Antimicrobial Copper Alloy Silicone Sheets

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Solution Overview

Problem

There is a need for materials and methods that can effectively reduce the duration for which viruses, bacteria, and other microorganisms survive on surfaces, as current disinfecting methods are cumbersome and not always effective in preventing the transmission of infectious diseases like COVID-19.

Innovation Solution

The development of antimicrobial material sheets using cost-efficient materials like copper alloy fabrics and silicone polymers, which are calendered or roto-cured to create durable, antimicrobial surfaces suitable for various products, including those with high touch areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If disinfectant is applied to surfaces to kill viruses and bacteria, then the antimicrobial effect is achieved, but the process becomes cumbersome and requires frequent manual intervention

Engineering Contradiction:

Improveantimicrobial effectVSAvoiddisinfection process

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent incorporates antimicrobial agents (silver, copper, zinc, or their alloys) into the material sheets during manufacturing, so that the antimicrobial protection is already present before the product is put into service. This preliminary action eliminates the need for subsequent disinfection applications, as the surface continuously exhibits antimicrobial properties without requiring manual intervention.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The material sheets possess inherent antimicrobial capabilities through the integrated metallic agents that continuously inhibit microbial growth on contact. The surface serves itself by maintaining antimicrobial activity without external assistance, automatically preventing microbial contamination rather than requiring periodic disinfectant treatment.

Inventive Principle:

Principle #25Self-service

2Duration of action of stationary object

If antimicrobial agents are integrated into material sheets during manufacturing, then continuous antimicrobial protection is achieved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvecontinuous antimicrobial protectionVSAvoidmanufacturing process

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The patent utilizes the inherent properties of metallic materials (silver, copper, zinc, or their alloys) that naturally exhibit antimicrobial characteristics. By selecting materials with these inherent properties and controlling their integration into the sheet structure during manufacturing, the process achieves continuous antimicrobial protection without requiring complex additional treatment steps or multiple processing stages.

Inventive Principle:

Principle #35Parameter changes

3Strength

If metallic fabrics are calendered with polymer to create fused material sheets, then durable antimicrobial surfaces are produced, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvedurability of antimicrobial surfaceVSAvoidcalendering process

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent combines metallic fabrics (containing silver, copper, zinc, or their alloys) with polymer materials through calendering to create composite material sheets. This composite structure integrates the antimicrobial properties of the metal with the durability and flexibility of the polymer, producing a fused material that maintains both antimicrobial effectiveness and mechanical strength while accommodating standard manufacturing tolerances.

Inventive Principle:

Principle #40Composite materials

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

These antimicrobial surfaces significantly reduce the presence of microorganisms, providing continuous protection against disease transmission without the need for frequent disinfection, making them suitable for everyday objects and critical in healthcare settings.

Implementation Method 1

calendered with a polymer... to create a fused material sheet

Methodology Applied

Scientific EffectHeat: Heating

Implementation Method 2

calendered with a polymer... to create a fused material sheet

Methodology Applied

Scientific EffectPressure: Pressurisation

Implementation Method 3

roto-cured to create durable, antimicrobial surfaces

Methodology Applied

Scientific EffectThermal curing: Heating

Data Source

PatentUS11872793B2Method of preparing antimicrobial sheets for articles of manufacture having antimicrobial properties

Publication Date: 2024.01.16 KELLY PATRICK

AI summary

A method of preparing antimicrobial material sheets suitable for manufacturing a wide range of products having antimicrobial properties. In exemplary embodiments, a fabric having antimicrobial agents may be calendered with a polymer such as a silicone compound or an elastomer, in order to create a fused material sheet that contains the antibacterial properties of the fabric. In exemplary embodiments, the antimicrobial agent is copper, a copper alloy, silver, a silver alloy, or other suitable antimicrobial agent from which a fabric may be created. In some exemplary embodiments, an uncured silicone composition and copper alloy fabric are calendered to obtain an antimicrobial material sheet suitable for compression molding a wide range of products. In some exemplary embodiments, an uncured silicone composition and copper alloy fabric are calendered and roto-cured to obtain a cured antimicrobial material sheet or sheet rolls that maybe suitable for die-cutting.