Antimicrobial solid surfaces and treatments and processes for preparing the same

Abstract

Provided is an antimicrobial non-isotactic polymer based hard or semi-flexible surface in a thermoset and/or thermoplastic resin matrix wherein the active antimicrobial ingredient is copper oxide! Processes for preparing the same and applications thereof are also described. The invention is directed to polymeric solid panels and slab possessing and polymer resin treatments imparting antibacterial, antifungal, antiviral and sporicidal properties.

1 . A composite structural solid material comprising a polymeric resin and copper oxide particles substantially uniformly dispersed therein optionally further comprising a filler material, wherein said copper oxide is present at a concentration ranging from 10 to 50% w/w % and wherein a portion of said copper oxide particles are surface exposed. 
     
     
         2 . The composite structural solid material of  claim 1 , wherein said polymeric resin comprises epoxy, acrylic or polyester resins or thermoset resins or a combination thereof. 
     
     
         3 . (canceled) 
     
     
         4 . The composite structural solid material of  claim 1 , wherein said composite structural solid material further comprises calcium carbonate, marble, granite, quartz, feldspar, marble and quartzite and mixtures thereof. 
     
     
         5 . The composite structural solid material of  claim 1 , wherein said filler material comprises fumed silica, sand, clay, kaolin, fly ash, cement, broken ceramics, mica, silicate flakes, broken glass, glass beads, glass spheres, mirror fragments, steel grit, aluminum grit, carbides, plastic beads, pelletized rubber, ground polymer composites, wood chips, sawdust, paper laminates, pigments, colorants, and mixtures thereof. 
     
     
         6 . The composite structural solid material of  claim 1 , wherein said filler material makes up to between 10% and 75% by weight of the total composition. 
     
     
         7 . The composite structural solid material of  claim 1 , wherein said copper oxide particle have a size ranging from a preferred size of 5 to about 20 microns but can be of almost any size. 
     
     
         8 . A finished product comprising the composite structural solid material of  claim 1 , wherein said finished product comprises a work top, tabletop, a countertop and backsplash, architectural facings and moldings, walkways, home finishing, patio furniture, hospital furniture, hospital bed fittings, handles, decorative stone, indoor and outdoor tile, flooring, mantles, wall facings both cladding sheets and decorative surfacing, bathroom fixtures, imitation stone structures cast and molded structures, and other related materials for which incorporation of the composite structural solid material there within is appropriate. 
     
     
         9 . The composite structural solid material of  claim 1 , wherein said composite structural solid material is cast into a sheet or is cast using a compression molding process or is cast using an extrusion process or is cast using an injection molding process. 
     
     
         10 - 12 . (canceled) 
     
     
         13 . The composite structural liquid material of  claim 1 , wherein said composite structural liquid material is sprayed or painted on a surface or wherein said composite structural liquid material is used as a glue or binder for composite constructions and parts such as glass reinforced plastic, fiber glass composites, carbon fiber composites, Keval composites and the like. 
     
     
         14 . (canceled) 
     
     
         15 . A mixed batch process for the manufacture of a composite structural solid material comprising a polymeric resin and copper oxide particles substantially uniformly dispersed therein the process comprising the steps of:
 mixing a polymeric resin, a filler and optionally a pigment;   mixing a catalyst with a mixture of said polymeric resin, filler and optionally said pigment;   simultaneously mixing copper oxide or a copper oxide containing composition with said catalyst to said mixture of said polymeric resin, filler and optionally said pigment or stepwise mixing copper oxide or a copper oxide containing composition with said mixture of said polymeric resin, filler and optionally said pigment and said catalyst to form a polymerizable composite structural material;   distributing said polymerizable composite structural material in a mold; and   providing conditions for polymerization of said polymerizable composite structural material,   thereby preparing a composite structural solid material.   
     
     
         16 . The process of  claim 15 , wherein said process further comprises adjusting a viscosity level of said mixture by altering the quantity of filler added to said mixture, by altering the concentration of catalyst added to said mixture or a combination thereof. 
     
     
         17 . The process of  claim 15 , wherein said catalyst is methyl ethyl ketone. 
     
     
         18 . The process of  claim 15 , wherein said polymeric resin comprises epoxy, acrylic or polyester resins or wherein said polymeric resin comprises thermoplastic resins, thermoset resins or a combination thereof. 
     
     
         19 - 20 . (canceled) 
     
     
         21 . The process of  claim 15 , wherein said filler comprises calcium carbonate, marble, granite, quartz, feldspar, marble and quartzite and mixtures thereof. 
     
     
         22 . The process of  claim 15 , wherein said filler material comprises fumed silica, sand, clay, fly ash, cement, broken ceramics, mica, silicate flakes, broken glass, glass beads, glass spheres, mirror fragments, steel grit, aluminum grit, carbides, plastic beads, pelletized rubber, ground polymer composites, wood chips, sawdust, paper laminates, pigments, colorants, and mixtures thereof. 
     
     
         23 . The process of  claim 15 , wherein said filler material makes up to between 10 and 30% by weight of the total composition. 
     
     
         24 . The process of  claim 15 , wherein said copper oxide particle have a size ranging from about 5 to about 20 microns. 
     
     
         25 . (canceled) 
     
     
         26 . The process of  claim 15 , further comprising the step of preparing a finished product incorporating said composite structural solid material. 
     
     
         27 . The process of  claim 26 , wherein said finished product comprises a tabletop, a countertop, architectural facings, walkways, home finishing, patio furniture, decorative stone, indoor and outdoor tile, flooring, mantles, wall facings, bathroom fixtures, and imitation stone structures tabletop, a countertop, architectural facings and moldings, walkways, home finishing, patio furniture, hospital furniture, hospital bed fittings, handles, decorative stone, indoor and outdoor tile, flooring, mantles, wall facings both cladding sheets and decorative surfacing (painting), bathroom fixtures, imitation stone structures cast and molded structures, and other related materials for which incorporation of the composite structural solid material there within is appropriate. 
     
