METHOD OF MAKING SAME

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This non-provisional application claims priority from U.S. Provisional Patent Application serial number 61 /426,614, entitled ANTIMICROBIAL COLLOIDAL SILVER AND GOLD PRODUCTS AND METHOD OF MAKING SAME filed on December 23, 2010, which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention is related generally to the field of antimicrobial products, and in particular antimicrobial gel, foam, fabric, coated paper, and polymer products having colloidal silver or gold additives.

BACKGROUND OF THE INVENTION

[0003] In the areas of physical fitness and personal hygiene, the current technology has not addressed the need for substantially sterile surfaces on physical fitness equipment, facilities, and areas where a user's personal items are placed. Those surfaces can be soft or hard, made of gelatinous, foam, coated paper, fabrics or polymer materials, and permanent or temporary or removable.

SUMMARY OF THE INVENTION

[0004] One aspect of the present invention includes gelatinous or foam materials combined with the Colloidal Silver or Gold additive to formulate an antimicrobial product having cushioning properties. Embodiments of the present invention can include gelatinous materials selected from a group consisting of thermosetting polymer, Styrene-Ethylene-Butadiene-Styrene polymer (SEBS), Thermoplastic Elastomer (TPE), and Polyurethane (PU) gelatin with and without a raised geometry on an outer surface. The foam can be any commercially available foam product including, but not limited to, Polystyrene and Polyurethane. Another aspect of the present invention includes coated paper that may be any commercially available paper product coated with any commercially available paper coating, including but not limited to polyester. Yet another aspect of the present invention includes fabric that may include, but is not limited to bamboo, cotton, and / or polyester with industrial dye. Other polymer products may be made out of polypropylene or other similar polymers

[0005] For a better understanding of the present invention, together with other and further objects thereof, reference is made to the accompanying drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present invention is illustratively shown and described in reference to the accompanying drawings, in which:

[0007] FIG. 1 is a top view of an exemplary embodiment of a flat mat of the present invention, which has a top surface with a plurality semi-circular projections arranged in rows on a flat surface;

[0008] FIG. 2 is a end view of the exercise pad of FIG. 1;

[0009] FIGS. 3 and 4 are perspective views of an embodiment of the flat mat of FIG. 1;

[0010] FIG. 5 is an end view of the flat mat of the embodiment of FIG. 1 rolled with ends attached thereto;

[0011] FIG. 6 is a perspective view of the roller flat mat of FIG. 5 rotated in a counter-clockwise position; [0012] FIG. 7 is a perspective view of the roller flat mat of FIG. 5 rotated in a clockwise position;

[0013] FIG. 8 is a side view of the roller flat mat of FIG. 5;

[0014] FIG. 9 is a perspective view of another embodiment of the present invention for an exercise roller, which has an outer surface with a plurality semi-circular projections arranged in rows and an insert therein having opposing ends without semi-circular projections;

[0015] FIG. 10 is a perspective view of the exercise roller of FIG. 9 rotated counter-clockwise;

[0016] FIG. 1 1 is an end view of the exercise roller of FIG. 9;

[0017] FIG. 12 is a side view of the exercise roller of FIG. 9;

[0018] FIG. 13 is a side view of another embodiment of the present invention for an exercise roller, which has an outer surface with a plurality of semi-circular projections arranged in rows and an insert therein having semicircular projections in proximity of the outer edges of the present invention;

[0019] FIG. 14 is an end view of the exercise roller of FIG. 13;

[0020] FIG. 15A is a side view of the present invention in the form of a flat mat without a plurality of semi-circular projections arranged in rows;

[0021] FIG. 15B is a perspective view of the flat mat of FIG. 15A;

[0022] FIGS. 16A is a side view of the fiat mat in the form of a block without a plurality of semi-circular projections arranged in rows;

[0023] FIG. 16B is a perspective view of the block of FIG. 16A;

[0024] FIG. 17 is a perspective view of the present invention in the form of a Pilates mat with a plurality of semi-circular projections arranged in rows; [0025] FIG. 18A is a top view of an alternative embodiment of a flat mat illustrating an alternative projection with a square base section having side that rise to form a semi-circular top section; and

[0026] FIG. 18B is a side view of the alternative embodiment of FIG. 18A; and

[0027] FIG. 19 is a perspective view of an alternative embodiment shaped in the form of a wedge;

[0028] FIG. 20A is a top view of an antimicrobial towel; and

[0029] FIG. 20B is an isometric view of the embodiment of FIG. 20A;

[0030] FIG. 21A is a top view of an antimicrobial tray for food, personal hygiene items, or personal instruments; and

[0031] FIG. 2 IB is an isometric view of the alternative embodiment of FIG. 21 A.

