Title of Invention

"ANTIMICROBIAL INSULATION"

Abstract Insulation that exhibits antimicrobial characteristics is disclosed. A method for making the insulation is also disclosed. Suitable antimicrobial agents that may be applied to the insulation or any components thereof include propiconazole, sodium pyrithione, tolyl diiodomethyl sulfone; tebuconazole; thiabendazole; 3-iodo-2propynyl butylcarbamate; triclosan, quaternary ammonium compounds, metals, and mixtures thereof.
Full Text CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of PCT/US04/19360,
filed on June 16, 2004, which claims priority from: U.S. provisional application
60/525,910, filed on December 1,2003; U.S. provisional application 60/529,164, filed
on December 12, 2003; U.S. provisional application 60/551,485, filed on March 9,
2004; U.S. provisional application 60/551,426, filed on March 9, 2004; U.S.
provisional application 60/568,821, filed May 6, 2004; and U.S. provisional
application 60/568,961, filed on May 7, 2004, each of which is incorporated by
reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to insulation and methods for
making insulation. In particular, the present invention relates to an efficient and
economical method for producing insulation that possesses antimicrobial (e.g.,
antibacterial and antifungal) properties.
[0003] Insulation is a ubiquitous construction material. It is found in
practically all residential and commercial construction and its importance in the
construction of new structures cannot be over emphasized. The primary function of
insulation is to act as a heat transfer barrier between the interior of a structure and the
outside environment. Thus insulation, if properly installed, can greatly reduce heating
and air conditioning costs. Insulation can also serve as a sound barrier, moisture
barrier, and vapor/air barrier.
[0004] The diverse functions of insulation led to the development of many
different types of insulation. Some insulation is blown loosely into attics. Other
insulation consists of foam sheets nailed to walls. The present invention pertains to
arguably the most common form of insulation -fiberglass batting that has one side
faced with Kraft paper. This type of insulation generally comes in large rolls which
are then unrolled to form a mat in attics and walls.

[0005] For the remainder of this document the term insulation will refer to
paper faced fiberglass batting.
[0006] One of the problems traditionally associated with the use of insulation
is the susceptibility of kraft paper to moisture absorption in damp environments.
Unfortunately, insulation used in interior construction sometimes can encounter water
due to leaks in roofs, windows, or plumbing. Furthermore, many geographical areas
are characterized by high humidity which also provides a source of water that can be
absorbed by kraft paper faced insulation Although the fiberglass component of the
insulation is not hospitable to the growth of microbes, the kraft paper facing of the
insulation is susceptible to supporting microbial growth, specifically fungal and
bacterial growth.
[0007] The growth of fungus and bacteria on insulation is undesirable for
many reasons. First, it traps moisture in the insulation which can lead to
promulgation of even more fungus and bacteria and weakening of adjacent structural
members. Unpleasant odors and staining are also associated with microbial growth.
More seriously, many people are susceptible to life threatening allergic responses
when exposed to fungal spores. The issues created by. microbial growth on insulation,
especially the human health issues, drives a continuing need for insulation that is
resistant to microbial growth.
[0008] To date, the patent literature has failed to address the issue of
biological contamination of insulation. However, the patent literature contains several
examples of attempts to address the problem of microbial growth on a somewhat
related material: wallboard. Wallboard is a construction material used to form
walls. Wallboard is somewhat similar to insulation in that it comprises a structural
material (a sheet of gypsum instead of fiberglass) attached to one or two sheets of
kraft paper. The kraft paper used in insulation, however, is usually thinner than that
used with wallboard.
[0009] Commonly assigned US Patent Application Serial No. 10/250,143,
from with this, application claims priority, discusses the need to provide built-in and
long-lasting antimicrobial protection to the kraft paper used in the production of
wallboard.


[0010] The current invention is an extension and improvement of the work
begun in the 143 application and continued in subsequent applications from which
the present application also claims priority.
BRIEF SUMMARY OF PREFERRED EMBODIMENTS
[0011] The present invention derives from research directed at developing a
commercially viable process for making, insulation that exhibits antimicrobial
characteristics. One result of this research was the development of insulation which
exhibits antimicrobial characteristics and resists the growth of microbes. In broad
terms, the insulation according to the invention comprises an insulating material such
as fiberglass, a non-woven covering adjacent the insulating material, and an
antimicrobial composition. In many embodiments the insulating material will be
attached to the non-woven covering by an adhesive. The antimicrobial composition is
preferably intimately associated with the non-woven covering, the adhesive or both.
[0012] The invention also encompasses a method for producing insulation that
exhibits antimicrobial characteristics and resists the growth of microbes. The method
comprises the steps of contacting a non-woven covering to an insulating material, and
applying an antimicrobial composition to the non-woven covering. The method also
comprises adding an antimicrobial composition to the insulation or to a component
thereof at levels sufficient to exhibit efficacy against microbes.
DETAILED DESCRIPTION
[0013] Turning now to the specifics of the invention, in one broad aspect, the
invention is insulation that exhibits antimicrobial characteristics and resists the growth
of microbes. As used herein, the term microbes encompasses bacteria, fungi, and
other such forms of life that are generally considered by those skilled in the art to fall
within the realm of microbiology. Fungus (i.e., mold and mildew), however, is a
primary concern with insulation. Accordingly, and for ease of discussion, this
detailed description will often make reference to fungus and antifungal agents. This
method of presentation should not be interpreted as limiting the scope of the invention
in any way.


[0014] The term efficacy, as used herein, is defined as the characteristic of
inhibiting the growth of a microbe on a substrate.
[0015] The term non-metallic antimicrobial agent as used herein means
antimicrobial agents, other than quaternary ammonium compounds, that do not
contain or utilize metal ions (e.g., Ag, Cu).
[0016] The term antimicrobial composition, as used herein, includes
individual antimicrobial agents (e.g., silver, triclosan, zinc oxide, etc.) and various
combinations of antimicrobial agents and other additives.
[0017] In its broadest aspects, the insulation according to the invention
comprises an insulating material, a non woven covering adjacent the insulating
material and an antimicrobiail composition. In most instances the non-woven covering
will be connected to the insulating material using an adhesive. In many instances the
adhesive is an asphalt or tar-like adhesive that is well known in the industry.
[0018] The insulating material may be any of the commonly known insulating
materials. Perhaps the most commonly, known and used insulating material is
fiberglass batting. This type of. insulating material is found in most commercially
available lines of insulation including the well known pink colored insulation
available from Owens-Corning. Fiberglass batting is the preferred insulating material
for use in the practice of the invention.
[0019] The non-woven covering used in the practice of the invention may be
any type of non-woven material capable of attachment to and support of insulating
material. Synthetic polymer non-woven mats are examples of acceptable non-woven
material.
[0020] More preferably, the non-woven covering used in the practice of the
invention is made from natural polymers such as cellulose. Kraft paper is the non-
woven material of choice used in the insulation industry. Accordingly, a particularly
preferred non-woven covering for use with the invention is kraft paper.
[0021] The antimicrobial composition and the various methods of applying the
antimicrobial composition to the non-woven covering represent the most diverse


