g., a
reverse-rolling technique) to apply the slurry to the sheet. FIG. 8
shows an embodiment of a system 800 that can be used to apply a
coating 810 by reverse-rolling. For instance, in certain variants,
in the non-metered, reverse-rolling process, the metal sheet 820 is
drawn below a first rolling element 830 (e.g., a coating roller) of
the coating device in a first direction 822. The first rolling
element 830 is in fluidic communication with a reservoir 840
containing a slurry of antimicrobial agent, polymer, and/or solvent
that is formed between the first rolling element 830 and a second
rolling element 832 (e.g., a doctor roll). The first rolling
element 830 draws the slurried mixture from the reservoir 840 and
deposits it on a surface of the first rolling element 831 which
distributes the slurried mixture to the sheet as the sheet passes
below the first rolling element 830. During reverse-rolling, the
region of the first rolling element 830 that is approximately
adjacent to the sheet 820 travels (e.g., rolls) in a second
direction 834, which is opposite to the first direction 822 (the
direction of movement of the sheet). In some implementations, when
reverse-rolling is used, the final coating is substantially or
completely streak-free to the unaided eye (see, e.g., FIGS. 3B and
4B).
[0076] Without being bound to any particular mechanism, it is
believed that the antimicrobial agent adds contrast the coating. If
applied using certain methods, the contrast of a coating having an
antimicrobial agent, as disclosed herein, becomes large enough to
be visible by the naked eye. In some embodiments, whether a coating
is streak-free can be measured using the naked eye. In some
implementations, whether a coating is streak-free can be
quantified. In some embodiments, for instance, streak-free coatings
are those having a transmittance variation between any two points
on the surface that varies by less than: about 75%, about 50%,
about 30%, about 20%, about 10%, about 5%, about 2%, or about 1%
transmittance. In some embodiments, for instance, streak-free
coatings are those having a reflectance variation between any two
points on the surface that varies by less than: about 50%, about
25%, or about 5% reflectance. In certain implementations, the
coating is applied using other solution-based techniques (e.g.,
spray coating, spin-coating, dip-coating, inkjetting, or the like)
that result in streak-free materials.
[0077] In some embodiments, as the slurry cures, it forms a
homogeneous distribution of antimicrobial agent within the coating.
In some embodiments, a gradient of antimicrobial agent can be
formed in the coating by, for example, depositing additional layers
of slurry (with different concentrations of antimicrobial agent)
onto the sheet. In some embodiments, a gradient can be formed by
changing the curing rate (e.g., by slowing or increasing the curing
speed using lower or higher cure temperatures etc.). In some
embodiments, a gradient can be formed by depositing additional
layers of higher or lower concentration slurry over partially cured
other layers of slurry. In some embodiments, a gradient can be
formed by changing the concentration of antimicrobial agent and/or
polymer in solution. For example, in certain implementations, in
more dilute solutions, the cure rate can be slowed so that more of
the antimicrobial agent can settle in the direction of gravity
during the curing process, forming a more concentrated layer in
that direction. Any of the methods described in this specification
can be used to form antimicrobial agent gradients that are either
more concentrated at the surface of the coating or more
concentrated at the surface of the household good (which can be
especially useful in applications where, for example, the
antimicrobial diffuses towards the surface of the coating over
time). In some variants, gradients can be used to advantageously
maintain or increase antimicrobial effect over time.
[0078] In some embodiments, uneven application of coatings to
surfaces is reduced or minimized using the disclosed methods and/or
substantially even (or uniform) coatings result. In certain
implementations, visible streaking in the coating can be caused by
the uneven application of the coating to the surface of the
trashcan. In certain implementations, the methods used to deposit
the coating result in a substantially uniform coating thickness on
the sheet material. In certain implementations, the thickness of
the coating can be equal to or greater than about 10 .mu.m and/or
less than or equal to about 20 .mu.m. In some embodiments, the
thickness can be less than or equal to: about 100 .mu.m, about 80
.mu.m, about 70 .mu.m, about 60 .mu.m, about 50 .mu.m, about 40
.mu.m about 30 .mu.m, about 20 .mu.m, about 10 .mu.m, about 5
.mu.m, values between the aforementioned values, ranges spanning
those values, or otherwise. In some embodiments, the coating is of
substantially uniform thickness. In some embodiments, the thickness
of the coating varies by less than or equal to: about 100%, about
90%, about 80%, about 70%, about 60%, about 50%, about 40%, about
30%, about 20%, about 10%, about 5%, about 2%, values between the
aforementioned values, ranges spanning those values, or otherwise
as measured between any two points on a coated surface. In some
embodiments, this level of uniformity results in a coating that
appears substantially streak-free. In some embodiments, the coating
is generally planar, substantially flat, substantially smooth and
uniform, and/or substantially contiguous, such that streaks are not
generally visible upon casual visual observation.