[0032] FIG. 22A is a top view of a rectangular antimicrobial sheet;

[0033] FIG. 22B is an isometric view of the embodiment of FIG. 22A;

[0034] FIG. 23A is a top view of an oval antimicrobial sheet;

[0035] FIG. 23B is an isometric view of the alternative embodiment of FIG. 23A;

[0036] FIG. 24A is a top view of an antimicrobial bench liner;

[0037] FIG. 24B is an isometric view of the alternative antimicrobial bench liner of FIG. 24A;

[0038] FIG. 25A-B is a top view of an antimicrobial chair arm liner; [0039] FIG. 25C-D is an isometric view of the alternative antimicrobial chair arm liner of FIG. 25A-B, respectively;

[0040] FIG. 26A is a top view of an antimicrobial drawer liner;

[0041] FIG. 26B is an isometric view of the alternative antimicrobial drawer liner of FIG. 26A;

[0042] FIG. 27A is a top view of an antimicrobial place mat;

[0043] FIG. 27B is an isometric view of the alternative antimicrobial place mat of FIG. 27A;

[0044] FIG. 28A is a front view of an antimicrobial seat back cover;

[0045] FIG. 28B is a top view of an antimicrobial seat bottom cover;

[0046] FIG. 28C is an isometric view of the alternative antimicrobial seat covers of FIG. 28A-B;

[0047] FIG. 29A-B is a top view of an antimicrobial shower liner;

[0048] FIG. 30A-B is a top view of antimircrobial table clothes;

[0049] FIG. 30C-D is an isometric view of the alternative antimicrobial seat covers of FIG. 30A-B, respectively; and

[0050] FIGS. 31A-B are pictorial views of one embodiment of the non- hemispheric spherical cap projection of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0051] As used herein in the specification and claims, including as used in the examples and unless otherwise expressly specified, all numbers may be read as if prefaced by the word "about", even if the term does not expressly appear. Also, any numerical range recited herein is intended to include all subranges subsumed therein.

[0052] The phrase "cross-linked network" means the one polymer chain is linked or bonded to another polymer chain.

[0053] The phrase "monolithic structure" means a solid, single part and not an assembly of two or more components.

[0054] The phrase "comprehensively suspended colloidal silver or gold" means silver or gold particulates are suspended evenly throughout the gel or foam, coated paper, fabric or other polymer material or suspended unevenly but along a target surface, such as the outer surface, of the gel or foam, coated paper, fabric or other polymer material, all of which provides sufficient antimicrobial protection for its intended purpose.

[0055] One embodiment of the present invention comprises a gelatinous material with a colloidal silver additive (alternatively, a colloidal gold additive) suspended substantially evenly within the gelatin material. The colloidal silver additive concentration is about 200 to about 2000 PPM depending on customer bacteria kill percentage requirements. The gelatinous material can either be a thermosetting polymer, Styrene-Ethylene-Butadiene-Styrene polymer (SEBS), Thermoplastic Elastomer (TPE), or Polyurethane (PU) gelatin. The thermo- reversible solid material is composed of a liquid organic phased entrapped in a three-dimensionally cross-linked network. The solubility of the liquid organic can add elasticity to a product creating a jelly-like substance or gelatinous material. The combination of organic material plus SEBS material creates a thermoplastic elastomer. The polymers will be used in a final form in hardness and softness ranging from 0 to 40 on the shore A scale and harder consistencies on the Shore DD Scale from 0 to 80. The range of the TPE Gels will be from 0 to 40 on the 00 scale of measurement (Durometer). For the purpose of illustration, one embodiment of the gelatinous material is: [0056] Substance A: Polymeric Methylene diphenyl di-isocyanate (MDI) 100%;

[0057] Substance B: 265 Molecular weight (Mw) polyether triol 100%; [0058] Ratio A:B about 1: 1; [0059] Shore D about 80; and

[0060] Anti-microbial Colloidal silver or gold concentration of about 200 to about 2000 PPM.

