Patent ID: 12207652

DETAILED DESCRIPTION

Reference will now be made in detail to presently preferred compositions, embodiments and methods of the present invention, which constitute the best modes of practicing the invention presently known to the inventors. The Figures are not necessarily to scale. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for any aspect of the invention and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.

Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word “about” in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, “parts of,” and ratio values are by weight; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description, and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation; and, unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.

It must also be noted that, as used in the specification and the appended claims, the singular form “a,” “an,” and “the” comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components.

The phrase “composed of” means “including” or “comprising.” Typically, this phrase is used to denote that an object is formed from a material.

The term “comprising” is synonymous with “including,” “having,” “containing,” or “characterized by.” These terms are inclusive and open-ended and do not exclude additional, unrecited elements or method steps.

The phrase “consisting of” excludes any element, step, or ingredient not specified in the claim. When this phrase appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

The phrase “consisting essentially of” limits the scope of a claim to the specified materials or steps, plus those that do not materially affect the basic and novel characteristic(s) of the claimed subject matter.

With respect to the terms “comprising,” “consisting of,” and “consisting essentially of,” where one of these three terms is used herein, the presently disclosed and claimed subject matter can include the use of either of the other two terms.

The term “substantially,” “generally,” or “about” may be used herein to describe disclosed or claimed embodiments. The term “substantially” may modify a value or relative characteristic disclosed or claimed in the present disclosure. In such instances, “substantially” may signify that the value or relative characteristic it modifies is within ±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative characteristic.

It should also be appreciated that integer ranges explicitly include all intervening integers. For example, the integer range 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4 . . . 97, 98, 99, 100. Similarly, when any range is called for, intervening numbers that are increments of the difference between the upper limit and the lower limit divided by 10 can be taken as alternative upper or lower limits. For example, if the range is 1.1. to 2.1 the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as lower or upper limits. In the specific examples set forth herein, concentrations, temperature, and reaction conditions (e.g. pressure, flow rates, etc.) can be practiced with plus or minus 50 percent of the values indicated rounded to three significant figures. In a refinement, concentrations, temperature, and reaction conditions (e.g., pressure, flow rates, etc.) can be practiced with plus or minus 30 percent of the values indicated rounded to three significant figures of the value provided in the examples. In another refinement, concentrations, temperature, and reaction conditions (e.g., flow rates, etc.) can be practiced with plus or minus 10 percent of the values indicated rounded to three significant figures of the value provided in the examples.

In the examples set forth herein, concentrations, temperature, and reaction conditions (e.g., pressure, flow rates, etc.) can be practiced with plus or minus 50 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples. In a refinement, concentrations, temperature, and reaction conditions (e.g., pressure, flow rates, etc.) can be practiced with plus or minus 30 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples. In another refinement, concentrations, temperature, and reaction conditions (e.g., pressure, flow rates, etc.) can be practiced with plus or minus 10 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples.

For all compounds expressed as an empirical chemical formula with a plurality of letters and numeric subscripts (e.g., CH2O), values of the subscripts can be plus or minus 50 percent of the values indicated rounded to or truncated to two significant figures. For example, if CH2O is indicated, a compound of formula C(0.8-1.2)H(1.6-2.4)O(0.8-1.2). In a refinement, values of the subscripts can be plus or minus 30 percent of the values indicated rounded to or truncated to two significant figures. In still another refinement, values of the subscripts can be plus or minus 20 percent of the values indicated rounded to or truncated to two significant figures.

Throughout this application, where publications are referenced, the disclosures of these publications in their entireties are hereby incorporated by reference into this application to more fully describe the state of the art to which this invention pertains.

Abbreviations

“DLC” means diamond-like carbon.

“CAE” means cathodic arc evaporation.

“PVD” means physical vapor deposition.

