Stabilized antimicrobial agents, thermoplastic compositions containing same and products produced therefrom

Abstract: The invention relates to a stabilized antimicrobial agent characterised in that it is comprised of (a) an antimicrobial agent which is a bisphenoxarsine compound or bisphenarsazine compound or mixtures thereof having the formula: wherein: Y is selected from the group consisting of oxygen and nitrogen; and X is selected from the group consisting of oxygen and sulfur; and (b) a stabilizing amount of a free radical scavenger which is: (i) an inorganic compound capable of undergoing a redox reaction having the formula (M +b ) x (A -c ) y II wherein: M is a transition metal selected from copper, iron, nickel, cobalt, cerium, and vanadium; A is an anion of an inorganic or organic salt; and, bx = cy; or (ii) a piperidine derivative having the formula: wherein: R¹, R², R³, and R⁴ are independently selected from the group consisting of an alkyl having 1 to about 10 carbon atoms; and Z is a divalent hydrocarbon; or mixtures of (i) and (ii).

Description: This invention relates to stabilized antimicrobial agents, and more particularly, concerns the stabilization of microbial agents against thermal, oxidative, and/or ultraviolet light degradation and their use in the melt spinning of thermoplastic materials in fiber manufacturing. Antimicrobial agents are incorporated into thermoplastic fiber materials in order to protect the fiber materials against bacterial attack and to reduce the occurrence of mildew and other undesirable growth on the fiber in its final form, such as carpeting. During the manufacture of synthetic fiber, the antimicrobial agents of the fiber are exposed to very harsh conditions. For instance, the agents of the fiber are melted with thermoplastic polymers and held at elevated temperatures prior to spinning. During spinning, the agents are subjected to high pressures and are further heated because of friction during their extrusion. Furthermore, the extruded filaments containing the antimicrobial agents are exposed to atmospheric gases during their processing. Because of these harsh conditions, the antimicrobial agents can undergo thermal degradation. Antimicrobial agents are also subject to oxidative degradation when the agents are exposed to contaminates which cause oxidative degradation. This problem is particularly acute when the contaminate and antimicrobial agents are exposed to moisture and/or heat or are present with the antimicrobial agents at high temperature, i.e., melt-spinning. Furthermore, antimicrobial agents are subject to deterioration when they are utilized in an outdoor environment or otherwise subjected to ultraviolet light radiation. As a result of either thermal, oxidative, or ultraviolet light degradation on the antimicrobial agents, the agents lose some or all of their potency. Therefore, large amounts of antimicrobial agents must be included in synthetic articles such as films or fibers to ensure that the article has sufficient resistance to microbial attack. Thus, there is a need for antimicrobial agents which have increased thermal, oxidative, or ultraviolet stability, and combinations thereof. By the present invention, stabilized antimicrobial agents are provided, as well as articles such as fibers, which contain the stabilized antimicrobial agents. US-A- 4 624 679 describes a thermoplastic composition which will be resistant to microbial attack after being processed at an elevated temperature, comprising a homogeneous mixture of: A. a polyamide resin; B. an antimicrobial agent; and C. an amount of an antioxidant effective to reduce degradation of said antimicrobial agent while said composition is being melt-processed. The antimicrobial agent may be a phenoxarsine or phenarsazine. It has been surprisingly found that certain antimicrobial agents comprising bisphenoxarsine and bisphenarsazine ... compounds can be stabilized against degradation caused by heat, ultraviolet light, oxidation, or combinations thereof by incorporating with the compounds certain free radical scavengers. The present invention provides a stabilized antimicrobial agent characterised in that it is comprised of (a) an antimicrobial agent which is a bisphenoxarsine compound or bisphenarsazine