[0061] One embodiment of the present invention is illustrated in FIGS. 1- 8 illustrates a fiat mat 2 and examples of its possible adaptable configurations. FIG. 1 is a top view of an exemplary embodiment being a flat mat 2 of the present invention; which has a top surface 4 with a plurality of semi-circular or non-hemispheric spherical cap projections 6 arranged in rows 8 on a flat surface 10. FIG. 2 is an end view of the flat mat 2 of FIG. 1. FIGS. 3 and 4 are perspective views of an embodiment of flat mat 2 of FIG. 1 illustrating cutout 12 along width 14 of bottom surface 16 at end 18 and cutout 20 along width 14 of top surface 10 at opposing end 22. FIGS. 3 and 4 illustrate top surface cutout 20 having length 24 and depth 26 substantially the same dimensions as bottom surface cutout 12 with length 28 and depth 30, respectively, such that when flat mat 2 is rolled into a substantially circular form having a diameter 35, as shown in FIG. 5, end 18 and opposing end 20 are received into top surface cutout 20 and bottom surface cutout 12, respectively. Another acceptable embodiment of ends 18, 22 is any combination of cutout depths 26, 30 or end thicknesses 32, 34 with a sum total thickness approximately equivalent to flat mat thickness 36. Ends 18, 22 are removably attachable by any suitable attachment mechanism such as hook/loop, adhesive, male/female snaps, and clamps such that a first end attachment mechanism cooperates with a second end attachment mechanism to hold end 18 and opposing end 22 together. [0062] With regards to non-hemispheric spherical cap projections 6, a spherical cap 130 as shown in FIG. 31 is a portion of a sphere 132 cut off by a plane 134. If the plane 134 passes through the center of the sphere, so that the height h of the cap 130 is equal to the radius r of the sphere 132, then the spherical cap 130 is called a hemisphere. If the plane 134 does not pass through the center c of the sphere 132, so that the height h of the cap 130 is not equal to the radius r of the sphere 132, then the spherical cap 130 is a non-hemisphere .

[0063] If the radius of the sphere is r, the radius of the base b (along plane 134) of the cap is a, and the height of the cap is h, then the volume of the spherical cap is:

V = ¾3a ² + h ² ),

[0064] 6 ^;i

[0065] and the curved surface area of the spherical cap is: [0066] A = 2nrh.

[0067] The parameters a, h and r are not independent:

[0068] r ² = (r - h)2 + a ² = r2 + h ² - 2rh + a ² ,

_ a ² + fr ²

[0069] ^~~ 2h .

[0070] Substituting this into the area formula gives:

[0072] Note also that in the upper hemisphere of the diagram, =r— ² -^ , and in the lower hemisphere ft^+vV^-a ² ; hence in either hemisphere so an alternative expression for the volume is [0073] 3 ^J .

[0074] Now returning to FIG. 3 IB that illustrates pad thickness T, the spacing S between projections, height h, radius a of the base b, where 2a is the diameter of base b. Spacing S and height h are both less than radius a of the base b, where 2a is the diameter of base b.

[0075] FIG. 6 is a perspective view of the flat mat 2 in a rolled configuration as illustrated in FIG. 5 rotated in a counter-clockwise position.

[0076] FIG. 7 is a perspective view of the fiat mat 2 in a rolled configuration as illustrated in FIG. 5 rotated in a clockwise position.

[0077] FIG. 8 is a side view of the flat mat 2 in a rolled configuration as illustrated in FIG. 5.

[0078] Another embodiment of the present invention is an exercise roller 38 illustrated in FIGS. 9-12 showing flat mat 2 wrapped around an insert 40 connecting at overlapping end section 50 of ends 18, 22 and the end attachment mechanisms are engaged to enclose insert 40 within fiat mat 2. FIG. 9 is a perspective view of embodiment 38 of the present invention, which has an top or outer surface 4 with a plurality semi-circular projections 6 arranged in rows 8 and an insert 40 therein having opposing ends 42, 44 without semi-circular or non-hemispheric spherical cap projections 6. FIG. 10 is a perspective view of exercise roller 38 of FIG. 9 rotated counter-clockwise. FIG. 11 is an end view of exercise roller 38 of FIG. 9 showing end surface 52. FIG. 12 is a side view of exercise roller 38 of FIG. 9 illustrating length 51 of insert 40 relative to width 14 of fiat mat 2. Insert 40 can be constructed of foam or styro-foam. Diameter 48 of insert 40 is substantially equivalent to length 46 of semi-circular projection portion of flat mat 2 (see FIG. 1) plus overlapping end section 50, which is the longer of either top surface cutout length 24 or bottom surface cutout length 28, or diameter 35. Length 51 of insert 40 can be substantially equal to or greater than width 14 of flat mat 2. FIG. 12 illustrates length 51 being greater than width 14. The embodiment where length 51 equals width 14, which effectively eliminates opposing ends 42, 44 without semi-circular projections 6, such that ends 52 are substantially adjacent to semi-circular projections 6.

