COMPOSITION AND PROCESS FOR REMOVING MILDEW AND FUNGAL GROWTH

Abstract

Compositions and process for removing mildew, mold and fungal growth from various surfaces, e.g., metal comprising powder and/or granule chemicals, consisting essentially of a combination of inorganic and organic active ingredients, including corrosion inhibitors, surfactants, activators, buffer reagents with or without water.

Claims

1. Process for removing mildew and fungal growth from various surfaces by treating said surfaces with effective amounts of compositions consisting essentially of, in parts by weight, from about: (a) 5.0 to 35 parts of an inorganic perborate with about 0.0 to 30 parts of pyrrolidone, (b) from about 2.0 to 35 parts of an inorganic silicate with about 1.0 to 5.0 parts of a triazole, (c) from about 1.0 to 10 parts of an inorganic sulfate with about 1.0 to 10 parts of a phenol, (d) from about 1.0 to 5.0 parts of a diamine, (e) from about 1.0 to 7.5 parts of at least one carbonate, (f) and from 0.0 to 120 parts of water.

2. The process of claim 1 wherein the perborate is a metal perborate.

3. The process of claim 1 wherein the silicate is metasilicate and the triazole is benzotriazole.

4. The process of claim 1 wherein the sulfate is a metal sulfate and the phenol is an alkyl phenol.

5. The process of claim 1 wherein the water content of the total composition is about one liter.

6. The process of claim 1 wherein the water content of the composition ranges from about 0.0 to 120 parts.

7. The process of claim 1 wherein the phenol is aryl phenol.

8. The process of claim 1 wherein the diamine is tetraacetylethylene diamine.

9. The process of claim 1 wherein the carbonate is a combination of mono and polycarbonates.

10. The process of claim 1 wherein the perborate is 10 parts, the pyrrolidone is 20 parts, the silicate is 4 parts, the triazole is 3.0 parts, the sulfate is 4.0 parts, the phenol is 3.0 parts, the diamine is 5.0 parts and the carbonates is 7.5 parts.

11. The process of claim 1 wherein the surface is a metal surface.

12. The process of claim 1 wherein the surface is a nonmetal surface.

Description

SUMMARY AND DESCRIPTION OF THE INVENTION

[0008] Ingredients of the invention (mildew remover dry kit) are made of stable solid materials (powder and/or granules), soluble in water, and commercially available as shown in Tables (1 and 2). The Composition comprises at least two different compounds as follows: Two Active Ingredients (one organic and one inorganic), two Corrosion Inhibitors (one organic and one inorganic), Non-ionic Surfactants, Anionic Surfactants, Active Ingredient Activator (organic) and two Buffer Reagents.

[0009] The specific compounds set forth in Tables 1-5 are species identified in the following generic compounds which are operable in the invention.

[0010] The carbonates include salts of the carbonic acid, containing the radical CO.sub.3. The carbonates of the alkali metals are water-soluble; all others are insoluble, bi-Acid.

[0011] The diamines are compounds containing 2 NH.sub.2 groups, aliphatic-compounds containing 2 amino groups attached to a carbon chain, e.g., ethylenediamine, aromatic-compounds containing 2 amino groups attached to a carbon ring e.g., phenylenediamene, heterocyclic-saturated ring compounds with the amino group in the ring, e.g., diethylenediamine, homocyclic-Aromatic diamines.

[0012] The sulfates M.sub.2SO.sub.4, are salts of sulfuric acid, acid-MHSO.sub.4. basic-M(OH)SO.sub.4, A subsulfate, bi-Acid s, hydrogen-Acid s, hypo-M.sub.2S.sub.2O.sub.6, dithionate, neutral-, normal-sulfate, pyro-M.sub.2S.sub.2O.sub.7, thio-M.sub.2S.sub.2O.sub.3.

[0013] The triazoles, C.sub.2H.sub.3N.sub.369.06, Pyrrodiazole, 1,2,4 Common t.,pyrro-(a,b)-diazole, colorless needles, m.120, soluble in water, benzosee benzotriazole, and diphenylsee diphenyltriazole.

[0014] The silicates are salts derived from silica or the silicic acids, silicates are derived from M.sub.4SiO.sub.4, orthosilicate, and M.sub.2SiO.sub.3, metasilicate, which may combine to form polysilicates.

[0015] The borates are salts of boric acid, DI-MH.sub.2BO.sub.3. Acid borate, pyro-b, hypo-MH.sub.3BO, metaa salt containing the BO.sub.3 radical, pyroa salt containing the >B.sub.4O.sub.7 radical.