aspect of the invention. If synthetic polymer non-woven material is used then the
antimicrobial composition can be added to the polymer melt prior to formation of the
non-woven mat. Furthermore, the antimicrobial compositions that may be used in the
conjunction with synthetic polymer non-woven coverings include all of the
antimicrobial agents, or combinations of agents, commonly used with synthetic
polymers. Such agents include, but are not limited to chlorinated phenols (e.g.,
triclosan), quaternary ammonium compounds, azoles, and metals (e.g., silver zeolites,
silver ions). Those skilled in the art are well versed at adding such agents to polymers
and can choose the appropriate agent and loading levels for the polymer of interest
without undue experimentation.
[0022] Similarly, if kraft paper is the non-woven covering, the antimicrobial
agents utilized in the practice of the invention may include any antimicrobial
composition capable of imparting antimicrobial characteristics to insulation and
particularly the non-woven (e.g., kraft paper) covering. Many of these antimicrobial
agents are discussed or cited in priority document U.S. Patent Application Serial
Number 10/250,143, which is incorporated herein by reference. Such agents include,
but are not limited to chlorinated phenols (e.g., triclosan), quaternary ammonium
compounds, azoles, and metals (e.g., silver zeolites, silver ions).
[0023] Likewise, the antimicrobial composition may be applied to the kraft
paper in any of several ways. For example, the paper may be treated by adding
antimicrobial compositions to the fiber/pulp slurry during formation of the paper.
Although this method can be effective, it tends to be cost prohibitive. Alternatively,
the paper may be surface treated with an antimicrobial composition.
[0024] Spraying the paper covering with the antimicrobial composition, either
before or after contact with the insulation material, is within the scope of the
invention. Those skilled in the art of papermaking are very familiar with spraybars
and their use and how they can be easily adopted for use with the present invention.
[0025] Another method of treating the paper surface is to apply the
antimicrobial composition as a uniform coating on one side or both sides of the paper
covering as the paper covering is made. For example, the antimicrobial composition


could be applied to the paper at the calendar stack rolls using a water bath that is
sometimes present in papermaking processes
[0026] In some instances the papermaking process may determine both the
method of application and the antimicrobial composition used. Each papermaking
process is unique in some respect and those skilled in the art can easily determine
which application method and antimicrobial composition is best for their particular
process.
[0027] Regardless of the manner of applying the antimicrobial composition,
all embodiments of the invention contain a quantity of antimicrobial composition
sufficient to exhibit efficacy against microbes and particularly various species of
fungi. More specifically, the preferred embodiments of the invention contain a
quantity of antimicrobial composition sufficient to inhibit microbial growth on a
substrate tested in accordance with AATCC (American Association of Chemists &
Colorists) Test Method 30, Part III. Those skilled in the art are familiar with this test
method and its parameters.
[0028] As an aid to the reader, and to those skilled in the art, there are several
preferred combinations of application methods and antimicrobial compositions for use
with embodiments of the invention that employ kraft paper. (Please note that these
antimicrobial compositions could also be used with synthetic polymers.) The
following paragraphs will present three particularly preferred antimicrobial agents and
ways of applying each. It should also be noted that the methods of application
discussed herein can be used with any of the antimicrobial compositions. The
following compositions and methods of application are exemplary and should not be
interpreted to limit the scope of the invention.
Antimicrobial Composition #1
[0029] In one embodiment the antimicrobial composition is an antimicrobial
system that comprises a first antimicrobial agent in a first carrier and a second
antimicrobial agent in a second carrier. Preferably, the first and second carriers are at
least partly soluble in each other. This adds to the stability of the antimicrobial
system by minimizing the formation of two liquid phases.


[0030] For example and as discussed in more detail below, one antimicrobial
agent suitable for use in the practice of the invention is propiconazole which is
commercially available from Janssen Pharmacetica under the trade name WOCOSEN.
Another antimicrobial agent suitable for use in the present invention is diiodomethyl-
4-tolylsulfone which is commercially available from Dow Chemical under the trade
name AMICAL. Both commercial embodiments can be obtained in carriers that are
soluble in each other which improve the system's stability.
[0031] Commercially available antimicrobial agents suitable for use in the
antimicrobial system can come in surfactant based carriers. Although surfactant
based carriers can be used in the practice of the invention care should be taken when
using such carriers to ensure that the application system does not become burdened
with foam. Foam can sometimes develop if the application system provides for the
agitation of the antimicrobial composition. Foam can detrimentally effect the smooth
and uniform distribution of the active ingredients. In some instances a small quantity
of an anti-foaming agent can be added to the antimicrobial composition to reduce the
foam Preferred anti-foaming agents are ethoxylated co-polymers of polyethylene
glycoL
[0032] Testing has shown that acceptable efficacy of treated paper can be
obtained by roll coating the paper using an antimicrobial system in which the
combined concentration of two antimicrobial agents was less than 1000 ppm and in
many instances less than 500 ppm
[0033] Accordingly, in preferred embodiments the first antimicrobial agent
used in the antimicrobial system is selected from the group consisting of
propiconazole, sodium pyrithione, and mixtures thereof Both agents are
commercially available in various concentrations and can be diluted to the extent
necessary by those skilled in the art.
[0034] Preferably, the second antimicrobial agent used in the antimicrobial
system is selected from the group consisting oftolyl diiodomethyl sulfone;
tebuconazole, thiabendazole;; and 3-iodo-2-propynyl butylcarbamate, and mixtures
thereof These agents are commercially available as well.


[0035] Those skilled in the art can readily adjust the relative quantities of each
of the antimicrobial agents in the antimicrobial system to achieve the desired levelsof
efficacy. In general, higher concentrations translate to higher efficacy. However, a
preferred embodiment of the antimicrobial system is an emulsion comprising by
weight about 0.1% to 0.8% propiconazole, 0.1% to 0.5% tolyl diiodomethyl sulfone,
and 0.05% -0.15% 3-iodo-2-propynyl butylcarbamate, in water.
[0036] Emulsions using 0.20% propiconazole, 0.175% tolyl diiodomethyl
sulfone, and 0.10% 3-iodo-2-propynyl butylcarbamate, in water, applied to 50 lb. per
square foot paper showed acceptable efficacy when applied to the surface of the paper
at between about 5% and about 20% wet pickup based on the dry weight of the paper.
Wet pickup between about 5% and about 7% showed acceptable results and would be
preferable due to cost considerations. The quantity picked up by the paper can be
adjusted in several ways known to those skilled in the art.
Examples
[0037] Various combinations of the following antimicrobial agents were
thoroughly mixed together at ambient conditions in water as shown in Table 1 below.



[0038] The formulations in Table 1 were applied to 50 lb. kraft paper stock
using a wire-wound rod to control lay down. Approximate pickup was about 15%.
The paper samples were tested via AATCC Method 30, Part II to evaluate the
compositions for antifungal efficacy. The test organism was A. Niger. After
incubation for seven (7) days, the samples were evaluated based upon the following
scale; 0 represents no observed growth; 1 represents growth apparent only under a
microscope; and 2 represents growth visible to the naked eye. In addition, there may
be zones of inhibition where growth of the organisms is inhibited from growing
anywhere in the vicinity of the samples. Thus, results are reported as a rating, with
zones of inhibition where applicable. The results of this testing are shown in Table 2.
The romannumerals identify the various combinations of ingredients.



(I) - Formulation of Table 1 containing water and no binder.
(II) - Formulation of Table 1 including 1% by weight silicone coating (RE 29).
(III) - Formulation of Table 1 including 1% by weight of cationic polymer having
affinity for paper.
(IV) - Formulation of Table I including 1% by weight of a silane coupling agent.
[0039] As the results show, A, B, C, and D formulations showed no observed
growth. The untreated controls showed no efficacy.
[0040] Additional lab tests were run to determine if efficacy could be achieved
using lesser concentrations of antimicrobial agents. Several combinations of active
agents were tested at various concentrations to observe efficacy. The combinations
shown below were applied to 2 inch by 2 inch squares of 50 lb. kraft paper and tested
using AATCC Method 30, Part 111. The results are shown in Tables 3 and 4.



