Multicomposite Copper Microparticles for Sustained Antibacterial Release

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Solution Overview

Problem

Current antibacterial and biocidal materials for packaging and surfaces require immediate and sustained release of copper ions to inhibit microbial growth, but existing copper compounds often lead to toxicity and bulkiness, and fail to maintain efficacy at low concentrations.

Innovation Solution

A microstructured multicomposite copper microparticle comprising five different copper compounds (Antlerite, Brochantite, Chalcantite, Natrochalcite, and Hydrated Copper Sulfate Hydroxide) with varying solubilities, allowing for immediate and sustained antibacterial and biocidal effects without bulkiness, achieved through a spray drying process of copper hydroxide and sulfate solutions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If copper compounds are used to provide antibacterial and biocidal activity, then microbial growth inhibition is improved, but toxicity increases

Engineering Contradiction:

Improveantibacterial and biocidal activityVSAvoidtoxicity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The copper compound is segmented into five distinct crystalline phases (Antlerite, Brochantite, Chalcantite, Natrochalcite, and Hydrated Copper Sulfate Hydroxide) with different solubilities. This segmentation allows controlled release of copper ions at varying rates, providing sustained antibacterial activity while reducing acute toxicity through diluted concentration release.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the physical and chemical parameters of copper compounds by creating a multicomposite structure with five different crystalline phases. Each phase has distinct solubility parameters that control copper ion release kinetics, transforming the single-phase high-toxicity material into a multi-phase system with reduced toxicity and sustained efficacy.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If high concentrations of copper compounds are used to ensure antibacterial efficacy, then microbial growth inhibition is improved, but the material becomes bulky and loses translucency

Engineering Contradiction:

Improveantibacterial efficacyVSAvoidmaterial bulkiness

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The invention creates a composite material system combining five different copper compound phases in a single microparticle structure. This composite approach allows achieving high antibacterial efficacy through synergistic effects of multiple phases while maintaining low overall copper concentration, thus avoiding bulkiness and preserving material translucency.

Inventive Principle:

Principle #40Composite materials

3Speed

If immediate release of copper ions is provided for rapid antibacterial effect, then microbial growth inhibition speed is improved, but sustained release capability deteriorates

Engineering Contradiction:

Improverate of microbial growth inhibitionVSAvoidsustained antibacterial activity

Core Design Contradiction:

SpeedVSDuration of action of stationary object

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multicomposite structure is pre-configured with phases of varying solubilities before application. The most soluble phases provide immediate copper ion release for rapid initial antibacterial effect, while less soluble phases provide sustained release over time, creating a built-in temporal release profile without requiring external control mechanisms.

Inventive Principle:

Principle #10Preliminary action

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 microparticle provides a homogeneous, translucent material with enhanced antibacterial and biocidal activity at low copper concentrations, ensuring effective inhibition of microbial growth while minimizing toxicity and maintaining efficacy over time.

Implementation Method 1

a spray drying process in a hot air flow

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

5 different types of copper compounds, all regular and crystalline... with varying solubilities, allowing for immediate and sustained antibacterial and biocidal effects

Methodology Applied

Scientific EffectDissolution: Solvation

Data Source

PatentEP3621922B1Microstructured multicomposite copper microparticle with antibacterial and/or biocidal activity that comprises 5 different types of copper compounds

Publication Date: 2023.07.19 COPPERPROTEK SPA

Figure 1~1d
Figure 2~2b
Figure 3

AI summary

A copper microparticle with antibacterial and/or biocidal activity, wherein each microparticle has a regular, crystalline and microstructured composition that comprises 5 different copper compounds: Antlerite Cu3 +2(SO4) (OH) 4, Brochantite Cu4 +2SO4 (OH) 6, Chalcantite Cu+2SO4.5H2O, Natrochalcite NaCu2+2 ( SO4 ) 2OH ·H2O and Hydrated copper sulfate hydroxide Cu3 (SO4) 2 (OH) 2 -4H2O/2CuSO4 -Cu (OH) 2, with the microparticle having a size of between 5 and 50 μm. A process for preparing copper microparticles with antibacterial and/or biocidal activity. A concentrated polymeric composition (masterbatch) with antibacterial and/or biocidal activity that is incorporated during the extrusion process to molten polymers for forming rigid or flexible products such as fibers, filaments, and sheets. A use of a copper microparticle with antibacterial and/or biocidal activity. A use of a concentrated polymeric composition (masterbatch) with antibacterial and/or biocidal activity.