Antimicrobial Phase-Separable Glass Polymer Composite Surface Treatment
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Solution Overview
Problem
Existing polymer/glass composite articles demonstrate limited antimicrobial efficacy due to insufficient surface concentration and duration of antimicrobial agents, necessitating the development of durable antimicrobial composite articles with controlled antimicrobial activity that do not require activation.
Innovation Solution
A composite article comprising a polysulfone matrix with phase-separable glass particles containing copper-containing antimicrobial agents, where the particles are distributed at a specific volume fraction to ensure effective antimicrobial activity, and surface treatment methods like hand-sanding and plasma treatment are employed to enhance exposure and efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polymer/glass composite articles are used to provide antimicrobial properties, then antimicrobial activity is achieved, but the antimicrobial efficacy is insufficient due to low surface concentration of antimicrobial agents
Solution Approach 1:
The patent applies local quality by creating a phase-segregated structure where copper-containing glass particles are concentrated at the composite surface rather than uniformly distributed throughout the bulk material. This phase separation ensures high local concentration of antimicrobial agents at the surface, directly addressing the insufficient surface concentration problem while maintaining overall composite integrity
Solution Approach 2:
The patent uses composite materials by combining polymer matrix with copper-containing glass particles to create a multi-phase composite structure. The glass particles serve as reservoirs for copper antimicrobial agents, and the phase separation mechanism ensures these agents are positioned at the surface, achieving both structural integrity and antimicrobial functionality
2Duration of action of stationary object
If copper-containing glass particles are distributed throughout the composite, then antimicrobial agents are provided, but the duration of antimicrobial action is insufficient
Solution Approach 1:
The patent applies preliminary action by pre-positioning copper-containing glass particles within the polymer matrix during composite fabrication. These particles are strategically distributed and phase-separated to the surface beforehand, creating a reservoir of antimicrobial agents that will be gradually released over time, ensuring both initial efficacy and sustained long-term action
Solution Approach 2:
The patent achieves continuity of useful action through the phase-separated structure where copper-containing glass particles continuously release antimicrobial copper ions at the surface. This creates a sustained gradient of copper concentration that maintains antimicrobial efficacy over extended periods, preventing microbial regrowth without requiring reapplication
3Quantity of substance
If the exterior surface is treated to expose more glass particles, then surface concentration of antimicrobial agents is increased, but the structural integrity may be compromised
Solution Approach 1:
The patent applies phase transitions by utilizing the phase separation behavior of copper-containing glass particles within the polymer matrix. During processing or service, these particles naturally segregate to the surface phase, increasing surface concentration of antimicrobial agents without requiring aggressive surface treatments that would compromise structural integrity. The phase transition is controlled and preserves composite strength
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite articles achieve significant log reductions in bacteria and viruses, maintaining antimicrobial efficacy for extended periods without external activation, demonstrating improved durability and effectiveness compared to traditional copper oxide-based composites.
Implementation Method 1
a plurality of second phase particles comprising a phase-separable glass with a copper-containing antimicrobial agent
Implementation Method 2
ensure that the microbes present on the surfaces of such article are in residence for a sufficient duration to be killed or neutralized by the antimicrobial agents within the composite articles
Data Source
Figure 1~1A
Figure 1B
Figure 2~3
AI summary
A method of making an antimicrobial composite article, including the steps: providing a matrix comprising a polymeric material; providing a plurality of second phase particles comprising an antimicrobial agent; melting the matrix to form a matrix melt; distributing the plurality of second phase particles in the matrix melt at a second phase volume fraction to form a composite melt; forming a composite article from the composite melt; and treating the composite article to form an antimicrobial composite article having an exterior surface comprising an exposed portion of the matrix and the plurality of second phase particles. The distributing step can employ an extrusion process. The forming a composite article step can employ an injection molding process. The treating step can employ abrading and plasma-treating the article to define the exterior surface.