Copper Antimicrobial Coating Corrosion Resistance via Oxidation and Composite Layers
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Solution Overview
Problem
Copper and copper alloys with antimicrobial properties are prone to corrosion, which affects their durability and efficacy in microbial killing, necessitating the development of antimicrobial coatings with improved corrosion resistance.
Innovation Solution
A coated substrate comprising a base layer of zirconium or titanium-based materials with one or more copper-containing antimicrobial layers, where copper atoms are in the +1 or +2 oxidation state, enhancing corrosion resistance and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper and copper alloys are used for antimicrobial properties, then microbial killing efficacy is improved, but corrosion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining copper-containing antimicrobial layers with base layers made of corrosion-resistant materials such as zirconium carbonitride, titanium carbonitride, chromium oxide, or diamond-like carbon. This creates a multi-layer coating structure where the copper layer provides antimicrobial efficacy while the base layer provides corrosion resistance, thus resolving the contradiction between antimicrobial performance and corrosion resistance
Solution Approach 2:
The patent changes the oxidation state parameter of copper atoms from the typical 0 state to +1 or +2 oxidation states. This parameter change improves both corrosion resistance and durability while maintaining antimicrobial properties, as oxidized copper forms more stable compounds that are less prone to further corrosion yet retain biocidal activity
2Reliability
If copper and copper alloys are used for antimicrobial properties, then microbial killing efficacy is improved, but durability deteriorates
Solution Approach 1:
The multi-layer composite structure protects the copper-containing antimicrobial layers from degradation over time. The base layers act as protective barriers that prevent mechanical damage and environmental degradation, thereby extending the service life and durability of the antimicrobial coating while maintaining its efficacy
Solution Approach 2:
Changing copper to oxidized states (+1 or +2) improves durability because oxidized copper compounds are chemically more stable and less prone to degradation than metallic copper. This parameter change ensures long-term stability and extended service life of the antimicrobial coating
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 solution provides a coated substrate with improved corrosion resistance and durability, maintaining effective antimicrobial properties while reducing the tendency to corrode.
Implementation Method 1
each of the one or more copper-containing antimicrobial layers includes copper atoms in the +1 oxidation state and/or the +2 oxidation state
Data Source
Figure 1~2
Figure 3A~3Ac
Figure 3B
AI summary
A coated substrate includes a base substrate and a base layer disposed over the substrate. Typically, the base layer is composed of a component selected from the group consisting of zirconium carbonitrides, zirconium oxycarbides, titanium carbonitrides, titanium oxycarbides, and combinations thereof. One or more copper-containing antimicrobial layers are disposed over the base layer such that each of the one or more copper-containing antimicrobial layers includes copper atoms in the +1 oxidation state and/or the +2 oxidation state.