Title of Invention

SILVER-BASED INORGANIC ANTIMICROBIAL AGENT AND ANTIMICROBIAL PRODUCT THEREOF

Abstract A silver-based inorganic antimicrobial agent represented by Formula [1] below AgaMbZrc(PO4)3nH2O [1] Wherein : M is at least one type of ion selected from an alkali metal ion, such as herein described, a hydrogen ion, and an ammonium ion, a, b, and c are positive numbers and satisfy 1.5 < c < 2 and a + b + 4c = 9, and n is no greater than 2. The present invention is also directed to an antimicrobial product comprising the said silver-based inorganic antimicrobial agent.
Full Text

Technical Field
[0001]
The present invention relates to a silver-supporting zirconium phosphate;
this is a novel silver-based inorganic antimicrobial agent that has excellent heat
resistance, chemical resistance, and processability and that gives little
discoloration when mixed with a plastic. Furthermore, the present invention
relates to an antimicrobial product comprising the silver-based inorganic
antimicrobial agent.
Background Art
[0002]
In recent years, zirconium phosphate-based inorganic ion exchangers
have been utilized in various applications by making use of their characteristics.
With regard to the zirconium phosphate-based inorganic ion exchangers, there
are amorphous ones, crystalline ones having a 2-dimensional layer structure, and
crystalline ones having a 3-dimensional network structure. Among them,
hexagonal zirconium phosphate, which has a 3-dimensional network structure, is
excellent in terms of heat resistance, chemical resistance, radiation resistance,
low thermal expansion properties, etc., and is applied to the immobilization of
radioactive waste, solid electrolytes, gas adsorbing/separating agents, catalysts,
antimicrobial agent starting materials, etc.
[0003]
Various hexagonal zirconium phosphates are known to date. Examples
thereof include AxNH4(1-x)Zr2(PO4)3nH2O (ref. e.g. Patent Publication 1),
AZr2(PO4)3nH2O (ref. e.g. Patent Publication 2), and HnR1-nZr2(PO4)3mH2O (ref.
e.g. Patent Publication 3).
Zirconium phosphates in which the ratio of Zr to P varies are also known.
Examples thereof include Na1+4xZr2-x(PO4)3 (ref. e.g. Nonpatent Publication 1),
Na1+2xMgxZr2-x(PO4)3 (ref. e.g. Nonpatent Publications 1 and 2), and

Na1+xZr2SixP3-xO12 (ref. e.g. Nonpatent Publications 2 and 3).
[0004]
With regard to a process for synthesizing these hexagonal zirconium
phosphates, a calcination method in which synthesis is carried out by mixing
starting materials and then calcining the mixture at 1,000°C or higher using a
calcining furnace, etc., a hydrothermal method in which synthesis is carried out by
mixing starting materials in water or in a state in which they contain water and then
heating under pressure, a wet method in which synthesis is carried out by mixing
starting materials in water and then heating at normal pressure, etc. are known.
[0005]
Among these methods, the calcination method enables zirconium
phosphate having an appropriately adjusted P/Zr ratio to be synthesized just by
mixing starting materials and heating them at high temperature. However, in the
calcination method it is not easy to mix the starting materials uniformly, and it is
difficult to get a zirconium phosphate having a homogeneous composition.
Furthermore, since it is necessary to carry out grinding and classification after
calcination in order to obtain particles, there are problems with quality and
productivity. Moreover, it is obviously impossible to synthesize a crystalline
zirconium phosphate containing ammonia by the calcination method. On the
other hand, the wet method and the hydrothermal method can give homogeneous
fine particulate zirconium phosphate, but apart from one having a P/Zr ratio of 1.5,
and one having a P/Zr ratio of 2 represented by Formula [3] below, no crystalline
zirconium phosphate is known.
NH4ZrH(PO4)2 [3]
[0006]
Silver, copper, zinc, tin, mercury, lead, iron, cobalt, nickel, manganese,
arsenic, antimony, bismuth, bariµm, cadmiµm, chromiµm, etc. ions have for a long
time been known as metal ions that exhibit antimold properties, antimicrobial
properties, and antialgal properties (hereinafter, abbreviated to antimicrobial
metal ions). In particular silver ion is widely used as a silver nitrate aqueous
solution having a disinfecting action and a sterilizing action. However, many of

the above-mentioned metal ions that exhibit antimold properties, antimicrobial
properties, or antialgal properties are harmful to the human body; there are
various restrictions on the application method, storage method, disposal method,
etc., and, their applications are also limited.
[0007]
In order to exhibit antimold properties, antimicrobial properties, and
antialgal properties, it is sufficient to apply a trace amount of antimicrobial metal
to an application target. Because of this, there have been proposed as
antimicrobial agents having antimold properties, antimicrobial properties, and
antialgal properties an organic supported antimicrobial agent having an
antimicrobial metal ion supported on an ion-exchange resin, a chelate resin, etc.
and an inorganic antimicrobial agent having an antimicrobial metal ion supported
on a clay mineral, an inorganic ion-exchanger, or a porous body.
[0008]
With regard to the above-mentioned various types of antimicrobial agents,
compared with the organic supported type inorganic antimicrobial agents have the
advantages of higher safety, a longer lasting antimicrobial effect and, moreover,
excellent heat resistance.
As one of the inorganic antimicrobial agents, an antimicrobial agent in
which alkali metal ions such as sodium ions in a clay mineral such as
montmorillonite or zeolite are ion-exchanged with silver ions is known. Since the
skeleton structure of the clay mineral itself has poor acid resistance, silver ions
are easily leached in, for example, an acidic solution, and the antimicrobial effect
does not last long.
Furthermore, since silver ions are unstable toward exposure to heat and
light and are easily reduced to metallic silver, there are problems with long-term
stability, such as coloration being caused.
[0009]
In order to increase the silver ion stability, there is one in which silver ions
and ammonium ions are supported on a zeolite by ion-exchanging so that they
coexist. However, the prevention of coloration does not reach a practical level