[0041] As the above data indicates, acceptable inhibition of microbial growth
can be achieved using relatively low concentrations of antimicrobial agents. As low
as 400 ppm combined active agent can achieve zero growth and a zone of inhibition.
[0042] Preferably, the antimicrobial system is applied to the non-woven
covering (i.e., paper) such that the first antimicrobial agent is present in or on the non-
woven covering in a concentration between about 50 ppm and about 1200 ppm, more
preferably between about 200 ppm and 1200 ppm In particularly preferred

embodiments, the first antimicrobial agent is propiconazole and is present in a
concentration between about 80 ppm and 1000 ppm; more preferably between about
500 ppm and 1000 ppm
[0043] Likewise, the; second antimicrobial agent preferably is present in the
non-woven covering at a concentration between about 40 ppm and 1600 ppm; more
preferably between about 60 ppm and 1400 ppm In particularly preferred .
embodiments, the second antimicrobial agent isolyl diiodomethyl sulfone (Amical
Flowable from Dow) and is present in a concentration between about 40 ppm and
1600 ppm; more preferably between about 60 ppm and 1400 ppm.
Antimicrobial Composition #2
[0044] In another embodiment, the antimicrobial composition used in the
practice of the invention comprises a microemulsion of a quaternary ammonium
antimicrobial agent, a phenol, and water.
[0045] In its most basic form, this embodiment of the antimicrobial
composition comprises an aqueous microemulsion. The microemulsion comprises a
quaternary ammonium antimicrobial agent, a phenol, and water. Interestingly, the
composition need not contain the volatile alcohols (e.g., ethanol) that are usually used
to form emulsions of quaternary ammonium antimicrobial agents. Each of these
elements, and other preferred and optional elements, will be discussed in more detail
below.
[0046] Quaternary ammonium antimicrobial agents suitable for use in the
antimicrobial composition include, but are not limited' to, N-alkyldimethyl benzyl
ammonium saccharinate, 1,3,5-Triazine- 1,3,5(2 H,4H,6H)-triethariol; 1-
Decanaminium, N-decyl-N, N-dimethyl-, chloride (or) Didecyl dimethyl ammonium
chloride; 2-(2-(p-(DiisobuyI) cresosxy)ethoxy)ethyl dimethyl benzyl ammonium
chloride; 2-(2-(p- (Di isobutyl)phenoxy)ethoxy)ethyl dimethyl benzyl ammonium
chloride; alkyl 1 or 3 benzyl-l-(2-hydroxethyl)-2-imidazolinium chloride; alkyl bis(2-
hydroxyethyl) benzyl ammonium chloride; alkyl dimethyl benzyl ammonium
chloride; alkyl dimethyl 3,4-dichIorobenzyl ammonium chloride (100% C12); alkyl
dimethyl 3,4-dichlorobenzyl ammonium chloride (50% C14, 40% C12, 10% C 16);
alkyl dimethyl 3,4-dichlorobenzyl ammonium chloride (55% C14, 23% C12, 20% C

16); alkyl dimethyl benzyl ammonium chloride; alkyl dimethyl benzyl ammonium
chloride (100% C14); alkyl dimethyl benzyl ammonium chloride (100% C16); alkyl
dimethyl benzyl ammonium chloride (41% C14, 28% C12); alkyl dimethyl benzyl
ammonium chloride (47% C12, 18% C14); alkyl dimethyl benzyl ammonium chloride
(55% C16, 20% C 14); alkyl dimethyl benzyl ammonium chloride (58% C14, 28%
C16); alkyl dimethyl benzyl ammonium chloride (60% C14, 25% C12); alkyl
dimethyl benzyl ammonium chloride (61% C11, 23% C14); alkyl dimethyl, benzyl
ammonium chloride (61% C12, 23% C14); alkyl dimethyl benzyl ammonium chloride
(65% C12, 25% C 14); alkyl dimethyl benzyl ammonium chloride (67% C12, 24% C
14); alkyl dimethyl benzyl ammonium chloride (67% C12, 25% C14); alkyl dimethyl
benzyl ammonium chloride (90% C14, 5% C 12); alkyl dimethyl benzyl ammonium
chloride (93% C14, 4% C 12); alkyl dimethyl benzyl ammonium chloride (95% C16,
5% C18); alkyl dimethyl benzyl ammonium chloride (and) didecyl dimethyl
ammonium chloride; alkyl dimethyl benzyl ammonium chloride (as in fatty acids);
alkyl dimethyl benzyl ammonium chloride (C12-C16); alkyl dimethyl benzyl
ammonium chloride (C12-C18); alkyl dimethyl benzyl and dialkyl dimethyl
ammonium chloride; alkyl dimethyl dimethy benzyl ammonium chloride; alkyl
dimethyl ethyl ammonium' bromide (90% C14, 5% C16, 5% C12); alkyl dimethyl
ethyl ammonium bromide (mixed alkyl and alkenyl groups as in the fatty acids of
soybean oil); alkyl dimethyl ethylbenzyl ammonium chloride; alkyl dimethyl
ethylbenzyl ammonium chloride (60% C14); alkyl dimethyl isoproylbenzyl
ammonium chloride (50% C12, 30% C14, 17% C16, 3% C18); alkyl trimethyl
ammonium chloride (58% C18, 40% C16, 1% C14, 1% C12); alkyl trimethyl
ammonium chloride (90% C18, 10% C 16); alkyldimethyl(ethylbenzyl) ammonium
chloride (C12-18); Di-(C8-10)-alkyl dimethyl ammonium chlorides; dialkyl dimethyl
ammonium chloride; dialkyl dimethyl ammonium chloride;, dialkyl dimethyl
ammonium chloride; dialkyl methyl benzyl ammonium chloride; didecyl dimethyl
ammonium chloride; diisodecyl dimethyl ammonium chloride; dioctyl dimethyl
ammonium chloride; dodecyl bis (2-hydroxyethyl) octyl hydrogen ammonium
chloride; dodecyl dimethyl benzyl ammonium chloride; dodecylcarbamoyl methyl
dimethyl benzyl ammonium chloride; heptadecyl hydroxyethylimidazolinium
chloride; hexahydro-1,3,5-thris(2-hydroxyethyl)- s-triazine; myristalkonium chloride
(and) Quat KNIUM 14; N,N-Dimethyl-2- hydroxypropylammoniurn chloride
polymer; n-alkyl dimethyl benzyl ammonium chloride; n-alkyl dimethyl ethylbenzyl


ammonium chloride; n-tetradecyl dimethyl benzyl ammonium chloride monohydrate;
octyl decyl dimethyl ammonium chloride; octyl dodecyl dimethyl ammonium
chloride; octyphenoxyethoxyethyl dimethyl benzyl ammonium chloride;
oxydiethylenebis (alkyl dimethyl ammonium chloride); quaternary ammonium
compounds, dicoco alkyldimethyL chloride; trimethoxysily propyl dimethyl octadecyi
ammonium chloride; trimethoxysilyl quats, trimethyl dodecylbenzyl ammonium
chloride; n-dodecyl dimethyl: ethylbenzyl ammonium chloride; n-hexadecyl dimethyl
benzyl ammonium chloride; n-tetradecyl dimethyl benzyl ammonium chloride; n-
tetradecyl dimethyl ethyylbenzyl ammonium chloride; and n-octadecyl dimethyl
benzyl ammonium chloride.
[0047] In particularly preferred embodiments the quaternary ammonium
antimicrobial agent comprises a dimethylbenzyl ammonium compound such as N-
alkyl dimethylbenzyl ammonium saccharinate. N-alkyl dimethylbenzyl ammonium
saccharinate is commercially available from Stepan Chemical Company of Northfield,
Illinois, under the trade name ONYXCIDE™ 3300. This particular form of
ONYXIDE™ is approximately 95% active and is a solid at room temperature but will
form a liquid at elevated temperature. It is light yellow-orange in color and is
insoluble in water.
[0048] The phenol utilized in the practice of the invention is preferably an
alkyl phenol, a styrenated phenol, or a combination of the two. Such phenols are
commercially available from a number of sources.
[0049] The precise phenol utilized in the practice of the invention will likely
be determined by the overall process. If it is determined that an alkyl phenol is best
for a particular process, the alkyl phenol utilized in this embodiment preferably
comprises at least one alkyl phenol having at least one an alkyl group selected from
the group consisting of C7 alkyls, CS alkyls, C9 alkyls, C10 alkyls, and C11 alkyls.
[0050] In most preferred embodiments the alkyl phenol comprises an alkyl
phenol having a C9 alkyl group.
[0051] Alkyl phenols suitable for use in this embodiment are commercially
available from a number of sources. Particularly preferred commercially available
alkyl phenols include TRITON™ X-207 sold by Dow Chemical Company.