[0079] Yet another embodiment of the present invention is a monolithic exercise roller 54 illustrated in FIGS. 13-14 showing a cylinder 53 having diameter 57 that can be constructed of foam, styro-foam, TPE, SEBS, PU and Urethane Gels, as well as silicone materials, with Colloidal Silver additives suspended therein. Outer surface 56 of cylinder 53 has raised geometry 58 that traverses the entire circumference 55 in various dimensional shapes and designs including but not limited to raised semi-circular bumps or projections as shown in FIGS. 13-14 in close proximity of and adjacent to the outer edges 62, 64. This monolithic structure eliminates the need to wrap a substrate with the Colloidal Silver suspended therein around the perimeter of the cylinder.

[0080] Yet another embodiment of the present invention is a monolithic exercise roller 54 illustrated in FIGS. 13-14 showing a cylinder 53 having diameter 57 that can be constructed of foam, styro-foam, TPE, SEBS, PU and Urethane Gels, as well as silicone materials, with Colloidal Silver additives suspended therein. Outer surface 56 of cylinder 53 has raised geometry 58 that traverses the entire circumference 55 in various dimensional shapes and designs including but not limited to raised semi-circular bumps or projections as shown in FIGS. 13-14 in close proximity of and adjacent to the outer edges 62, 64. This monolithic structure eliminates the need to wrap a substrate with the Colloidal Silver suspended therein around the perimeter of the cylinder.

[0081] Examples of flat mat 2 can have total lengths defined as the sum of top surface cutout length 24, bottom surface cutout length 28, and semicircular projection portion length 46 about 18 inches to about 26 inches. Flat mat 2 can have widths about 14 inches to about 40 inches. However, lengths and widths longer or shorter are acceptable.

[0082] Examples of the exercise rollers 38, 54 can have lengths about 14 inches to about 40 inches and diameters about 6 inches to about 8 inches. However, lengths longer or shorter and diameters larger or smaller are acceptable.

[0083] FIG. 15A is a side view of the present invention in the form of a flat mat 66 without a plurality of semi-circular projections arranged in rows. FIG. 15B is a perspective view of the flat mat 66.

[0084] FIGS. 16A is a side view of the present invention in the form of a block 68 without a plurality of semi-circular projections arranged in rows. FIG. 16B is a perspective view of the block 68. An alternative embodiment of block 68 can include a plurality of semi-circular projections arranged in rows.

[0085] FIG. 17 is a perspective view of the present invention in the form of a Pilates mat 70 with a plurality of semi-circular projections 6 arranged in rows 8.

[0086] FIGS. 18A-B illustrate an alternative embodiment illustrating an alternative mat 138 with projections 140 having a square base section 142 with sides 44 that rise upward to blend with a semi-circular top section 146.

[0087] FIG. 19 illustrates a wedge-shaped exercise device 100 that can be made of the gelatinous material disclosed above or any commercially available foam product. Wedge-shaped exercise device 100 can have any width Wl, sides S, length LI, and height H. Wedge-shaped exercise device 100 is shown in Fig. 19 elevated over exercise mat 102 having width W2, length L2, and thickness T. An example of a wedge-shaped exercise devices 100 has Wl= 18 inches, S = 12 inches, L = 14 inches. An example of an accompanying exercise mat 102 has W2 = 22 inches, L2 = 68 inches, T = 3/8 inches. [0088] Yet another antimicrobial colloidal silver product according to the present invention is a shoe insert (not shown).

[0089] Alternative embodiments of the present invention for all products can be capability of generating heating. The products can be microwaveable or include induction heating elements power by AC or DC sources. The induction heating elements can either be embedded within the gel material of the formed product or attached to an outer surface of the formed product. The maximum temperature of the heating element is less than the boiling point of material, depending on the composition of the gel material.

[0090] Further alternative embodiments of the present invention for all products can be capable of being cooled to greater than the freezing point of the gel material such that the properties of malleability and cushioning are still present. The freezing point ranges depends on the composition of the gel material. The product can be place in the refrigerator or freezer to achieve the desired cooling temperature.