even in this system, and a fundamental solution to the problem has yet to be
found.
Furthermore, as another inorganic antimicrobial agent, there is an
antimicrobial agent having an antimicrobial metal supported on an adsorptive
active carbon. However, in this agent since a soluble antimicrobial metal salt is
only physically adsorbed or attached, when contacted with moisture the
antimicrobial metal ion is rapidly leached, and the antimicrobial effect does not
last long.
[0010]
Recently, an antimicrobial agent having antimicrobial metal ions supported
on a special zirconium phosphate salt has been proposed. For example, one
represented by Formula [4] below is known (ref. e.g. Patent Publication 4).
M1M2xHyAz(PO4) 2nH2O [4]
(In Formula [4], M1 is one type selected from 4-valent metals, M2 is one type
selected from silver, copper, zinc, tin, mercury, lead, iron, cobalt, nickel,
manganese, arsenic, antimony, bismuth, bariµm, cadmiµm, and chromiµm, A is
one type selected from alkali metal ions and alkaline earth metal ions, n is a value
satisfying O This antimicrobial agent is known as a material that is chemically and
physically stable and exhibits antimold and antimicrobial properties for a long
period of time. However, when it is kneaded with a synthetic resin such as nylon,
the entire resin might be colored, the processability is poor due to the particle size,
and it cannot be used as a product.
[0011]
[Patent Publication 1] JP-A-6-48713 (JP-A denotes a Japanese unexamined
patent application publication.)
[Patent Publication 2] JP-A-5-17112
[Patent Publication 3] JP-A-60-239313
[Patent Publication 4] JP-A-3-83906
[Nonpatent Publication 1] C. JAGER and three others, '31P and 29Si NMR

Investigatios of the Structure of NASICON-Strukturtyps', Expermentelle Technik
der Physik, 1988, Vol. 36, No. 4/5, p339-348
[Nonpatent Publication 2] C. JAGER and two others, '31P MAS NMR STUDY
OF, THE NASICON SYSTEM Na1+4yZr2-y(PO4)3 Chemical Physics Letters, 1988,
Vol. 150, No. 6, p503-505
[Nonpatent Publication 3] H. Y-P. HONG, 'CRYSTAL STRUCTURE AND
CRYSTAL CHEMISTRY IN THE SISTEM Na1+xZr2SixP3-xO12 Mat. Res. Bull., Vol.
11,p173-182
Disclosure of Invention
Problems to be Solved by the Invention
[0012]
The present invention is to provide a silver-based inorganic antimicrobial
agent that has excellent heat resistance and chemical resistance, that gives little
resin coloration, and that has excellent processability, and to provide an
antimicrobial product employing same.
Means for Solving the Problems
[0013]
As a result of an intensive investigation by the present inventors in order to
solve the above-mentioned problems, it has been found that the problems can be
solved by a silver ion-containing zirconium phosphate represented by Formula [1]
below, and the present invention has thus been accomplished. The
above-mentioned silver ion-containing zirconium phosphate is suitably produced
by wet synthesis.
AgaMbZrc(PO4)3.nH2O [1]
In Formula [1], M is at least one type of ion selected from an alkali metal
ion, a hydrogen ion, and an ammonium ion, a, b, and c are positive numbers and
satisfy 1.5 [0014]
Furthermore, the present invention is preferably a silver-based inorganic

antimicrobial agent having silver ions supported on a zirconium phosphate
represented by Formula [2] below.
Mb1Zrc(PO4)3.nH2O [2]
In Formula [2], M is at least one type of ion selected from an alkali metal
ion, a hydrogen ion, and an ammonium ion, b1 and c are positive numbers and
satisfy 1.5 Furthermore, the present invention is preferably a silver-based inorganic
antimicrobial agent employing a zirconium phosphate prepared by a wet synthesis
method using greater than 1.5 but less than 2 moles of phosphoric acid or a salt
thereof relative to 1 mole of a zirconium compound.
Moreover, the present invention is an antimicrobial product containing the
above-mentioned silver-based inorganic antimicrobial agent.
Effects of the Invention
[0015]
The silver-based inorganic antimicrobial agent of the present invention has
excellent antimicrobial activity and discoloration resistance properties compared
with existing zirconium phosphate-based antimicrobial agents.
Best Mode for Carrying Out the Invention
[0016]
The present invention is explained below. The silver-based inorganic
antimicrobial agent of the present invention is represented by Formula [1] above.
[0017]
Examples of the alkali metal ion denoted by M in Formula [1] include Li, Na,
K, Rb, and Cs, and it may be used on its own or in a combination of a plurality of
types. Particularly preferred alkali metal ions are Na ions and K ions from the
viewpoint of ion-exchangeability and ease of synthesis, and Na ions are more
preferable.
M in Formula [1] is at least one type selected from the group consisting of
an alkali metal ion, a hydrogen ion, and an ammonium ion, is preferably one

