Antimicrobial Polymer Surfaces With Silane-Treated Copper Oxide

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Solution Overview

Problem

Existing composite structural solid materials face limitations in incorporating high copper oxide loadings due to interference with cross-linkage and chemical binding, affecting both antimicrobial efficacy and product integrity, while copper surfaces are expensive and aesthetically unappealing.

Innovation Solution

A method for producing composite structural solid materials with copper oxide loadings ranging from 10% to 50% w/w % by uniformly dispersing copper oxide particles within a polymeric resin matrix, ensuring structural integrity and aesthetic appearance through controlled mixing and polymerization processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If copper oxide loading is increased to improve antimicrobial efficacy, then antimicrobial activity is enhanced, but cross-linkage and chemical binding are disrupted affecting product integrity

Engineering Contradiction:

Improveantimicrobial efficacyVSAvoidproduct integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses silane-treated copper oxide particles as an intermediary solution. The silane coating on the copper oxide particles acts as a mediator that prevents direct interference with the polymer cross-linking process while still allowing the copper oxide to maintain its antimicrobial activity. This resolves the contradiction by enabling high copper oxide loading (improving antimicrobial efficacy) without disrupting the chemical binding mechanisms (preserving product integrity).

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the surface chemistry parameter of copper oxide particles through silane treatment. This modification alters how the copper oxide particles interact with the polymer matrix, allowing them to remain dispersed and effective without interfering with cross-linkage. The parameter change enables simultaneous achievement of high antimicrobial activity and maintained product strength.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If copper and its alloys are used to control microbial burden, then antimicrobial effectiveness is achieved, but cost and aesthetic appearance deteriorate

Engineering Contradiction:

Improveantimicrobial effectivenessVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces expensive copper and copper alloys with a more cost-effective alternative: silane-treated copper oxide particles embedded in a polymer matrix. This substitution maintains antimicrobial effectiveness while significantly reducing material cost, addressing the contradiction between effectiveness and manufacturing cost.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If copper and its alloys are used to control microbial burden, then antimicrobial effectiveness is achieved, but aesthetic appearance and maintenance difficulty worsen

Engineering Contradiction:

Improveantimicrobial effectivenessVSAvoidaesthetic maintenance

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces copper and copper alloys with silane-treated copper oxide particles in a polymer matrix, which do not suffer from oxidation staining. This substitution maintains antimicrobial effectiveness while eliminating the aesthetic degradation and maintenance issues associated with metal surfaces, resolving the contradiction between effectiveness and ease of operation.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 method achieves rapid and effective microbiocidal activity against bacteria, fungi, and spores, with a 99.9% reduction in microbial count within 2 hours and 90% spore reduction within 24 hours, maintaining product strength and appearance.

Implementation Method 1

The effect of ionic kill mechanisms is well documented. Copper oxide has been demonstrated to be an effective antimicrobial agent

Methodology Applied

Scientific EffectIonic kill mechanism:

Implementation Method 2

interference with cross linkage and chemical binding mechanisms, necessary for the creation of the solid surface polymeric panels and slab material

Methodology Applied

Scientific EffectCross-linkage: Chemical Bonding

Data Source

PatentUS20250228238A1Antimicrobial Solid Surfaces and Treatments and Processes for Preparing the Same

Publication Date: 2025.07.17 EOS SURFACES LLC

AI summary

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.