[0079] In some embodiments, the methods described herein result in
a material that is substantially optically transparent. For
example, in certain implementations, the optical transmittance of
the coating over the visible spectrum is at least: about 65%, about
75%, about 85%, about 95%, about 98%, values between the
aforementioned values, ranges spanning those values, or
otherwise.
Certain Protective Coverings
[0080] Some embodiments pertain to protective coverings for the
coatings disclosed herein. A flow chart describing an embodiment of
a method 900 is provided in FIG. 9. As shown, in certain variants,
a plurality of metal sheets is obtained 901. In some embodiments,
sheets of a different material can be used (plastic, composite,
etc.). A slurry of antimicrobial agent in a polymer/solvent
solution is layered onto a plurality of metal sheets 902 which are
then cured to form a coated sheets 903. A protective film is then
adhered to the coated sheets using an adhesive 904. The sheets are
then stacked 905 and transported to a fabricating facility 906. At
the facility, the protective films and adhesive is removed without
leaving residue from the adhesive on the coated sheet 907. The
sheets are then cut and shaped to form household goods 908. In
certain implementations, as described above, the dried coated sheet
be cut and shaped in appropriate ways to form walls, lids, foot
pedals, and handles for metal household goods including trashcans.
In some implementations, finished goods can be protected by
applying an adhesive and a protective film to antimicrobially
coated household goods.
[0081] During shipping of sheets to make a household good or a
household good itself, the surfaces of the sheet or sheet good can
be protected by depositing films onto those surfaces. Rubber
adhesives can be used to adhere protective films onto portions of
the sheets or household goods. However, it has been found that some
rubber adhesives leave deposits (e.g., residue, etc.) on the
coatings (see FIG. 10A). This can result in streaks and other
visual imperfections 1020 on the coating 1001 after the protective
film 1010 is removed, as is pointed-to by the arrow in FIG. 10A. In
certain instances, the residue can leave an unwanted sticky region
on the coating. In certain instances, these residues cannot be
readily washed away from the coatings.
[0082] Certain embodiments are configured to ameliorate at least
one of these problems, or other problems. For example, some
embodiments adhere or otherwise connect a protective film to a
coated sheet of material such that removal of the film does not
leave an appreciable residue on the coated material. In some
embodiments, acrylic or silicone rubber adhesive is used to adhere
the film to the coated sheet of material, which has been found to
reduce or eliminate appreciable residue on the coating 1001 after
removal of the film 1011 (see FIG. 10B which lacks residue). In
certain implementations, the use of acrylic or silicone or rubber
adhesive leads to a more visually appealing result once the
protective film is removed. In some variants, the substantially
complete removal of residue helps avoid areas (e.g., on top of the
residue) where the antimicrobial activity of the coating could be
blocked. In some embodiments, rubber may be used as an adhesive
(with or without one or more other adhesives).
[0083] Some embodiments pertain to methods of applying protective
films to antimicrobial coatings. In certain implementations, the
adhesive is applied to a coated sheet of material using a
solution-based technique (e.g., spray coating, spin-coating,
dip-coating, inkjetting, rolling, or the like). Once applied, a
protective film (e.g., a polymeric material) is deposited onto the
adhesive, such as by rolling the film onto the coated sheet of
material.
SUMMARY
[0084] Several illustrative embodiments of coatings and methods of
coating have been disclosed. Although this disclosure has been
described in terms of certain illustrative embodiments and uses,
other embodiments and other uses, including embodiments and uses
which do not provide all of the features and advantages set forth
herein, are also within the scope of this disclosure. Components,
elements, features, acts, or steps can be arranged or performed
differently than described and components, elements, features,
acts, or steps can be combined, merged, added, or left out in
various embodiments. All possible combinations and subcombinations
of elements and components described herein are intended to be
included in this disclosure. No single feature or group of features
is necessary or indispensable.
[0085] Certain features that are described in this disclosure in
the context of separate implementations can also be implemented in
combination in a single implementation. Conversely, various
features that are described in the context of a single
implementation also can be implemented in multiple implementations
separately or in any suitable subcombination. Moreover, although
features may be described above as acting in certain combinations,
one or more features from a claimed combination can in some cases
be excised from the combination, and the combination may be claimed
as a subcombination or variation of a subcombination.