[0052] In a similar fashion, the particular styrenated phenol utilized in the
practice of the invention will depend upon the overall process. In preferred
embodiments, the styrenated phenol is preferably non-ionic. Preferred styrenated
phenols include CHROMASIST™ WEZ and STAND APOL HS™, both of which are
commercially available from Cognis Corporation whose North American office is in
Cincinnati, Ohio.
[0053] Water makes up the other primary component of this embodiment of
the antimicrobial composition.
[0054] The antimicrobial composition may contain other additives. Two such
additives are anti-foaming agents and anti-freezing agents.
[0055] The alkyl phenols and styrenated phenols used in this embodiment of
the antimicrobial, composition can be susceptible to foaming depending upon the
particular application. Therefore, it is envisioned that some commercial applications
will contain anti-foaming agents.
[0056] For example, this embodiment of the antimicrobial composition
according to the invention may be used to treat kraft paper. One method of treating
this type of paper is to add the antimicrobial composition to the water box, a device
toward the end of the paper process that returns a certain quantity of water to the '
paper after the paper has undergone heat based drying.
[0057] The water box is often agitated due to the continuous movement of
paper through it. This agitation can cause foaming upon the addition of the claimed
antimicrobial composition. Generally, the presence of foam is detrimental to the water
box portion of a paper process. Therefore an anti-foarning agent is added to the
composition according to the invention when the invention is used to treat paper at the
water box.
[0058] Preferred anti-foaming agents are ethoxylated co-polymers of
polyethylene glycol. In some instances, the commerical formulations of stryrenated
phenols and alkyl phenols may contain a quantity of an antifoaming agent.. For
example, TRITON™ X-207 contains a small quantity of polyethylene glycol.


Accordingly, if TRITON™ X-207 is the source of the phenol additional antifoaming
agent may not be needed.
[0059] Likewise, anti-freezing agents may be added to the composition
according to the invention. The anti-freezing agents are not thought to be critical to
the actual performance of the invention. Instead they are used to keep the
composition from freezing ox becoming too viscous during transport in cold weather.
The anti-freezing agents may be left out of the composition if they are found to
interfere with the addition of the antimicrobial agent in any particular process. A
preferred anti-freezing agent is dipropylene glycol.
[0060] The relative quantities of each of the discussed components may vary
to accommodate particular process requirements. Again, those skilled in the art are
fully capable of making these adjustments without undue experimentation.
[0061] In preferred embodiments the quaternary ammonium antimicrobial
agent is present in the antimicrobial composition in an amount between about 1 wt. %
and 30 wt. %. In particularly preferred embodiments the quaternary ammonium
antimicrobial agent is present between about 15 wt % and 20 wt. % of the overall
composition.
[0062] As an example of how the invention may be tailored to meet specific
process requirements, it was determined that a composition having approximately 17
wt. % ONYXIDE™ 3300 successfully and efficiently imparted antimicrobial
characteristics to kraft paper in one particular papermaking process.
[0063] Likewise, the total phenol content of the antimicrobial composition
(e.g., alkyl, styrenated, or combination of the two) is between about 10 wt. % and
about 60 wt. % of the total composition. Preferred embodiments utilize between
about 20 wt. % to about 50 wt. % alkyl phenol and about 1. wt. % to about 10 wt. %
styrenated phenol.
[0064] In one exemplary paper making process, it was determined that a
combination of alkyl and styrenated phenol worked best for that particular process.
Specifically, the preferred total phenol content in that embodiment was between about
25 wt. % and about 50 wt. %. Optimization of that particular process resulted in the


alkyl phenol being close to about 44 wt. % while the styrenated phenol was close to
about 5 wt. %.
[0065] It is anticipated that in most applications the quantity of anti-foaming
agent needed for successful practice of the invention will range between about 0 wt.
% to about 20 wt. %:
[0066] The remainder of the antimicrobial composition comprises water. In
preferred embodiments the quantity of water present in the claimed composition will
be between about 5 wt.% and about 30 wt. %, more preferably between about 10 wt.
% and about 20 wt. %. Again, the exact quantity of water will depend upon the
particular application and those skilled in the art a capable of making the necessary
adjustments.
[0067] The invention also encompasses a method of making the antimicrobial
composition.
[0068] In broad terms, the method comprises the steps of blending a phenol
with a quaternary ammonium antimicrobial agent, heating the blended phenol and
quaternary ammonium antimicrobial agent if necessary (some combinations of
phenol/quaternary agent may not require heat), and admixing a quantity of water.
[0069] In preferred embodiments, the phenol (e.g., TRITON™ X-207) is
blended with the quaternary ammonium antimicrobial agent (e.g., ONYXIDE™) in
the presence of heat. The heat is applied because in many instances the quaternary
ammonium antimicrobial agent is a solid at room temperature. Care should be taken
not to heat the admixture of phenol and antimicrobial agent to a point where there is
unacceptable volatilization of either.
[0070] If ONYXIDE™ is the antimicrobial agent, a mixing temperature of
between about 65° C and about 75° C is recommended. At this temperature the
ONYXIDE™ melts into the phenol to form a liquid.
[0071] Anti-foaming agents and anti-freezing agents such as those discussed-
previously can be added at this point if needed or desired.


[0072] Once the antimicrobial agent and the phenol are mixed the heat may be
removed. As the admixture cools to room temperature water is added with stirring.
[0073] The relative amounts of antimicrobial agent, phenol, and water utilized
in the method are the same as those discussed in relation to the composition.
Likewise, the relative amounts of anti-foaming agents, anti-freezing agents, and
additional antimicrobial agents, if used, are the same as those discussed in relation to
the composition.
Antimicrobial Composition #3
[0074] The term non-metallic as used herein means antimicrobial agents, other
than quaternary ammonium compounds, that do not contain or utilize metal ions (e.g.,
Ag,Cu).
[0075] In another embodiment, the antimicrobial composition comprises a
microemulsion of a quaternary ammonium antimicrobial agent and two different types
of non-metallic antimicrobial agents. The microemulsion can come in two forms.
One is an aqueous microemulsion well suited for aqueous systems. The other is a
non-aqueous microemulsion well suited for non-aqueous or organic solvent type
systems. In the context of insulation it is expected that the aqueous microemulsion
will be the more frequently used form
[0076] Turning now to more specific embodiments of this antimicrobial
composition, one embodiment is an aqueous antimicrobial composition that can
impart antimicrobial characteristics to kraft paper and many different products. In its
most basic form, this embodiment of the invention comprises an aqueous
microemulsion. The microemulsion comprises a quaternary ammonium antimicrobial
agent, a phenol, a first non-metallic antimicrobial agent, a second non-metallic
antimicrobial agent, and water. Interestingly, the composition need not contain the
volatile alcohols (e.g., ethanol) that are usually used to form emulsions of quaternary
ammonium antimicrobial agents. Each of these elements, and other preferred and
optional elements, will be discussed in more detail below.