having an alkali metal ion, a hydrogen ion, and an ammonium ion, and is more
preferably one having an alkali metal ion and a hydrogen ion.
[0018]
IN Formula [1], a is O at least 0.03, and in addition a is preferably no greater than 1, and more preferably
no greater than 0.6. When a is less than 0.01, sufficient antimicrobial properties
might not be exhibited.
[0019]
In Formula [1], b is O at least 0.3. It is not preferable for b to be less than 0.1 since discoloration easily
occurs in some cases. Furthermore, b is less than 3, preferably less than 2,
more preferably no greater than 1.8, yet more preferably no greater than 1.72, and
particularly preferably no greater than 1.5.
[0020]
In Formula [1], b is the total number of alkali metal, hydrogen, and/or
ammonium ions. When there is an ammonium ion, there is a case in which no
hydrogen ion is present, but when comparing alkali metal ions and hydrogen ions,
it is preferable that there are more hydrogen ions.
When there is no ammonium ion, there is a case in which no hydrogen ion
is present, but when comparing alkali metal ions and hydrogen ions, it is
preferable that there are more hydrogen ions. When there is no ammonium ion,
it is preferable for hydrogen ion to be present.
[0021]
In the present invention, the alkali metal ion is preferably less than 2 in
Formula [1], more preferably less than 1.8, and yet more preferably less than 1.4,
and it is preferably at least 0.01, more preferably at least 0.03, and yet more
preferably at least 0.05.
In the present invention, the hydrogen ion is preferably less than 2 in
Formula [1], more preferably less than 1.8, and yet more preferably less than 1.4,
and it is preferably at least 0.01, more preferably at least 0.03, and yet more
preferably at least 0.05.

In the present invention, the ammonium ion is preferably less than 1 in
Formula [1], more preferably less than 0.8, and yet more preferably less than 0.4,
and it is preferably at least 0.01, more preferably at least 0.03, and yet more
preferably at least 0.05.
[0022]
In Formula [1], c is 1.5 preferably at least 1.8, and is yet more preferably at least 1.82. Furthermore, c is
preferably less than 1.99, more preferably no greater than 1.98, and yet more
preferably no greater than 1.97.
It is not preferable for c to be 1.5 or less since it is difficult to obtain a
homogeneous zirconium phosphate represented by Formula [2] in some cases.
[0023]
In Formula [1], n is no greater than 2, preferably no greater than 1, more
preferably 0.01 to 0.5, and yet more preferably 0.03 to 0.3. It is not preferable for
n to be greater than 2 since the absolute amount of moisture contained in the
silver-based inorganic antimicrobial agent of the present invention is large and
foaming or hydrolysis might occur during processing, etc.
[0024]
As a zirconium phosphate used when synthesizing the silver-based
inorganic antimicrobial agent of the present invention, it is preferable to use a
zirconium phosphate represented by Formula [2] above.
In Formula [2], M is at least one type of ion selected from the group
consisting of an alkali metal ion, a hydrogen ion, and an ammonium ion. b1 and c
are positive numbers that satisfy 1.5 than 2.
[0025]
A process for synthesizing a zirconium phosphate represented by Formula
[2] is a wet method in which various types of starting materials are reacted in an
aqueous solution. Specifically, an aqueous solution containing a zirconium
compound, ammonia or a salt thereof, oxalic acid or a salt thereof, phosphoric
acid or a salt thereof, etc. at predetermined amounts is adjusted so as to have a

pH of no greater than 4 and then heated at a temperature of at least 70°C, thus
carrying out synthesis. The zirconium phosphate thus synthesized is further
filtered, washed well with,water, then dried, and lightly ground, thus giving white
fine particulate zirconium phosphate.
[0026]
Examples of a zirconium compound that can be used as a starting material
for the synthesis of a zirconium phosphate represented by Formula [2] include
zirconium nitrate, zirconium acetate, zirconium sulfate, basic zirconium sulfate,
zirconium oxysulfate, and zirconium oxychloride, and zirconium oxychioride is
preferable from the viewpoint of reactivity, economy, etc.
[0027]
Examples of ammonia or a salt thereof that can be used as a starting
material for the synthesis of a zirconium phosphate represented by Formula [2]
include ammonium chloride, ammonium nitrate, ammonium sulfate, aqueous
ammonia, ammonium oxalate, and ammonium phosphate, and ammonium
chloride and aqueous ammonia are preferable.
[0028]
Examples of oxalic acid or a salt thereof that can be used as a starting
material for the synthesis of a zirconium phosphate represented by Formula [2]
include oxalic acid dihydrate, sodium oxalate, ammonium oxalate, sodium
hydrogen oxalate, and ammonium hydrogen oxalate, and oxalic acid dihydrate is
preferable.
[0029]
As phosphoric acid or a salt thereof that can be used as a starting material
for the synthesis of a zirconium phosphate represented by Formula [2], a soluble
or acid-soluble salt is preferable; examples thereof include phosphoric acid,
sodium phosphate, potassium phosphate, and ammonium phosphate, and
phosphoric acid is more preferable. The concentration of the phosphoric acid is
preferably on the order of 60% to 85%.
[0030]
The molar ratio of phosphoric acid or a salt thereof to the zirconium

