Antimicrobial polymer systems using multifunctional organometallic additives for thermoset hosts

Abstract

Described are antimicrobial polymer products made from mixtures of antimicrobial organometallic additives dispersed throughout a polymer host matrix.

1 - 17 . (canceled) 
     
     
         18 . An antimicrobial coating for coating a substrate, comprising:
 a thermoset liquid coating on the substrate,   wherein the thermoset liquid coating includes a polymer host matrix and at least one antimicrobial organometallic additive,   wherein the at least one antimicrobial organometallic additive is dispersed homogenously throughout and suspended within the polymer host matrix, thereby forming a substantially homogenous solid solution with the polymer host matrix, and   wherein the at least one antimicrobial organometallic additive includes at least one additive selected from the group consisting of silver stearate, cupric stearate and zinc stearate.   
     
     
         19 . The antimicrobial coating of  claim 18 , wherein the substrate is a hospital-grade flooring material. 
     
     
         20 . The antimicrobial coating of  claim 18 , wherein
 the substrate includes a metal, and   the thermoset powder coating is in direct contact with the metal of the substrate.   
     
     
         21 . The antimicrobial coating of  claim 18 , wherein the antimicrobial activity of the flooring material is 99% or greater. 
     
     
         22 . The antimicrobial coating of  claim 18 , wherein the polymer host matrix comprises an epoxy resin. 
     
     
         23 . The antimicrobial coating of  claim 18 , wherein
 the antimicrobial coating is formed on the substrate by heating a powder mixture on the substrate to melt the mixture to form the thermoset liquid coating on the substrate, and   the powder mixture includes a thermosetting powder and the at least one antimicrobial organometallic additive.   
     
     
         24 . The antimicrobial coating of  claim 23 , wherein
 the thermoset liquid coating is formed on the substrate by heating a dry powder mixture on a portion of the substrate to melt the dry powder mixture to form the thermoset liquid coating on the substrate,   the dry powder mixture comprises the polymer host matrix and the at least one antimicrobial organometallic additive, and   the dry powder mixture is applied to the substrate as a dry powder mixture.   
     
     
         25 . The antimicrobial coating of  claim 24 , wherein the dry powder mixture is applied to a metal of the substrate using an electrostatic powder coat process. 
     
     
         26 . The antimicrobial coating of  claim 18 , wherein the at least one antimicrobial organometallic additive comprises cupric stearate. 
     
     
         27 . The antimicrobial coating of  claim 26 , wherein the at least one antimicrobial organometallic additive further comprises silver stearate or zinc stearate. 
     
     
         28 . The antimicrobial coating of  claim 18 , wherein the at least one antimicrobial organometallic additive comprises a mixture of at least two additives selected from the group consisting of silver stearate, cupric stearate and zinc stearate. 
     
     
         29 . The antimicrobial coating of  claim 28 , wherein the at least two antimicrobial organometallic additives collectively comprise no more than about 3% by volume of the total volume of the polymer host matrix and the at least two antimicrobial organometallic additives together. 
     
     
         30 . The antimicrobial coating of  claim 28 , wherein the least two antimicrobial organometallic additives comprise zinc stearate. 
     
     
         31 . The antimicrobial coating of  claim 30 , wherein the at least two antimicrobial organometallic additives further comprise silver stearate or cupric stearate. 
     
     
         32 . A thermoset surface protectant, comprising:
 a polymer host matrix and at least one antimicrobial organometallic additive,   wherein the at least one antimicrobial organometallic additive is dispersed homogeneously throughout and suspended within the polymer host matrix, thereby forming a substantially homogenous solution with the polymer host matrix,   wherein the at least one antimicrobial organometallic additive includes at least one additive selected from the group consisting of silver stearate, cupric stearate and zinc stearate; and   wherein a majority of metallic species dispersed throughout the polymer host matrix are in the at least one antimicrobial organometallic additive.   
     
     
         33 . The thermoset surface protectant of  claim 32 , wherein the thermoset surface protectant has a degree of antimicrobial activity of 99% or greater. 
     
