A GERM-REPELLENT PLASTIC, A MANUFACTURING METHOD THEREFOR, AND A GERM-REPELLENT PLASTIC ITEM MADE THEREFROM

Abstract

A germ-repellent plastic contains an anti-biofouling compound, and a basic plastic. The anti-biofouling compound is optionally selected from the group of a polyol, a polyether polyol, a polyol derivative, and a combination thereof; or the anti-biofouling compound is selected from the group consisting of a polyether, a poly (ethylene glycol) ether, a polysorbate, and a combination thereof; or the anti-biofouling compound is selected from the group consisting of poly (ethylene glycol) sorbitan monolaurate, poly (ethylene glycol) sorbitan monooleate, poly (ethylene glycol) sorbitol hexaoleate, ceteareth, and a combination thereof. The basic plastic is not a blend of a low-density polyethylene polymer and an ethyl vinyl acetate copolymer, a blend of a polypropylene polymer and an ethyl vinyl acetate copolymer, a blend of polyolefin elastomer polymers and a polyvinyl chloride polymer. A method for manufacturing such a germ-repellent plastic and a germ-repellent plastic item are also described.

Claims

1-27. (canceled)

28. A germ-repellent plastic comprising: a) an anti-biofouling compound; and b) a basic plastic, wherein the basic plastic is not a blend of a low-density polyethylene polymer and an ethyl vinyl acetate copolymer, a blend of a polypropylene polymer and an ethyl vinyl acetate copolymer, or a blend of polyolefin elastomer polymers and a polyvinyl chloride polymer.

29. The germ-repellent plastic according to claim 28, wherein the basic plastic is a thermoplastic.

30. The germ-repellent plastic according to claim 28, wherein the anti-biofouling compound is comingled with an intermediate plastic to form a masterbatch, and wherein the masterbatch is comingled with the basic plastic to form the germ-repellent plastic.

31. The germ-repellent plastic according to claim 30, wherein the masterbatch comprises from about 0.001% by weight to about 50% by weight of the germ-repellent plastic.

32. The germ-repellent plastic according to claim 30, wherein the intermediate plastic comprises at least one polymeric segment that is compatible with the basic plastic.

33. The germ-repellent plastic according to claim 30, wherein the intermediate plastic does not contain the same polymeric segment as the basic plastic.

34. The germ-repellent plastic according to claim 30, wherein the anti-biofouling compound comprises from about 0.01% by weight to about 25% by weight of the masterbatch.

35. The germ-repellent plastic according to claim 28, wherein the basic plastic has a Tg greater than or equal to about 60° C.

36. The germ-repellent plastic according to claim 35 wherein the basic plastic is selected from the group consisting of acrylonitrile butyl styrene, polyethylene terephthalate, and a combination thereof, and wherein the anti-biofouling compound and the basic plastic are directly comingled to form the germ-repellent plastic.

37. The germ-repellent plastic according to claim 35, wherein the anti-biofouling compound comprises from about 0.001% by weight to about 50% by weight of the germ-repellent plastic.

38. The germ-repellent plastic according to claim 35, wherein the basic plastic comprises from about 50% by weight to about 99.999% by weight of the germ-repellent plastic.

39. A method for manufacturing a germ-repellent plastic comprising the steps of: i) providing an anti-biofouling compound; ii) providing a basic plastic wherein the basic plastic is not a blend of a low-density polyethylene polymer and an ethyl vinyl acetate copolymer, a blend of a polypropylene polymer and a ethyl vinyl acetate copolymer, or a blend of polyolefin elastomer polymers, or a polyvinyl chloride polymer; and iii) comingling the anti-biofouling compound with the basic plastic.

40. The method for manufacturing the germ-repellent plastic according to claim 39, wherein the basic plastic is a thermoplastic.

41. The method for manufacturing the germ-repellent plastic according to claim 39, further comprising the steps of: iv) providing an intermediate plastic; v) comingling the anti-biofouling compound with the intermediate plastic to form a masterbatch; and vi) comingling the masterbatch with the basic plastic to form the germ-repellent plastic.