compound (the zirconium compound being 1) when synthesizing a zirconium
phosphate represented by Formula [2] is greater than 1.5 but less than 2,
preferably from 1.51 to less, than 1.71, more preferably 1.52 to 1.67, and
particularly preferably 1.52 to 1.65.
That is, the process for synthesizing a zirconium phosphate represented
by Formula [2] is preferably a wet method in which the number of moles of
phosphoric acid or a salt thereof per mole of zirconium compound is greater than
1.5 but less than 2.
[0031]
Furthermore, the molar ratio of phosphoric acid or a salt thereof to
ammonia or a salt thereof (ammonia or a salt thereof being 1) when synthesizing a
zirconium phosphate represented by Formula [2] is preferably 0.3 to 10, more
preferably 1 to 10, and particularly preferably 2 to 5.
That is, the process for synthesizing a zirconium phosphate represented
by Formula [2] is a wet method in which ammonia or a salt thereof is used.
[0032]
The molar ratio of phosphoric acid or a salt thereof to oxalic acid or a salt
thereof (oxalic acid or a salt thereof being 1) when synthesizing a zirconium
phosphate represented by Formula [2] is preferably 1 to 6, more preferably 1.5 to
5, yet more preferably 1.51 to 4, and particularly preferably 1.52 to 3.5.
That is, the process for synthesizing a zirconium phosphate represented
by Formula [2] is a wet method in which oxalic acid or a salt thereof is used.
[0033]
The solids concentration of a reaction slurry when synthesizing a
zirconium phosphate represented by Formula [2] is preferably at least 3 wt %, and
more preferably from 7% to 15 wt % from the viewpoint of economic etc. efficiency.
[0034]
The pH when synthesizing a zirconium phosphate represented by Formula
[2] is preferably at least 1 but no greater than 4, more preferably 1.5 to 3.5, yet
more preferably 2 to 3, and particularly preferably 2.2 to 3. It is not preferable for
the pH to be greater than 4 since a zirconium phosphate represented by Formula

[2] cannot be synthesized in some cases. It is not preferable for the pH to be less
than 1 since a zirconium phosphate represented by Formula [2] cannot be
synthesized in some cases For adjustment of the pH, it is preferable to use
sodium hydroxide, potassium hydroxide, aqueous ammonia, etc., and it is more
preferable to use sodium hydroxide.
[0035]
The synthesis temperature when synthesizing a zirconium phosphate
represented by Formula [2] is preferably at least 70°C, more preferably at least
80°C, yet more preferably at least 90°C, and particularly preferably at ieast 95°C.
Furthermore, the synthesis temperature is preferably no higher than 150°C, and
more preferably no higher than 120°C. It is not preferable for the temperature to
be less than 70°C since the zirconium phosphate of the present invention cannot
be synthesized in some cases. It is not preferable for the temperature to be
higher than 150°C since it is disadvantageous in terms of energy.
[0036]
It is desirable to carry out stirring when synthesizing a zirconium
phosphate represented by Formula [2] so that the starting materials are
homogenously mixed and the reaction proceeds uniformly.
The time for synthesis of a zirconium phosphate represented by Formula
[2] depends on the synthesis temperature. For example, the time for synthesis of
the zirconium phosphate of the present invention is preferably at least 4 hours,
more preferably 8 to 72 hours, and yet more preferably 1O to 48 hours.
[0037]
As a zirconium phosphate represented by Formula [2], it is possible to
synthesize one having a median diameter of 0.1 to 5 urn. The median diameter
of a zirconium phosphate represented by Formula [2] is preferably 0.1 to 5 µrn,
more preferably 0.2 to 3 µm, and yet more preferably 0.3 to 2 µm. When the
processability into various types of products is taken into consideration, not only
the median diameter but also the maximum particle diameter and the spread are
important. From this point, the maximum particle diameter of a zirconium
phosphate represented by Formula [2] is preferably no greater than 10 µm, and

more preferably no greater than 8 µm, and it is particularly preferable for it to be
no greater than 6 urn since an effect can be exhibited. The standard deviation for
the median diameter is preferably no greater than 1, and it is more preferable for it
to, be no, greater than 0.5 since an effect can be exhibited more effectively.
Furthermore, a silver-based inorganic antimicrobial agent represented by
Formula [1], which is obtained by subjecting a zirconium phosphate represented
by Formula [2] to silver ion exchange, preferably has the same median diameter,
maximum particle diameter, and standard deviation as those of the zirconium
phosphate of Formula [2] above. Since there is hardly any change in the median
diameter, the maximum particle diameter, and the standard deviation as a result of
silver ion exchange, by setting the median diameter, the maximum particle
diameter, and the standard deviation of the zirconium phosphate represented by
Formula [2] so as to be in the above-mentioned ranges it is possible to set the
median diameter, the maximum particle diameter, and the standard deviation of
the silver-based inorganic antimicrobial agent represented by Formula [1] in
desired ranges.
[0038]
As examples of zirconium phosphates represented by Formula [2], which
can be used as starting materials for the silver-based inorganic antimicrobial
agent of the present invention, those listed below can be cited. However, since
those having ammonium ion have low ion-exchangeability, when a high silver ion
exchange rate is required, the ammonium ion may be eliminated by carrying out
calcination, etc. as necessary, thus giving an H type, which has high
ion-exchangeability.
(NH4)1.4Zr1.9(PO4)30.05H2O
(NH4)1.24Zr1.94(PO4)30.15H2O
Na0.6(NH4)0.84Zr1.89(PO4)3:0.3H2O
Na(NH4)0.44Zr1.89(PO4)30.2H2O
Na0.6H0.3(NH4)0.42Zr1.92(PO4)3-0.2H2O
K0.92(NH4)0.44Zr1.91(PO4)3.0.1H2O
Na0.72(NH4)Zr1.82(PO4)3-0.2H2O