[0086] Any portion of any of the steps, processes, structures,
and/or devices disclosed or illustrated in one embodiment,
flowchart, or example in this disclosure can be combined or used
with (or instead of) any other portion of any of the steps,
processes, structures, and/or devices disclosed or illustrated in a
different embodiment, flowchart, or example. The embodiments and
examples described herein are not intended to be discrete and
separate from each other. Combinations, variations, and other
implementations of the disclosed features are within the scope of
this disclosure.
[0087] The terms "approximately," "about," and "substantially" as
used herein represent an amount close to the stated amount that
still performs a desired function or achieves a desired result. For
example, in some embodiments, as the context may dictate, the terms
"approximately", "about", and "substantially" may refer to an
amount that is within less than or equal to 10% of the stated
amount. The term "generally" as used herein represents a value,
amount, or characteristic that predominantly includes or tends
toward a particular value, amount, or characteristic.
[0088] Some embodiments have been described in connection with the
accompanying drawings. Moreover, while operations may be depicted
in the drawings or described in the specification in a particular
order, such operations need not be performed in the particular
order shown or in sequential order, or that all operations be
performed, to achieve desirable results. Other operations that are
not depicted or described can be incorporated in the example
methods and processes. For example, one or more additional
operations can be performed before, after, simultaneously, or
between any of the described operations. Additionally, the
operations may be rearranged or reordered in other implementations.
Also, the separation of various components in the implementations
described above should not be understood as requiring such
separation in all implementations, and it should be understood that
the described components and systems can generally be integrated
together in a single product or packaged into multiple products.
Additionally, other implementations are within the scope of this
disclosure.
[0089] Conditional language used herein, such as, among others,
"can," "could," "might," "may," "e.g.," and the like, unless
specifically stated otherwise or otherwise understood within the
context as used, is generally intended to convey that certain
embodiments include, while other embodiments do not include,
certain features, elements and/or steps. Thus, such conditional
language is not generally intended to imply that features, elements
and/or steps are in any way required for one or more embodiments or
that one or more embodiments necessarily include logic for
deciding, with or without author input or prompting, whether these
features, elements and/or steps are included or are to be performed
in any particular embodiment. The terms "comprising," "including,"
"having," and the like are synonymous and are used inclusively, in
an open-ended fashion, and do not exclude additional elements,
features, acts, operations, and so forth. Also, the term "or" is
used in its inclusive sense (and not in its exclusive sense) so
that when used, for example, to connect a list of elements, the
term "or" means one, some, or all of the elements in the list.
[0090] Conjunctive language such as the phrase "at least one of X,
Y, and Z," unless specifically stated otherwise, is otherwise
understood with the context as used in general to convey that an
item, term, etc. may be either X, Y, or Z. Thus, such conjunctive
language is not generally intended to imply that certain
embodiments require the presence of at least one of X, at least one
of Y, and at least one of Z.
[0091] Further, while illustrative embodiments have been described,
any embodiments having equivalent elements, modifications,
omissions, and/or combinations are also within the scope of this
disclosure. Moreover, although certain aspects, advantages, and
novel features are described herein, not necessarily all such
advantages may be achieved in accordance with any particular
embodiment. For example, some embodiments within the scope of this
disclosure achieve one advantage, or a group of advantages, as
taught herein without necessarily achieving other advantages taught
or suggested herein. Further, some embodiments may achieve
different advantages than those taught or suggested herein.
[0092] In summary, various embodiments and examples of
antimicrobial coatings and protective films have been disclosed.
This disclosure extends beyond the specifically disclosed
embodiments and examples to other alternative embodiments and/or
other uses of the embodiments, as well as to certain modifications
and equivalents thereof. Moreover, this disclosure expressly
contemplates that various features and aspects of the disclosed
embodiments can be combined with, or substituted for, one another.
Accordingly, the scope of this disclosure should not be limited by
the particular disclosed embodiments described above, but should be
determined only by a fair reading of the claims.
EXAMPLES
Example 1: Fabrication of Coated Metal
[0093] Coatings were prepared using a metered-rolling process and a
reverse-rolling technique. Prior to coating, a slurry of
polyethylene polymer and solvent was prepared. To this solution was
added 1.25 wt % of AC10D grade AGION.RTM. (relative to the dry
weight of polyethylene) forming a mixture. This mixture was stirred
to achieve a uniform slurry. Once a uniform was achieved, it was
added to the reservoir of a metered-rolling device which
distributed the slurry on a stainless steel sheet via a roller
rotating in the same direction of the sheet movement. The sheet was
allowed to cure. FIGS. 3A and 4A show the resultant coated
sheet.
