Self-Sterilizing Surface Laminate Using Sulfonated Polymer Coatings
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Solution Overview
Problem
Existing surfaces, such as touch surfaces, are prone to microbial contamination and require frequent disinfection, which is impractical and can lead to the emergence of resistant pathogens, while current antimicrobial coatings using metals like copper are not durable.
Innovation Solution
A laminate structure with an antimicrobial layer comprising sulfonated polymers, such as perfluorosulfonic acid polymers, is applied electrostatically or adhesively to surfaces, capable of killing at least 90% of microbes within 120 minutes and is removably adhered using a support layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual disinfection is used on touch surfaces, then microbial contamination is reduced, but it is impractical, expensive, time consuming, and can lead to resistant pathogens
Solution Approach 1:
The touch surface is equipped with a self-sterilizing function through the laminate structure containing sulfonated polymer. When microbes contact the surface, the sulfonated polymer automatically kills them without requiring manual intervention. This transforms the disinfection process from a manual service to a self-service system, resolving the contradiction between reliability and ease of operation.
2Reliability
If metals like copper are used to impart antimicrobial properties, then antimicrobial protection is achieved, but the metals are leachable and therefore not durable
Solution Approach 1:
The patent changes the chemical composition parameter from metallic elements (copper, silver) to sulfonated polymer compounds. This parameter change maintains the antimicrobial function while eliminating the leaching problem that caused poor durability. The sulfonated polymer provides stable, long-lasting antimicrobial protection without the durability issues of metal-based coatings.
3Reliability
If copper nanoparticle coatings are applied to surfaces, then antiviral and antibacterial properties are achieved, but the protection takes over 2 hours to kill bacteria
Solution Approach 1:
The patent changes the chemical composition from copper nanoparticles to sulfonated polymer with specific functional groups. This parameter change dramatically accelerates the microbe-killing speed from over 2 hours to within minutes of contact, while maintaining effective antiviral and antibacterial capability. The sulfonated polymer's chemical structure enables faster microbial cell wall disruption.
4Productivity
If a self-sterilizing surface is designed to kill microbes quickly, then protection efficiency is improved, but the surface may become more complex
Solution Approach 1:
The patent uses a composite laminate structure consisting of a support layer and an antimicrobial layer containing sulfonated polymer. This composite material approach achieves high microbe-killing efficiency while maintaining relatively simple construction. The laminate structure combines the mechanical support function with the antimicrobial function in an integrated but simple configuration.
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 laminate structure effectively kills at least 99% of microbes within 30 minutes, providing durable antimicrobial protection and is suitable for various substrates, including high-touch surfaces.
Implementation Method 1
The sulfonated polymer has been shown to be effective in killing at least 99% of microbes within 30 minutes of contact with the laminate structure
Implementation Method 2
The laminate structure is removably adhered to the surfaces electrostatically, adhesively, or by mechanical means
Implementation Method 3
The laminate structure comprises an antimicrobial layer and a second layer... The laminate structure is removably adhered to the surfaces electrostatically, adhesively, or by mechanical means
Data Source
AI summary
The disclosure relates to laminate structures to cover or protect substrates or surfaces. The laminate structure comprises a support layer and a self-sterilizing/antimicrobial layer comprising a sulfonated polymer, capable of killing microbes within minutes and for an extended period of time. The sulfonated polymer has a sufficient degree of sulfonation to kill in less than 120 minutes at least 90% of microbes in contact with the surfaces, and for extended protection of the surfaces for at least one month. The laminate structure is particularly suitable for protecting high-touch surfaces such as door knobs, touch-screens, tables, as well as for use with facemasks, face shields, or as self-sterilizing wraps for surgical instruments and supplies. The laminates can also be used as garments or to cover/protect personnel having contagious diseases, etc., to decrease the transmission of microbes.