compound or mixtures thereof having the formula: wherein: X is selected from the group consisting of oxygen and nitrogen; and Y is selected from the group consisting of oxygen and sulfur; and (b) a stabilizing amount of a free radical scavenger which is: (i) an inorganic compound capable of undergoing a redox reaction having the formula (M+ b ) x (A -c ) y II wherein: M is a transition metal selected from copper, iron, nickel, cobalt, cerium, and vanadium; A is an anion of an inorganic or organic salt; and, bx = cy ; or (ii) a piperidine derivative having the formula: wherein: R¹, R², R³, and R⁴ are independently selected from the group consisting of an alkyl having 1 to about 10 carbon atoms; and Z is a divalent hydrocarbon; or mixtures of (i) and (ii). The stabilized antimicrobial agents of the present invention find particular application during the melt spinning of synthetic polymers to form various articles such as carpets, films, etc. Articles containing the stabilized antimicrobial agent have an advantage over articles containing unstabilized agents, as lesser amounts of antimicrobial agents are required to achieve the desired level of antimicrobial activity, and antimicrobial activity is maintained in the articles over longer periods of time. Examples of bisphenoxarsine and bisphenarsazine compounds of the formula I useful in the present invention include 10,10'-oxybisphenoxarsine (OBPA); 10,10'-oxybisphenarsazine; 10,10'-thiobisphenarsazine; 10,10'-thiobisphenoxarsine; and mixtures thereof. Examples of the anion A in the compounds represented by the general formula: (M +b ) x (A -c ) y II are halide including fluoride, chloride, bromide, and iodide, sulfate, or aliphatic carboxylates. Suitable copper compounds of the general formula II include cuprous and cupric halides such as cuprous and cupric fluoride, cuprous and cupric chloride, cuprous and cupric bromide, cuprous and cupric iodide, cuprous and cupric sulfate, cupric nitrate, cuprous and cupric salts of organic acids such as cuprous and cupric acetate, and cuprous and cupric formate, and mixtures thereof. Suitable iron compounds of the general formula II include ferrous and ferric salts of halides such as ferrous and ferric fluoride, ferrous and ferric chloride, ferrous and ferric bromide, ferrous and ferric sulfate, ferrous and ferric nitrate, and ferrous and ferric salts of organic acids such as ferrous and ferric acetate, and ferrous and ferric formate, and mixtures thereof. Suitable nickel compounds of the general formula II include nickel halides such as nickel fluoride, nickel chloride, nickel bromide, nickel sulfate, nickel nitrate, nickel salts of organic acids as a nickel acetate and nickel formate, and mixtures thereof. Suitable cobalt compounds of the general formula II include cobaltous halides such as cobaltous fluoride, cobaltous chloride, and cobaltous bromide, cobaltous sulfate, cobaltous nitrate, cobalt salts of organic acids such as cobaltous acetate and cobaltous formate, and mixtures thereof. Suitable cerium compounds of the general formula II include cerous halides such as cerous fluoride, cerous chloride and cerous bromide, cerous sulfate, cerous nitrate, cerium salts or organic acids such as cerous acetate and cerous formate, and mixtures thereof. Suitable vanadium compounds of the general formula II include vanadium halides such as vanadium trifluoride, vanadium tetrafluoride, vanadium pentafluoride, vanadium trichloride, vanadium tetrachloride, vanadium pentachloride, vanadium tribromide, vanadium tetrabromide, and vanadium pentabromide, vanadium trisulfate, vanadium trinitrate, vanadium salts of organic acids such as vanadium triformate and vanadium triacetate, and mixtures thereof. R¹, R², R³ and R⁴ in general formula III may, for example be independently selected from methyl, ethyl, isopropyl, pentyl, hexyl, heptyl, and decyl; and, Z in general formula III is preferably an alkylene group having about 6 to about 12 carbon atoms such as hexylene, heptylene, octylene, nonylene, decylene, undecylene, and dodecylene. Representative examples of piperidine derivatives of general formula III include: [bis(2,2,6,6-tetramethyl-4-piperidinyl)succinate]; [bis(2,2,6,6-tetraethyl-4-piperidinyl)malonate]; [bis(2,2,6,6-tetrapropyl-4-piperidinyl)glutarate]; [bis(2,2,6,6-tetrabutyl-4-piperidinyl)adipate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)pimelate]; [bis(2,2,6,6-tetrapentyl-4-piperidinyl)suberate]; [bis(2,2-dimethyl-6,6-diethyl-4-piperidinyl)azelate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)azelate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)sebacate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)suberate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)pimalate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)adipate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)glutarate]; bis(2,2,6,6-tetramethyl-4-piperidinyl)malonate]; and mixtures thereof. The preferred piperidine derivative of general formula III is [bis(2,2,6,6-tetramethyl-4-piperidinyl)sebacate], TINUVIN 770, which is available from Ciba-Geigy Corporation. The preparation of this compound is carried out by reacting 2,2,6,6-tetramethyl piperidin-4-ol with sebacic acid. In addition, the free radical scavenger can include a mixture containing one or more piperidine derivatives of general formula III and one or more inorganic compounds of general formula II. A particularly preferred mixture comprises cuprous iodide and [bis(2,2,6,6-tetramethyl-4-piperidinyl) sebacate]. The invention also provides a thermoplastic composition which is resistant to microbial attack comprising a synthetic polymer and an antimicrobial agent characterised in that the antimicrobial agent is a stabilised antimicrobial agent as hereinbefore defined. Synthetic polymers suitable for use in the present invention include saturated polymers such as polyolefins, e.g., polyethylene and polypropylene, polyvinyl chloride, polyurethane, polyamides such as nylon 6 and nylon 66, polyethylene terephthalate (polyester), polystyrene, styrene-butadiene copolymers, and other elastomers. The precise manner that the scavenger stabilizes the antimicrobial compound from degradation is not fully understood and need not be. Although the invention is not intended to be limited by any particular theory of operation, it is believed the addition of the free radical scavenger to the antimicrobial bisphenoxarsine and bisphenarsazine compounds prevents the oxidation of the trivalent arsenic group to the pentavalent state and thus prevents the conversion of the bisphenoxarsine and bisphenarsazine compounds to phenarsinic acid. Regardless of the theory proposed, it is sufficient to point out that the free radical scavengers operate successfully in the manner disclosed herein. The amount of free radical scavenger which is necessary for stabilization of the antimicrobial agents will depend on a number of factors, including the antimicrobial agent and free radical scavenger utilized, and thus, there are no set parameters. As a general guideline, the amount of scavenger may be from about 0.1 to about 25 times by weight base on the weight of antimicrobial agent utilized. Generally, an amount sufficient to stabilize the antimicrobial agent will be an amount in the range from about 0.01 to about 5.0 weight percent based on the combined weight of the polymer and antimicrobial agent. More preferably, the amount will be 0.05% to about 1.0% weight percent based on the combined weight of the polymer and the antimicrobial agent. The amount of antimicrobial agent included with the synthetic polymer depends on a number of factors including the activity of the agent and the conditions (temperature, time, etc.) of the fabrication. Generally, the antimicrobial agent may be present in the thermoplastic composition in an amount in the range of from about 0.005% to 2.5% by weight based on the weight of the synthetic polymer and, more preferably, in an amount in the range of from 0.005% to about 0.05% by weight based on the weight of polymer. Amounts in this range generally provide sufficient antimicrobial activity to the polymer. Various methods of including the free radical scavenger and antimicrobial agent in the polymer can be utilized, and are known to persons skilled in the art. In a particularly preferred method, the free radical scavenger, antimicrobial and polymer are melt-processed by heating the ingredients to an elevated temperature, i.e., a temperature sufficient to melt the