Na0.3H0.34(NH4)Zr1.84(PO4)3.0.1H2O
Na(NH4)0.76Zr1.81(PO4)3.0.1H2O
Na0.6H0.4(NH4)0.6Zr1.85(PO4)3-0.3H2O
Na1.2Zr1.95(PO4)3.0.1H2O
Na0.24H1.36Zr1.85(PO4)3.0.11H2O
H1.4Zr1.9(PO4)3.0.15H2O
K0.6H0.6Zr1.95(PO4)30.1H2O
Na1.12Zr1.97(PO4)3
NaH0.12Zr1.97(PO4)3
Na1.48Zr1.88(PO4)3
Na0.48HZr1.88(PO4)3
Na0.72HZr1.82(PO4)3
Na0.6H1.12Zr1.82(PO4)3
[0039]
In order to obtain the silver-based inorganic antimicrobial agent of the
present invention, it is necessary to subject a zirconium phosphate represented by
Formula [2] to silver ion exchange. A method for carrying out this silver ion
exchange may involve immersing a zirconium phosphate represented by Formula
[2] in an aqueous solution containing an appropriate concentration of silver ion.
It is preferable to carry out stirring, etc. during this immersion, thus making a
uniformly mixed state. The amount immersed may be a concentration that can
be mixed with the aqueous solution uniformly, and the zirconium phosphate
represented by Formula [2] is preferably no greater than 20 wt %. For the
preparation of an aqueous solution containing silver ions, it is preferable to use an
aqueous solution in which silver nitrate is dissolved in ion-exchanged water. The
temperature of the aqueous solution at the time of ion exchange may be 0°C to
100°C and is preferably 20°C to 80°C. Since this ion exchange takes place
quickly, the immersion time may be less than 5 min, but in order to obtain a
uniform and high silver ion exchange rate, it is preferably 3O min to 5 hours.
Even if this is carried out for 5 hours or more, there are cases in which silver ion
exchange does not progress further.

After completion of the silver ion exchange, this is washed well with
ion-exchanged water etc. and dried, thus giving the silver-based inorganic
antimicrobial agent of the, present invention.
[0040] ,
In order to improve the discoloration resistance of the silver-based
inorganic antimicrobial agent of the present invention, it is preferable to calcine
the silver-based inorganic antimicrobial agent obtained above. This calcination
for improving the discoloration resistance may be carried out prior to silver ion
exchange, but in order to obtain sufficient discoloration resistance, it is particularly
preferable to carry it out subsequent to silver ion exchange. The calcination
temperature is preferably 550°C to 1,000°C, more preferably 600°C to 900°C, and
yet more preferably 650°C to 800°C in order to improve the discoloration
resistance. The calcination time is preferably at least 1 hour, more preferably at
least 2 hours, and yet more preferably at least 4 hours in order to improve the
discoloration resistance. This calcination time is preferably no longer than 48
hours, and more preferably no longer than 36 hours.
After completion of the calcination, if left as it is for a long period of time,
there is a possibility of moisture absorption, and it is therefore preferable to cool
within 24 hours, and more preferably within 18 hours. Since the silver-based
inorganic antimicrobial agent of the present invention sometimes aggregates after
calcination, the aggregated material may be ground using a grinder. In this case,
taking into consideration moisture absorption, etc., the grinding time is better to be
short.
[0041]
Examples of the silver-based inorganic antimicrobial agent of the present
invention are as follows.
Ag0.2H1.2Zr1.9(PO4)3.0.05H2O
Ag0.1H1.14Zr1.94(PO4)-0.15H2O
Ag0.2Na0.4(NH4)0.84Zr1.89(PO4)3.0.3H2O
Ag0.3Na0.1H1.04Zr1.89(PO4)3.0.2H2O
Ag0.5Na0.2H0.3(NH4)0.32Zr1.92 (PO4)30.2H2O

Ag0.4K0.6H0.36Zr1.91(PO4)3.0.1H2O [0042]
The form of the silver-based inorganic antimicrobial agent of the present
invention when used is not particularly limited, and it may be mixed with another
component as appropriate according to the intended purpose or made into a
composite with another material. For example, the silver-based inorganic
antimicrobial agent of the present invention may be used in various forms such as
a powder, a powder-containing dispersion, powder-containing particles, a
powder-containing paint, a powder-containing fiber, a powder-containing paper, a
powder-containing plastic, a powder-containing film, or a powder-containing
aerosol and, moreover, various types of additives or materials such as a
deodorant, a flame retardant, a corrosion inhibitor, a fertilizer, or a building
material may be used in combination as necessary.
[0043]
The silver-based inorganic antimicrobial agent of the present invention
may contain various types of additives as necessary in order to improve the ease
of kneading into a resin or other physical properties. Specific examples thereof
include a pigment such as zinc oxide or titanium oxide, an inorganic
ion-exchanger such as zirconium phosphate or a zeolite, a dye, an antioxidant, a
light stabilizer, a flame retardant, an antistatic agent, a foaming agent, an impact
modifier, glass fiber, a lubricant such as a metal soap, a desiccant, a filler, a
coupling agent, a nucleating agent, a flowability improving agent, a deodorant,
wood flour, a fungicide, an antifoulant, a corrosion inhibitor, a metal powder, a UV
absorber, and a UV shielding agent.
[0044]
An antimicrobial resin composition can easily be obtained by adding the
silver-based inorganic antimicrobial agent of the present invention to a resin.
The type of resin that can be used is not particularly limited; the resin may be any
of a natural resin, a synthetic resin, and a semi-synthetic resin, and the resin may
be either a thermoplastic resin or a thermosetting resin. The resin may be any
one of a resin for molding, a resin for fiber, and a rubber resin, and specific