[0077] Quaternary ammonium antimicrobial agents utilized in this
composition include those listed in the previous embodiments of the antimicrobial
composition.
[0078] In particularly preferred embodiments the quaternary ammonium
antimicrobial agent comprises a dimethylbenzyl ammonium compound such as N-
alkyl dimethylbenzyl ammomum saccharinate. N-alkyl dimethylbenzyl ammonium
saccharinate is commercially available from Stepan Chemical Company of Northfield,
Illinois, under the tradename ONYXCIDE™ 3300. This particular form of
ONYXIDE™ is approximately 95% active and is a solid at room temperature but will
form a liquid at elevated temperature. It is light yellow-orange in color and is
insoluble in water.
[0079] The phenol utilized in the practice of the invention may comprise an
alkyl phenol having at least one an alkyl group selected from the group consisting of
C7 alkyls, C8 alkyls, C9 alkyls, C10 alkyls, and C11 alkyls.
[0080] In most preferred embodiments the alkyl phenol comprises an alkyl
phenol having a C9 alkyl group.
[0081] Alkyl phenols suitable for use in the practice of the claimed invention
are available commercially from a number of sources. A particularly preferred
commercially available alkyl phenol is sold by Dow Chemical Company under the
tradename TRITON™ X-207.
[0082] Alternatively., the phenol utilized in the practice of the invention can'
comprise a styrenated phenol. Two examples of styrenated phenols acceptable for use
with the invention are CHROMASIST WEZ and STANDAPOL HS. Both are
available from Cognis Corporation of Cincinnati, Ohio. Both are identified by CAS #
3217120. Technical data sheets indicate that the primary difference between the two
is the level of ethoxylation.
[0083] The different phenols that may be employed in the practice of this
embodiment of the invention are an example of both the flexibility of the invention
and the choices that one skilled in the art may have to make in the practice of the
invention. Those skilled in the art will recognize that one phenol may work better in


one particular paper or insulation making process The fine tuning of the invention to
suit a particular process is anticipated and should not limit the scope of the invention
in any way. Those skilled in the art will be able to make the small necessary
adjustments to adapt the invention to their particular process without undue
experimentation.
[0084] The non-metallic antimicrobial agents used in this embodiment of the
invention are preferably selected from the azole family of antimicrobial agents..
Generally speaking, azoles comprise a large class of compounds characterized by a
five membered ring which contains an atom of nitrogen and at least one other
noncarbon atom (e.g., nitrogen, oxygen, and sulphur). Certain azoles exhibit
antimicrobial (i.e., antifungal) properties. Triazoles are a subclass of azoles that are
often used as antimicrobial agents.
[0085] Two of the more well known antimicrobial triazoles are propiconazole
and tebuconazole. The cheroical name for propiconazole (CAS No. 50207-90-1) is 1
[[2-(2,4-dichlorophenyl)-4-propyl-1,3-dioxolan-2-yl]methyl]-1H-1,2,4-triazole. The
chemical name for tebuconazole (CAS No. 107534-96-3) is α-[2-(4-
chlorophenyl)ethyl]-α-(1,1 -dlimethy lethyl)-1H-1,2,4-triazole-1 -ethanol.
[0086] Tebuconazole is commercially available from a number of sources. A
particularly preferred form of tebuconazole is available from Bayer Corporation under
the tradename PREVENTOL™ A8. Similarly, propiconazole is available from a
number of sources. A particularly preferred form of propiconazole is available from
Janssen Pharmaceutica under the tradename WOCOSEN™ TECHNICAL.
[0087] In particularly preferred embodiments, the first and second non-
metallic antimicrobial agents are propiconazole and tebuconazole. Either agent can
be the "first" or "second"; the particular designation does not matter. For ease of
discussion however, tebuconazole will generally be referred to as the first non-
metallic agent and propiconazole will be the second non-metallic agent.
[0088] A small quantity of a glycol may be present in the composition
according to the invention if desired. Glycols can add to the stability of the emulsion
and provide other benefits such as retarding foam Preferred glycols include alkyl


glycols with polyethylene glycol, polypropylene glycol, and dipropylene glycol being
preferred.
[0089] Water makes up the other primary component of the claimed
antimicrobial composition.
[0090] The antimicrobial composition according to the invention may contain
other additives. Two such additives are anti-foaming agents and anti-freezing agents.
[0091] Some phenols used in the practice of the invention can be susceptible
to foaming depending upon the particular application. Therefore, it is envisioned that
many commercial embodiments of the invention will contain anti-foarning agents.
[0092] For example, this composition may be used to treat kraft paper. Such
paper is used to form the outer surface on insulation. One method of treating this type
of paper is to add the antimicrobial composition to the water box, a device toward the
end of the paper process that returns a certain quantity of water to the paper after the
paper has undergone heat based drying.
[0093] The water box is often agitated due to the continuous movement of
paper through it. This agitation can cause foaming upon the addition of the claimed
antimicrobial compositioa Generally, the presence of foam is detrimental to the
water box portion of a paper process. Therefore an anti-foaming agent is added to the
composition according to the invention when the invention is used to treat paper at the
water box.
[0094] The paper can also be treated using a spraybar. Foam buildup in the
spraybar can be detrimental to a process so an antifoaming agent can be used there as
well.
[0095] Preferred anti-foaming agents are ethoxylated co-polymers of
polyethylene glycol. In some instances, the commercial formulations of phenols may
contain a quantity of an antifoaming agent. For example, TRITON™ X-207 contains
a small quantity of polyethylene glycol. Accordingly, if TRITON™ X-207 is one
source of the phenol additional antifoaming agent may not be needed.


[0096] Likewise, anti-freezing agents may be added to the composition
according to the invention. They are used to keep the composition from freezing or
becoming too viscous during transport in cold weather. In most instances a glycol
will serve the function of an anti-freezing agent. A preferred anti-freezing agent is
dipropylene glycol.
[0097] One of the benefits of the present composition is that it provides a
novel and improved platform for taking advantage of the antimicrobial properties of
various azoles and tebuconazole and propiconazole in particular. For some years now
those skilled in the art have: been aware ofa general synergy between tebuconazole
and propiconazole. In other words, by using tebuconazole and propiconazole in
combination, one can achieve a greater antimicrobial effect for a given amount of
antimicrobial agent.
[0098] Tebuconazole: and propiconazole are also well known for their
hydrophobicity and difficulty of use in an aqueous environment. They resist forming
aqueous emulsions and to the extent they can be forced into some type of aqueous
emulsion the emulsions tend to be delicate and are easily destabilized (e.g., the actives
form crystals in water and precipitate out or they form distinct phases with water).
[0099] The composition according to the invention, however, provides a stable
aqueous emulsion of a quaternary ammonium antimicrobial agent and azoles,
particularly tebuconazole and propiconazole. This composition can be as dilute as
about 0.02 wt. % of combined azole (e.g., 100 ppm of tebuconazole and 100 ppm of
propiconazole) or as concentrated as about 50 wt. % combined azole. This
characteristic provides great flexibility in how the composition may be used.
[0100] Although Applicant does not wish to be bound by any particular,
theory, it is believed that the quaternary ammonium compound in conjunction with
the phenol provides a stabilizing effect on the two azoles. In particular,
dimethylbenzyl ammonium compounds such as ONYXIDE™ 3300 have been shown
to provide a stabilizing effect on aqueous emulsions having combinations of azoles
such as tebuconazole and propiconazole.
[0101] Turning now to more specific embodiments of the invention, the
relative quantities of each of the listed components may vary to accommodate