[0091] Embodiments of the present invention can be formed from of other polymer materials with silver or gold additives for creating bacteria-free antimicrobial areas in multi-use or multi-person facilities, such as gyms, hotels, food courts, restaurants, cruise ships. The various embodiments include coated polymer sheets, polymer trays, bamboo and/ or cotton towels and fabric, polymer foam, or polymer mats containing nano-silver or nano-gold.

[0092] One example of a present invention embodiment is a physical surface that can kill existing bacteria and / or prevent the growth of new bacteria,. This surface is made of either natural fibers, man-made fibers, or polymers and is treated with an anti-microbial, in particular nano-silver particles, that are either added to the polymer directly, added to the dye used in the production of the natural fiber products, or added to a coating which is then used to coat the natural fiber, man-made fibers, or polymer products. The present invention embodiment may be designed in a number of shapes and sizes (see Figs. 20A-B, 22A-B, 23A-B), and may resemble, but are not limited to traditional items such as bath mats, rugs, towels, fabrics, shower curtains, bed linens, drawer liners, bag and luggage liners, trays (see Figs. 21A-B), place mats, and tablecloths. The present invention embodiment may also be in the form of polymer sheets similar to pieces of paper with or without adhesive on one side for use. The silver or gold concentration of any embodiment formulations of the embodiments disclosed herein are about 200 to about 2000 PPM. For example:

[0093] Anti-microbial towels 102 can be made from bamboo, cotton, and /or polyester with industrial dye mixed with nano-silver or gold in a concentration about 200 to about 2000 PPM in the dye. FIGS. 20A-B illustrate the general rectangular shape of the towel 102 having a length XI and width Yl, wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements.

[0094J Anti-microbial food tray 104 can be made of a polypropylene with colorants mixed with nano-silver or gold in a concentration about 200 to about 2000 PPM in the colorants. FIGS. 21A-B illustrate the general rectangular shape, of the tray 104 having a length X2 and width Y2, wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements.

[0095] Liners 106, 108 for items including but not limited to bags or dresser or cabinet drawers includes coated polyester paper stock including nano-silver or gold in a concentration about 200 to about 2000 PPM blended with a resin solution and coated onto the polyester to form a layered antimicrobial structure on the paper stock.

[0096] FIGS. 22A-B and 23A-B illustrate the general rectangular and oval shapes, respectively, of the polyester coated paper stock, liners, and other present invention embodiment 106, 108 having lengths X3, X4 and widths Y3, Y4, respectively, wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements.

[0097] FIGS. 24A-B illustrate the general rectangular shape of a bench of another embodiment of the present invention embodiment 110 having a length X5 and a width Y5 wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements.

[0098] FIGS. 25A-B and 25C-D illustrate the general rectangular shapes of a chair arm liners of another embodiment of the present invention embodiment 112, 114 having lengths X6 and widths Y6, respectively, wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements. The corners of chair arm liners 112 are rounded. The corners of chair arm liners 114 are square.

[0099] FIGS. 26A-B illustrate the general rectangular shape of a bench of another embodiment of the present invention embodiment 116 having a length X7 and a width Y7 wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements.

[00100] FIGS. 27A-B illustrate the general rectangular shape of a bench of another embodiment of the present invention embodiment 118 having a length X8 and a width Y8 wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements.

[00101] FIGS. 28A-B illustrate the general rectangular shape of a seat back cover and seat bottom cover, respectively, of another embodiment of the present invention embodiment 120, 122 having lengths X9, X10, respectively, and widths Y9, YIO, respectively, wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements. FIG. 28C is a perspective view of the seat front and seat back relatively placed in position for use. [00102] FIGS. 29A-B illustrate the general rectangular shape of a shower liner of another embodiment of the present invention embodiment 124 having a length XI 1 and a width Yl l wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements.

[00103] FIGS. 30A-B and 30C-D illustrate the general rectangular and circular shapes, respectively, of the table clothes of another embodiment of the present invention embodiment 126, 128 having a length X12 and a width Y12, and a diameter D13, respectively, wherein the length, width, and thickness (not shown) can be any dimensions to meet customer or user requirements.

[00104] While the disclosure has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the embodiments. Thus, it is intended that the present disclosure cover the modifications and variations of this disclosure provided they come within the scope of the appended claims and their equivalents