Thermoplastic particles which comprise an antiviral or antimicrobial agent

Abstract

This invention relates to novel porous materials that possess antiviral and/or antimicrobial properties. The invention encompasses a porous material having antiviral or antimicrobial properties-which is comprised of a porous substrate and an antiviral or antimicrobial agent. The invention also encompasses a process for making porous materials that possess antiviral and/or antimicrobial properties and the products of the process.

What is claimed is:  
     
         1 . A porous thermoplastic material which comprises a porous thermoplastic substrate and an antiviral or antimicrobial agent.  
     
     
         2 . The porous thermoplastic material of claim I wherein the porous thermoplastic substrate is a porous thermoplastic selected from the group consisting of polyolefins, nylons, polycarbonates, poly(ether sulfones), and mixtures thereof.  
     
     
         3 . The porous thermoplastic material of  claim 2  wherein the thermoplastic is a polyolefin selected from the group consisting of: ethylene vinyl acetate; ethylene methyl acrylate; polyethylenes; polypropylenes; ethylene-propylene rubbers; ethylene-propylenediene rubbers; poly(1-butene); polystyrene; poly(2-butene); poly(1-pentene); poly(2-pentene); poly(3-methyl-1-pentene); poly(4-methyl-1-pentene); 1,2-poly-1,3-butadiene; 1,4-poly-1,3-butadiene; polyisoprene; polychloroprene; poly(vinyl acetate); poly(vinylidene chloride); and mixtures and derivatives thereof.  
     
     
         4 . The porous thermoplastic material of  claim 3  wherein the polyolefin is a polyethylene.  
     
     
         5 . The porous thermoplastic material of  claim 1  wherein the antiviral or antimicrobial agent is selected from the group consisting of: phenolic and chlorinated phenolic compounds; resorcinol and its derivatives; bisphenolic compounds; benzoic esters; halogenated carbanilides; polymeric antimicrobial agents; thazolines; trichloromethylthioimides; natural antimicrobial agents; metal salts; broad-spectrum antibiotics, and mixtures thereof.  
     
     
         6 . The porous thermoplastic material of  claim 5  wherein the antiviral or antimicrobial agent is selected from the group consisting of: 2,4,4′-trichloro-2′-hydroxydiphenyl ether; 3-(4-chlorophenyl)-1-(3,4-dichlorophenyl)urea; poly(iminoimidocarbonyl iminoimidocarbonyl iminohexamethylene hydrochloride); silver ions; and salts and mixtures thereof.  
     
     
         7 . The porous thermoplastic material of  claim 1  which further comprises a lubricant, colorant, or filler.  
     
     
         8 . The porous thermoplastic material of  claim 7  wherein the filler is selected from the group consisting of: carbon black, cellulose fiber powder, siliceous fillers, polyethylene fibers and filaments, and mixtures thereof.  
     
     
         9 . A porous thermoplastic material which comprises: 
 a sintered porous polyethylene substrate; and    an antiviral or antimicrobial agent selected from the group consisting of 2,4,4′-trichloro-2′-hydroxy-diphenyl ether, 3-(4-chlorophenyl)-1-(3,4-dichlorophenyl)urea, poly(iminoimidocarbonyl iminoimidocarbonyl iminohexamethylene hydrochloride), silver ions, and salts and mixtures thereof.    
     
     
         10 . A porous thermoplastic material which comprises: 
 a sintered porous polyethylene core; and    a coating layer disposed over at least part of the porous polyethylene core;    wherein the coating layer comprises an antiviral or antimicrobial agent.    
     
     
         11 . The porous thermoplastic material of  claim 10  wherein the coating layer further comprises a thermoplastic or hydrogel material.  
     
     
         12 . The porous thermoplastic material of  claim 11  wherein the thermoplastic or hydrogel material is hydrophilic polyurethane.  
     
     
         13 . A particle comprising an antiviral or antimicrobial agent disposed within and/or on the surface of a thermoplastic core.  
     
     
         14 . The particle of  claim 13  which has a diameter of from about 5 μm to about 1000 μm.  
     
     
         15 . The particle of  claim 14  wherein the thermoplastic core is made of a thermoplastic selected from the group consisting of polyolefins, nylons, polycarbonates, poly(ether sulfones), and mixtures thereof; and the antiviral or antimicrobial agent is selected from the group consisting of: 2,4,4′-trichloro-2′-hydroxy-diphenyl ether; 3-(4-chlorophenyl)-1-(3,4-dichlorophenyl)urea; poly(iminoimidocarbonyl iminoimidocarbonyl iminohexamethylene hydrochloride); silver ions; and salts and mixtures thereof.  
     
     
         16 . A process for making a porous thermoplastic material which comprises sintering thermoplastic particles to form a porous substrate and contacting the porous substrate with an antiviral or antimicrobial agent.  
     
     
         17 . The method of  claim 16  wherein the thermoplastic particles are particles of polyolefins, nylons, polycarbonates, poly(ether sulfones), or mixtures thereof.  
     
     
         18 . The method of  claim 16  wherein the antiviral or antimicrobial agent is selected from the group consisting of: 2,4,4′-trichloro-2′-hydroxy-diphenyl ether; 3-(4-chlorophenyl)-1-(3,4-dichlorophenyl)urea; poly(iminoimidocarbonyl iminoimidocarbonyl iminohexamethylene hydrochloride); silver ions; and salts and mixtures thereof.  
     
     
         19 . A product of the process of  claim 16 .  
     
     
         20 . A process for making a porous thermoplastic material which comprises sintering thermoplastic particles to form a porous substrate, and contacting the porous substrate with a coating mixture which comprises an antiviral or antimicrobial agent.  
     
     
         21 . The method of  claim 20  wherein the coating mixture further comprises a thermoplastic or hydrogel material.  
     
     
         22 . The method of  claim 21  wherein the thermoplastic or hydrogel material is hydrophilic polyurethane.  
     
     
         23 . The method of  claim 20  wherein the thermoplastic particles are particles of polyolefins, nylons, polycarbonates, poly(ether sulfones), or mixtures thereof.  
     
     
         24 . The method of  claim 20  wherein the antiviral or antimicrobial agent is selected from the group consisting of: 2,4,4′-trichloro-2′-hydroxy-diphenyl ether; 3-(4-chlorophenyl)-1-(3,4-dichlorophenyl)urea; poly(iminoimidocarbonyl iminoimidocarbonyl iminohexamethylene hydrochloride); silver ions; and salts and mixtures thereof.  
     
     
         25 . A product of the process of  claim 20 .  
     
     
         26 . A process for making a porous thermoplastic material which comprises sintering thermoplastic particles which comprise an antiviral or antimicrobial agent.  
     
     
         27 . The method of  claim 26  wherein the thermoplastic particles are formed by underwater pelletizing a mixture comprised of a thermoplastic and an antiviral or antimicrobial agent.  
     
     
         28 . The method of  claim 26  wherein the thermoplastic particles are selected from the group consisting of particles of: polyolefins, nylons, polycarbonates, poly(ether sulfones), and mixtures thereof.  
     
     
         29 . The method of  claim 28  wherein the polyolefin is polyethylene.  
     
     
         30 . The method of  claim 26  wherein the antiviral or antimicrobial agent is selected from the group consisting of: 2,4,4′-trichloro-2′-hydroxy-diphenyl ether; 3-(4-chlorophenyl)-1-(3,4-dichlorophenyl)urea; poly(iminoimidocarbonyl iminoimidocarbonyl iminohexamethylene hydrochloride); silver ions; and salts and mixtures thereof.  
     
     
         31 . A product of the process of  claim 26.