particular process requirements. Accordingly, each of the listed components may be
present in different amounts depending upon the particular needs of the user. Again,
those skilled in the art are fully capable of making these adjustments without undue
experimentation.
[0102] In preferred embodiments the quaternary ammonium antimicrobial
agent is present in the overall composition in an amount between about 0.33 wt. %
and 20 wt, %. In particularly preferred embodiments the quaternary ammonium
antimicrobial agent is present between about 2 wt. % and 16 wt. % of the overall
composition, most preferably between about 3 wt. % and 9 wt. %.
[0103] Likewise, the phenol (i.e., alkyl phenol, styrenated phenol, or
combinations of them) is preferably present in the overall composition in an amount
between about 30 wt. % and about 80 wt. % of the total composition. In preferred
embodiments the phenol is present in the composition between about 40 wt. % and
about 70 wt. %, most preferably between about 45 wt. % and 65 wt. %.
[0104] The first non-metallic antimicrobial agent is preferably present in the
overall composition in an amount between about 5 wt. % and about 45 wt. %,- more
preferably between about 12 wt. % and about 30 wt. %. As noted previously, the first
non-metallic antimicrobial agent is preferably tebuconazole.
[0105] The second non-metallic antimicrobial agent is preferably present in
the overall composition in an amount between about 5 wt. % and about 45 wt. %,
more preferably between about 12 wt. % and about 30 wt. %. As noted previously, the
second non-metallic antimicrobial agent is preferably propiconazole.
[0106] A small quantity of a glycol may be present in the composition
according to the invention. Preferred glycols include alkyl glycols with polyethylene .
glycol, polypropylene glycol, and dipropylene glycol being preferred. Dipropylene
glycol is particularly preferred. It is anticipated that in most applications the quantity
of glycol will be between about 0 wt. % and about 4 wt. %. of the total compositioa
[0107] As mentioned earlier, if foaming is an issue an anti-foaming agent can
be added. The anti-foaming agents suitable for use with the invention include those
compounds commonly used as anti-foaming agents. In preferred embodiments an


additional amount of a glycol can be added as an anti-foaming agent. The glycol used
as an anti-foaming agent can be more of the same glycol discussed previously or a
different glycol.
. [0108] A preferred anti-foaming agent is an ethoxylated co-polymer such as
polyethylene glycol which is commercially available from Cognis Corporation. It is
anticipated that in most applications the quantity of anti-foaming agent needed for
successful practice of the invention will range between about 0 wt. % to about 3 wt.
%, more preferably between about 0.5 wt. % and 1.5 wt. %. The quantity of
antifoaming agent can be adjusted upwards or downwards depending upon the
particular application. Those skilled in the art can readily determine the appropriate
quantity of antifoaming agent to use without undue experimentation.
[0109] The remainder of the composition according to the invention comprises
water. In preferred embodiments the quantity of water present in the claimed
composition will be between about 0 wt. % and about 15 wt. %, more preferably
between about 3 wt. % and. about 9 wt. %. Again, the exact quantity of water will
depend upon the particular application and those skilled in the art are capable of
making the necessary adjustments.
[0110] Further embodiments of the invention include those products that
incorporate the claimed antimicrobial composition. Indeed, one of the novel aspects
of the invention is that it serves as a very versatile tool for incorporating antimicrobial
agents into a variety of diverse products. For example, the antimicrobial composition
according to the invention has been shown to be particularly effective at imparting
antimicrobial characteristics to paper used in the production of wallboard and
insulation.
[0111] Preliminary work also indicates that the antimicrobial composition
according to the invention is an excellent tool for providing antimicrobial protection
to products such as paint and polymers, with latex exterior paints and extruded vinyl.
(e.g., vinyl siding, vinyl windows) being particularly suitable for use with the
invention. It is also anticipated that the antimicrobial composition according to the
invention can be added to other solids such as ceramics and cementitious binders to
impart antimicrobial characteristics.


[0112] The invention also encompasses a method of making an antimicrobial
composition. In broad terms, the method according to the invention comprises the
steps of blending a phenol with a quaternary ammonium antimicrobial agent. Heat
may be necessary during this blending step and particularly if the phenol is an alkyl
phenol and the quaternary agent is an N-alkyl dimethylbenzyl ammonium compound.
To this phenol/quaternary mixture is admixed a quantity of a first non-metallic
antimicrobial agent then a quantity of a second non-metallic antimicrobial agent. The
first and second non-metallic agents can also be mixed together prior to mixing with,
the phenol/quaternary mixture. Toward the end of the process a quantity of water is
added with mixing. Heat may be added to any step if needed.
[0113] In preferred embodiments that use an alkyl phenol, the alkyl phenol
(e.g., TRTION™ X-207) is usually blended with the quaternary ammonium
antimicrobial agent (e.g., ONYXIDE™ 3300) in the presence of heat. The heat is
applied because in many instances the quaternary ammonium antimicrobial agent is a
solid at room temperature. If the quaternary ammonium antimicrobial agent is a liquid
or available as a flowable composition heat may still be used to aid in the mixing.
Care should be taken not to heat the admixture of alkyl phenol and quaternary
antimicrobial agent to a point where there is unacceptable volatilization of either. In
preferred embodiments the temperature is kept below about 200 °C.
[0114] If TRITON™ X-207 is the alkyl phenol and ONYXIDE™ 3300 is the
antimicrobial agent, a mixing temperature of between about 65° C and about 75° C" is
recommended. At this temperature the ONYXIDE™ 3300 melts into the TRITON™
X-207 to form a liquid.
[0115] The steps of admixing a first non-metallic antimicrobial agent and
admixing a second non-metallic antimicrobial agent may occur separately..
Alternatively, the first and second non-metallic antimicrobial agents can be admixed
together then added to the quaternary ammonium antimicrobial agent.
[0116] The admixing of the non-metallic antimicrobial agents can be'
accomplished in the presence of heat, if needed. For example, WOCOSEN™
TECHNICAL (i.e., propiconazole) is normally a very viscous liquid at room
temperature. PREVENTOL™ A8 (i.e., tebuconazole) is normally a solid white


powder at room temperature. Heating both of them will aid in the admixture to the
quaternary ammonium/alkyl phenol mixture. In a preferred embodiment, the
tebuconazole and propiconazole are mixed together in the presence of form a less
viscous solution that can then be added to the quaternary ammonium/alkyl phenol
mixture. In this, embodiment the tebuconazole and propiconazole mixture is heated to
between about 65 °C and 75 °C with stirring.
[0117] Heating can continue during the admixture of the non-metallic
antimicrobial agents and the quaternary ammonium antimicrobial agents if needed.
Glycols and any anti-foaming agents or anti-freezing agents such as those discussed
previously can be added at this point.
[0118] Once the quaternary ammonium antimicrobial agent, phenol, and non-
metallic antimicrobial agents are mixed heat may be removed. As the admixture
cools to room temperature water is added with stirring.
[0119] If styrenated phenols are used in place of the alkyl phenols the method
according to the invention is very similar to that recited above. The primary
difference in using a styrenated phenol is that less heat may be required during
mixing. Of course, the use of heat will always be somewhat dependent upon the
precise active ingredients chosen by the practitioner.
[0120] The relative amounts of quaternary ammonium antimicrobial agent,
alkyl phenol, non-metallic antimicrobial agents, and water utilized in the practice of
the method according to the invention are the same as those discussed in relation to
the composition according to the invention. Likewise, the relative amounts of anti-
foaming agents, anti-freezing agents, and additional antimicrobial agents, if any, are
the same as those discussed in relation to the composition according to the inventioa
[0121] An alternative embodiment of the invention is particularly well suited
for use in non-aqueous systems. In this embodiment the invention comprises a non-
aqueous microemulsion. The microemulsion comprises a quaternary ammonium
antimicrobial agent, a first non-metallic antimicrobial agent, a second non-metallic
antimicrobial agent, and a glycol. The preferred quaternary ammonium antimicrobial
agent, first non-metallic antimicrobial agent, and second non-metallic antimicrobial


agent are the same as in the previous embodiment. Almost any glycol can be used in
the practice of the invention but dipropylene glycol is a preferred glycol.
[0122] The preferred quantities of each element in the composition according
to the invention is as follows: first non-metallic antimicrobial agent - about 10 wt. %
to about 33 wt. %; second non-metallic antimicrobial agent - about 10 wt. % to about
33 wt. %; quaternary ammonium antimicrobial agent - about 0.33 wt. % to about 17
wt. %; glycol - about 17 wt. % to about 80 wt. %.
[0123] The method of making this embodiment of the invention is generally
similar to the method of making the aqueous embodiment. The various components
are mixed together in the appropriate quantities in the presence of heat, if needed. For
example, several samples of the composition according to the invention were made in
the following manner.
[0124] The first non-metallic antimicrobial agent (e.g., WOCOSEN
TECHNICAL) was blended with dipropylene glycol under heat (approximately 65 °C)
in the desired relative amounts. To this mixture was added the quaternary ammonium
compound (e.g., ONYXEDE 3300) while maintaining heat. The second non-metallic
antimicrobial agent (e.g.. PREVENTOL A8) was then added with heat and mixing.
The entire mixture was then stirred under heat until a clear microemulsion was
formed.
[0125] The above non-aqueous embodiment of the invention is well suited for
imparting antimicrobial characteristics to products produced in a non-aqueous
environment.