polymer and allow the polymer to be melt processed, wherein the resulting composition is fabricated as a useful article in various forms such as a film, fibre, sheet, filament, yarn, and other shapes. Nylon 6 is usually melt processed at above 255 degrees Centigrade and nylon 66 is melt processed at above 270 degrees Centigrade. The antimicrobial and free radical scavengers are preferably incorporated in the polymer melt using known machines, such as extruders, kneaders, static mixers and stirrers. In addition, various additives of the type normally used, such as lubricants and mould release agents, nucleating agents, pigments, dyes, reinforcing or non-reinforcing fillers, such as mineral fibres, glass and asbestos fibres, microbeads of glass, talcum, silicon dioxide or mica, antistatic agents, and plasticizers may be added to the polymers. Compositions specifically contemplated for use herein include polyamides, such as nylon 6 or nylon 66, 10,10'-oxybisphenoxarsine as the antimicrobial compound, and cupric iodide or [bis(2,2,6,6-tetramethyl-4-piperidinyl)sebacate] as the free radical scavenger. Nylon is a particularly desirable application because of its desirable properties as a fibre in a carpet. Preferably, the nylon, 10,10'-oxybisphenoxarsine, and free-radical scavenger are melt-spun into a nylon fibre by extruding nylon, the antimicrobial agent, and the free radical scavenger at a melt temperature of, for example, above 255 degrees Centigrade for nylon 6, through a spinneret to form a number of molten streams and processing the molten streams by standard procedures known to one skilled in the art to converge the formed filaments into yarn. The molten streams are preferably quenched in an inert atmosphere, i.e., an atmosphere substantially free of oxygen such as a nitrogen, steam, or carbon dioxide atmosphere. The yarn finds particular application in carpets. While combining the free radical scavenger with the antimicrobial agent improves the stability of the antimicrobial agent, the resultant distribution of the antimicrobial agent and free radical is unknown; one can assume a random distribution, but it is possible that the scavenger and antimicrobial agent interact. The accompanying drawing is a graph which illustrates the effectiveness of cuprous iodide as a stabilizer for an antimicrobial agent comprising 10,10'-oxybisphenoxarsine and is referred to hereinafter in Example I. The invention will be further exemplified by the following examples which are presented to illustrate certain specific embodiments of the invention, but are not intended to be construed so as to be restrictive of the scope thereof. EXAMPLE I The stability of OBPA using cuprous iodide (CuI) as a free radical scavenger in a nylon 6 fibre was compared to the stability of OBPA without any scavenger in nylon. The tests were carried out by mixing, as chips, an amount of 5,000 ppm of OBPA with the nylon. In test 2, an amount of 1,000 ppm cuprous iodide was mixed with OBPA, and this admixture was mixed with nylon 6. The mixtures were melt extruded to form strands, which, when draw-knitted, yielded 28 filaments at a total denier of 92. Next, the resulting hoselegs were exposed in a Xenon Weatherometer and measured for ppm of undegraded OBPA per exposure time. The amount of undegraded OBPA was measured by Soxhlet extracting a sample with methanol and assaying it by high performance liquid chromatography. The results of these tests are shown in Table I. OBPA CONCENTRATION (ppm) WEATHEROMETER TIME (hours) TEST NUMBER 0 48 143 1 Control - OBPA, No CuI 3,060 840 340 2 OBPA With CuI 2,740 1,500 890 The results of these tests show the effectiveness of cuprous iodide in stabilizing OBPA against light degradation. A plot of the effectiveness of the scavenger is shown in the FIGURE. Stability was measured by the following ratio: From the FIGURE, it can be seen that over 2.5 times more undegraded OBPA remained after 143 hours when cuprous iodide was utilized when compared to unstabilized OBPA after the same amount of time. EXAMPLE II The stability of OBPA in polypropylene fiber using [bis(2,2,6,6-tetramethyl-4-piperidinyl)sebacate (BTMPS) was compared with OBPA in polypropylene fiber without any scavenger. The tests were carried out by mixing an