TABLE-US-00001 TABLE (1) Composition of Formula #4 Parts by Weight Percentage Chemicals Weight (g) % Active Ingredient 1-Sodium Perborate 25.0 50.5 2-Pyrrolidone 0.0 to 30 Corrosion Inhibitors 1-Sodium Metasilicate 4.0 8.1 2-Benzotriazol 3.0 6.1 Surfactants 1-Sodium Lauryl Sulfate 4.0 8.1 2-RHODACAL DS-10 3.0 6.1 Active Ingredient Activator 1-Tetraacetylethylene- 3.0 6.0 diamine (TAED) Buffer reagents 1-Sodium Carbonate 2.5 5.0 2-Sodium Bicarbonate 5.0 10.1 Water One Liter 100.0

TABLE-US-00002 TABLE (2) Composition of Formula #5 Parts by Weight Percentage Chemicals Weight (g) % Active Ingredients 1- Sodium Perborate 10.0 or 5.0-35 18.3 2- Peroxydel-30 20 or 10-30 36.7 Corrosion Inhibitors 1- Sodium Metasilicate 4.0 or 2.0-35 7.3 2- Benzotriazol 3.0 or 1.0-5.0 5.5 Surfactants 1- Sodium Lauryl Sulfate 4.0 or 1.0-10 7.3 2- RHODACAL DS-10 3.0 or 1.0-10 5.5 Active Ingredient Activator 1- Tetraacetylethylene- diamine (TAED) 3.0 or 1.0-5.0 5.5 Buffer Reagents 1- Sodium Carbonate 2.5 or 1.0-5.0 4.6 2- Sodium Bicarbonate 5.0 or 1.0-10 9.2 Water One Liter or 0 to 120.sup. 100.0 parts by weight Note: Peroxydel-30: 2-Pyrrolidone RHODACAL DS-10 (Benzene Sulfonic Acid, Dodecyl, branched, Sodium Salt)

[0016] For example, the compositions (Formulas 4 and 5) are dissolved in water and used within about 24 hours to remove mildew from aircraft surfaces. After 24 hours, the efficiency rapidly declines, and by 96 hours, the formula is comparable to water in its effectiveness. The cleaning procedure for removing mildew from aircraft surfaces is specifically described herein.

[0017] Prior to applying the mildew remover, clean all affected surfaces to remove oil and dirt using standard aircraft cleaning materials and processes specified in NAVAIR 01-1A-509-2 and other applicable documents. Liberally apply the mildew remover to affected surfaces using clean cheesecloth, clean cotton rags, soft bristle brushes or any related authorized cleaning gear per NAVAIR 01-1A-509-2. Scrubbing may be required. Allow mildew remover to remain on the surface for about 5-15 minutes. Thoroughly rinse treated surfaces with fresh water to ensure no residue remains. Inspect surfaces for any remaining mildew. Black or brown mildew growth should be removed; however, residual mildew staining remaining on the paint is acceptable and may appear light brown and/or gray in color. Re-apply mildew remover as necessary followed by thorough rinsing. Inspect treated surfaces for detergent residue. If any indication of residue remains, rinse treated surfaces again with fresh water and re-inspect. Repeat the process as necessary to remove all residues.

[0018] The compatibility of the compositions of this invention with metals and non-metals were studied in accordance with the requirements of MIL-PRF-8557E specification. The following test methods were considered important for use of the invention as follows:

Sandwich Corrosion Test (ASTM F 1110-02)

Total Immersion Corrosion (ASTM F 483-02)

Hydrogen Embrittlement (ASTM F 519-97)

Cadmium Corrosion Test (ASTM F 1111-98)

Effect on Painted Surfaces (ASTM F 502-02)

Effect on Plastics (ASTM F 484-02)

Effect of Polyimide Wire (Section 4.5.11, MIL-PRF-85570E)

pH Value (ASTM E 70-02)

[0019] The compatibility test results for the compositions or formulations on metals and non-metals are shown in Table 3. The test results indicate that the formulation is safe to use on different metals and non-metals surfaces without causing any damage. Besides the use of the formulations on aircraft surfaces, the formulations could be used for removing mildew from other surfaces such as boats, ships and other industrial applications.