Example
[0126] The following formulation, made in accordance with the above
method, has shown commercially acceptable efficacy against the proliferation of
microbes on kraft paper. All percentages are weight percentages.
[0127] Tebuconazole (WOCOSEN™ TECHNICAL) 19%
[0128] Propiconazole (PREVENTOL™ A8) 18.5%

[0129] Quaternary Ammonium (ONYXIDE™ 3300) 9.5 %
[0130] Alkyl Phenol (TRITON™ X-207) 43%.
[0131] Glycol (dipropylene glycol) 5%
[0132] Water 5%
Adhesive
[0133] The adhesive that attaches, the fiberglass batting to the non-woven
covering may also serve as a carrier for antimicrobial compositions. Several types of
adhesives may be used depending upon the physical and chemical characteristics of
the insulation and the non-woven covering. In preferred embodiments, however, the
adhesive is an asphalt or tar-like compound such as those that are commonly used in
the manufacture of insulation.
[0134] In most instances, the antimicrobial compositions can be added to the
adhesive prior to application of the adhesive to the non woven covering. Simple
mixing or blending of the antimicrobial agent with the adhesive will probably be the .
most effective method of addition in most instances. Other methods of combining the
antimicrobial composition with adhesives will be readily apparent to those skilled in
the art.
[0135] The antimicrobial compositions that can be used in combination with
the adhesive include all of those discussed previously, including the preferred
antimicrobial compositions. Preferred embodiments utilize an antimicrobial
composition that includes agents selected from the group consisting of triclosan,
propiconazole, sodium pyrithione, tolyl diiodomethyl sulfone; tebuconazole;
thiabendazole; 3-iodo-2-propynyl butylcarbamate, metal ions, n-octyl-isothiazolinone,
quaternary ammonium compounds, and mixtures thereof. N-octyl-isothiazolinone
(OIT) and silver ions or silver zeolites are particularly preferred.
[0136] The weight percent of antimicrobial composition in the adhesive may
vary from very little (e.g., less than 100 ppm)to very great (e.g., over 5000 ppm). The
exact amount will depend upon the particular use of the insulation and the amount of
antimicrobial composition used in conjunction with the non-woven covering.

Method
[01371 The invention also encompasses a method of manufacturing insulation
which exhibits antimicrobial properties. The various examples set forth above discuss
several methods of manufacture (e.g., spraying the non-woven covering). The above
discussed methods are exemplary only and should not be interpreted as limiting the
scope of the invention.
[0138] In very broad terms the method according to the invention comprises
the steps of applying an antimicrobial composition to the non-woven covering and
contacting a non-woven covering to an insulating material. The order of these steps
may be reversed if such reversal is better suited to the overall process.
[0139] The step of contacting the non-woven covering to the insulating
material includes any contacting step currently used in the industry. Such steps could
include melt pressing synthetic polymer non-woven coverings to insulation or coating
a non-woven covering with an adhesive then contacting the non-woven covering to
the insulation. The use of tar like adhesives to contact paper coverings to fiberglass
batting is probably the most commonly used method in the industry.
[0140] Likewise, the step of applying an antimicrobial composition to the non-
woven covering comprises any of the methods discussed above including spraying,
coating, dipping, etc. or otherwise contacting the antimicrobial composition to the
non-woven covering. Adding the antimicrobial composition to an adhesive prior to or
concurrent with contacting the non-woven covering to the adhesive is also included in
the scope of this step.
[0141] Lastly, the antimicrobial compositions utilized in the method according
to the invention include all of those antimicrobial compositions capable of providing a
commercially acceptable level of efficacy against the microbe of concern. Particularly
preferred embodiments of the method include the specific antimicrobial compositions
discussed above.

WE CLAIM :
1. Insulation which exhibits antimicrobial characteristics and resists the growth
of microbes, the insulation comprising:
an insulating material;
a non-woven covering adjacent said insulating material; and
an antimicrobial composition.
2. Insulation as claimed in claim 1, wherein said insulation material comprises
fiberglass.
3. Insulation as claimed in claim 2, wherein said non-woven covering comprises
kraft paper.
4. Insulation as claimed in claim 3, comprising an adhesive composition
between said kraft paper and said insulating material, wherein said adhesive
composition comprises an antimicrobial composition.
5. Insulation as claimed in claim 4, wherein said adhesive composition comprises
asphalt and said antimicrobial composition comprises an antimicrobial agent selected
from the group consisting of triclosan, propiconazole, sodium pyrithione, tolyl
diiodomethyl sulfone; tebuconazole; thiabendazole; 3-iodo-2-propynyl
butylcarbamate, metallic antimicrobial agents, n-octyl-isothiazolinone, quaternary
ammonium compounds, and mixtures thereof.
6. Insulation as claimed in claim 5, wherein said antimicrobial agent is n-
octylisothiazolinone.
7. Insulation as claimed in claim 5, wherein said antimicrobial composition
comprises a metallic antimcicrobial agent and said agent is silver.
8. Insulation as claimed in claim 3, wherein said antimicrobial composition
comprises an antimicrobial system having at least a first antimicrobial agent and a

second antimicrobial agent wherein said first and. second antimicrobial agents are
present at levels sufficient to exhibit efficacy against microbes.
9. Insulation as claimed in claim 8, wherein said antimicrobial system comprises
a first antimicrobial agent present in a first carrier and said second antimicrobial agent
present in a second carrier and wherein said first and second carrier are soluble in
each other.
10. Insulation as claimed in claim 9, wherein said antimicrobial system is an
emulsion of said first and second antimicrobial agents.
11. Insulation as claimed in claim 10, wherein said first antimicrobial agent is
selected from the group comprising propiconazole, sodium pyrithione, and mixtures
thereof.
12. Insulation as claimed in claim 10, wherein said second antimicrobial agent is
selected from the group consisting of tolyl diiodomethyl sulfone; tebuconazole;
thiabendazole; and 3-iodo-2-propynyl butylcarbamate, and mixtures thereof .
13. Insulation as claimed in claim 3, wherein said antimicrobial composition
comprises:
a quaternary ammonium antimicrobial agent,
an alkyl phenol,
a styrenated phenol, and
water.
14. Insulation as claimed in claim 13, wherein said quaternary ammonium
antimicrobial agent comprises an alkyl ammonium compound.
15. Insulation as claimed in claim 13, wherein said alkyl phenol comprises at least
one alkyl phenol having an alkyl group selected from the group consisting of C7
alkyls, C8 alkyls, C9 alkyls, C10 alkyls, and C11 alkyls.
16. Insulation as claimed in claim 13,

wherein said quaternary ammonium antimicrobial agent is between 1
wt. % and 30 wt. % of the total composition,
said alkyl phenol is between 20 wt. % to 50 wt. % of the total
composition, and
said styrenated phenol is between 1 wt. % to 10 wt. % of the total
composition.
17. Insulation as claimed in claim 13, wherein said quaternary ammonium
antimicrobial agent comprises an alkyl ammonium compound.
18. Insulation as claimed in claim 17, wherein said quaternary ammonium
antimicrobial agent comprises an N-alkyl dimethylbenzyl ammonium compound.
19. Insulation as claimed in claim 3, wherein said antimicrobial composition
comprises:
a quaternary ammonium antimicrobial agent,
a phenol,
a first non-metallic antimicrobial agent,
a second non-metallic antimicrobial agent, and
water.
20. Insulation as claimed in claim 19 wherein
said quaternary ammonium antimicrobial agent is is between 0.33 wt. %
and 20 wt. % of the total composition;
said phenol is between 30 wt. % to 80 wt. % of the total composition,
said first non-metallic antimicrobial agent is between 5 wt. % to 45 wt. %
of the total composition;

said second non-metallic antimicrobial agent is between 5 wt. % to 45
wt. % of the total composition; and
said water is between 0 wt. % to 9 wt. % of the total composition.
21. Insulation as claimed in claim 20, wherein said quaternary ammonium
antimicrobial agent comprises an alkyl ammonium compound.
22. Insulation as claimed in claim 20, wherein at least one of said first and second
non-metallic antimicrobial agents are selected from the group consisting of azoles.
23. Insulation as claimed in claim 22, wherein said first non-metallic antimicrobial
agent comprises tebuconazole and said second non-metallic antimicrobial agent
comprises propiconazole.

