Oxidized Phosphorus Copper Coatings for Color Stability
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Solution Overview
Problem
Copper-based coatings used in nautical and hospital settings face issues with color stability and antimicrobial efficacy, requiring frequent reapplication and being costly due to the need for solid copper, which is not always feasible or aesthetically pleasing.
Innovation Solution
A synthetic coating composed of oxidized and/or phosphorus copper powder, with a copper content of at least 60% by mass and particle sizes optimized to prevent fine powder issues, is used in combination with a binder and catalyst to create a stable, long-lasting, and aesthetically pleasing composite that retains antimicrobial properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional copper powder is used in composite coatings, then antimicrobial properties are achieved, but color stability deteriorates over time due to oxidation
Solution Approach 1:
The patent changes the chemical composition parameters of the copper powder by introducing phosphorus content (2-16% by mass) and controlling particle size distribution (not more than 70% of grains with diameter less than 45μm). This modifies the oxidation behavior to produce a stable deep black color while preserving antimicrobial copper content of at least 60% by mass
Solution Approach 2:
The patent creates a composite copper powder material combining copper with phosphorus to form a new material system. This composite structure provides both the deep black aesthetic appearance and stable antimicrobial properties, resolving the contradiction between color stability and antimicrobial efficacy
2Reliability
If solid copper is used to ensure antimicrobial properties, then antimicrobial efficacy is maximized, but cost increases significantly
Solution Approach 1:
The patent optimizes the copper content parameter to at least 60% by mass in the composite powder, which is sufficient for antimicrobial efficacy but represents a fraction of the copper content required for solid copper applications. This parameter optimization reduces material cost while maintaining functional performance
Solution Approach 2:
The patent uses a composite powder formulation that provides antimicrobial protection through a thin coating layer, replacing the need for expensive solid copper components. The optimized copper content delivers long-lasting antimicrobial efficacy at a fraction of the material cost
3Manufacturing precision
If fine copper powder is used to improve coating homogeneity, then coating quality improves, but manufacturing difficulties increase due to powder handling issues
Solution Approach 1:
The patent establishes a particle size distribution parameter where not more than 70% by mass of grains have a diameter less than 45μm. This controlled size distribution ensures adequate coating homogeneity while preventing the handling and application difficulties associated with excessively fine powders
Solution Approach 2:
The patent applies different particle size characteristics to different portions of the powder distribution, with a controlled proportion of fine particles for homogeneity and a significant portion of coarser particles for ease of handling and application
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 coating provides a deep black color that lasts over time, maintains antimicrobial efficacy, and is cost-effective by using a fraction of the copper content of solid copper, making it suitable for nautical and hospital applications.
Implementation Method 1
a first solution to stabilize the color of the coating over time was to use CuP 8 powder in the composite used to form the coating... A complementary solution found by the Applicant was to oxidize the micronized copper aggregates before their incorporation into the coating
Data Source
Figure 1
AI summary
The present invention relates to a synthetic coating containing oxidized and/or phosphorous copper, the method for obtaining the coating and the uses of said coating. The present invention further relates to an oxidized and/or phosphorous copper powder making it possible to obtain the coating of interest, the method for manufacturing said coating and its uses.