FIGS.1A and1Bprovide cross sections of a substrate coated with a bioactive layer and having an indicator layer. Referring toFIG.1A, bioactive coated substrate10includes a base substrate12and indicator layer14disposed over and optionally contacting the base substrate. The term “base substrate” refers to the substrate before is coated to form the bioactive substrate set forth below. Bioactive layer16is disposed over and optionally contacts indicator layer14. Characteristically, indicator layer14can serve as a visual indication that the outermost bioactive layer16is compromised. In particular, the indicator layer has a color sufficiently different from the bioactive layer to be visually perceived by a user when the bioactive layer wears away thereby providing a visual alert to a user that bioactive layer16is compromised. With respect to setting the color of the various layers so that color differences can be determined, it should be appreciated that the color of each of the layers set forth above can independently be changed by adjusting the thicknesses and or stoichiometries of the layer. In a refinement, indicator layer14typically has a thickness from about 20 to 300 nm. In another refinement, the bioactive layer16has a thickness from about 50 to 1500 nm. Each of the layers of bioactive coated substrate10can be made by CVD, PVD which could be sputtering or CAE.

FIG.1Bprovides a schematic cross-section of a bioactive coated substrate having a plurality of alternating bioactive layers and interlayers22. In this variation, bioactive coated substrate10′ includes a base substrate12and optional base layer18disposed over and optionally contacting the base substrate. A plurality of alternating bioactive layers16′ and interlayers22are disposed over substrate12and base layer18if present. Typically, there can be 1 to 10 bioactive layers16′ and 1 to 10 interlayers22. Characteristically, the base layer18and/or at least one of the interlayers22is an indicator layer. Typically, the outermost layer of coated substrate10′ is a bioactive layer. In a refinement, the base layer18and/or interlayers22can be composed of zirconium carbonitride, zirconium nitride, zirconium oxycarbide, zirconium oxynitride or zirconium oxycarbonitride. In another refinement, the interlayers22can also be bioactive layers but with a different thickness and/or stoichiometry than the bioactive layers it contacts on opposite faces. In this regard, interlayers22can be composed of various copper alloys, as set forth below. In another refinement, the interlayers22can be composed of a metal nitride. For example, interlayers22can be composed of zirconium nitride (ZrN), titanium nitride (TiN), zirconium oxycarbides (ZrOC), zirconium oxides (ZrO2), diamond-like-carbon (DLC) or a combination thereof. In another variation, one or more of interlayers22can be an indicator layer. Each of the layers of bioactive coated substrate10can be made by CVD, PVD which could be sputtering or CAE.

In a refinement, base layer18and/or interlayers22each independently have a thickness from about 20 to 300 nm. In another refinement, the bioactive layer16has a thickness from about 50 to 1500 nm.

In some variations of the coated substrates depicted inFIGS.1A and1B, the indicator layer can be composed of zirconium carbonitride, zirconium nitride, zirconium oxycarbide, zirconium oxynitride or zirconium oxycarbonitride, titanium nitride, zirconium oxide, titanium oxide, or diamond like carbon. Indicator layer14typically has a thickness from about 20 to 300 nm. It should be appreciated that the present embodiment is not limited by the particular deposition methods for depositing indicator layer14and bioactive layer16. For example, these layers can be made by CVD, PVD which could be sputtering or CAE.

Bioactive layers16and16′ ofFIGS.1A and1Bcan be any material with bioactive properties. In particular, the bioactive layers16and16′ are antimicrobial layers. Therefore, the bioactive layers16and16′ can include a material with antimicrobial properties. In a refinement, the bioactive layers16and16′ can be composed of a component (with antimicrobial properties) selected from the group consisting of bioactive metals, bioactive metal alloys, bioactive metal-containing compounds (e.g., metal oxides), and combinations thereof. For example, bioactive layers16and16′ can be composed of copper metal, silver metal, copper metal-containing compounds, silver metal containing compounds, and combinations thereof.

In another refinement, bioactive layers16and16′ can be composed of a component selected from the group consisting of include copper alloys, copper-containing compounds, and combinations thereof. Such copper-containing compounds include copper atoms in the +1 or +2 oxidation state or combinations of copper atoms thereof. Examples of copper-containing compounds include, but are limited to copper, copper oxides, copper nitrides, copper oxides containing carbon atoms, and combinations thereof. In one variation, copper alloys include copper and nickel. Typically, each copper alloy includes nickel in an amount from about 8 to 28 weight percent of the total weight of the bioactive layer with the copper being present in an amount from about 72 to 92 weight percent of the total weight of the bioactive layer. In a refinement, the copper alloy includes nickel in an amount from about 10 to 25 weight percent of the total weight of the bioactive layer and copper in an amount form about 75 to 90 weight percent of the total weight of the bioactive layer. In some variations, the copper alloy can independently include additional elements such as iron, zirconium, tungsten, chromium, and combinations thereof. In a refinement, each of these additional elements is independently present in an amount from about 0.01 to about 5 weight percent of the total weight of the bioactive layer. In a refinement, each of these additional elements are independently present in an amount from about 0.01 to about 5 weight percent of the total weight of the bioactive layer. Examples of copper alloys are CuVerro® White Bronze and CuVerro® Rose commercially available from Olin Brass located in Louisville, KY.