     
         34 . The thermoset surface protectant of  claim 32 , wherein the thermoset surface protectant is a hospital-grade thermoset surface protectant. 
     
     
         35 . The thermoset surface protectant of  claim 32 , wherein the polymer host matrix comprises an epoxy resin powder. 
     
     
         36 . The thermoset surface protectant of  claim 34  being a thermoset powder coating. 
     
     
         37 . The thermoset surface protectant of  claim 36 , wherein the thermoset powder coating is formed by heating a powder mixture on a substrate to melt the powder mixture to form the thermoset powder coating on the substrate;
 the powder mixture comprises the polymer host matrix and the at least one antimicrobial organometallic additive; and   the at least one antimicrobial organometallic additive is dispersed homogeneously throughout and suspended within the polymer host matrix, thereby forming a substantially homogenous solution with the polymer host matrix.   
     
     
         38 . The thermoset surface protectant of  claim 37 , wherein
 the thermoset powder coating is formed by heating a dry powder mixture on a portion of the substrate to melt the dry powder mixture to form the thermoset powder coating on the substrate,   the dry powder mixture comprises the polymer host matrix and the one or more antimicrobial organometallic additives, and   the dry powder mixture is applied to the substrate as a dry powder mixture.   
     
     
         39 . The thermoset surface protectant of  claim 38 , wherein the dry powder mixture is applied to the portion of the substrate using an electrostatic powder coat process. 
     
     
         40 . The thermoset surface protectant of  claim 32 , wherein the at least one antimicrobial organometallic additive comprises cupric stearate. 
     
     
         41 . The thermoset surface protectant of  claim 40 , wherein the at least one antimicrobial organometallic additive further comprises silver stearate or zinc stearate. 
     
     
         42 . The thermoset surface protectant of  claim 32 , wherein the at least one antimicrobial organometallic additive comprises zinc stearate. 
     
     
         43 . The thermoset surface protectant of  claim 42 , wherein the at least one antimicrobial organometallic additive further comprises silver stearate or cupric stearate. 
     
     
         44 . A method of applying a thermoset protectant to a substrate, comprising:
 applying a liquid thermoset resin on a surface of the substrate to form a thermoset coating on the substrate;   wherein the liquid mixture includes at least one antimicrobial organometallic additive mixed with a thermosetting resin to form a thermoset coating;   the thermoset coating includes a polymer host matrix and the at least one antimicrobial organometallic additive;   the at least one antimicrobial organometallic additive is dispersed homogeneously throughout and suspended within the polymer host matrix, thereby forming a substantially homogenous solution with the polymer host matrix;   the least one antimicrobial organometallic additive includes at least one additives selected from the group consisting of silver stearate, cupric stearate and zinc stearate; and   the majority of metallic species dispersed throughout the polymer host matrix are in the at least one antimicrobial organometallic additive.   
     
     
         45 . The method of  claim 44 , wherein the thermoset coating is chemically or mechanically bonded to a portion of the substrate. 
     
     
         46 . The method of  claim 44 , wherein the at least one antimicrobial organometallic additive is water insoluble or sparingly soluble in water and comprises a long-chain fatty acid chemically bonded to the metal portion. 
     
     
         47 . The method of  claim 44 , wherein the substrate is a hospital-grade flooring substrate. 
     
     
         48 . The method of  claim 44 , wherein the thermoset protectant has a degree of antimicrobial activity of 99% or greater. 
     
     
         49 . The method of  claim 44 , wherein the polymer host matrix comprises an epoxy resin. 
     
     
         50 . The method of  claim 44 , wherein the at least one antimicrobial organometallic additive comprises cupric stearate. 
     
     
         51 . The method of  claim 50 , wherein the at least one antimicrobial organometallic additive further comprises silver stearate or zinc stearate. 
     
     
         52 . The method of  claim 44 , wherein the at least one antimicrobial organometallic additive comprises zinc stearate. 
     
     
         53 . The method of  claim 52 , wherein the at least one antimicrobial organometallic additive further comprises silver stearate or cupric stearate. 
     