examples of the resin include resins for molding or fiber such as polyethylene,
polypropylene, vinyl chloride, ABS resin, AS resin, MBS resin, nylon resin,
polyester, polyvinylidene chloride, polystyrene, polyacetal, polycarbonate, PBT,
acrylic. resin, fluorine resin, polyurethane elastomer, polyester elastomer,
melamine, urea resin, ethylene tetrafluoride resin, unsaturated polyester resin,
rayon, acetate, acrylic, polyvinyl alcohol, cupra, triacetate, and vinylidene, and
rubber resins such as natural rubber, silicone rubber, styrene butadiene rubber,
ethylene propylene rubber, fluorine rubber, nitrile rubber, chlorosulfonated
polyethylene rubber, butadiene rubber, synthetic natural rubber, butyl rubber,
urethane rubber, and acrylic rubber. The silver-based inorganic antimicrobial
agent of the present invention may be formed into a composite with a fiber such as
a natural fiber, thus giving an antimicrobial fiber.
[0045]
The proportion of the silver-based inorganic antimicrobial agent of the
present invention in the antimicrobial resin composition is preferably 0.03 to 5
parts by weight relative to 10O parts by weight of the antimicrobial resin
composition, and more preferably 0.1 to 2.O parts by weight. If it is less than 0.03
parts by weight, the antimicrobial properties of the antimicrobial resin composition
might be insufficient, and on the other hand if it is present at more than 5 parts by
weight, there is hardly any further improvement of the antimicrobial effect, it is not
cost-effective, and the physical properties of the resin might be greatly degraded.
[0046]
A method for adding the silver-based inorganic antimicrobial agent of the
present invention to a resin and processing into a resin molding may be any
known method. For example, there are (1) a method in which an attachment
agent for enhancing the adhesion between a silver-based inorganic antimicrobial
agent powder and a resin or a dispersant for improving the dispersibility of the
antimicrobial agent powder is used, and mixing with the resin in the form of pellets
or a powder is carried out directly in a mixer, (2) a method in which mixing is
carried out as described above, the mixture is molded into pellets using an
extruder, and this molding is then added to resin pellets, (3) a method in which the

silver-based inorganic antimicrobial agent is molded into high concentration
pellets using a wax, and the pellets thus molded are then added to resin pellets,
and (4) a method in which a paste composition is prepared by mixing and
dispersing the silver-based inorganic antimicrobial agent in a highly viscous liquid
such as a polyol, and this paste is then added to resin pellets.
[0047]
When molding the above-mentioned antimicrobial resin composition, any
known processing techniques and equipment may be used, according to the
characteristics of various types of resins. Preparation can be easily carried out
by a mixing, addition, or kneading method while heating at an appropriate
temperature and applying an appropriate increased or decreased pressure;
specific operations may be carried out by a standard method, and moldings in
various forms such as lump, sponge, film, sheet, filament, pipe, or a composite
thereof may be obtained.
[0048]
The form in which the silver-based inorganic antimicrobial agent of the
present invention is used is not particularly limited, and it is not limited to being
added to a resin molding or a polymer compound. It may be mixed, according to
the intended purpose where antimold, antialgal, and antimicrobial properties are
required, with another component as appropriate or may be made into a
composite with another material. For example, it may be used in various forms
such as a powder, a powder-containing dispersion, granules, an aerosol, or a
liquid.
[0049]
Application
The silver-based inorganic antimicrobial agent of the present invention can
be used in various fields where antimold, antialgal, and antimicrobial properties
are required, that is, it can be used as an electrical appliance, a kitchen product, a
fiber product, a housing/building material product, a toiletry product, a paper
product, a toy, a leather product, stationery, and other products.
To illustrate more specific applications, examples of the electrical

appliances include dish washers, dish dryers, refrigerators, washing machines,
kettles, televisions, personal computers, radio cassettes, cameras, video cameras,
water purifiers, rice cookers, vegetable cutters, cash registers, bedding dryers,
faxes, ventilators, and air-conditioners, and examples of the kitchen products
include tableware, chopping boards, straw cutters, trays, chopsticks, teapots,
thermos flasks, knives, ladle handles, turners, lunch boxes, rice spoons, bowls,
colanders, sink strainers, scouring brush containers, bins, and draining bags.
[0050]
Examples of the fiber products include shower curtains, cotton batting,
air-conditioner filters, stockings, socks, napkins, sheets, bedding covers, pillows,
gloves, aprons, curtains, diapers, bandages, masks, and sportswear, and
examples of the housing/building materials include decorative boards, wall paper,
flooring boards, window films, handles, carpets, mats, artificial marble, handrails,
jointing, tiles, and waxes. Examples of the toiletry products include toilet seats,
bathtubs, tiles, chamber pots, bins, toilet brushes, bathtub covers, pumice stones,
soap containers, bathroom chairs, clothes baskets, showers, and washbasins,
examples of the paper products include wrapping paper, powder paper, medicine
boxes, sketch books, medical charts, exercise books, and origami paper, and
examples of the toys include dolls, soft toys, papier-mache, blocks, and puzzles.
[0051]
Examples of the leather products include shoes, bags, belts, watch straps,
interior products, chairs, gloves, and hanging straps, and examples of the
stationery include ball-point pens, mechanical pencils, pencils, erasers, crayons,
paper, notebooks, floppy disks, rulers, Post-it, and staplers. Examples of the
other products include insoles, cosmetics containers, scouring brushes, powder
puffs, hearing aids, musical instruments, cigarette filters, adhesive paper sheets
for cleaning, hanging strap handles, sponges, kitchen towels, cards, microphones,
hairdressing articles, vending machines, razors, telephones, medical
thermometers, stethoscopes, slippers, clothing cases, toothbrushes, sandpit sand,
food wrapping films, antimicrobial sprays, and paint.
[0052]

