Antimicrobial Cuprous Oxide Coatings for Cost-Effective Durability

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Solution Overview

Problem

Current antimicrobial coatings face challenges such as high production costs, undesirable properties like softness, poor abrasion resistance, and unsuitable appearances, making them impractical for various applications.

Innovation Solution

A coated article featuring a substrate with an adhesion layer composed of copper oxide, zirconium oxide, or their combinations, topped with an antimicrobial copper suboxide layer that is at least five times thicker than the adhesion layer, providing effective antimicrobial properties without using metals other than copper.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If silver or other metals are used for antimicrobial coatings, then antimicrobial properties are achieved, but cost increases and appearance or abrasion resistance becomes unsuitable

Engineering Contradiction:

Improveantimicrobial propertiesVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the material parameter from expensive metals (silver) to copper-based compounds (cuprous oxide, cupric oxide), achieving cost reduction while maintaining antimicrobial properties through copper's inherent biocidal characteristics

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite oxide layers (cuprous oxide and cupric oxide) combined with zirconium oxide adhesion layers, creating a multi-layer coating that provides both antimicrobial activity and mechanical durability, resolving the trade-off between cost and performance

Inventive Principle:

Principle #40Composite materials

2Reliability

If nanoparticle vapor deposition is used to deposit antimicrobial nanoparticles, then antimicrobial properties are achieved, but process complexity and cost increase

Engineering Contradiction:

Improveantimicrobial propertiesVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex nanoparticle vapor deposition processes with conventional coating techniques applied to copper-based oxide layers, simplifying the manufacturing process while maintaining antimicrobial effectiveness through the inherent properties of copper compounds

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses readily available copper-based materials that can be applied through standard coating processes rather than expensive nanoparticle deposition, achieving cost-effective antimicrobial coatings through simple, scalable manufacturing

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Strength

If antimicrobial coatings are made thicker to improve durability, then abrasion resistance improves, but the coating becomes less aesthetically suitable

Engineering Contradiction:

Improveabrasion resistanceVSAvoidappearance

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent employs composite oxide structures where cuprous oxide and cupric oxide layers provide both protective and aesthetic properties, with the multi-layer composition enabling thickness optimization that maintains both durability and appearance quality

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent optimizes the thickness parameters of individual oxide layers to achieve the minimum required for durability while maintaining aesthetic appearance, using the specific optical and physical properties of copper oxides to balance protection with visual quality

Inventive Principle:

Principle #35Parameter changes

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 offers a cost-effective, durable, and aesthetically suitable antimicrobial coating that inhibits microbial growth, addressing the limitations of existing antimicrobial materials by ensuring the antimicrobial copper suboxide layer is significantly thicker and composed of copper-based materials only.

Implementation Method 1

at least one adhesion layer disposed over the substrate. The at least one adhesion layer includes a component selected from the group consisting of a copper oxide, a zirconium oxide, and combinations thereof

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

an antimicrobial copper suboxide layer disposed over the at least one adhesion layer... the antimicrobial copper suboxide layer is at least 5 times thicker than the at least one adhesion layer

Methodology Applied

Scientific EffectAntimicrobial action:

Data Source

PatentUS20240334938A1Antimicrobial cuprous oxide-containing coatings

Publication Date: 2024.10.10 VAPOR TECHNOLOGIES INC

AI summary

A coated article having an antimicrobial coating is provided. The coated article includes a substrate and at least one adhesion layer disposed over the substrate. The at least one adhesion layer includes a component selected from the group consisting of a copper oxide, a zirconium oxide, and combinations thereof. Advantageously, an antimicrobial copper suboxide layer disposed over the at least one adhesion layer.