[0094] A second slurry was formed using the same ingredients and
techniques described above. This mixture was added to the reservoir
of a reverse-rolling device which distributed the slurry on a
stainless steel sheet via a roller rotating in the direction
opposite the direction of the sheet. The sheet was allowed to cure.
FIGS. 3B and 4B show the resultant coated sheet.
[0095] As shown in the figures, the reverse-rolling technique
resulted in an antimicrobial coating that was streak-free and
uniform relative to the antimicrobial coating formed using the
metered-rolling technique.
Example 2: Antimicrobial Testing
[0096] Several experiments were performed using the Japanese
Industrial Standard ("JIS") method Z 2801 antimicrobial evaluation
method to show the antimicrobial activity of a sheet metal coated
using the reverse-rolling process described in Example 1. The JIS
method Z 2801 is a quantitative test designed to assess the
performance of antimicrobial finishes on hard, non-porous surfaces.
The method can be conducted using contact times ranging from ten
minutes up to 24 hours. For a JIS Z 2801 test, non-antimicrobial
control surfaces are used as the baseline for calculations of
microbial reduction. The method can be used to determine the
antimicrobial activity of a diverse array of surfaces including
plastics, metals, and ceramics. The test microorganism(s) selected
for this test were Escherichia coli 8739 (a Gram-negative bacteria)
and Staphylococcus aureus 6538 (a Gram-positive bacteria).
Testing Method
[0097] The test microorganism was prepared by growth in a Tryptic
Soy Broth. The suspension of test microorganism was standardized by
dilution in a nutritive broth (this affords microorganisms the
opportunity to proliferate during the test). Control and test
substances were wiped clean with 70% ethanol and allowed to dry
prior to testing. Control and test surfaces (50 mm.times.50 mm)
were inoculated with microorganisms (where the testing parameter
was 0.400 mL at a concentration of 4.times.10.sup.5 CFU/Carrier),
and then the microbial inoculum was covered with a thin, sterile
film (40 mm.times.40 mm). Covering the inoculum spreads it,
prevents it from evaporating, and ensures close contact with the
antimicrobial surface. Microbial concentrations were determined at
"time zero" by elution followed by dilution and plating to Tryptic
Soy Agar. A control was run to verify that the
neutralization/elution method effectively neutralizes the
antimicrobial agent in the antimicrobial surface being tested.
Inoculated, covered control and antimicrobial test surfaces were
allowed to incubate undisturbed in a humid environment for 24
hours, at 36.degree. C..+-.1.degree. C. After incubation, microbial
concentrations were determined. Reduction of microorganisms
relative to the control surface were calculated. The neutralizer
was D/E Broth (10 mL). The enumeration plate media was tryptic soy
agar. The enumeration plate was incubated for 24.+-.6 hours at
36.degree. C..+-.1.degree. C.
[0098] Results were calculated using the following formulae:
Percent .times. .times. Reduction = ( B - A B ) .times. 100
##EQU00001##
Where B=Number of viable test microorganisms on the control
carriers after the contact time; and A=Number of viable test
microorganisms on the test carriers after the contact time.
Log 10 .times. .times. Reduction = Log .function. ( B A )
##EQU00002##
Where B=Number of viable test microorganisms on the control
carriers after the contact time; and A=Number of viable test
microorganisms on the test carriers after the contact time.
Results of E. Coli Testing
TABLE-US-00001 [0099] TABLE 1 Percent Log.sub.10 Reduction
Reduction Compared to Compared to Test Carrier Control at Control
at Microorganism Contact Time Type CFU/Carrier Contact Time Contact
Time E. coli Time Zero Inoculum 2.30E+05 N/A 8739 Only 24 Hours
Control 2.35E+07 B 1.50 <5.00E+00 >99.99998% >6.67 E 1.25
<5.00E+00 >99.99998% >6.67
[0100] The data collected using E. Coli on 50 mm.times.50 mm
carriers (covered by 40 mm.times.40 mm films) is shown in Table 1.
FIG. 5 shows a graph plotting E. Coli CFU/Carrier against the
control and experimental samples. The limit of detection for this
study is 5 CFU/Carrier. Values less than the limit of detection are
shown as <5.00E+00 on the table and zero on the graph.
Results of S. aureus Testing
TABLE-US-00002 TABLE 2 Percent Log.sub.10 Reduction Reduction
Compared to Compared to Test Contact Carrier Control at Control at
Microorganism Time Type CFU/Carrier Contact Time Contact Time S.
aureus Time Zero Inoculum 3.85E+05 N/A 6538 Only 24 Hours Control
9.50E+06 B 1.50 5.00E+00 99.99995% 6.28 E 1.25 <5.00E+00
>99.99995% >6.28
[0101] The data collected using S. aureus on 50 mm.times.50 mm
carriers (covered by 40 mm.times.40 mm films) is shown in Table 2.