42. The method for manufacturing the germ-repellent plastic according to claim 39 wherein the basic plastic has a Tg greater than or equal to about 60° C.

43. The method for manufacturing the germ-repellent plastic according to claim 42, wherein the basic plastic is selected from the group consisting of acrylonitrile butyl styrene, polyethylene terephthalate, and a combination thereof, and wherein the anti-biofouling compound is comingled directly with the basic plastic to form the germ-repellent plastic.

44. The method for manufacturing the germ-repellent plastic according to claim 39 wherein the comingling step takes place in an extruder, a mould, and a combination thereof; or an extruder.

45. The method for manufacturing the germ-repellent plastic item according to claim 44 further comprising the step of thermoforming the plastic item.

46. A method for manufacturing a germ-repellent plastic comprising the steps of: i) providing an anti-biofouling compound; ii) providing a basic plastic having a Tg greater than or equal to about 60° C.; and iii) comingling the anti-biofouling compound with the basic plastic, wherein there is substantially no intermediate plastic.

47. A germ-repellent plastic item comprising the germ-repellent plastic according to claim 28.

Description

EXAMPLE 1

[0072] 100 g of an ethylene/acrylic acid/maleic acid terpolymer intermediate plastic in the presence of 10 g of a ceteareth anti-biofouling compound to form a masterbatch. The basic plastic is a commercially-available PP polymer. The masterbatch is combined with the basic plastic at a weight ratio of 1:45. The masterbatch and the basic plastic are fed into a single-screw extruder having a temperature ranging from 110° C. in the front to 200° C. in the rear to form a germ-repellent plastic (A). The single-screw extruder extrudes the germ-repellent plastic (A) in the form of a sheet.

[0073] The weight percentage in the final plastic sheet is therefore: 2% ethylene/acrylic acid/maleic acid terpolymer intermediate plastic, 0.2% ceteareth anti-biofouling compound, and 97.8% PP polymer.

[0074] A comparative plastic (Control 1) containing the same PP polymer is also prepared in an identical manner, except that that this comparative sample did not contain any masterbatch, intermediate plastic, or anti-biofouling compound.

[0075] A swab test (above) is conducted comparing germ-repellency of the germ-repellent plastic (A) with that of the comparative plastic (Control 1).

EXAMPLE 1, Table 1:

[0076]

TABLE-US-00001 Sheet Sample with E. coli Replicate 1 Replicate 2 Average comparative 2.00 × 10.sup.1 8.00 × 10.sup.1 5.00 × 10.sup.1 plastic (Control 1) germ-repellent 0 0 0 plastic (A)

[0077] As can be seen in Table 1, with E. coli, the germ-repellent plastic (A) of the present invention provides a greater than 99.9% reduction in the swab test as compared to the comparative plastic (Control 1).

EXAMPLE 1, Table 2:

[0078]

TABLE-US-00002 Sheet Sample with S. aureus Replicate 1 Replicate 2 Average comparative 8.99 × 10.sup.3 9.92 × 10.sup.3 9.46 × 10.sup.3 plastic (Control 1) germ-repellent  2.8 × 10.sup.2 1.12 × 10.sup.2 1.96 × 10.sup.2 plastic (A)

[0079] As can be seen in Table 2, with S. aureus, the germ-repellent plastic (A) of the present invention provides a 97% reduction in the swab test as compared to the comparative plastic (Control 1). In other words, the germ-repellent plastic (A) only has 3% of the adhesion of the comparative plastic (Control 1).

[0080] The Melt Flow Index (MFI) is tested according to ASTM D1238-10 at conditions of 230° C. and 2.16 kg. The MFI of the PP germ-repellent plastic (A) was +15.4% as compared to the unmodified PP (Control 1).

EXAMPLE 2

[0081] A germ-repellent plastic (B) and a comparative plastic (Control 2) were prepared as in EXAMPLE 1, except that the basic plastic is HDPE, and the single-screw extruder temperature ranges from 110° C. in the front to 190° C. in the back when preparing the germ-repellent plastic.

[0082] A swab test (above) is conducted comparing germ-repellency of the germ-repellent plastic (B) with that of the comparative plastic (Control 2).