24. Insulation as claimed in claim 20, wherein said phenol comprises an alkyl
phenol having an alkyl group selected from the group consisting of C7 alkyls, C8
alkyls, C9 alkyls, C10 alkyls, and C11 alkyls.
25. Insulation as claimed in claim 1, wherein said antimicrobial composition is
present in an amount sufficient to prevent macroscopic growth on the wallboard in
accordance with AATTCC Test Method 30 Part DDL
26. Insulation as claimed in claim 3, wherein said antimicrobial composition
comprises a quaternary ammonium antimicrobial agent a first non-metallic
antimicrobial agent, a second non-metallic antimicrobial agent, and a glycol.
27. A method of manufacturing insulation which exhibits antimicrobial properties,
the method comprising:
contacting a non-woven covering to an insulating material, and
applying an antimicrobial composition to the non-woven covering.
28. The method as claimed in claim 27, wherein contacting the non-woven
covering to the insulating material comprises application of an adhesive to the non-
woven material or the insulation material or both.

29. The method as claimed in claim 28, wherein applying an antimicrobial
composition to the non-woven covering comprises adding the antimicrobial
composition to the adhesive prior to application of the adhesive.
30. The method as claimed in claim 27, wherein applying an antimicrobial
composition to the non-woven covering comprises spraying the non-woven covering.
31. The method as claimed in claim 27, wherein applying the antimicrobial
composition to the non-woven covering comprises coating the non-woven covering.
32. The method as claimed in claim 27, wherein the antimicrobial composition
comprises an antimicrobial system having at least a first antimicrobial agentand a
second antimicrobial agent wherein said first and second antimicrobial agents are
present at levels sufficient to exhibit efficacy against microbes.
33. The method as claimed in claim 32, wherein said antimicrobial system
comprises a first antimicrobial agent present in a first carrier and said second
antimicrobial agent present in a second carrier and wherein said first and second
carrier are soluble in each other.
34. The method as claimed in claim 33, wherein said first antimicrobial agent is
selected from the group comprising propiconazole, sodium pyrithione, and mixtures
thereof, and said second antimicrobial agent is selected from the group consisting of
tolyl diiodomethyl sulfone; tebuconazole; thiabendazole; and 3-iodo-2-propynyl
butylcarbamate, and mixtures thereof.
35. The method as claimed in claim 27, wherein said antimicrobial composition
comprises:
a quaternary ammonium antimicrobial agent,
an alkyl phenol,
a styrenated phenol, and
water.

36. The method as claimed in claim 35, wherein said antimicrobial composition
comprises:
a quaternary ammonium antimicrobial agent,
an alkyl phenol,
a first non-metallic antimicrobial agent,
a second non-metallic antimicrobial agent,
a glycol, and
water.


Insulation that exhibits antimicrobial characteristics is disclosed. A method for making the insulation is also disclosed.
Suitable antimicrobial agents that may be applied to the insulation or any components thereof include propiconazole, sodium
pyrithione, tolyl diiodomethyl sulfone; tebuconazole; thiabendazole; 3-iodo-2propynyl butylcarbamate; triclosan, quaternary ammonium
compounds, metals, and mixtures thereof.

Documents:

03766-kolnp-2006 abstract.pdf

03766-kolnp-2006 claims.pdf

03766-kolnp-2006 correspondence others.pdf

03766-kolnp-2006 description(complete).pdf

03766-kolnp-2006 form-1.pdf

03766-kolnp-2006 form-3.pdf

03766-kolnp-2006 form-5.pdf

03766-kolnp-2006 gpa.pdf

03766-kolnp-2006 international publication.pdf

03766-kolnp-2006 international search authority report.pdf

03766-kolnp-2006 pct other.pdf

03766-kolnp-2006 priority document.pdf

3766-KOLNP-2006-(23-09-2011)-ABSTRACT.pdf

3766-KOLNP-2006-(23-09-2011)-AMANDED CLAIMS.pdf

3766-KOLNP-2006-(23-09-2011)-DESCRIPTION (COMPLETE).pdf

3766-KOLNP-2006-(23-09-2011)-EXAMINATION REPORT REPLY RECIEVED.PDF

3766-KOLNP-2006-(23-09-2011)-FORM 1.pdf

3766-KOLNP-2006-(23-09-2011)-FORM 2.pdf

3766-KOLNP-2006-(23-09-2011)-FORM 3.pdf

3766-KOLNP-2006-(23-09-2011)-OTHERS.pdf

3766-KOLNP-2006-(23-09-2011)-PETITION UNDER RULE 137.pdf

3766-KOLNP-2006-ASSIGNMENT.pdf

3766-KOLNP-2006-CORRESPONDENCE OTHERS 1.1.pdf

3766-KOLNP-2006-CORRESPONDENCE.pdf

3766-KOLNP-2006-EXAMINATION REPORT.pdf

3766-KOLNP-2006-FORM 18 1.1.pdf

3766-kolnp-2006-form 18.pdf

3766-KOLNP-2006-FORM 3-1.1.pdf

3766-KOLNP-2006-FORM 3.pdf

3766-KOLNP-2006-FORM 5.pdf

3766-KOLNP-2006-GPA.pdf

3766-KOLNP-2006-GRANTED-ABSTRACT.pdf

3766-KOLNP-2006-GRANTED-CLAIMS.pdf

3766-KOLNP-2006-GRANTED-DESCRIPTION (COMPLETE).pdf

3766-KOLNP-2006-GRANTED-FORM 1.pdf

3766-KOLNP-2006-GRANTED-FORM 2.pdf

3766-KOLNP-2006-GRANTED-SPECIFICATION.pdf

3766-KOLNP-2006-OTHERS.pdf

3766-KOLNP-2006-REPLY TO EXAMINATION REPORT.pdf


Patent Number 252878
Indian Patent Application Number 3766/KOLNP/2006
PG Journal Number 23/2012
Publication Date 08-Jun-2012
Grant Date 06-Jun-2012
Date of Filing 13-Dec-2006
Name of Patentee MICROBAN PRODUCTS COMPANY
Applicant Address 11515 VANSTORY DRIVE, SUITE 125, HUNTERSVILLE, NC 28078
Inventors:
# Inventor's Name Inventor's Address
1 PAYNE STEPHEN A 405 WEST 7TH STREET, #201, CHARLOTTE, NC 28202
2 SWOFFORD HOWARD WAYNE 1567 LITTLE HILL ROAD, NEWTON, NC 28658
3 DRAKE KEVIN DEAN 9336 CULCAIRN ROAD, HUNTERSVILLE, NC 28078
PCT International Classification Number B32B27/12
PCT International Application Number PCT/US2005/015506
PCT International Filing date 2005-05-04
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 PCT/US04/19360 2004-06-16 IB