Examples
The present invention is explained below by reference to Examples, but
the present invention should not be construed as being limited thereby.
The median diameter was measured using laser diffraction type particle
size distribution on a volume basis, and the standard deviation was determined
from the measurement results.
The amount of zirconium was calculated by first dissolving a sample using a strong acid and subjecting this liquid to measurement with an ICP emission
spectrophotometer. The amount of phosphorus was calculated by first dissolving
a sample using a strong acid and subjecting this liquid to measurement with an
ICP emission spectrophotometer. The amounts of sodium and potassium were
calculated by first dissolving a sample using a strong acid and subjecting this
liquid to measurement with an atomic absorption spectrometer. The amount of
ammonia was calculated by first dissolving a sample using a strong acid and
subjecting this liquid to measurement by an indophenol method.
[0053]
Synthetic Example 1
After 0.1 mol of oxalic acid dihydrate, 0.195 mol of zirconium oxychloride
octahydrate, and 0.1 mol of ammonium chloride were dissolved in 30O mL of pure
water, 0.3 mol of phosphoric acid was added thereto while stirring. The pH of this
solution was adjusted to 2.7 using a 20% aqueous solution of sodium hydroxide,
and the solution was then stirred at 98°C for 14 hours. Subsequently, the
precipitate thus obtained was washed well and dried at 120°C, thus synthesizing a
zirconium phosphate compound.
When the compositional formula etc. of this zirconium phosphate
compound was measured, the compositional formula was
Na0.5(NH4)0.67Zr1.95(PO4)3.0.11H2O.
[0054]
Synthetic Example 2
After 0.1 mol of oxalic acid dihydrate, 0.19 mol of zirconium oxychloride
octahydrate, and 0.1 mol of ammonium chloride were dissolved in 30O mL of pure

water, 0.3 mol of phosphoric acid was added thereto while stirring. The pH of this
solution was adjusted to 2.7 using a 20% aqueous solution of sodium hydroxide,
and the solution was then stirred at 98°C for 14 hours. Subsequently, the
precipitate thus obtained was washed well and dried at 120°C, thus synthesizing a
zirconium phosphate compound.
When the compositional formula etc. of this zirconium phosphate
compound was measured, the compositional formula was
Na0.235(NH4)1.36Zr1.85(PO4)30.13H2O.
[0055]
Synthetic Example 3
After 0.1 mol of oxalic acid dihydrate, 0.19 mol of zirconium oxychloride
octahydrate, and 0.15 mol of ammonium chloride were dissolved in 30O mL of pure
water, 0.3 mol of phosphoric acid was added thereto while stirring. The pH of this
solution was adjusted to 2.7 using a 20% aqueous solution of sodium hydroxide,
and the solution was then stirred at 98°C for 14 hours. Subsequently, the
precipitate thus obtained was washed well and dried at 120°C, thus synthesizing a
zirconium phosphate compound.
When the compositional formula etc. of this zirconium phosphate
compound was measured, the compositional formula was
Na0.54(NH4)0.86Zr1.9(PO4)3.0.12H2O.
[0056]
Synthetic Example 4
After 0.1 mol of oxalic acid dihydrate, 0.195 mol of zirconium oxychloride
octahydrate, and 0.11 mol of ammonium chloride were dissolved in 30O ml_ of pure
water, 0.3 mol of phosphoric acid was added thereto while stirring. The pH of this
solution was adjusted to 2.9 using a 20% aqueous solution of sodium hydroxide,
and the solution was then stirred at 98°C for 14 hours. Subsequently, the
precipitate thus obtained was washed well and dried at 120°C, thus synthesizing a
zirconium phosphate.
When the compositional formula etc. of this zirconium phosphate was
measured, the compositional formula was

Na0.5(NH4)0.7Zr1.95(PO4)30.1H2O,
and the median diameter was 0.45 |jm.
[00571
Synthetic Example 5
After 0.1 mol of oxalic acid dihydrate, 0.185 mol of zirconium oxychloride
octahydrate, and 0.14 mol of ammonium chloride were dissolved in 30O mL of pure
water, 0.3 mol of phosphoric acid was added thereto while stirring. The pH of this
solution was adjusted to 2.9 using a 20% aqueous solution of sodium hydroxide,
and the solution was then stirred at 98°C for 14 hours. Subsequently, the
precipitate thus obtained was washed well and dried at 120°C, thus synthesizing a
zirconium phosphate.
When the compositional formula etc. of this zirconium phosphate was
measured, the compositional formula was
Na0.24(NH4)1.36Zr1.85(PO4)3.0.11H2O,
and the median diameter was 0.42 µm.
[0058]
Synthetic Example 6
After 0.1 mol of oxalic acid dihydrate and 0.19 mol of zirconium oxychloride
octahydrate were dissolved in 30O mL of pure water, 0.3 mol of phosphoric acid
was added thereto while stirring. The pH of this solution was adjusted to 2.9
using 28% aqueous ammonia, and the solution was then stirred at 98°C for 14
hours. Subsequently, the precipitate thus obtained was washed well and dried at
120°C, thus synthesizing a zirconium phosphate.
When the compositional formula etc. of this zirconium phosphate was
measured, the compositional formula was
(NH4)1.4Zr1.9(PO4)3.0.15H2O
and the median diameter was 0.3O µm.
[0059]
Synthetic Example 7
After 0.1 mol of oxalic acid dihydrate, 0.195 mol of zirconium oxychloride
octahydrate, and 0.07 mol of ammonium chloride were dissolved in 30O mL of pure

