Zirconium Phosphate Silver Antibacterial Agent
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Solution Overview
Problem
Conventional silver-based antibacterial agents face challenges with heat resistance, chemical resistance, and resin coloring, and are poor in processability when blended with plastics, limiting their durability and practical applications.
Innovation Solution
A zirconium phosphate-based silver antibacterial agent with a specific composition, represented by the formula Ag a Na b H c (H 3 O) d Zr e Hf f (PO 4) 3 ·nH 2 O, where a, b, c, d, e, and f are within defined ranges, is synthesized through ion-exchange and calcination, enhancing its stability and compatibility with plastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional silver-based antibacterial agents are used, then antibacterial effect is achieved, but heat resistance and chemical resistance are poor
Solution Approach 1:
The patent uses a composite structure where silver ions are incorporated into the hexagonal zirconium phosphate crystal lattice. The zirconium phosphate framework provides thermal and chemical stability, while the silver ions maintain antibacterial activity. This composite approach resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The patent optimizes the P/Zr ratio parameter in the zirconium phosphate structure to enhance both thermal stability and silver ion retention. By adjusting this compositional parameter, the material achieves improved heat resistance while maintaining effective silver ion release for antibacterial action.
2Reliability
If conventional silver-based antibacterial agents are used, then antibacterial effect is achieved, but resin coloring occurs
Solution Approach 1:
The patent controls the P/Zr ratio and silver ion content parameters to prevent excessive silver aggregation that causes coloring. By optimizing these compositional parameters, the material maintains antibacterial efficacy while minimizing color change in plastic products.
Solution Approach 2:
The silver ions are distributed uniformly within the zirconium phosphate crystal structure at the atomic level, preventing localized aggregation that would cause visible coloring. This uniform distribution maintains antibacterial activity while keeping the material visually compatible with clear or light-colored plastics.
3Reliability
If conventional silver-based antibacterial agents are used, then antibacterial effect is achieved, but processability when blended with plastics is poor
Solution Approach 1:
The patent optimizes particle size and surface characteristics of the zirconium phosphate by controlling synthesis parameters. This results in improved flow properties and dispersion characteristics, enabling easy blending with plastics through conventional processing methods while maintaining antibacterial effectiveness.
Solution Approach 2:
The hexagonal zirconium phosphate structure provides a porous framework that facilitates uniform dispersion of silver ions and improves compatibility with plastic matrices. This structure enhances processability by allowing better mixing and distribution during manufacturing while preserving antibacterial function.
4Manufacturing precision
If calcining method is used to synthesize zirconium phosphate, then P/Zr ratio control is achieved, but uniform mixing of raw materials is difficult and productivity is low
Solution Approach 1:
The patent uses a wet chemical synthesis method where reagents are pre-mixed in solution before crystallization occurs. This preliminary mixing in liquid phase ensures homogeneous distribution of elements, eliminating the need for difficult solid-state mixing and subsequent high-temperature calcining, thus improving both precision and productivity.
Solution Approach 2:
The patent replaces mechanical mixing and high-temperature calcining with solution-based chemical synthesis. By using wet chemistry methods, the process achieves uniform composition through molecular-level mixing in solution, substituting mechanical operations with chemical processes that are more efficient and precise.
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 resulting silver-based antibacterial agent exhibits improved heat resistance, chemical resistance, and prevention of coloring, along with enhanced processability, making it suitable for use in plastic products with sustained antibacterial efficacy.
Implementation Method 1
zirconium phosphate based inorganic ion exchangers have been utilized in various applications by virtue of their features
Implementation Method 2
a calcining method in which raw materials are mixed, and thereafter calcined at not less than 1000°C using a calcining furnace to effect the synthesis
Data Source
AI summary
The present invention provides a silver based inorganic antibacterial agent excellent in heat resistance and chemical resistance, lowered in resin coloring and excellent in processability. The present invention has been completed by finding out that problems can be solved by a silver ion-containing zirconium phosphate represented by the following general formula (1) which is produced by a wet synthesis under specific production conditions. AgsNabHc(H3O)dZreHff(PO4)3·nH2O (1) wherein, in the formula (1), a, b, c, d, e and f are positive numbers satisfying 1.75<(e+f)<2.25 and a+b+c+d+4(e+f)=9; and n is not more than 2.