EXAMPLE 2, Table 1:

[0083]

TABLE-US-00003 Sheet Sample with E. coli Replicate 1 Replicate 2 Average comparative 1.80 × 10.sup.2 2.20 × 10.sup.2 2.00 × 10.sup.2 plastic (Control 2) germ-repellent 0 0 0 plastic (B)

[0084] As can be seen in Table 1, with E. coli, the germ-repellent plastic (B) of the present invention provides a >99% reduction in the swab test as compared to the comparative plastic (Control 2).

EXAMPLE 2, Table 2:

[0085]

TABLE-US-00004 Sheet Sample with S. aureus Replicate 1 Replicate 2 Average comparative 2.35 × 10.sup.4 4.95 × 10.sup.4 3.65 × 10.sup.4 plastic (Control 2) germ-repellent 3.24 × 10.sup.3 1.90 × 10.sup.3 2.57 × 10.sup.3 plastic (B)

[0086] As can be seen in Table 2, with S. aureus, the germ-repellent plastic (B) of the present invention provides a 92% reduction in the swab test as compared to the comparative plastic (Control 2). In other words, the germ-repellent plastic (B) only has 8% of the adhesion of the comparative plastic (Control 2).

[0087] The Melt Flow Index (MFI) is tested according to ASTM D1238-10 at conditions of 190° C. and 2.16 kg. The MFI of the HDPE germ-repellent plastic (B) was +1.4% as compared to the unmodified HDPE (Control 2).

EXAMPLE 3

[0088] The masterbatch is prepared according to EXAMPLE 1, except that the basic plastic is EVA to form a germ-repellent plastic (C). The temperature at the front of the single-screw extruder is 110° C. and the temperature at the back is 190° C.

[0089] A comparative plastic sample (Control 3) containing only the basic plastic (EVA) is also prepared in an identical manner, except that no masterbatch, intermediate plastic, or anti-biofouling compound is included.

[0090] A swab test (above) is conducted comparing germ-repellency of the germ-repellent plastic sample (C) with that of the comparative plastic sample (Control 3).

EXAMPLE 3, Table 1:

[0091]

TABLE-US-00005 Sheet sample with E. coli Replicate 1 Replicate 2 Average comparative 2.00 × 10.sup.2 1.94 × 10.sup.2 1.97 × 10.sup.2 plastic (Control 3) germ-repellent 0 0 0 plastic (C)

[0092] As can be seen in Table 1, with E. coli, when formed as a sheet, the germ-repellent plastic (C) of the present invention provides a >99% reduction in the swab test as compared to the comparative plastic (Control 3).

EXAMPLE 3, Table 2:

[0093]

TABLE-US-00006 Tube sample with S. aureus Replicate 1 Replicate 2 Average comparative 1.16 × 10.sup.5 1.36 × 10.sup.5 1.26 × 10.sup.5 plastic (Control 3) germ-repellent  2.6 × 10.sup.3 1.80 × 10.sup.3 2.20 × 10.sup.3 plastic (C)

[0094] As can be seen in Table 2, with S. aureus, when formed as a sheet, the germ-repellent plastic (C) of the present invention provides a 98% reduction in the swab test as compared to the comparative plastic (Control 3).

[0095] The Melt Flow Index (MFI) is tested according to ASTM D1238-10 at conditions of 190° C. and 2.16 kg. The MFI of the EVA germ-repellent plastic (C) was +11.7% as compared to the unmodified EVA (Control 3).

EXAMPLE 4

[0096] 100 parts of commercially-available ABS is comingled with 5 parts PEG sorbitol hexaoleate in a twin-screw extruder to form a germ-repellent plastic (D). The twin-screw extruder has a temperature range from 150° C. in the front to 210° C. in the back.

[0097] The germ-repellent plastic is then formed into a sheet via hot press moulding at a temperature of 200° C.

[0098] A comparative plastic sample (Control 4) containing only ABS is also prepared in an identical manner, except that no masterbatch, intermediate plastic, or anti-biofouling compound is included.

[0099] A swab test (above) is conducted comparing germ-repellency of the germ-repellent plastic sample (D) with that of the comparative plastic sample (Control 4).