amount of 1,000 ppm of OBPA, polypropylene chips and, in Test 2, 2,500 ppm of BTMPS, melt extruding the mixture to form strands, drawing the strands, and knitting the drawn strands into hoselegs. The hoselegs were then exposed to constant room fluorescent lighting. The amounts, in parts per million, of undegraded OBPA were determined in the same manner as in Example I. The results of these tests are shown in Table II. OBPA CONCENTRATION (ppm) LIGHT EXPOSURE TIME (weeks) TEST NUMBER 0 (After Extrusion) 4.0 10.0 1 Control, OBPA, No BTMPS 520 20 0 2 OBPA With BTMPS 980 450 160 The results of these tests show the effectiveness of BTMPS in stabilizing OBPA against thermal and light degradation. EXAMPLE III An amount at a use level of 500 ppm of OBPA, which was included as a concentrate in polystyrene or nylon, was mixed together with nylon 6 chips. In Test 2, an amount of 2,500 ppm of BTMPS was mixed with the OBPA and this admixture was mixed with nylon 6. The mixture was melt extruded into either an air or nitrogen quenching system to form filaments. After drawing and texturing, the filaments comprised typical carpet filaments. Next, the filaments were knitted into hoselegs and exposed to a Xenon Weatherometer. The amounts, in parts per million, of undegraded OBPA were determined in the same manner as in Example I. The results of these tests are shown in Table III. The results of these tests show the effectiveness of BTMPS in reducing the thermal degradation of OBPA even in the presence of polystyrene which promotes a decomposition of OBPA in nylon. Removal of the oxidation potential on melt spinning with a nitrogen atmosphere will increase the stability of OBPA, but will not reduce the susceptibility of OBPA to light degradation. EXAMPLE IV An amount of 500 ppm of OBPA was mixed together with caprolactam (nylon 6), and, optionally, stabilizer BTMPS and melt extruded into either air or nitrogen quenching system to form filaments. After drawing and texturing, the filaments comprised typical carpet filaments. The filaments were knitted into hoselegs and exposed to fluorescent light. The amounts, in parts per million, of undegraded OBPA was determined in the same manner as Example I. The results are shown in Table IV. The results of these tests show that the rate of OBPA decomposition by room fluorescent light is less with OBPA stabilized with BTMPS. In addition, OBPA was less stable when spun into a oxygen-containing environment, and this instability continues in the dark, but does not accelerate or otherwise alter the antimicrobial sensitivity in light. EXAMPLE V An antimicrobial agent comprising OBPA, as a 5% by weight concentration in a nylon 6 pellet, was added to nylon 6 in an amount to theoretically afford the nylon 6 filaments produced therefrom 500 ppm of OBPA. Prior to extrusion, certain samples were blended with certain scavengers by either mixing the scavenger in pellet form or tumbling the scavenger in powdered form with the OBPA and nylon. The samples were tested for OBPA concentration at certain time intervals in the manner described in Example I above. Samples remained either in darkness, or under room fluorescent lights, or under a Xenon Weatherometer. The results of these tests are shown in Table V. The results of these tests show the benefit of using the scavengers to provide increased antimicrobially active concentrations from losses due to thermal decay, oxidation induced decay per time (in darkness), and photolytic decay. The amount of stabilization appears to be dependent on the nature of the polymer utilized; the nature and amount of other additives used like delustrants, antistatic agents, colorants, and retardants; extrusion conditions, especially the quenching media; and the exposure conditions, light in particular. Although certain preferred embodiments of the invention have been herein described for illustrative purposes, it will be appreciated that various modifications and innovations of the procedures recited may be affected without departure from the basic principles which underlie the invention. Changes of this type are therefore deemed to lie within the spirit and scope of the invention except as may be necessarily limited to the amended claims of reasonable equivalents thereof.

