Two component aliphatic polyurethane/polyurea/polyaspartic coating

Abstract

A polymer based antimicrobial coating composition comprising water; polyol; paint additives; hexamethylene diisocyanate (HDI hardener); a catalyst; and an antimicrobial agent, wherein said water takes up between 30% to 35% of the polymer composition by weight, and the polymer has a pentane adipate diol with dimethyl propionic acid functionality with an acid number from 75 to 95 and hydroxyl number from 320 to 360, and amounts to 12% to 15% of the polymer composition by weight.

Claims

1. A polymer based antimicrobial coating composition comprising: water; polyol; paint additives; hexamethylene diisocyanate (HDI hardener); a catalyst; and an antimicrobial agent, wherein said water takes up between 30% to 35% of the polymer composition by weight, and the polymer has a pentane adipate diol with dimethyl propionic acid functionality with an acid number from 75 to 95 and hydroxyl number from 320 to 360, and amounts to 12% to 15% of the polymer composition by weight.

2. The polymer composition of claim 1, wherein the paint additive is a defoamer.

3. The polymer composition of claim 1, wherein the paint additive amounts to 4% to 7% of the polymer composition by weight.

4. The polymer composition of claim 1, wherein the polymer composition has an ultraviolet light stabilizer, that amounts to 2% to 3% of the polymer composition by weight.

5. The polymer composition of claim 1, wherein the polymer composition has the HDI hardener with an NCO content of 18% to 20% by weight with an equivalent weight from 190 to 240, amount from 30% to 35% by weight.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. As used herein, the word “exemplary” or “illustrative” means “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” or “illustrative” is not necessarily to be construed as preferred or advantageous over other implementations. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure which is defined by the claims. For purposes of description herein, the terms.

(2) One approach to reduce risk of infection in a hospital is to apply an antimicrobial coating to the floor. But, one challenge is to make this coating durable, especially on a floor with a lot of foot and machine traffic. One type of coating in accordance with an embodiment of the present invention is described below. It is a two-component aliphatic polymer-based coating with antimicrobial properties, which offers an improved way to prevent growth of various infectious diseases. The tradename is STERIL-101, which is a clear gloss high performance polymer. This polymer is water based, and does not use any volatile organic compound (“VOC”). Further, it has no odor.

(3) This polymer product has been tested by an independent Antimicrobial Test Laboratory for resistance to a wide range of microbial agents. Results are attached as Exhibit A to this specification. For example, STERIL-101 eliminated the MRSA with a reduction of 99.999.5%. See Exhibit B, Antimicrobial Test Laboratories, Study Report, Page 9, Carrier Type B.

(4) The STERIL-101 coating can be applied to a surface using a conventional paint brush, roller, or spray system. The coating can cure to a tack free finish in 4 to 5 hours, depending on temperature. The coating is also highly chemical and acid resistant, and its effectiveness can last up to 5 years with just one coat application at a rate of 300 to 400 sq.ft/gallon. The coating can be applied to almost any surface or material including fabric.

(5) In a preferred embodiment, STERIL-101 is a two-component (Part A and Part B) aliphatic polyurethane/polyurea/polyaspartic, clear, high-gloss protective coating with antimicrobial properties. The coating can be supplied as a high-solid concentrate and is mixed at 1:1 ratio and then reduced 50% with water. This combination results in a solid content from 45% to 50% solids by weight.

(6) Part A of the polymer compound primarily comprises of water at approximately 66%, polyols at approximately 22% of the polymer's total composition, and paint additives in the composition account for approximately 12% of the polymer's total composition. In addition, part B of the polymer compound primarily comprises of solid hexamethylene diisocyanate (“HDI”).

(7) Part A is formulated with an equivalent molecular weight ranging approximately-between 340 to 375. Note that the hydroxyl number of approximately 150-OH. The stoichiometric indexing ratio of NCO to OH is approximately OH=1, NCO=2.33. The indexing is “NCO high” due to the water content of the part A. See Docket No. RHART.001.P2.

(8) The catalyst used is dibutyltin dilaurate, a organotin compound.

(9) The antimicrobial agent is a 2:1 blend of emulsified water-based silver solution and zinc-pyrithione.

(10) The formulation is mixed at room temperature (72° F.) and is a water based polymer dispersion system. Preferably, mixing speed is low to medium. When the formulation is completed, the result is a clear dispersion with a slight yellow tint and no odor.

(11) The polymer would include water that takes up between 30% to 35% of the polymer total composition.

(12) The polymer would include carboxylic functional acrylate rheology additive with an acid number from 40 to 70, which would amount to 2% to 4% of the polymer's total composition.

(13) The polymer would include a paint additive that is also a defoamer.

(14) The paint additive in the polymer would amounts to 4% to 7% of the total polymer composition.

(15) The resulting polymer would contain an ultraviolet light stabilizer that amounts to 2% to 3% of the polymer's total composition.

(16) The polymer would contain reactive surfactant, 3-n-pentadecylphenol, with an equivalent weight of from 250 to 300, amounting between 2% to 4% of the polymer's total composition.

(17) The polymer would contain a diamine with an equivalent weight ranging from 130 to 160, and amount to 5% to 7% of the polymer's total composition.

(18) The resulting polymer would contain the chemical pentane adipate-diol with dimethyl propionic acid functionality with an acid number ranging from 75 to 95 and a hydroxyl number ranging from 320 to 360, amount to about 12% to 15% of the polymer's total composition.

(19) The polymer would have trimethylol propane (“TMP”) with an equivalent weight ranging from 35 to 50, and amounting 3% to 5% of the polymer's total composition.

(20) The polymer would also have a polyaspartic ester with an equivalent weight ranging from 250 to 300, and amounting 3% to 5% contribution to the polymer's total composition.

(21) The polymer would also contain a HDI hardener with an NCO content of 18% to 20% that also has an equivalent weight ranging from 190 to 240, and amounts from 30% to 35%.

(22) Antimicrobial additive, e.g., silver solution and zinc pyrithione, amount from 0.75% to 1.25% Docket No. RHART.001.P2

(23) Some notable advantages to the formulation described above:

(24) The polymer provides excellent antimicrobial properties, as shown in Exhibit A.

(25) The polymer comprises of high performance chemical and acid resistance and excellent U.V. resistance, especially that of non-yellowing presentation.

(26) When part A and Part B of the polymer are mixed at a 1:1 ratio, the resulting polymer compound can be reduced up to 60% with just water and still maintain its effectiveness.

(27) The polymer has the property of having zero VOC.

(28) The polymer product has a 1.5 hour working time and will dry to a tack free high gloss finish in 4 to 5 hours at room temperature (i.e. 72° F., 50% relative humidity).

(29) Good adhesion qualities for many surfaces, including aluminum and stainless steel, without the need of a primer.

(30) In the foregoing specification, the invention has been described with reference to specific embodiments thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the invention. For example, the reader is to understand that the specific ordering and combination of process actions described herein is merely illustrative, and the invention may appropriately be performed using different or additional process actions, or a different combination or ordering of process actions. For example, this invention is particularly suited for antimicrobial coatings; however, the invention can be used for any coating in general. As a further example, each feature of one embodiment can be mixed and matched with other features shown in other embodiments. Additionally and obviously, features may be added or subtracted as desired. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.

(31) Since many modifications, variations, and changes in detail can be made to the described preferred embodiments of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalence.