CN1989005A - Antimicrobial insulation - Google Patents

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.

Description

Antimicrobial Insulation

Cross References to Related Applications

This application is the partial continuation application of PCT/US04/19360 that proposes on June 16th, 2004, and it claims the right of priority from following: U.S. provisional application 60/525,910 that proposes on December 1st, 2003; 2003 12 U.S. Provisional Application 60/529,164, filed March 12; U.S. Provisional Application 60/551,485, filed March 9, 2004; U.S. Provisional Application 60/551,426, filed March 9, 2004; US Provisional Application 60/568,821; and US Provisional Application 60/568,961, filed May 7, 2004, each of which is hereby incorporated by reference in its entirety.

Background of the invention

[0002] The present invention generally relates to insulation and methods of making insulation. In particular, the present invention relates to an efficient and economical method of producing insulation with antimicrobial (eg antibacterial and antifungal) properties.

[0003] Thermal insulation is a ubiquitous building material. It is especially found in all residential and commercial buildings and its importance in the construction of new structures cannot be overemphasized. The main function of an insulator is to act as a heat transfer barrier between the interior of the structure and the external environment. Thus, insulation, if installed correctly, can greatly reduce heating and air conditioning costs. Insulation can also be used as a sound barrier, moisture barrier, and vapor/air barrier.

[0004] The various functions of insulation have led to the development of many different types of insulation. Some insulation was loose blown to the attic. Other insulation includes foam boards nailed to the wall. The present invention arguably concerns the most common form of insulation - a fiberglass batting, which has one side faced with kraft paper. This type of insulation generally goes into large rolls which are then rolled out to form cushions on attics and walls.

[0005] For the remainder of this document, the term insulation will refer to a 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 humid environments. Unfortunately, insulation used in interior structures can sometimes encounter water due to leaks in roofs, windows, or pipes. In addition, many geographic areas are characterized by high humidity, which also provides a source of water that can be absorbed by kraft paper faced insulation. While the fiberglass component of the insulation is not conducive to microbial growth, the kraft paper facing of the insulation tends to support microbial growth, especially fungal and bacterial growth.

[0007] The growth of fungi and bacteria on insulation is undesirable for a number of reasons. First, it traps moisture in the insulation, which can lead to the spread of even more fungi and bacteria and weaken adjacent components. Unpleasant odors and coloring are also accompanied by microbial growth. More seriously, many people are susceptible to life-threatening allergic reactions when exposed to fungal spores. Problems arising from microbial growth on insulation, particularly human health concerns, drive the continuing need for insulation resistant to microbial growth.

[0008] At present, the patent literature has not yet solved the problem of biological contamination of thermal insulation. However, the patent literature contains several examples of attempts to solve the problem of microbial growth on a slightly related material: siding. Siding is a structural material used to form interior walls. Siding is somewhat similar to insulation in that it consists of structural material (sheets of plaster instead of fiberglass) attached to a sheet or two of kraft paper. However, the kraft paper used in insulation is usually thinner than that used with siding.

[0009] Commonly assigned US Patent Application Serial No. 10/250,143 from which this application claims priority discusses the need to provide inherent and durable antimicrobial protection for kraft paper used in siding production.

[0010] The present invention is an extension and improvement of work begun in the '143 application and continued in a later application from which this application also claims priority.

Brief description of the preferred embodiment

[0011] The present invention arose from research aimed at developing a commercially viable method for the manufacture of insulation exhibiting antimicrobial properties. One result of this research is the development of insulation that exhibits antimicrobial properties and resists microbial growth. Broadly, insulation according to the invention comprises an insulating material such as fiberglass, a non-woven covering adjacent to said insulating material and an antimicrobial composition. In many embodiments, the insulating material will be attached to the nonwoven cover by an adhesive. Preferably the antimicrobial composition is intimately associated with the nonwoven cover, the adhesive, or both.

[0012] The present invention also encompasses a method of producing insulation that exhibits antimicrobial properties and resists microbial growth. The method comprises the steps of contacting a nonwoven covering with an insulating material and applying an antimicrobial composition to the nonwoven covering. The method also comprises adding an antimicrobial composition to the insulation or a component thereof at a level sufficient to exhibit antimicrobial efficacy.

Detailed description of the invention

Turning now to the details of the invention, in one broad aspect, the invention is an insulation that exhibits antimicrobial properties and resists microbial growth. As used herein, the term microorganism includes bacteria, fungi, and other such forms of life generally recognized by those skilled in the art as belonging to the field of microbiology. However, fungi (ie mold and mildew) are primarily associated with insulation. Therefore, for ease of discussion, this detailed description will often refer to fungi and antifungal agents. This method presented should not be construed as limiting the scope of the invention in any way.

[0014] The term efficacy, as used herein, is defined as the property of inhibiting the growth of microorganisms on a substrate.

[0015] The term non-metallic antimicrobial agent as used herein means an antimicrobial agent which, unlike quaternary ammonium compounds, does not contain or use metal ions (eg, Ag, Cu).

[0016] The term antimicrobial composition, as used herein, includes individual antimicrobial agents (eg, silver, triclosan, zinc oxide, etc.) and combinations of various antimicrobial agents and other additives.

[0017] In its broadest aspect, insulation according to the invention comprises an insulating material, a nonwoven covering adjacent to the insulating material, and an antimicrobial composition. In most cases the non-woven covering will be attached to the insulating material with an adhesive. In many cases the binder is a bituminous or tar-like binder well known in the industry.

[0018] The insulating material may be any generally known insulating material. Perhaps the most common, known and used insulation material is fiberglass batting. This type of insulation can be found in most commercially available types of insulation including the well known pink insulation available from Owens-Corning. Fiberglass batting is the preferred insulating material for use in the practice of this invention.

[0019] The nonwoven cover used in the practice of the present invention may be any type of nonwoven material capable of attaching to and supporting an insulating material. Synthetic polymeric nonwoven mats are examples of satisfactory nonwoven materials.

[0020] More preferably, the nonwoven coverings used in the practice of the present invention are made from natural polymers such as cellulose. Kraft paper is the nonwoven material of choice used in the insulation industry. Kraft paper is therefore particularly preferred as the nonwoven covering used in the manner according to the invention.

[0021] The antimicrobial composition and various methods of applying the antimicrobial composition to a nonwoven covering represent the most diverse aspects of the invention. If a synthetic polymeric nonwoven material is used, the antimicrobial composition can be added to the polymer melt prior to the formation of the nonwoven mat. Additionally, antimicrobial compositions that may be used in conjunction with synthetic polymeric nonwoven covers include all antimicrobial agents, or combinations of agents, commonly used with synthetic polymers. Such agents include, but are not limited to, chlorinated phenols (eg, triclosan), quaternary ammonium compounds, azoles, and metals (eg, silver zeolites, silver ions). Those skilled in the art are well versed in the incorporation of such agents into polymers and are able to select the appropriate agent and loading level for the polymer of interest without undue experimentation.

[0022] Similarly, if the kraft paper is the nonwoven covering, then the antimicrobial agent used in the practice of the present invention may include any antimicrobial agent capable of imparting antimicrobial properties to the insulation and particularly the nonwoven (e.g., kraft paper) covering. microbial composition. Many of these antimicrobial agents are discussed or cited in priority document US Patent Application Serial No. 10/250,143, which is hereby incorporated by reference. Such agents include, but are not limited to, chlorinated phenols (eg, triclosan), quaternary ammonium compounds, pyrroles, and metals (eg, silver zeolites, silver ions).

[0023] Likewise, the antimicrobial composition can be applied to kraft paper in any of several ways. For example, the paper may be treated by adding an antimicrobial composition to the fibers/pulp during the paper formation process. Although this approach can be effective, it tends to be cost prohibitive. Alternatively, the paper may be surface treated with an antimicrobial composition.

[0024] It is within the scope of the invention to spray the paper covering with the antimicrobial composition, either before or after contacting the insulation material. Those skilled in the art of papermaking are very familiar with spray bars and their use and how they can be readily adapted to the present invention.

[0025] Another method of treating the paper surface is to apply the antimicrobial composition as a uniform coating on one or both sides of the paper covering when the paper covering is manufactured. For example, the antimicrobial composition can be applied to the paper using a water bath on calendar stack rolls, which is sometimes present in the papermaking process.

[0026] In some cases, the papermaking process may determine the coating method and antimicrobial composition used. Each papermaking process is unique in some respects and those skilled in the art can readily determine which coating method and antimicrobial composition is best for their particular process.

[0027] Regardless of the manner in which the antimicrobial composition is applied, all embodiments of the present invention contain some amount of antimicrobial composition sufficient to exhibit efficacy against microorganisms and, in particular, different species of fungi. More specifically, preferred embodiments of the present invention comprise an antimicrobial composition sufficient to inhibit the growth of microorganisms on substrates tested according to 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 those skilled in the art, there are several preferred combinations of coating methods and antimicrobial compositions for use with embodiments of the invention employing kraft paper. (Note that these antimicrobial compositions can also be used with synthetic polymers.) The following paragraphs will provide three particularly preferred antimicrobial agents and methods of application for each. It should also be noted that the coating methods discussed herein can be used with any antimicrobial composition. The following compositions and coating methods are exemplary and should not be construed as limiting the scope of the invention.

Antimicrobial Composition #1

[0029] In one embodiment, the antimicrobial composition is an antimicrobial system comprising a first antimicrobial agent in a first carrier and a second antimicrobial agent in a second carrier. Preferably, said first and second carriers are at least partially soluble in each other. This increases 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 present invention is propiconazole, which is sold by Janssen Pharmacetica under the tradename WOCOSEN. Another antimicrobial agent suitable for use in the present invention is diiodomethyl-4-tolylsulfone, which is commercially available from Dow Chemical under the tradename AMICAL. Both commercial implementations are available in mutually soluble carriers, which improves the stability of the system.

[0031] Commercially available antimicrobial agents suitable for use in antimicrobial systems can be incorporated into the surfactant-based carrier. While surfactant based vehicles may be used in the practice of the present invention, care should be taken when utilizing such vehicles to ensure that the coating system does not become foam loaded. Foam can sometimes develop if the coating system provides agitation of the antimicrobial composition. Foaming can adversely affect the smooth and even distribution of active ingredients. In some cases, small amounts of antifoaming agents may be added to the antimicrobial composition to reduce the foam. Preferred antifoams are ethoxylated copolymers of polyethylene glycol.

[0032] Tests have shown that desirable efficacy of treated paper can be obtained by roll coating the paper with an antimicrobial system in which the combined concentration of the two antimicrobial agents is less than 1000 ppm and in many cases less than 500ppm.

[0033] Accordingly, in a preferred embodiment the first antimicrobial agent used in the antimicrobial system is selected from the group consisting of propiconazole, sodium pyrithione and mixtures thereof. Both reagents are commercially available in various concentrations and can be diluted to the necessary extent by one skilled in the art.

Preferably, the second antimicrobial agent used in the antimicrobial system is selected from tolyl diiodomethyl sulfone, tebuconazole, and 3-iodo-2-propynyl butyl carbamate and its Group of mixtures. These reagents are also commercially available.

[0035] One skilled in the art can readily adjust the relative amounts of each antimicrobial agent in the antimicrobial system to achieve a desired level of efficacy. Generally, higher concentrations translate to higher efficacy. However, a preferred embodiment of the antimicrobial system comprises about 0.1% to 0.8% propiconazole, 0.1% to 0.5% tolyldiiodomethylsulfone, and 0.05% to 0.15% 3-iodo- Emulsion of 2-propynylbutylcarbamate in water.

[0036] When applied to the paper surface, the use of 0.20% propiconazole, 0.175% tolyldiiodomethyl sulfone, and 0.10% 3-iodo-2-propynyl butyl carbamate in water The emulsion showed acceptable efficacy at 50 lb./square foot applied to paper having a fiber wet pickup of about 5% to about 20% based on the dry weight of the paper. A fiber pick-up of between about 5% and about 7% shows acceptable results and would be preferred due to cost considerations. The amount of liquid absorbed by the paper can be adjusted in several ways known to those skilled in the art.

Example

[0037] The following combinations of various antimicrobial agents were thoroughly mixed together in water under ambient conditions, as shown in Table 1 below.

Table 1

Combination formula (ppm)

sample 2-zinc pyrithione DITS Propiconazole IPBC total ppm A 507 820 817 512 2656 B 0 1485 1566 0 3051 C 0 1109 1095 555 2759 D. 0 0 2396 554 2950 E (comparative) 1096 0 0 0 2556

DITS = diiodomethyl-4-tolylsulfone (diiodmethyl-4-tolysulfone)

IPBC = 3-iodo-2-propynylbutylcarbamate

An Pyrithione＝2-zinc pyrithione oxide

[0038] The formulation in Table 1 was applied to 50 lb. kraft paper stock with controlled lay down using a wire wound rod. Approximate liquid pick-up is about 15%. Samples of the paper were tested via AATCC Method 30, Part II, to evaluate the antifungal efficacy of the compositions. The organism tested was Aspergillus niger (A. Niger). After seven (7) days of incubation, the samples were evaluated based on the following criteria; 0 indicating no growth was observed; 1 indicating growth only visible under the microscope; and 2 indicating growth visible to the naked eye. Additionally, there may be zones of inhibition where growth of organisms anywhere around the sample is inhibited. Thus, results are reported as grades with suppression circles when applicable. The results of this test are shown in Table 2. Roman numerals identify different combinations of ingredients.

Table 2

Table 1 formulation combination Growth grade Inhibition circle (mm) A III 0 3 IV 0 - II 0 3 I 0 - B III 0 2 IV 0 2 II 0 3 I 0 - C III 0 6 IV 0 3 II 0 2 I 0 3 D III 0 4 IV 0 2 II 0 5 I 0 1 E (comparative) III 2 - IV 2 - II 2 - I 2 - Control - no antimicrobial IV 2 - I 2 -

(I) - Formulation of Table 1, containing water without binder.

(II) - Formulation of Table 1, including 1% by weight silicone coating (RE 29).

(III) - Formulation of Table 1 including 1% by weight of a cationic polymer having an affinity for paper.

(IV) - Formulation of Table I, including 1% by weight silane coupling agent.

[0039] As shown by the results, formulations A, B, C, and D showed no observable growth. Untreated controls showed no efficacy.

[0040] Additional laboratory tests were performed to determine if efficacy could be achieved with smaller concentrations of antimicrobial agent. Several active agent combinations were tested at various concentrations to observe efficacy. The combinations shown below were coated onto a 2 inch by 2 inch square of 50 lb. kraft paper and tested using AATCC Method 30, Part III. The results are shown in Tables 3 and 4.

table 3

sample# Prop.(ppm) TDS(ppm) IPBC(ppm) TRI(ppm) growth grade Suppression circle(mm) 1 300 100 0 9 2 300 100 0 10 3 200 100 100 0 3 4 100 100 100 100 0 9 5 100 100 0 7 6 500 100 0 15 7 500 100 0 16 8 400 0 11

Prop. = propiconazole (Wocosen Technical from Janssen)

TDS = Tolyldiiodomethylsulfone (Amical Flowable from Dow)

IPBC = Iodo-2-propynylbutylcarbamate (Polyphase CST from Troy)

Tri. = Triclosan (Ingrasan DP300 from Ciba)

Table 4

sample# Prop.(ppm) TDS(ppm) TDS2 IPBC(ppm) Teb.(ppm) growth grade Suppression circle(mm) control 0 0 0 0 0 Macro none 1 500 100 0 100 0 0 5 2 450 0 100 0 310 0 - 3 300 0 150 0 0 0 3

4 375 0 100 0 300 0 4 5 430 0 0 100 0 0 4 6 650 0 0 150 0 0 -

Prop. = propiconazole (Wocosen 250EC from Janssen)

TDS = Tolyldiiodomethylsulfone (Amical Flowable from Dow)

TDS2 = Tolyldiiodomethylsulfone (Amical 48 from Dow)

IPBC = iodo-2-propynylbutylcarbamate (Omacide IPBC40 from Arch)

Teb. = Tebuconazole (Preventol A8 from Bayer)

[0041] As the above data show, acceptable inhibition of microbial growth can be achieved with relatively low concentrations of antimicrobial agents. Combination actives as low as 400ppm can achieve zero growth and inhibition zone.

[0042] Preferably, the antimicrobial system is applied to a nonwoven covering (i.e., paper) such that the first antimicrobial agent is present in or on the nonwoven covering at a concentration between about 50 ppm and about 1200 ppm, more preferably A preferred concentration is between about 200 ppm and 1200 ppm. In a particularly preferred embodiment, the first antimicrobial agent is propiconazole and is present at a concentration of between about 80 ppm and 1000 ppm; more preferably at a concentration of between about 500 ppm and 1000 ppm.

[0043] Likewise, it is preferred that the second antimicrobial agent is present in the nonwoven cover at a concentration between about 40 ppm and about 1600 ppm, more preferably between about 60 ppm and 1400 ppm. In a particularly preferred embodiment, the second antimicrobial agent is isolyl diiodomethyl sulfone (Amical Flowable from Dow) and is present at a concentration between about 40 ppm and 1600 ppm; more preferably at a concentration between about 60 ppm and Between 1400ppm.

Antimicrobial Composition #2

[0044] In another embodiment, the antimicrobial composition used in the practice of the present 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 contains a quaternary ammonium antimicrobial, phenol and water. Interestingly, the composition need not contain volatile alcohols (eg, ethanol) that are often used to form quaternary ammonium antimicrobial emulsions. Each of these ingredients, as well as other preferred and optional ingredients, are discussed in more detail below.

[0046] Quaternary ammonium antimicrobial agents suitable for use in antimicrobial compositions include, but are not limited to, N-alkyldimethyl benzyl ammonium saccharinate (N-alkyldimethyl benzyl ammonium saccharinate), 1,3,5- Triazine-1,3,5(2H,4H,6H)-triethanol; 1-decyl ammonium, N-decyl-N,N-dimethyl-, chloride (or) didecyldimethyl chloride ammonium chloride; 2-(2-(p-(diisobutyl)methylphenoxy (cresosxy)ethoxy)ethyldimethylbenzyl ammonium chloride; 2-(2-(p-(diisobutyl Base) phenoxy) ethoxy) ethyl dimethyl benzyl ammonium chloride; alkyl 1 or 3 benzyl-1-(2-hydroxyethyl)-2-imidazolinium chloride; alkyl Bis(2-hydroxyethyl)benzyl ammonium chloride; Alkyl dimethyl benzyl ammonium chloride; Alkyl dimethyl 3,4-dichlorobenzyl ammonium chloride (100% C12); Alkyl di Methyl 3,4-dichlorobenzyl ammonium chloride (50% C14, 40% C12, 10% C16); Alkyl dimethyl 3,4-dichlorobenzyl ammonium chloride (55% C14, 23% C12, 20% C16); 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% C14); 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% C14); Alkyl dimethyl benzyl ammonium chloride (67% C12, 24% C14); Alkyl dimethyl benzyl ammonium chloride (67% C12, 25% C14); Alkyl dimethyl benzyl ammonium chloride (90% C14, 5% C12); Alkyl dimethyl benzyl ammonium chloride (93% C14, 4% C12); 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 chlorides (C12-C16); Alkyl dimethyl benzyl ammonium chlorides (C12-C18); Alkyl dimethyl benzyl and dialkyl dimethyl ammonium chlorides; Alkyl dimethyl dimethyl benzyl ammonium chloride; Alkyl dimethyl ethyl ammonium bromide (90% C14, 5% C16, 5% C12); Alkyl dimethyl ethyl ammonium bromide (mixed alkyl and alkenyl groups such as in soybean oil fatty acid); alkyl dimethyl ethyl benzyl ammonium chloride; alkyl dimethyl ethyl benzyl ammonium chloride (60% C14); alkyl di Methylisopropylbenzyl ammonium chloride (50% C12, 30% C14, 17% C16, 3% C18); alkyltrimethyl ammonium chloride (58% C18, 40% C16, 1% C14, 1 %C12); Alkyltrimethylammonium chloride (90%C18, 10%C16); Alkyldimethyl(ethylbenzyl)ammonium chloride (C12-18); Di-(C8-10)- Alkyldimethylammonium chloride; Dialkyldimethylammonium chloride; Dialkyldimethylammonium chloride; Dialkyldimethylammonium chloride; Dialkylmethylbenzylammonium chloride; Didecyldimethylammonium chloride; Diisodecyldimethylammonium chloride; Dioctyldimethylammonium chloride; Dodecylbis(2-hydroxyethyl)octylammonium hydrogen chloride; Alkyl dimethyl benzyl ammonium chloride; dodecylcarbamoylmethyl dimethyl benzyl ammonium chloride; heptadecyl hydroxyethyl imidazolinium chloride; hexahydro-1,3, 5-tris(2-hydroxyethyl)-s-triazine; myristalkonium chloride (and) Quat RNIUM 14; N,N-dimethyl-2-hydroxypropane n-Alkyl dimethyl benzyl ammonium chloride; n-Alkyl dimethyl benzyl ammonium chloride; n-tetradecyl dimethyl benzyl ammonium chloride Hydrate; Octyl decyl dimethyl ammonium chloride; Octyl dodecyl dimethyl ammonium chloride; Octyl phenoxyethoxyethyl dimethyl benzyl ammonium chloride chloride); oxydiethylenebis(alkyldimethylammonium chloride); quaternary ammonium compound, dicocoalkyldimethyl, chloride; trimethoxysilylpropyldimethyloctadecyl Alkyl ammonium chloride; trimethoxysilyl quaternary ammonium compound, trimethyl dodecyl benzyl ammonium chloride; n-dodecyl dimethyl ethyl benzyl ammonium chloride; n-deca Hexaalkyldimethylbenzylammonium chloride; n-tetradecyldimethylbenzylammonium chloride; n-tetradecyldimethylethylbenzylammonium chloride; and n-octadecyl Dimethylbenzyl ammonium chloride.

[0047] In a particularly preferred embodiment, the quaternary ammonium antimicrobial agent comprises a dimethyl benzyl ammonium compound such as N-alkyl dimethyl benzyl ammonium saccharinate. N-Alkyldimethylbenzylammonium saccharinates are 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 temperatures. It is pale orange in color and insoluble in water.

[0048] The phenols used in the practice of the present invention are preferably alkylphenols, styrenated phenols, or a combination of the two. Such phenols are commercially available from a number of sources.

[0049] The specific phenols used in the practice of this invention will likely be determined by all methods. If it is determined that an alkylphenol is best for a particular process, then the alkylphenol used in this embodiment preferably comprises at least one alkylphenol having at least one alkyl group selected from the group consisting of C7 alkyl, C8 The group consisting of alkyl, C9 alkyl, C10 alkyl, and C11 alkyl.

[0050] In a most preferred embodiment, the alkylphenol comprises an alkylphenol having a C9 alkyl group.

[0051] Alkylphenols suitable for use in this embodiment are commercially available from a number of sources. A particularly preferred commercially available alkylphenol includes TRITON ^™ X-207 sold by the Dow Chemical Company.

[0052] In a similar fashion, the particular styrenated phenol used in the practice of this invention will depend on the overall process. In a preferred embodiment, the styrenated phenol is preferably nonionic. Preferred styrenated phenols include CHROMASIST ^™ WEZ and STANDAPOL HS ^™ , both commercially available from Cognis Corporation, the North American office of which is located in Cincinnati, Ohio.

[0053] Water constitutes the other essential component of this embodiment of the antimicrobial composition.

[0054] The antimicrobial composition may contain other additives. Two such additives are defoamers and antifreeze.

[0055] The alkylphenols and styrenated phenols used in this embodiment of the antimicrobial composition may be susceptible to foaming, depending on the particular application. Therefore, it is envisioned that some industrial applications will contain defoamers.

[0056] For example, this embodiment of the antimicrobial composition according to the invention may be used to treat kraft paper. One way to treat this type of paper is to add the antimicrobial composition to a water tank, which is a device at the end of paper processing that returns a quantity of water to the the paper.

[0057] The tank is normally agitated due to the continuous movement of the paper through it. This agitation can generate foam upon addition of the claimed antimicrobial composition. In general, the presence of foam is detrimental to the water tank section of paper processing. Antifoams are therefore added to the composition according to the invention when the invention is used for the treatment of paper in water tanks.

[0058] A preferred antifoam agent is an ethoxylated copolymer of polyethylene glycol. In some cases, commercial formulations of styrenated phenols and alkylphenols may contain some antifoaming agents. For example, TRITON ^™ X-207 contains a small amount of polyethylene glycol. Therefore, if TRITON ^™ X-207 is the source of phenol, no additional defoamer may be required.

[0059] Likewise, antifreeze agents may be added to compositions according to the invention. The antifreeze is not considered critical to the actual performance of the invention. Rather they are used to prevent the composition from freezing or becoming too viscous during transport in cold weather. The antifreeze agents may be excluded from the composition if they are found to interfere with the addition of antimicrobial agents in any particular way. A preferred antifreeze is dipropylene glycol.

[0060] The relative amounts of each of the discussed components can be varied to suit the needs of a particular process. Furthermore, those skilled in the art are well within the ability to make these adjustments without undue experimentation.

[0061] In a preferred embodiment, the quaternary ammonium antimicrobial agent is present in the antimicrobial composition in an amount between about 1% and 30% by weight. In particularly preferred embodiments, the quaternary ammonium antimicrobial agent is present at about 15% and 20% by weight of the total composition.

[0062] As an example of how the present invention can be tailored to meet the needs of a particular process, in one particular papermaking process, it was determined that a composition having about 17% by weight of ONYXIDE ^™ 3300 was successful and effective in imparting antimicrobial properties to kraft paper.

[0063] Likewise, the total phenolic content (eg, alkyl, styrenated, or a combination of both) of the antimicrobial composition is between about 10% and about 60% by weight of the total composition. A preferred embodiment uses between about 20% and about 50% by weight alkylphenol and between about 1% and about 10% by weight styrenated phenol.

[0064] In one exemplary papermaking process, it was determined that a combination of alkylphenols and styrenated phenols worked best for the particular process. Specifically, the preferred total phenol content in that embodiment is between about 25% and about 50% by weight. Optimization of a particular method resulted in approximately 44% by weight of alkylphenols and approximately 5% by weight of styrenated phenols.

[0065] It is expected that the amount of antifoam required for the successful practice of the present invention in most applications will be between about 0% and about 20% by weight.

[0066] The balance of the antimicrobial composition comprises water. In preferred embodiments the amount of water present in the claimed composition will be between about 5% and about 30% by weight, more preferably between about 10% and about 20% by weight. Again, the precise amount of water will depend on the particular application and those skilled in the art will be able to make the necessary adjustments.

[0067] The present invention also encompasses methods of making the antimicrobial compositions.

[0068] Broadly, the method comprises the steps of mixing the phenol with the quaternary ammonium antimicrobial and heating the mixed phenol and quaternary ammonium antimicrobial if necessary (some phenol/quaternary agent combinations may not needs to be heated), and mix in some water.

[0069] In a preferred embodiment, the phenol (eg, TRITON ^(TM) X-207) is mixed with the quaternary ammonium antimicrobial agent (eg, ONYXIDE ^(TM )) in the presence of heat. Heat is applied since in many cases quaternary ammonium antimicrobials are solid at room temperature. Care should be taken not to heat the mixture of phenol and antimicrobial to such an extent that there is unacceptable volatilization of either.

[0070] If ONYXIDE ^(TM) is an antimicrobial agent, a mixing temperature between about 65°C and about 75°C is recommended. At this temperature the ONYXIDE ^™ melts into the phenol to form a liquid.

[0071] If needed or desired, antifoaming agents and antifreeze agents such as those previously discussed can be added at this point.

[0072] Once the antimicrobial agent and phenol are mixed, the heating can be removed. As the mixture cooled to room temperature, water was added with stirring.

[0073] The relative amounts of antimicrobial agent, phenol and water used in the method are the same as those discussed with respect to the composition. Likewise, the relative amounts of antifoam, antifreeze, and additional antimicrobial agents, if used, are the same as those discussed with respect to the composition.

Antimicrobial Composition #3

[0074] The term non-metal as used herein means an antimicrobial agent which, unlike quaternary ammonium compounds, does not contain or use metal ions (eg, 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 be used in two forms. One is an aqueous microemulsion well suited for aqueous systems. The other is non-aqueous microemulsions which are well suited for non-aqueous or organic solvent type systems. In the context of thermal insulation, it is required that the aqueous microemulsions will be in the form more commonly used.

[0076] Turning now to more specific embodiments of such antimicrobial compositions, one embodiment is an aqueous antimicrobial composition that can impart antimicrobial properties 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 volatile alcohols (eg, ethanol) that are often used to form emulsions of quaternary ammonium antimicrobial agents. Each of these ingredients, as well as other preferred and optional ingredients, are discussed in more detail below.

[0077] Quaternary ammonium antimicrobial agents useful in this composition include those listed in the previous embodiments of the antimicrobial composition.

[0078] In a particularly preferred embodiment, the quaternary ammonium antimicrobial agent comprises a dimethyl benzyl ammonium compound such as N-alkyl dimethyl benzyl saccharin ammonium. N-Alkyldimethylbenzyl ammonium saccharin 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 temperatures. It is light orange in color and insoluble in water.

[0079] The phenol used in the practice of the present invention may contain an alkylphenol having at least one alkyl group selected from the group consisting of C7 alkyl, C8 alkyl, C9 alkyl, C10 alkyl, and C11 alkyl composed of groups.

[0080] In the most preferred embodiment, the alkylphenol comprises an alkylphenol having a C9 alkyl group.

[0081] Alkylphenols suitable for use in the practice of the claimed invention are commercially available from a number of sources. A particularly preferred commercial alkylphenol is sold by the Dow Chemical Company under the tradename TRITON ^™ X-207.

[0082] Alternatively, the phenols used in the practice of the present invention may comprise styrenated phenols. Two examples of styrenated phenols suitable for use with the present invention are CHROMASIST WEZ and STANDAPOL HS. Both are commercially available from Cognis Corporation of Cincinnati, Ohio. Both are identified by CAS#3217120. The technical data sheet states that the main 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 examples of the flexibility of the invention and the choices one skilled in the art may have to make in the practice of the invention. Those skilled in the art will understand that a phenol may work better in a particular paper or insulation manufacturing process. Fine tuning of the invention to suit a particular method is contemplated and should not limit the scope of the invention in any way. Those skilled in the art will be able to make minor but necessary adjustments without undue experimentation to adapt the invention to their particular methods.

[0084] The non-metallic antimicrobial agent used in this embodiment of the invention is preferably selected from the azole family of antimicrobial agents. In general, pyrroles comprise a broad class of compounds characterized by five-membered rings containing one nitrogen atom and at least one other non-carbon atom (eg, nitrogen, oxygen, and sulfur). Certain azoles exhibit antimicrobial (ie, antifungal) properties. Triazoles are a subclass of azoles that are often used as antimicrobial agents.

[0085] Two or more well-known antimicrobial triazoles are propiconazole and tebuconazole. The chemical name of 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 of tebuconazole (CAS No.107534-96-3) is α-[2-(4-chlorophenyl)ethyl]-α-(1,1-dimethylethyl)-1H-1 , 2,4-triazole-1-ethanol.

[0086] Tebuconazole is commercially available from a number of sources. A particularly preferred form of tebuconazole is commercially available from Bayer Corporation under the tradename PREVENTOL ^(TM) A8. Likewise, propiconazole is available from many sources. A particularly preferred form of propiconazole is available from Janssen Pharmaceutical under the tradename WOCOSEN ^(TM) TECHNICAL.

[0087] In particularly preferred embodiments, the first and second non-metallic antimicrobial agents are propiconazole and tebuconazole. Either reagent can be "first" or "second"; the specific designation is not important. However, for ease of discussion, tebuconazole will generally be referred to as the first non-metallic agent and propiconazole will be the second non-metallic agent.

[0088] If desired, small amounts of glycols may be present in the compositions according to the invention. Glycols can increase the stability of emulsions and provide other benefits such as delayed foam. Preferred diols include alkyl glycols, with polyethylene glycol, polypropylene glycol, and dipropylene glycol being preferred.

[0089] Water constitutes the other essential ingredient of the claimed antimicrobial composition.

[0090] The antimicrobial composition according to the present invention may contain other additives. Two such additives are defoamers and antifreeze.

[0091] Some phenolics used in the practice of this invention may be prone to foaming, depending on the particular application. Accordingly, it is contemplated that many commercial embodiments of the present invention will contain an antifoaming agent.

[0092] For example, this composition can be used to treat kraft paper. Such papers are used to form the outer surface on the insulation. One way to treat this type of paper is to add the antimicrobial composition to the water tank, which is a device at the end of paper processing that returns a certain amount of water after the paper has undergone heat-based drying. to the paper.

[0093] The tank is normally agitated due to the continuous movement of the paper through it. This agitation can generate foam upon addition of the claimed antimicrobial composition. In general, the presence of foam is detrimental to the water tank section of paper processing. Antifoams are therefore added to the composition according to the invention when the invention is used for the treatment of paper in water tanks.

[0094] The paper can also be treated with a spray bar. Foam buildup in the spray wand can be detrimental to the process, so defoamers can also be used there.

[0095] A preferred antifoam agent is an ethoxylated copolymer of polyethylene glycol. In some cases, commercial formulations of phenolics may contain some antifoaming agents. For example, TRITON ^™ X-207 contains a small amount of polyethylene glycol. Therefore, if TRITON ^™ X-207 is a source of phenol, no additional defoamer may be required.

[0096] Likewise, antifreeze agents may be added to compositions according to the invention. They are used to prevent the composition from freezing or becoming too viscous during transport in cold weather. In most cases the glycol will function as an antifreeze. A preferred antifreeze is dipropylene glycol.

[0097] One of the benefits of the present composition is that it provides a new and improved platform for exploiting the antimicrobial properties of various azoles and especially tebuconazole and propiconazole. The general synergy between tebuconazole and propiconazole has been known to those skilled in the art for many years now. In other words, by utilizing tebuconazole and propiconazole in combination, a greater antimicrobial effect can be achieved for a given amount of antimicrobial agent.

[0098] Tebuconazole and propiconazole are also well known for their hydrophobicity and difficulty of use in aqueous environments. They resist the formation of aqueous emulsions and to the extent that they can be forced into some types of aqueous emulsions, which tend to be fragile and prone to instability (for example, active substances form crystals in water and precipitate out or they mix with water form different phases).

[0099] However, the compositions according to the present invention provide stable aqueous emulsions of quaternary ammonium antimicrobial agents and azoles, especially tebuconazole and propiconazole. This composition can be diluted to about 0.02% by weight of the combined pyrrole (eg, 100 ppm tebuconazole and 100 ppm propiconazole) or concentrated to about 50% by weight of the combined pyrrole. This feature provides great flexibility in how the composition can be used.

[0100] While applicants do not wish to be bound by any particular theory, it is believed that the combination of the quaternary ammonium compound and the phenol provides a stabilizing effect on both azoles. In particular, dimethyl benzyl ammonium compounds such as ONYXIDE ^™ 3300 have been shown to provide a stabilizing effect on aqueous emulsions with azoles such as tebuconazole and propiconazole.

[0101] Turning now to more specific embodiments of the invention, the relative amounts of each listed component may vary to suit the needs of a particular process. Thus, each listed component may be present in varying amounts depending on the particular needs of the user. Again, those skilled in the art are well able to make these adjustments without undue experimentation.

[0102] In a preferred embodiment, the quaternary ammonium antimicrobial agent is present in an amount of between about 0.33% and 20% by weight of the total composition. In particularly preferred embodiments, the quaternary ammonium antimicrobial agent is present in an amount of between about 2 (weight) % and 16 (weight) %, most preferably about 3 (weight) % and 9 (weight) % of the total composition. Quantity exists.

[0103] Likewise, it is preferred that the phenols (i.e., alkylphenols, styrenated phenols, or combinations thereof) in the total composition be between about 30% by weight and about 80% by weight of the total composition The amount in between exists. In a preferred embodiment the phenol is present in the composition at between about 40% and about 70% by weight, most preferably between about 45% and about 65% by weight.

[0104] Preferably the first non-metallic antimicrobial agent is present in the total composition in an amount between about 5% by weight and about 45% by weight, more preferably between about 12% by weight and about 30% by weight . As previously indicated, the first non-metallic antimicrobial agent is preferably tebuconazole.

[0105] Preferably the second non-metallic antimicrobial agent is present in the total composition in an amount between about 5% by weight and about 45% by weight, more preferably between about 12% by weight and about 30% by weight . As previously indicated, the first non-metallic antimicrobial agent is preferably propiconazole.

[0106] Small amounts of glycols may be present in the compositions according to the invention. Preferred glycols include alkyl glycols, preferably polyethylene glycol, polypropylene glycol, and dipropylene glycol. Dipropylene glycol is particularly preferred. It is expected that in most applications the amount of diol will be between about 0% and about 4% by weight of the total composition.

[0107] As previously stated, if foaming is an issue, then a defoamer can be added. Antifoaming agents suitable for use in the present invention include those compounds commonly used as antifoaming agents. In a preferred embodiment, an additional amount of glycol may be added as an antifoaming agent. The diols used as antifoaming agents can be more of the same diols discussed above or different diols.

[0108] A preferred antifoaming agent is an ethoxylated copolymer such as polyethylene glycol, which is commercially available from Cognis Corporation. It is expected that the amount of defoamer required for successful practice of the present invention in most applications will be between about 0% by weight and about 3% by weight, more preferably between 0.5% by weight and about 1.5% by weight within range. The amount of defoamer can be adjusted up or down, depending on the specific application. The appropriate amount of antifoaming agent can be readily determined by one skilled in the art without undue experimentation.

[0109] The remainder of the composition according to the invention comprises water. In preferred embodiments, the amount of water present in the claimed compositions will be between about 0% and about 15% by weight, more preferably between 3% and about 9% by weight. Again, the precise amount of water will depend on the particular application and those skilled in the art will be able to make the necessary adjustments.

[0110] Further embodiments of the present invention include those products incorporating the claimed antimicrobial compositions. Indeed, one of the novel aspects of the invention is that it serves as a very versatile tool for incorporating antimicrobials into a wide variety of different products. For example, it has been shown that the antimicrobial composition according to the invention is particularly effective in imparting antimicrobial properties to paper used in the production of wallboard and insulation.

[0111] Preliminary work has also shown that the antimicrobial composition according to the invention is an excellent tool for providing antimicrobial protection to products such as paints and polymers, latex exterior paints and extruded vinyl (e.g. vinyl side panels, vinyl windows) are particularly suitable for use with the present invention. It is also contemplated that the antimicrobial compositions according to the invention may be added to other solids such as ceramics and cementitious adhesives to impart antimicrobial properties.

[0112] The present invention also includes methods of making the antimicrobial compositions. Broadly, the method according to the invention comprises the step of mixing a phenol with a quaternary ammonium antimicrobial agent. Heating may be necessary during this mixing step and especially if the phenol is an alkylphenol and the quaternary agent is an N-alkyldimethylbenzyl ammonium compound. To this phenol/quaternary salt mixture was mixed some of the first non-metallic antimicrobial and then some of the second non-metallic antimicrobial. The first and second non-metallic reagents may also be mixed together prior to mixing with the phenol/quaternary salt mixture. To the end of the process add some water with mixing. Heat can be added to either step if desired.

[0113] In preferred embodiments using alkylphenols, the alkylphenol (e.g., TRTION ^™ X-207) is typically mixed with the quaternary ammonium antimicrobial agent (e.g., ONYXIDE ^™ 3300) in the presence of heat . Heat is applied since in many cases the quaternary ammonium antimicrobials are solid at room temperature. If the quaternary ammonium antimicrobial is liquid or available as a flowable composition, heat may still be used to aid in mixing. Care should be taken not to heat the mixture of alkylphenol and quaternary ammonium antimicrobial to such an extent that there is unacceptable volatilization of either. In a preferred embodiment the temperature is maintained below about 200°C.

[0114] If TRITON ^™ X-207 is an alkylphenol and ONYXIDE ^™ 3300 is an antimicrobial, the recommended mixing temperature is between about 65°C and 75°C. At this temperature the ONYXIDE ^™ 3300 melts into the TRITON ^™ X-207 to form a liquid.

[0115] The steps of admixing the first non-metallic antimicrobial agent and admixing the second non-metallic antimicrobial agent may occur separately. Alternatively, the first and second non-metallic antimicrobial agents may be mixed together and then added to the quaternary ammonium antimicrobial agent.

[0116] Mixing of the non-metallic antimicrobial agent can be accomplished in the presence of heat, if desired. For example, WOCOSEN ^™ TECHNICAL (ie, propiconazole) is generally a very viscous liquid at room temperature. PREVENTOL ^™ A8 (ie, tebuconazole) is generally a solid white powder. Heating both of them will aid mixing of the quaternary ammonium/alkylphenol mixture. In a preferred embodiment, the tebuconazole and propiconazole are mixed together forming a less viscous solution which can then be added to the quaternary ammonium/alkylphenol mixture. In this embodiment, the tebuconazole and propiconazole mixture is heated to between about 65°C and 75°C with stirring.

[0117] If desired, heating may be continued during mixing of the non-metallic antimicrobial agent and the quaternary ammonium antimicrobial agent. Glycols and any antifoam or antifreeze agents, such as those previously discussed, can be added at this point.

[0118] Once the quaternary ammonium antimicrobial, phenol, and non-metallic antimicrobial are mixed, they can be removed by heating. When the mixture cooled to room temperature, water was added with stirring.

[0119] If styrenated phenols are used instead of alkylphenols, the process according to the invention is very similar to that enumerated above. The main difference in using styrenated phenols is that less heating may be required during mixing. Of course, the use of heat will always be somewhat, depending on the precise active ingredient chosen by the professional.

[0120] The relative amounts of quaternary ammonium antimicrobial agent, alkylphenol, non-metallic antimicrobial agent, and water used in the practice of the method according to the present invention are the same as those discussed with respect to the composition of the present invention. Likewise, the relative amounts of antifoam, antifreeze, and additional antimicrobial agents, if any, are the same as those discussed with respect to the compositions of the present invention.

[0121] Alternative embodiments of the present invention are particularly suitable for use in non-aqueous systems. In this embodiment, the invention comprises non-aqueous microemulsions. The microemulsion comprises a quaternary ammonium antimicrobial agent, a first non-metallic antimicrobial agent, a second non-metallic antimicrobial agent, and a glycol. Preferred quaternary ammonium antimicrobial agents, first non-metallic antimicrobial agents, and second non-metallic antimicrobial agents are the same as in the previous embodiments. Almost any diol can be used in the practice of this invention, but dipropylene glycol is the preferred diol.

[0122] The preferred amount of each component in the composition according to the present invention is as follows: first non-metallic antimicrobial agent - about 10 (weight)% to about 33 (weight)%; second non-metallic antimicrobial agent - about 10% by weight to about 33% by weight; quaternary ammonium antimicrobial agents - about 0.33% by weight to about 17% by weight; glycols - about 17% by weight to about 80% by weight )%.

[0123] Methods of making embodiments of the present invention are generally similar to methods of making aqueous embodiments. The various components are mixed together in appropriate amounts in the presence of heat, if necessary. For example, several examples of compositions according to the invention were carried out in the following manner.

[0124] A first non-metallic antimicrobial agent (eg, WOCOSEN TECHNICAL) is mixed with dipropylene glycol in the required relative amounts under heat (approximately 65°C). To this mixture is added the quaternary ammonium compound (eg, ONYXIDE 3300) while maintaining the heat. A second non-metallic antimicrobial agent (eg, PREVENTOL A8) is then added with heating and stirring. The whole mixture was then stirred with heating until a clear microemulsion formed.

[0125] The above non-aqueous embodiments of the invention are well suited for imparting antimicrobial properties to products produced in non-aqueous environments.

Example

[0126] The following formulations, made according to the above method, have shown commercially acceptable efficacy against microbial growth on kraft paper. All percentages are by weight.

Tebuconazole (WOCOSEN ^™ TECHNICAL) 19%

Propiconazole (PREVENTOL ^™ A8) 18.5%

[0129] Quaternary ammonium (ONYXIDE ^™ 3300) 9.5%

Alkylphenol (TRITON ^™ X-207) 43%

Glycol (dipropylene glycol) 5%

[0132] Water 5%

Adhesive

[0133] The adhesive that attaches the fiberglass batting to the nonwoven cover may also serve as a carrier for the antimicrobial composition. Depending on the physical and chemical properties of the insulation and the nonwoven cover, several types of adhesives can be used. In preferred embodiments, however, the binder is a bitumen or a tar-like compound, such as those commonly used in insulation manufacture.

[0134] In most cases, the antimicrobial composition can be added to an adhesive, which is then applied to the nonwoven covering. In most cases, simple mixing or blending of the antimicrobial agent with the adhesive will likely be the most effective method of addition. Other methods of combining the antimicrobial composition with the adhesive will be apparent to those skilled in the art.

[0135] Antimicrobial compositions that may be used in combination with the adhesive include all of those previously discussed, including the preferred antimicrobial compositions. A preferred embodiment uses a compound selected from the group consisting of triclosan, propiconazole, sodium pyrithione, diiodomethyl sulfone tolyl; tebuconazole; thiazole benzimidazole; 3-iodo-2-propynylbutylamino Formic acid esters, metal ions, n-octyl-isothiazolinone, quaternary ammonium compounds, and mixtures thereof consist of agents of the group consisting of antimicrobial compositions. n-Octyl-isothiazolinone (OIT) and silver ions or silver zeolites are particularly preferred.

[0136] The weight percent of the antimicrobial composition in the adhesive can vary from very small (eg, less than 100 ppm) to very large (eg, greater than 5000 ppm). The precise amount will depend on the particular use of the insulation and the amount of antimicrobial composition used with the nonwoven cover.

method

[0137] The present invention also encompasses methods of making insulation exhibiting antimicrobial properties. The various examples described above discuss several methods of manufacture (eg, spray coating the nonwoven covering). The methods discussed above are exemplary only and should not be construed as limiting the scope of the invention.

[0138] In a very broad sense, the method according to the invention comprises the steps of applying an antimicrobial composition to said nonwoven covering and contacting the nonwoven covering to an insulating material. The order of these steps can be reversed if such a reversal is more suitable for the overall method.

[0139] The step of contacting the nonwoven cover to the insulating material includes any contacting step commonly used in the industry. Such contacting steps may include melt pressing a synthetic polymeric nonwoven cover to the insulation or coating the nonwoven cover with an adhesive and then contacting the nonwoven cover to the insulation. The use of a tar-like adhesive to contact the paper covering to the fiberglass batting is probably the most commonly used method in the industry.

[0140] Likewise, the step of applying the antimicrobial composition to the nonwoven covering comprises any of the methods discussed above, including spraying, coating, dipping, etc. or otherwise contacting the antimicrobial composition to The nonwoven cover. It is also within the scope of this step to add the antimicrobial composition to the adhesive followed by or simultaneously with contacting the nonwoven cover to the adhesive.

[0141] Finally, the antimicrobial compositions used in the methods according to the invention include all those antimicrobial compositions capable of providing commercially acceptable levels of efficacy against the microorganisms of interest. Particularly preferred embodiments of the method include the specific antimicrobial compositions discussed above.

Claims (36)

1. the heat guard that shows antimicrobial property and resist growth of microorganism, described heat guard comprises:

Heat-insulating material;

The non woven coverstock of contiguous described heat-insulating material; With

Antimicrobial compositions.

2. according to the heat guard of claim 1, wherein said heat guard material comprises glass fibre.

3. according to the heat guard of claim 2, wherein said non woven coverstock comprises brown paper.

4. according to the heat guard of claim 3, it also comprises adhesive composition between described brown paper and described heat-insulating material, and wherein said adhesive composition comprises antimicrobial compositions.

5. according to the heat guard of claim 4, wherein said adhesive composition comprises pitch and described antimicrobial compositions comprises the antimicrobial that is selected from by the following group of forming: triclosan, propiconazole, 2-mercaptopyridine sodium oxide molybdena, tolyldiiodomethylsulbased; Tebuconazole; Thiabendazole; 3-iodo-2-propynyl butyl carbamate, metallic antimicrobials, just-and octyl group-OIT, quaternary ammonium compound, and composition thereof.

6. according to the heat guard of claim 5, wherein said antimicrobial be just-the octyl group OIT.

7. according to the heat guard of claim 5, wherein said antimicrobial compositions comprises metallic antimicrobials and described metallic antimicrobials is a silver.

8. according to the heat guard of claim 3, wherein said antimicrobial compositions comprises the antimicrobial system that has first antimicrobial and second antimicrobial at least, and wherein said first and second antimicrobials are to exist with the level that is enough to show antimicrobial efficacy.

9. heat guard according to Claim 8, described second antimicrobial that wherein said antimicrobial system is included in first antimicrobial that exists in first carrier and exists in second carrier, and wherein said first and second carriers are soluble in each other.

10. according to the heat guard of claim 9, wherein said antimicrobial system is the emulsion of described first and second antimicrobials.

11. according to the heat guard of claim 10, wherein said first antimicrobial be selected from by propiconazole, 2-mercaptopyridine sodium oxide molybdena, and composition thereof the group formed.

12. according to the heat guard of claim 10, wherein said second antimicrobial is selected from by tolyldiiodomethylsulbased; Tebuconazole; Thiabendazole; With 3-iodo-2-propynyl butyl carbamate, and composition thereof the group formed.

13. according to the heat guard of claim 3, wherein said antimicrobial compositions comprises:

The quaternary ammonium antimicrobial,

Alkyl phenol,

Styrenated phenol and

Water.

14. according to the heat guard of claim 13, wherein said quaternary ammonium antimicrobial comprises alkyl ammonium compound.

15. according to the heat guard of claim 13, wherein said alkyl phenol comprises at least a alkyl phenol with the alkyl that is selected from the group of being made up of C7 alkyl, C8 alkyl, C9 alkyl, C10 alkyl and C11 alkyl.

16. according to the heat guard of claim 13,

Wherein said quaternary ammonium antimicrobial is between about 1 weight % and about 30 weight % of whole compositions,

Described alkyl phenol be about 20 weight % at whole compositions between about 50 weight %, and

Described styrenated phenol is between about 1 weight % and about 10 weight % of whole compositions.

17. according to the heat guard of claim 13, wherein said quaternary ammonium antimicrobial comprises alkyl ammonium compound.

18. according to the heat guard of claim 17, wherein said quaternary ammonium antimicrobial comprises N-alkyl dimethyl benzyl ammonium compound.

19. according to the heat guard of claim 3, wherein said antimicrobial compositions comprises:

The quaternary ammonium antimicrobial,

Phenol,

The first nonmetal antimicrobial,

The second nonmetal antimicrobial and

Water.

20. according to the heat guard of claim 19, wherein

Described quaternary ammonium antimicrobial is between about 0.33 weight % and about 20 weight % of whole compositions;

Described phenol is that about 30 weight % at whole compositions are between about 80 weight %;

The described first nonmetal antimicrobial is between about 5 weight % and about 45 weight % of whole compositions;

The described second nonmetal antimicrobial is between about 5 weight % and about 45 weight % of whole compositions; And

Described water is between about 0 weight % and about 9 weight % of whole compositions.

21. according to the heat guard of claim 20, wherein said quaternary ammonium antimicrobial comprises alkyl ammonium compound.

22. according to the heat guard of claim 20, at least a in the wherein said first and second nonmetal antimicrobials is to be selected from the group of being made up of pyroles.

23. according to the heat guard of claim 22, the wherein said first nonmetal antimicrobial comprises Tebuconazole and the described second nonmetal antimicrobial comprises propiconazole.

24. according to the heat guard of claim 20, wherein said phenol comprises the alkyl phenol with the alkyl that is selected from the group of being made up of C7 alkyl, C8 alkyl, C9 alkyl, C10 alkyl and C11 alkyl.

25. according to the heat guard of claim 1, the amount that wherein said antimicrobial compositions exists is enough to prevent macroscopic view growth on the wallboard according to AATTCC method of testing 30 part III.

26. according to the heat guard of claim 3, wherein said antimicrobial compositions comprises quaternary ammonium antimicrobial, the first nonmetal antimicrobial, second nonmetal antimicrobial and the dihydroxylic alcohols.

27. a method of making the heat guard of performance anti-microbial properties, this method comprises:

With non woven coverstock touch heat-insulating material and

Antimicrobial compositions is coated to described non woven coverstock.

28., wherein described non woven coverstock is touched described heat-insulating material and comprises adhesive is coated to described non-woven material or described heat guard material or both according to the method for claim 27.

29., wherein antimicrobial compositions is coated to described non woven coverstock and is included in and described antimicrobial compositions is joined described adhesive before applying described adhesive according to the method for claim 28.

30., wherein antimicrobial compositions is coated to described non woven coverstock and comprises the described non woven coverstock of spraying according to the method for claim 27.

31., wherein antimicrobial compositions is coated to described non woven coverstock and comprises the described non woven coverstock of coating according to the method for claim 27.

32. method according to claim 27, wherein said antimicrobial compositions comprises the antimicrobial system that has first antimicrobial and second antimicrobial at least, and wherein said first and second antimicrobials are to exist with the level that is enough to show antimicrobial efficacy.

33. method according to claim 32, described second antimicrobial that wherein said antimicrobial system is included in first antimicrobial that exists in first carrier and exists in second carrier, and wherein said first and second carriers are soluble in each other.

34. according to the method for claim 33, wherein said first antimicrobial be selected from by propiconazole, 2-mercaptopyridine sodium oxide molybdena, and composition thereof the group formed; And described second antimicrobial is selected from by tolyldiiodomethylsulbased; Tebuconazole; Thiabendazole; With 3-iodo-2-propynyl butyl carbamate, and composition thereof the group formed.

35. according to the method for claim 27, wherein said antimicrobial compositions comprises:

The quaternary ammonium antimicrobial,

Alkyl phenol,

Styrenated phenol and

Water.

36. according to the method for claim 35, wherein said antimicrobial compositions comprises:

The quaternary ammonium antimicrobial,

Alkyl phenol,

The first nonmetal antimicrobial,

The second nonmetal antimicrobial,

Dihydroxylic alcohols and

Water.