     
         54 . The antimicrobial coating of  claim 18 , wherein the at least one antimicrobial organometallic additive comprises no more than about 3% by volume of the total volume of the polymer host matrix and the at least one antimicrobial organometallic additive together. 
     
     
         55 . The thermoset surface protectant of  claim 32 , wherein the at least one antimicrobial organometallic additive comprises no more than about 3% by volume of the total volume of the polymer host matrix and the at least one antimicrobial organometallic additive together. 
     
     
         56 . The method of  claim 44 , wherein the at least one antimicrobial organometallic additive comprises no more than about 3% by volume of the total volume of the polymer host matrix and the at least one antimicrobial organometallic additive together. 
     
     
         57 . The antimicrobial coating of  claim 18 , wherein the thermoset liquid coating is selected from the group consisting of a liquid epoxy, a 1-part epoxy, and a 2-part epoxy. 
     
     
         58 . The antimicrobial coating of  claim 18 , wherein the substrate is selected from the group consisting of a flooring system surface, a food processing surface, food storage surface, food service surface, doctor's office surface, healthcare facility surface, gymnasium surface. 
     
     
         59 . The antimicrobial coating of  claim 58 , wherein the surface is selected from the group consisting of walls, ceilings, floors, and doors. 
     
     
         60 . The antimicrobial coating of  claim 58 , wherein the surface is selected from the group consisting of concrete, wood, vinyl, metal, thermoset materials, and polyurethane materials. 
     
     
         61 . The thermoset surface protectant of  claim 32 , wherein the thermoset liquid coating is selected from the group consisting of a liquid epoxy, a liquid 1-part epoxy, and a liquid 2-part epoxy. 
     
     
         62 . The thermoset surface protectant of  claim 32 , wherein the substrate is selected from the group consisting of a flooring system surface, a food processing surface, food storage surface, food service surface, doctor's office surface, healthcare facility surface, gymnasium surface. 
     
     
         63 . The thermoset surface protectant of  claim 62 , wherein the surface is selected from the group consisting of walls, ceilings, floors, and doors. 
     
     
         64 . The thermoset surface protectant of  claim 62 , wherein the surface is selected from the group consisting of concrete, wood, vinyl and metal. 
     
     
         65 . An antimicrobial coating for coating a substrate, comprising:
 a thermoset liquid on the substrate,   wherein the thermoset liquid includes a polymer host matrix and at least one antimicrobial organometallic additive,   wherein the at least one antimicrobial organometallic additive is dispersed homogenously throughout and suspended within the polymer host matrix, thereby forming a substantially homogenous solid solution with the polymer host matrix, and   wherein the at least one antimicrobial organometallic additive includes at least one additive selected from the group consisting of silver stearate, cupric stearate and zinc stearate.   
     
     
         66 . The antimicrobial coating of  claim 28 , wherein the at least two antimicrobial organometallic additives collectively comprise no more than about 5% by volume of the total volume of the polymer host matrix and the at least two antimicrobial organometallic additives together. 
     
     
         67 . The thermoset surface protectant of  claim 32 , wherein the polymer host matrix comprises an epoxy resin liquid. 
     
     
         68 . The thermoset surface protectant of  claim 34 , wherein the thermoset surface protectant coating is formed from a liquid coating on the substrate;
 the liquid coating comprises the polymer host matrix and the at least one antimicrobial organometallic additive; and   the at least one antimicrobial organometallic additive is dispersed homogeneously throughout and suspended within the polymer host matrix, thereby forming a substantially homogenous solution with the polymer host matrix.   
     
     
         69 . The method of  claim 44 , wherein the polymer host matrix comprises a liquid epoxy resin. 
     
     
         70 . The antimicrobial coating of  claim 18 , wherein the surface is selected from the group consisting of concrete, wood, vinyl, metal, thermoset materials, and polyurethane materials. 
     
     
         71 . The surface protectant of  claim 32 , wherein the surface is selected from the group consisting of concrete, wood, vinyl, metal, thermoset materials, and polyurethane materials.