     
         28 . The process of  claim 15 , further comprising the step of casting said polymeric resin mixture containing copper oxide powder and catalyst into a sheet or further comprising the step of casting said polymeric resin mixture containing copper oxide powder and catalyst using a compression molding process or further comprising the step of casting said polymeric resin mixture containing copper oxide powder and catalyst using an extrusion process or further comprising the step of casting said polymeric resin mixture containing copper oxide powder and catalyst using an injection molding process. 
     
     
         29 - 31 . (canceled) 
     
     
         32 . A continuous pour process for the manufacture of a composite structural solid material comprising a polymeric resin and copper oxide particles substantially uniformly dispersed therein the process comprising the steps of:
 mixing a polymeric resin or a filler with copper oxide until well blended to form a resin-copper oxide paste or filler-copper oxide blend;   stepwise, subsequently mixing said resin-copper oxide paste or filler-copper oxide blend with a filler or resin, respectively and optionally a pigment to form a copper oxide containing blended composition;   stepwise, subsequently mixing a catalyst with said copper oxide containing blended composition to form a polymerizable composite structural material;   distributing said polymerizable composite structural material in a mold; and   providing conditions for polymerization of said polymerizable composite structural material,   thereby preparing a composite structural solid material.   
     
     
         33 . The process of  claim 32 , wherein said process further comprises adjusting a viscosity level of said mixture by altering the quantity of filler added to said mixture, by altering the concentration of catalyst added to said mixture or a combination thereof. 
     
     
         34 . The process of  claim 32 , wherein said resin-copper oxide paste or filler-copper oxide blend is mixed with a filler or resin, respectively and a second copper oxide containing composition and optionally a pigment. 
     
     
         35 . The process of  claim 32 , wherein said catalyst is methyl ethyl ketone. 
     
     
         36 . The process of  claim 32 , wherein said polymeric resin comprises epoxy, acrylic or polyester resins or said polymeric resin comprises thermoplastic resins, thermoset resins or a combination thereof. 
     
     
         37 - 38 . (canceled) 
     
     
         39 . The process of  claim 32 , wherein said filler comprises calcium carbonate, marble, granite, quartz, feldspar, marble and quartzite and mixtures thereof. 
     
     
         40 . The process of  claim 32 , wherein said filler material comprises fumed silica, sand, clay, fly ash, cement, broken ceramics, mica, silicate flakes, broken glass, glass beads, glass spheres, mirror fragments, steel grit, aluminum grit, carbides, plastic beads, pelletized rubber, ground polymer composites, wood chips, sawdust, paper laminates, pigments, colorants, and mixtures thereof. 
     
     
         41 . The process of  claim 32 , wherein said filler material makes up to between 10 and 30% by weight of the total composition. 
     
     
         42 . The process of  claim 32 , wherein said copper oxide particle have a size ranging from about 5 to about 20 microns. 
     
     
         43 . (canceled) 
     
     
         44 . The process of  claim 32 , further comprising the step of preparing a finished product incorporating said composite structural solid material. 
     
     
         45 . The process of  claim 44 , wherein said finished product comprises a tabletop, a countertop, architectural facings, walkways, home finishing, patio furniture, decorative stone, indoor and outdoor tile, flooring, mantles, wall facings, bathroom fixtures, and imitation stone structures tabletop, a countertop, architectural facings and moldings, walkways, home finishing, patio furniture, hospital furniture, hospital bed fittings, handles, decorative stone, indoor and outdoor tile, flooring, mantles, wall facings both cladding sheets and decorative surfacing (painting), bathroom fixtures, imitation stone structures cast and molded structures, and other related materials for which incorporation of the composite structural solid material there within is appropriate. 
     
     
         46 . The process of  claim 32 , further comprising the step of casting said polymeric resin mixture containing copper oxide powder and catalyst into a sheet or further comprising the step of casting said polymeric resin mixture containing copper oxide powder and catalyst using a compression molding process or further comprising the step of casting said polymeric resin mixture containing copper oxide powder and catalyst using an extrusion process or further comprising the step of casting said polymeric resin mixture containing copper oxide powder and catalyst using an injection molding process. 
     
     
         47 - 49 . (canceled) 
     
     
         50 . A composite structural solid material prepared by the process of  claim 32 , further comprising said polymeric resin mixture containing copper oxide powder and catalyst using a spray or paint application process. 
     
     
         51 . A method for imparting antimicrobial activity to a composite structural solid material, said method comprising preparing a composite structural solid material containing copper oxide dispersed therein, wherein said copper oxide is present at a concentration ranging from 10 to 50% w/w % and wherein a portion of said copper oxide particles are surface exposed. 
     
     
         52 . The method of  claim 51 , wherein an exposed surface of said composite structural solid material has an antimicrobial reduction activity representing a 90% reduction of microbial units within 24 hours of sample incubation. 
     
     
         53 . The method of  claim 52 , wherein an exposed surface of said composite structural solid material is characterized in its ability to be repeatedly exposed to organism challenge while maintaining said antimicrobial reduction activity during a period of time within said 24 hours of sample incubation. 
     
     
         54 . The method of  claim 51 , wherein said antimicrobial activity represents bactericidal, sporicidal, or bacteriostatic activity. 
     
     
         55 . The method of  claim 51 , wherein said antimicrobial activity represents fungicidal, viricidal, fungistatic or viristatic activity.