Claims: A stabilized antimicrobial agent characterised in that it is comprised of (a) an antimicrobial agent which is a bisphenoxarsine compound or bisphenarsazine compound or mixtures thereof having the formula: wherein: X is selected from the group consisting of oxygen and nitrogen; and Y is selected from the group consisting of oxygen and sulfur; and (b) a stabilizing amount of a free radical scavenger which is: (i) an inorganic compound capable of undergoing a redox reaction having the formula (M+ b ) x (A -c ) y II wherein: M is a transition metal selected from copper, iron, nickel, cobalt, cerium, and vanadium; A is an anion of an inorganic or organic salt; and, bx = cy ; or (ii) a piperidine derivative having the formula: wherein: R¹, R², R³, and R⁴ are independently selected from the group consisting of an alkyl having 1 to about 10 carbon atoms; and Z is a divalent hydrocarbon; or mixtures of (i) and (ii). A stabilized antimicrobial agent as claimed in claim 1, charactarized in that said antimicrobial agent is selected from 10,10'-oxybisphenoxarsine; 10,10'-oxybisphenarsazine; 10,10'-thiobisphenarsazine; 10,10'-thiobisphenoxarsine; and mixtures thereof and said scavenger is present in an amount in the range of from 0.1 to 25 times by weight of antimicrobial agent. A stabilized antimicrobial agent as claimed in claim 1 or 2, charactarised in that said free radical scavenger is selected from cuprous halide, cupric halide, cupric acetate, cupric formate, cuprous acetate, cuprous formate, ferrous halide, ferric halide, ferrous sulfate, ferric sulfate, and mixtures thereof. A stabilized antimicrobial agent as claimed in claim 1, 2 or 3, charactarised in that Z in formula III is an alkylene group having 6 to 12 carbon atoms. A stabilized antimicrobial agent as claimed in any one of claims 1 to 4, characterised in that said free radical scavenger is a piperidine derivative selected from [bis(2,2,6,6-tetramethyl-4-piperidinyl)sebacate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)pimelate]; [bis(2,2,6,6-tetrapentyl-4-piperidinyl)suberate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)malonate]; [bis(2,2,6,6-tetramethyl-4-piperidinyl)succinate]; [bis(2,2,6,6-tetrabutyl-4-piperidinyl)adipate]; [bis(2,2,6,6-tetrapropyl-4-piperidinyl)glutarate]; and mixtures thereof. A stabilized antimicrobial agent as claimed in claim 2, wherein said antimicrobial agent is 10,10'-oxybisphenoxarsine and said free radical scavenger is cuprous iodide, [bis(2,2,6,6-tetramethyl-4-piperidinyl)sebacate], or mixtures thereof. A stabilized antimicrobial agent as claimed in claim 2, charactarised in that said antimicrobial agent is 10,10'-oxybisphenoxyarsine and said free radical scavenger is cupric iodide. A thermoplastic composition which is resistant to microbial attack comprising: (a) a synthetic polymer; (b) 0.005% to 2.5% by weight, based on the weight of synthetic polymer, of an antimicrobial agent as defined in any one of claims 1, 2 or 6; (c) 0.1 to 25 times by weight based on the weight of antimicrobial agent utilised, of a free radical scavenger as defined in any one of claims 1, 3, 4, 5 or 6. A thermoplastic composition as claimed in claim 8, characterised in that said synthetic polymer is selected from polyolefins, polyamides, polyesters, and mixtures thereof. A thermoplastic composition as claimed in claim 9, characterised in that said synthetic polymer is nylon 6 or nylon 66, and said stabilized antimicrobial agent comprises 10,10'-oxybisphenoxarsine, and as free radical scavenger [bis(2,2,6,6-tetramethyl-4-piperidinyl)sebacate], cupric iodide, or mixtures thereof. A thermoplastic composition as claimed in any of claims 8 to 10, characterised in that said free radical scavenger is present in an amount in the range of from 0.05 to 1.0 weight percent based on the combined weight of said synthetic polymer and said antimicrobial agent.

Inventors: BURTON WENDEL LAWRENCE, BURTON, WENDEL LAWRENCE
Applicants: BASF CORP, BASF CORPORATION
Application year: 1988
Main classification: A01N55
IPC codes: C09K15, D01F1, C08K5, A01N55, A01N25, C09K3, C08K3, D01F6, A01N59