Cu-Based Antimicrobial Film with Surface Ion Enrichment

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Solution Overview

Problem

Conventional antimicrobial articles face challenges in maintaining effective antimicrobial efficacy due to issues such as insufficient surface concentration of antimicrobial agents, costly surface treatments, degradation of mechanical and optical properties, and oxidation of copper-based materials over time, leading to reduced effectiveness.

Innovation Solution

The development of antimicrobial films with an asymmetric distribution of copper-containing materials towards the surface, utilizing specific ligands and additives to enhance copper mobility and oxidation resistance, and selecting polymers that interact weakly with copper to maintain a copper reservoir, ensuring prolonged antimicrobial activity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If copper-based antimicrobial materials are used, then antimicrobial efficacy is improved, but oxidation of copper occurs over time reducing effectiveness

Engineering Contradiction:

Improveantimicrobial efficacyVSAvoidoxidation resistance

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

Ligands are introduced as intermediary substances that coordinate with copper ions, forming stable complexes that prevent oxidation while maintaining antimicrobial activity. The ligands act as mediators between the copper material and the environment, protecting the copper from oxidizing agents.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates composite material systems combining copper-containing materials with ligands and polymer matrices. This composite structure provides both the antimicrobial properties of copper and the oxidation resistance provided by the ligand-copper complexes and polymer environment.

Inventive Principle:

Principle #40Composite materials

2Quantity of substance

If surface treatments are applied to enhance antimicrobial properties, then surface concentration of antimicrobial agents is improved, but mechanical and optical properties deteriorate

Engineering Contradiction:

Improvesurface concentration of antimicrobial agentsVSAvoidmechanical properties

Core Design Contradiction:

Quantity of substanceVSStrength

Solution Approach 1:

The antimicrobial materials and ligands are incorporated into the polymer matrix during the manufacturing process, before the final product is formed. This preliminary incorporation ensures uniform distribution and proper bonding, achieving high surface concentration without requiring damaging post-manufacturing surface treatments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses composite polymer-copper-ligand materials where the antimicrobial components are integrated into the bulk material structure. This approach maintains mechanical integrity while providing sufficient surface concentration of antimicrobial agents through the composite's inherent properties.

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If copper is distributed uniformly throughout the film, then copper reservoir is maintained, but surface concentration for antimicrobial activity is reduced

Engineering Contradiction:

Improvecopper reservoirVSAvoidsurface concentration

Core Design Contradiction:

Stability of the object's compositionVSQuantity of substance

Solution Approach 1:

The patent creates local quality variations in copper distribution by using ligands that guide copper ion migration toward the surface. The bulk material maintains copper reservoir through uniform distribution, while the surface achieves higher concentration through ligand-mediated transport, creating different copper concentrations in different regions of the material.

Inventive Principle:

Principle #3Local quality

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 films achieve high antimicrobial efficacy with improved durability and reduced costs by maintaining copper at the surface, preventing oxidation, and enhancing mechanical properties while maintaining continuous antimicrobial performance.

Implementation Method 1

extracting ions from the antimicrobial material toward the outer surface

Methodology Applied

Scientific EffectIon extraction:

Implementation Method 2

utilizing specific ligands and additives to enhance copper mobility and oxidation resistance

Methodology Applied

Scientific EffectOxidation resistance: Oxidation

Implementation Method 3

the outer surface is configured to interact with surface microorganisms

Methodology Applied

Scientific EffectAntimicrobial action:

Data Source

PatentUS12584001B2High efficacy Cu-based anti-microbial films and substrates and methods of making the same

Publication Date: 2026.03.24 CORNING INC

AI summary

A method of forming an antimicrobial film, including providing a substrate with a polymer coating disposed thereon, the polymer coating including: an antimicrobial material, an inner surface contacting the substrate, and an outer surface opposite the inner surface; and extracting ions from the antimicrobial material toward the outer surface, such that the outer surface interacts with surface microorganisms. A composition, including a polymer; an antimicrobial material; and at least one of an organic solvent and an additive. The antimicrobial material comprises at least one of copper-containing glass particles, copper oxide particles, copper metal particles, copper salts, copper coordination complexes, cuprite crystals, and a combination thereof. Further, the additive can be selected to increase the oxidation resistance of the antimicrobial material.