EXAMPLE 4, Table 1:

[0100]

TABLE-US-00007 sheet sample with E. coli Replicate 1 Replicate 2 Average comparative 9.20 × 10.sup.2 8.00 × 10.sup.2 8.60 × 10.sup.2 plastic (Control 4) germ-repellent 2.00 × 10.sup.1 4.00 × 10.sup.1 3.00 × 10.sup.1 plastic (D)

[0101] As can be seen in Table 1, with E. coli, when formed as a sheet, the germ-repellent plastic (D) of the present invention provides a 96% reduction in the swab test as compared to the comparative plastic (Control 4).

EXAMPLE 4, Table 2:

[0102]

TABLE-US-00008 sheet sample with S. aureus Replicate 1 Replicate 2 Average comparative 1.82 × 10.sup.5 1.72 × 10.sup.5 1.77 × 10.sup.5 plastic (Control 4) germ-repellent 2.00 × 10.sup.4 1.40 × 10.sup.4 1.70 × 10.sup.4 plastic (D)

[0103] As can be seen in Table 2, with S. aureus, when formed as a sheet, the germ-repellent plastic (D) of the present invention provides a 90% reduction in the swab test as compared to the comparative plastic (Control 4).

[0104] The Melt Flow Index (MFI) is tested according to ASTM D1238-10 at conditions of 200° C. and 2.16 kg. The MFI of the ABS germ-repellent plastic (D) was +24.1% as compared to the unmodified ABS (Control 4).

EXAMPLE 5

[0105] 100 parts of commercially-available PET is comingled with 5 parts PEG sorbitol hexaoleate in a twin-screw extruder to form a germ-repellent plastic (E). The twin-screw extruder has a temperature range from 180° C. in the front to 240° C. in the back.

[0106] The germ-repellent plastic is then formed into a sheet via hot press moulding at a temperature of 240° C.

[0107] A comparative plastic sample (Control 5) containing only PET is also prepared in an identical manner, except that no masterbatch, intermediate plastic, or anti-biofouling compound is included.

[0108] A swab test (above) is conducted comparing germ-repellency of the germ-repellent plastic sample (E) with that of the comparative plastic sample (Control 5).

EXAMPLE 5, Table 1:

[0109]

TABLE-US-00009 Sheet sample with E. coli Replicate 1 Replicate 2 Average comparative 3.60 × 10.sup.2 4.00 × 10.sup.2 3.80 × 10.sup.2 plastic (Control 5) germ-repellent 2.02 × 10.sup.1 2.64 × 10.sup.1 2.33 × 10.sup.1 plastic (D)

[0110] As can be seen in Table 1, with E. coli, when formed as a tube, the germ-repellent plastic (E) of the present invention provides a 93% reduction in the swab test as compared to the comparative plastic (5).

EXAMPLE 5, Table 2:

[0111]

TABLE-US-00010 Sheet sample with S. aureus Replicate 1 Replicate 2 Average comparative 1.76 × 10.sup.5 1.81 × 10.sup.5 1.79 × 10.sup.5 plastic (Control 5) germ-repellent 6.94 × 10.sup.4 4.40 × 10.sup.4 5.67 × 10.sup.4 plastic (L)

[0112] As can be seen in Table 2, with S. aureus, when formed as a sheet, the germ-repellent plastic (E) of the present invention provides a 68% reduction in the swab test as compared to the comparative plastic (5).

[0113] The Melt Flow Index (MFI) is tested according to ASTM D1238-10 at conditions of 265° C. and 5.0 kg. The MFI of the PET germ-repellent plastic (E) was +24.1% as compared to the unmodified PET (Control 5).

[0114] It should be understood that the above only illustrates and describes examples whereby the present invention may be carried out, and that modifications and/or alterations may be made thereto without departing from the spirit of the invention.

[0115] It should also be understood that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately, or in any suitable subcombination.

[0116] The publications, references, etc. specifically cited herein are each hereby incorporated by reference in its entirety. However, no admission is made as to their availability and/or relevance as prior art, either alone or in combination.