Methods of Processing Chlorhexidine-Containing Polymerizable Compositions and Antimicrobial Articles Formed Thereby

Abstract

Advantageously, para-chloroaniline (PCA) is minimal in antimicrobial articles prepared according to the method of the invention. A method of forming an antimicrobial article according to the invention comprises steps of: providing a polymerizable composition; incorporating an antimicrobially effective amount of at least one chlorhexidine-containing antimicrobial agent into the polymerizable composition; and, polymerizing the polymerizable composition to form chlorhexidine-containing polymer of the antimicrobial article, wherein processing temperature during the method is less than about 80° C.

1 . A method of forming an antimicrobial article, the method comprising steps of:
 providing a polymerizable composition comprising at least two different components, wherein each of the at least two different components are mutually reactive with each other via chemically different reactive moieties to form a polymeric backbone, and wherein each of the at least two different components has an average molecular weight that is less than about 10% of the weight average molecular weight of the fully polymerized composition;   incorporating an antimicrobially effective amount of at least one chlorhexidine-containing antimicrobial agent into the polymerizable composition; and,   polymerizing the polymerizable composition to form chlorhexidine-containing polymer of the antimicrobial article, wherein the chlorhexidine-containing polymer is polyurethane-based,   wherein processing temperature during the method is less than about 80° C.   
     
     
         2 . The method of  claim 1 , wherein the processing temperature during the method is less than about 40° C. 
     
     
         3 . The method of  claim 1 , wherein the processing temperature during the method is about room temperature. 
     
     
         4 . The method of  claim 1 , wherein the processing temperature during the method is less than that temperature at which chlorhexidine decomposes to para-chloroaniline. 
     
     
         5 . The method of  claim 1 , wherein the antimicrobially effective amount of at least one chlorhexidine-containing antimicrobial agent in the antimicrobial article consists essentially of chlorhexidine free base. 
     
     
         6 . The method of  claim 1 , wherein the antimicrobially effective amount of at least one chlorhexidine-containing antimicrobial agent comprises chlorhexidine salt. 
     
     
         7 . The method of  claim 1 , wherein the method comprises continuously forming the chlorhexidine-containing polymer on a web. 
     
     
         8 . The method of  claim 1 , wherein the polymerizable composition is essentially free of solvents. 
     
     
         9 . The method of  claim 1 , wherein the chlorhexidine-containing polymer is essentially free of unreacted solvent. 
     
     
         10 . The method of  claim 1 , wherein polymerization of the polymerizable composition is initiated using at least one radiation source selected from ultraviolet radiation and electron beam radiation. 
     
     
         11 . The method of  claim 1 , wherein polymerization of the polymerizable composition is initiated without use of an external source of thermal radiation. 
     
     
         12 . The method of  claim 1 , wherein the chlorhexidine-containing polymer is a polymer film. 
     
     
         13 . The method of  claim 1 , wherein the chlorhexidine-containing polymer is an adhesive. 
     
     
         14 . The method of  claim 1 , wherein the chlorhexidine-containing polymer is a backing for an adhesive-coated antimicrobial article. 
     
     
         15 . The method of  claim 1 , wherein 100% reactive chemistry is used to form the chlorhexidine-containing polymer. 
     
     
         16 - 18 . (canceled) 
     
     
         19 . The antimicrobial article prepared according to the method of  claim 1 . 
     
     
         20 . An antimicrobial article comprising at least one chlorhexidine-containing polymer, wherein less than about 0.0001 mg/mL detectable para-chloroaniline is present in the chlorhexidine-containing polymer. 
     
     
         21 . The antimicrobial article of  claim 20 , wherein the article comprises about 10 weight % chlorhexidine free base based on total weight of the chlorhexidine-containing polymer. 
     
     
         22 . The antimicrobial article of  claim 20 , wherein essentially no detectable para-chloroaniline is present in the chlorhexidine-containing polymer. 
     
     
         23 . The antimicrobial article prepared according to the method of  claim 12 .