TABLE-US-00003 TABLE (3) Test of Formula #5 in accordance with MIL-PRF-85570 (Cleaning Compound, Aircraft Exterior) Mildew Remover Specification Dry Kit Requirements Limits Formulation pH (ASTM E 70) 7-10 9.23 Sandwich Corrosion Test Not more than distilled water Pass (ASTM F 110) No Visible Corrosion mg/cm.sup.2/day mg/cm.sup.2/day Total Immersion A1 7075 (250/12) 0.04 0.0002 Corrosion Test Steel 1020 (AMS 5046) 0.04 0.0000 (ASTM F 483) Ti 6Al 4V (AMS 9046) 0.04 0.0002 Cadmium Corrosion Mg AZ31B (AMS4377) 0.20 0.0004 (ASTM F 1111) mg/cm.sup.2/day 0.20 0.0004 Hydrogen No Failure to 150 hr. when loaded Pass Embrittlement at 45% (ASTM F 519 1a) Effect on Plastics Acrylic Type A Pass (ASTM F 484) No Crazing- 8 hrs. Acrylic Type C Pass No Crazing-8 hrs. Polycarbonate Pass MIL-P-83310-2 hrs. Effect on Painted No Softening > 1 Pencil Hardness Pass Surfaces (ASTM F 502) Effect on Polyimide No dielectric leakage Pass Wire No visual effect greater than that of distilled water

[0020] The initial efficacy test for the formulations was performed at Covance Laboratory. Two dry formulations (#4 and #5) were sent to Covance to perform the efficacy-screening test. The testing results indicate that both formulations are effective in removing two mildew fungi from hard surface as shown in Table 4. The ingredients of both formulations are identical (active and inert) with the exception of formulation #5, which contains one additional active ingredient (Peroxydel-30). It was noticed that formulation #5 dissolves faster and easier than formulation #4 in water. Miscibility of the dry kit in water is essential to prepare the cleaning solution. Based on this observation, formulation #5 was selected as the optimal formulation for the mildew remover dry kit. A detailed procedure for the efficacy test is described in the Covance Laboratory Report.

[0021] Formulation's 4 and 5 also meet the requirement of the EPA. The requirement of NAVCLEAN includes the efficacy of Formulations #4 and #5 as a fungicide and mildewcide and as cleaning agent intended particularly for use on metals. Moreover, it was unexpected to discover the effectiveness of formulation 4 and 5 as compared to Trichophyton Mentagrophytes and Aspergillus niger.

TABLE-US-00004 TABLE 4 Efficacy Screening Test for the Mildew Remover Dry Formulation Number of tubes exhibiting confirmed growth/Total Test Contact Time number of tubes.sup.a System (Minutes) Formulation #4 Formulation #5 Aspergillus 10 0/8 0/8 niger ATCC 6275 Trichophyton 10 0/8 0/8 Mentagrophytes ATCC 9533 .sup.aTubes checked for turbidity and streaked to Neopeptone agar on Day 3 and Day 10 post-exposure to determine presence of growth.

[0022] The initial efficacy screening test results for the dry formulations are shown in Table 4. This test was conducted for screening purpose. Eight carriers were inoculated per test organism (Aspergillus Niger ATCC 6275 and Trichophyton mentagrophytes ATCC 9533) and showed no growth after 10 minutes exposure (contact time). The acceptance criterion for the screening test was that the test organism would be killed on all eight carriers. To meet the requirements of the actual EPA registration for an initial claim, the test substance would need to kill the test organism on 59 out of 60 carriers with each of three separate samples from three lots (one at least 60 days old) when run under Good Laboratory Practice (GLP) Guidelines. To make additional claims about the test substance, the test organism must be killed on 10 out of 10 carriers from at least two separate batches.

[0023] To meet the fleet need, it is essential to identify and validate effective, safe and environmentally friendly products for mildew remover applications. The formulations or compositions will be used to remove mildew from weapon systems across DOD maintenance facilities as alternatives to the use of unauthorized cleaning solutions. The use of unauthorized products such as household chlorine bleach (sodium hypochlorite) can induce corrosion damage to critical metallic surfaces. Providing qualified product to all levels of maintenance will avoid risk of use of improper materials, which may compromise performance, safety and health. In addition, the outcomes of this invention are improving the fleet readiness and pollution prevention onboard ships and complying with the current EPA regulations. The novel formulas work quicker than current alternatives, are safer and have the potential to be used for other cleaning application and in other markets. The novel formulations are entirely dry, easier to transport, and have extended shelf life properties. The formulations will be implemented by NAVAIR for removing mildew from aircraft during normal cleaning procedures. Implementation will be accompanied by issuing an authorization letter and Interim Rapid Action Change (IRAC) to 01-1A-509, NAVAIR's general series manual for Cleaning and Corrosion Control. In addition, a commercial source or supplier needs to be developed so material is available for NAVAIR uses as well as other militaries like AMCOM, the Air Force, Coast Guard, etc. The invention formulation will benefit all existing rotorcraft in the Navy, Marine Corps, Army, Air Force, Coast Guard and National Guard. Some fixed wing aircraft, which generate mildew, can also benefit.

[0024] While this invention has been described by a number of specific examples, it is obvious that there are other variations and modifications which can be made without departing from the spirit and scope of the invention as particularly set forth in the appended claims.