In other variations, the bioactive layers16and16′ include silver, a silver alloy, a silver-containing compound (e.g., a silver oxide), or any combination thereof. Other metals that can exhibit antimicrobial properties include but are not limited to gallium (Ga), gold (Au), magnesium (Mg), titanium (Ti), and zinc (Zn). The bioactive layers14and14′ can include a combination of metals, metal oxides or metal alloys. This includes, for example, a bioactive layer14that includes copper (Cu) and silver (Ag).

In one refinement, each of the one or more of the bioactive layers16and16′ are independently composed of CuOx, where x is from 0.6 to 1.2. In another refinement, each of the one or more of the bioactive layers14and14′ independently composed of CuOaNb, where a is from 0.0 to 1.2 and b, is from 0.01 to 0.4. In still another refinement, each of the one or more of the bioactive layers14and14′ independently composed of CuOcCd, where c is from 0.0 to 1.2 and d, is from 0.01 to 0.4. In a variation, each of the one or more of the bioactive layers14and14′ independently composed of any combination of copper metal, CuOx, CuOaNb, and CuOcCd; Therefore, each of the one or more of the bioactive layers14and14′ independently composed of a combination of copper metal, CuOx, CuOaNb, and CuOcCdor a combination of copper metal and CuOxor a combination of copper metal and CuOaNb, a mixture of copper metal and CuOcCdor a combination of copper metal, CuOx, and CuOaNbor a combination of copper metal, CuOxand CuOcCdor a combination of copper metal, CuOaNb, and CuOcCdor a combination of CuOx, CuOaNb, and CuOcCdor a combination of CuOxand CuOaNbor a combination of CuOaNb, and CuOcCdor a combination of CuOx, CuOaNb, and CuOcCd. Some suitable bioactive layers can be composed of CuxOy, CuxNy, CuxOyNz, and CuxOyCzwhere x can be 1, 2, or 3; y can be 1, 2, or 3; and z can be 1, 2, or 3.

In another variation, the bioactive layer(s) is composed of a mixture of a copper metal alloy and a component selected from the group consisting of zirconium nitride, titanium nitride, zirconium oxycarbides, zirconium oxides, diamond-like-carbon, and combinations thereof.

In another variation, layers16and16′ are composed of a mixture of a copper alloy and at least one of zirconium nitride, titanium nitride, zirconium oxycarbides, zirconium oxides, or diamond-like-carbon.

Indicator layer14, base layer18, interlayers22, and bioactive layers16and16′ can be applied to any suitable substrate12. A suitable substrate12can be composed of any material that exhibits thermal stability at an operational (i.e., the temperature that the bioactive coated substrate is used at) or deposition temperatures for each of the layers. In particular, the substrate12should be thermally stable at a temperature of at least 80° C. In a refinement, the substrate12should be thermally stable at a temperature of at least 250° C. In some refinements, a suitable substrate12can be composed of any material that is electrically conductive. For example, suitable materials that the base substrate can be composed of include, but are not limited to, metals, metal alloys and/or carbon materials. Additional examples of suitable materials that the base substrate can be composed of include, but are not limited to, stainless steel, chromium-nickel plated brass, chromium-nickel-copper plated zinc, chromium-nickel-copper plated ABS plastic, and chromium-nickel-copper plated aluminum.

In another variation, base layer18and interlayers22are independently composed of zirconium or titanium, carbon, and nitrogen where zirconium is present in an amount of at least 50 mole percent with each of the carbon and nitrogen present in an amount of at least 0.02 and 0.1 mole percent, respectively. In a refinement, base layer18and interlayers22are independently composed of a compound having the following formula:
M1−x−yCxNy
where M is zirconium or titanium and x is 0.0 to 0.3 and Y is 0.1 to 0.5. In a refinement, x is 0.0 to 0.2 and y is 0.2 to 0.3. In another refinement, x is at least in increasing order of preference 0.0, 0.02, 0.03, 0.04, 0.05, 0.07, or 0.09 and at most in increasing order of preference, 0.5, 0.4, 0.3, 0.25, 0.2, 0.15, or 0.11. Similarly, in this refinement, y is at least in increasing order of preference 0.1, 0.15, 0.2, 0.25, 0.27, or 0.29 and at most in increasing order of preference, 0.6, 0.5, 0.40, 0.35, 0.33, or 0.31. In a further refinement, the base layer is composed of zirconium carbonitride described by Zr0.60C0.10N0.30.

