Anti-bacterial/anti-viral coatings, coating process and parameters thereof

• US 6,120,784 A
• Filed: 10/16/1998
• Issued: 09/19/2000
• Est. Priority Date: 02/20/1996
• Status: Expired due to Fees

• Current Assignee: Viro-Kote Incorporated
• Original Assignee: Viro-Kote Incorporated
• Inventors: Snyder, Donald E. Jr.
• Primary Examiner(s): Clardy, S. Mark
• Assistant Examiner(s): Shelborne, Kathryne E.
• Application Number:
  US09/172,588
• Time in Patent Office: 704 Days
• Field of Search: 424/404, 424/409, 424/414, 424/447, 423/236, 423/245, 423/289
• US Class Current: 424/404
• CPC Class Codes: C09D 5/14 Paints containing biocides, e.g. fungicides, insecticides or pesticides C09D5/16 takes precedence
• CPC Class Codes: D21H 19/10 Coatings without pigments D21H19/66 takes precedence
• CPC Class Codes: D21H 19/36 Coatings with pigments D21H19/66 takes precedence; metal powder D21H19/06
• CPC Class Codes: D21H 21/36 Biocidal agents, e.g. fungicidal, bactericidal, insecticidal agents
• CPC Class Codes: D21H 23/62 Reverse roll coating, i.e. applicator roll surface moving in direction opposite to that of the paper

Abstract

The invention relates to a method of imparting anti-pathogenic properties to a substrate material comprising: (a) preparing a coating composition containing an anti-pathogenic agent consisting essentially of PVP-I and N-9 in a ratio of from about 100:0 to about 0:100 of PVP-I to N-9, the coating composition further containing a pre-mix solution with which the anti-pathogenic agent is intimately mixed in a ratio of from about 6:4 to about 8:2 of agent to pre-mix on a dry basis, and having a percent solids content of from about 5% to about 35% solids; (b) feeding the anti-pathogenic coating composition into a coating machine; (c) loading substrate onto the coating machine; (d) operating the coating machine such that the coating composition comes into intimate contact with at least one surface of the substrate; and (e) drying the coated substrate material. The invention further relates to the preparation of coating composition, the composition itself and to providing the coating in a dual or multilayered format, wherein a first layer contains the active ingredient and a second layer contains the remaining coating components.

Claims

1. A method of imparting anti-pathogenic properties to a face mask substrate material comprising:

(a) preparing a first coating composition containing an anti-pathogenic agent consisting essentially of PVP-I and N-9 in a ratio of from about 100;

0 to about 0;

100 of PVP-I to N-9, and having a percent solids ranging from 10 percent to about 50 percent;

(b) applying said first coating to a surface of a substrate;

(c) preparing a second coating composition containing a premix solution comprising a hydrophilic polymeric binder, a nonionic surfactant, an excipient, and a solvent, and having a percent solids ranging from about 10 percent to about 50 percent;

(d) applying said second coating composition as a top coat over said first coating composition on said substrate; and

(e) drying the coated substrate material.

2. The method of claim 1 wherein the substrate material comprises a paper substrate of between 10 lb./3000 ft² and about 30 lb/3000 ft².

3. The method of claim 1 wherein the coating method used to apply the first and second coating compositions to the substrate is selected from roll coating, rod coating, spray coating, slot coating, and dip coating.

4. The method of claim 1 wherein the substrate is selected from the group consisting of paper, non-woven material, coated paper and laminates of paper, non-woven material and polymeric film.

5. A process for producing a substrate coated with a formulation containing multiple coating layers and suited for use as a face mask, and wherein at least one coating layer contains an anti-pathogenic component, comprising:

(a) depositing onto at least one surface of a face mask substrate material a first coating layer formulation in solution;

(b) fixing said first layer to said substrate;

(c) depositing onto at least one surface of said face mask substrate material a second coating layer formulation in solution;

(d) fixing said second layer to said substrate; and

(e) drying said substrate such that the coated face mask substrate, when dry, protects a user against air- or solution-borne pathogens and, when wet, releases the anti-pathogenic agent to substantially immediately eliminate the pathogens, the formulation containing the first and second coating layer formulations being characterized by the inclusion in at least one of said coating layers of at least one active ingredient selected from PVP-I and N-9.

6. The process of claim 5 wherein the first coating layer is deposited on a first surface of said substrate and the second coating layer is deposited over said first coating layer as a top coat.

7. The process of claim 5 wherein the first coating layer is deposited on a first layer of said substrate and the second coating layer is deposited on an opposing surface of said substrate.

8. The process of claim 5 wherein the first coating layer formulation contains PVP-I and N-9 in a ratio from about 100:

0 to about 0;

100 of PVP-I to N-9 and the second coating layers contains a premix solution comprising a hydrophilic polymeric binder, a nonionic surfactant, and excipient, and a solvent.

9. The process of claim 5 wherein the second coating layer and the first coating layer both contain N-9 active ingredient.

10. The process of claim 5 wherein the process further comprises the inclusion of additional coating layers, each of said layers capable of containing active ingredients in solution.

11. The process of claim 5 wherein the active ingredients are contained in the second coating layer formulation.

12. The process of claim 5 wherein at least one coating layer further contains a scavenger for free iodine.

13. A coated face mask material comprising a substrate material in intimate contact with at least one layer of a multi-layer coating, said coating containing in at least one layer thereof at least one anti-pathogenic agent, the multi-layer coating being characterized by the ability to release the at least one anti-pathogenic agent immediately upon contact with a solution-borne pathogen to eliminate substantially immediately the pathogenic activity of the pathogen, wherein the multi-layer coating layers each have a percent solids of from about 10 percent to about 50 percent.

14. The coated face mask material of claim 13 wherein the at least one anti-pathogenic agent is selected from PVP-I and N-9, and wherein the multi-layer coating further includes a premix solution comprising at least one of a hydrophilic polymeric binder, a nonionic surfactant, an excipient, an anti-pathogenic agent, a free iodine scavenger and a solvent.

15. The coated face mask material of claim 13 wherein at least one layer of the multi-layer coating includes a component to enhance the water resistance of the substrate.

16. The coated face mask material of claim 13 wherein at least one layer of the multi-layer coating includes a coloring component.

17. The coated face mask material of claim 13 wherein all layers of the multi-layer coating are coated one over top of the other on a single side of the substrate.

18. The coated face mask material of claim 13 wherein at least one layer of the multi-layer coating is coated on a first surface of said substrate and at least one other layer of said multi-layer coating is coated on a second surface of said substrate.

19. A face mask having anti-bacterial and anti-viral properties comprising a face mask substrate material coated with a coating formulation containing an anti-bacterial and anti-viral agent selected from PVP-I and N-9, and further containing a premix solution comprising at least one of a hydrophilic polymeric binder, a nonionic surfactant, an excipient, an anti-pathogenic agent, a free iodine scavenger and a solvent.

20. The face mask of claim 19 wherein the coating formulation is coated onto the face mask as a single coating layer.

21. The face mask of claim 19 wherein the coating formulation is coated onto the face mask in a multi-layer design.

22. The coated face mask of claim 21 wherein a first coating layer formulation contains PVP-I and N-9 in a ratio from about 100:

0 to about 0;

100 of PPV-I to N-9 and a second coating layer contains said premix solution.

23. The face mask of claim 21 wherein a second coating layer and a first coating layer both contain N-9 active ingredient.

24. The face mask of claim 21 wherein the active ingredients are contained in a second coating layer formulation.