FIG. 6 shows a graph plotting S. aureus CFU/Carrier against the
control and experimental samples. The limit of detection for this
study is 5 CFU/Carrier. Values less than the limit of detection are
shown as <5.00E+00 on the table and zero on the graph.
Example 3: Antimicrobial Testing
[0102] Below are experiments performed using the Sciessent LLC
antimicrobial evaluation methods to show the antimicrobial activity
of a sheet metal (2''.times.2'') coated using the reverse-rolling
process described in Example 1. Certain samples were abraded before
testing. The bacteria used were E. coli and S. aureus.
TABLE-US-00003 TABLE 3 E. Coli (ATCC#: 25922) Testing Organism
Count (CFU/ml) Zero 24 Hours Contact Contact Percent Sample
Identification Time Time Reduction** Assay (+) 2.5 .times. 10.sup.5
2.0 .times. 10.sup.7 No Reduction Assay (-) <10* <10* N/A
Untreated coated metal 4.6 .times. 10.sup.7 No samples Sciessent
ID# Reduction 150811-1A Coated metal samples 3.2 .times. 10.sup.4
99.93% (1.5% AC10D in coating) Sciessent ID# 150806-3B, Rep 1
Coated metal samples 2.8 .times. 10.sup.4 99.94% (1.5% AC10D in
coating) Sciessent ID# 150806-3B, Rep 2 Coated metal samples 1.04
.times. 10.sup.3 99.99% (1.5% AC10D in coating) - Abraded Sciessent
ID# 150806-3B, Rep 1 Coated metal samples 5.4 .times. 10.sup.2
99.999% (1.5% AC10D in coating) - Abraded Sciessent ID# 150806-36B,
Rep 2 Testing was performed in accordance with standard operating
procedures of Sciessent LLC. *.ltoreq.10 = Limits of Detection;
**is percent reduction calculated using: untreated T24 contact
time.
TABLE-US-00004 TABLE 4 S. Aureus (ATCC#: 6538) Testing Organism
Count (CFU/ml) Zero 24 Hours Contact Contact Percent Sample
Identification Time Time Reduction** Assay (+) 2.3 .times. 10.sup.5
6.5 .times. 10.sup.6 No Reduction Assay (-) <10* <10* N/A
Untreated coated metal 5.0 .times. 10.sup.7 No samples Sciessent
ID# Reduction 150811-1A Coated metal samples 7.8 .times. 10.sup.4
99.84% (1.5% AC10D in coating) Sciessent ID# 150806-3B, Rep 1
Coated metal samples 5.9 .times. 10.sup.4 99.90% (1.5% AC10D in
coating) Sciessent ID# 150806-3B, Rep 2 Coated metal samples 3.3
.times. 10.sup.4 99.93% (1.5% AC10D in coating) Sciessent ID#
150806-3B, Rep 3 Coated metal samples 7.0 .times. 10.sup.1 99.9999%
(1.5% AC10D in coating) - Abraded Sciessent ID# 150806-3B, Rep 1
Coated metal samples <10* 99.9999% (1.5% AC10D in coating) -
Abraded Sciessent ID# 150806-3B, Rep 2 Coated metal samples <10*
99.9999% (1.5% AC10D in coating) - Abraded Sciessent ID# 150806-3B,
Rep 3 Testing was performed in accordance with standard operating
procedures of Sciessent LLC. *.ltoreq.10 = Limits of Detection;
**is percent reduction calculated using: untreated T24 contact
time.
Example 4: Application of Protective Film to Coated Sheets
[0103] Protective film coatings were applied to a portion of sheet
metal coated using the reverse-rolling process described in Example
1. In one experiment, to the coated sheet was sprayed a rubber
adhesive (coinciding to FIG. 10A). In a second experiment, to the
coated sheet was sprayed an acrylic and/or silicone rubber adhesive
(coinciding to FIG. 10B). Soon after application of each adhesive,
film protective layers were applied to the adhesives on the coated
sheets. After 24 hours, the protective films were removed. After
removal of the protective film, a residue was noted on the coated
sheet where a rubber adhesive was used. The residue was washed
several times with ethanol but remained on the coated surface (see
FIG. 10A). No such residue was noted on the coated sheet where an
acrylic and/or silicone rubber adhesive was used (FIG. 10B).
* * * * *