In still another variation, base layer18and interlayers22are independently composed of zirconium or titanium, carbon, and oxygen where zirconium is present in an amount of at least 50 mole percent with each of the carbon and oxygen present in an amount of at least 0.02 and 0.1 mole percent, respectively. In a refinement, base layer18and interlayers22independently are independently composed of a compound having the following formula:
M1−x−yOxCy.
where M is zirconium or titanium and x is 0.1 to 0.4 and y is 0.5 to 0.2. In a further refinement, the base layer is composed of zirconium oxycarbide described by Zr0.50O0.35C0.15.

In accessing color differences between the indicator layer and bioactive layers16and16′, it should be appreciated that the bioactive layers16and16′ and indicator layer14(as well as the substrate and other layers) can be characterized by Lab color space coordinates L*, a*, and b* relative to CIE standard illuminant D50. In a refinement, at least one of Lab color space coordinates L*, a*, and b* relative to CIE standard illuminant D50 of the bioactive layer (e.g., typically the outermost bioactive layer) differs from that of the indicator layer by at least in increasing order of preference, 5%, 10%, 15%, 20%, 25% or 50%. In another refinement, each of the Lab color space coordinates L*, a*, and b* relative to CIE standard illuminant D50 of the bioactive layer (e.g., typically the outermost bioactive layer) differ from those of the indicator layer by at least in increasing order of preference, 5%, 10%, 15%, 20%, 25% or 50%. In a variation, Delta E (2000), which quantifies the distance between two points in the color space, can be used to quantify the difference between two colors. A visual or noticeable distinction between two colors can be impacted by various factors, including the viewer, the texture, and gloss. In a refinement, a delta E greater than or equal to 1.0 is a sufficient difference in color for the indicator. In another refinement, a delta E greater than or equal to 2.0 is a sufficient difference in color. In still another refinement, a delta E greater than or equal to 5.0 is a sufficient difference in color. In some variations, a delta E greater than or equal to, in increasing order of preference, 2.0, 5.0, 8.0, 10.0, 15.0, and 20.0, is a sufficient difference in color.

In another embodiment, the bioactive coated substrates ofFIGS.1A and1Bare included in an article. In a refinement, the useful article further includes an indicator layer as set forth above. Many healthcare or hospital surfaces may greatly benefit from a bioactive coated substrate. For example, useful articles can include but are not limited to bedrails, footboards, bed-side tables, knobs, handles, safety rails, carts, push plates, kick plates, mop plates, stretcher plates, spigots, drains, sinks, faucets, drain levers, water fountain components, sanitizers/soap dispensers, hand dryers, commonly used buttons, headrest, showerheads, countertops, hinges, locks, latches, trim, toilet or urinal hardware, light switches, armrest, thermostat controls, telephones, floor tiles, ceiling tiles, wall tiles, instrument handles (e.g. drug delivery systems, monitoring systems, hospital beds, office equipment, operating room equipment, stands and fixtures), IV poles, trays, pans, walkers, wheelchairs, keyboards, computer mouse surfaces, exercise equipment, rehabilitation equipment, physical therapy equipment, lamps, lighting systems, lids, hangers, remotes, cup holders, toothbrush holders, gown snaps, and window sills. Likewise, popular or common areas in general could benefit from articles with bioactive coated substrate s. For example, some articles or surfaces can include but are not limited to shopping carts, shopping cart handles, child seats, handrails, register keypads, register housings, ATMs, lockers, elevator controls, paper towel dispensers, toilet paper dispensers, vending machines, and restroom surfaces. Similar articles and surfaces can benefit in housing areas, mass transit, laboratories, religious gathering facilities, or any commonly visited facilities. Other uses can include but are not limited to writing utensils, eyeglass frames, combs, phone covers, tablet covers, headphone, and bottle openers to name a few.

While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.