Antimicrobial Particulate Composition Using Calcite Immobilizer
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Solution Overview
Problem
Scaling up the production of antimicrobial metal compositions, such as those using vaterite as an immobilizer, results in instability and reduced antimicrobial activity due to kinetically driven reactions, leading to inadequate leaching of metal species, which is not replicable at production scales while maintaining a light-colored product.
Innovation Solution
Utilizing calcite with a specific surface area higher than 8 m^2/g as the immobilizer for antimicrobial metal particles like silver or copper nanoparticles, and incorporating a reducing agent and water-soluble silver salt in a controlled temperature process to enhance leaching and stability, ensuring the antimicrobial efficacy and light coloration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vaterite is used as an immobilizer for antimicrobial metal particles, then light color and good antimicrobial efficiency can be obtained at laboratory scale, but the product becomes unstable and loses antimicrobial activity when scaled up to production scale
Solution Approach 1:
The patent changes the polymorphic form parameter of calcium carbonate from vaterite to calcite. This parameter change fundamentally alters the crystal structure and surface properties, enabling the material to maintain stability and antimicrobial activity at production scale while vaterite fails under the same conditions.
Solution Approach 2:
The patent accepts that vaterite is suitable only for small-scale/laboratory applications and replaces it with calcite for production-scale applications. This is analogous to using different materials for different scales - vaterite for research/development and calcite for manufacturing.
2Manufacturing precision
If the reaction time is extended at production scale, then complete reaction can be achieved, but the product becomes unstable and antimicrobial activity is reduced
Solution Approach 1:
The patent changes the calcium carbonate polymorph from vaterite to calcite, which fundamentally alters the reaction kinetics. Calcite provides a more stable reaction pathway that achieves completeness without compromising product stability, unlike vaterite which becomes unstable with extended reaction times at production scale.
3Reliability
If metal nanoparticles are used directly, then strong antimicrobial activity is achieved, but toxicity to humans and environmental harm occur
Solution Approach 1:
The patent uses calcite as an intermediary carrier material that immobilizes metal nanoparticles. The calcite acts as a mediator between the metal particles and the environment, providing the antimicrobial benefit while reducing direct toxicity and environmental harm through controlled release and immobilization.
Solution Approach 2:
The patent creates a composite material system combining calcite (inorganic porous material) with metal nanoparticles (silver, copper, or zinc). This composite approach allows the metal particles to provide antimicrobial activity while the calcite matrix reduces toxicity and enables controlled leaching, achieving a balance between efficacy and safety.
4Ease of manufacture
If calcite with low specific surface area is used, then production is easier, but leaching of metal species and antimicrobial activity are insufficient
Solution Approach 1:
The patent specifies a minimum specific surface area parameter (greater than 8 m²/g) for the calcite material. This parameter optimization ensures sufficient surface area for metal particle immobilization and adequate leaching of metal species, thereby maintaining antimicrobial activity while working with commercially available calcite.
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 approach achieves enhanced leaching of antimicrobial metal species and maintains effective antimicrobial activity at production scales while maintaining a light-colored appearance, surpassing previous methods in both efficacy and stability.
Implementation Method 1
antimicrobial metal particles immobilized on calcite
Implementation Method 2
incorporating a reducing agent and water-soluble silver salt in a controlled temperature process
Data Source
AI summary
The present invention relates to an antimicrobial particulate composition and a process for preparing the same. The invention also relates to a personal care composition comprising the antimicrobial particulate composition. The invention ensures desired efficacy on preparation at production scale while exhibiting a desired light coloured appearance of the composition.