water, 0.3 mol of phosphoric acid was added thereto while stirring. The pH of this
solution was adjusted to 2.7 using a 20% aqueous solution of sodium hydroxide,
and the solution was then stirred at 98°C for 14 hours. Subsequently, the
precipitate thus obtained was washed well and dried at 120°C, thus synthesizing a
zirconium phosphate.
When the compositional formula etc. of this zirconium phosphate was
measured, the compositional formula was
Na0.8(NH4)0.4Zr1.95(PO4)3.0.09H2O
and the median diameter was 0.45 µm.
[0060]
Synthetic Example 8
After 0.1 mol of oxalic acid dihydrate and 0.195 mol of zirconium
oxychloride octahydrate were dissolved in 30O mL of pure water, 0.3 mol of
phosphoric acid was added thereto while stirring. The pH of this solution was
adjusted to 2.7 using a 20% aqueous solution of sodium hydroxide, and the
solution was then stirred at 98°C for 14 hours. Subsequently, the precipitate thus
obtained was washed well and dried at 120°C, thus synthesizing a zirconium
phosphate.
When the compositional formula etc. of this zirconium phosphate was
measured, the compositional formula was
Na1.2Zr1.95(PO4)3.0.1H2O
and the median diameter was 0.44 µm.
[0061]
Synthetic Example 9
After 0.1 mol of oxalic acid dihydrate, 0.185 mol of zirconium oxychloride
octahydrate, and 0.14 mol of ammonium chloride were dissolved in 30O mL of pure
water, 0.3 mol of phosphoric acid was added thereto while stirring. The pH of this
solution was adjusted to 2.9 using a 20% aqueous solution of sodium hydroxide,
and the solution was then stirred at 98°C for 14 hours. Subsequently, the
precipitate thus obtained was washed well, dried at 120°C, and further calcined at
700°C for 4 hours, thus synthesizing a zirconium phosphate.

When the compositional formula etc. of this zirconium phosphate was
measured, the compositional formula was
- Na0.24H1.36Zr1.85(PO4)3.0.11H2O,
and the median diameter was 0.43 µm.
[0062]
Synthetic Example 10
After 0.1 mol of oxalic acid dihydrate and 0.19 mol of zirconium oxychloride
octahydrate were dissolved in 30O mL of pure water, 0.3 mol of phosphoric acid
was added thereto while stirring. The pH of this solution was adjusted to 2.9
using 28% aqueous ammonia, and the solution was then stirred at 98°C for 14
hours. Subsequently, the precipitate thus obtained was washed well, dried at
120°C, and further calcined at 700°C for 4 hours, thus synthesizing a zirconium
phosphate.
When the compositional formula etc. of this zirconium phosphate was
measured, the compositional formula was
H1.4Zr1.9(PO4)3.0.15H2O
and the median diameter was 0.3O urn.
[0063]
Synthetic Example 11
After 0.1 mol of oxalic acid dihydrate, 0.195 mol of zirconium oxychloride
octahydrate, and 0.07 mol of ammonium chloride were dissolved in 300 mL of pure
water, 0.3 mol of phosphoric acid was added thereto while stirring.
The pH of this solution was adjusted to 2.7 using a 20% aqueous solution
of potassium hydroxide, and the solution was then stirred at 98°C for 14 hours.
Subsequently, the precipitate thus obtained was washed well, dried at 120°C, and
further calcined at 700°C for 4 hours, thus synthesizing a zirconium phosphate.
When the compositional formula etc. of this zirconium phosphate was
measured, the compositional formula was
K0.6H0.6Zr1.95(PO4)3.0.1H2O
and the median diameter was 0.45 µm.
[0064]

Example 1
0.09 mol of the zirconium phosphate synthesized in Synthetic Example 1
was added to 45O mL of a.1 N aqueous solution of nitric acid in which 0.004 mol of
silver nitrate had been dissolved, and the mixture was stirred at 60°C for 2 hours
so as to support silver. Subsequently, it was washed well, dried at 120°C, and
then calcined at 720°C for 4 hours. The powder after calcining was lightly ground,
thereby giving a silver-based inorganic antimicrobial agent of the present
invention. When the compositional formula of this silver-based inorganic
antimicrobial substance was measured, the compositional formula was
Ag0.07Na0.48H0.67Zr1.95(PO4)3.0.1H2O.
The median diameter (µm) of this silver-based inorganic antimicrobial
substance, the standard deviation of the median diameter, the maximum particle
diameter (µm), and the minimum inhibitory concentration (MIC, µg/mL) for E. coli
were measured, and the results are given in Table 1.
[0065]
Example 2
0.09 mol of the zirconium phosphate synthesized in Synthetic Example 2
was added to 45O mL of a 1 N aqueous solution of nitric acid in which 0.015 mol of
silver nitrate had been dissolved, and the mixture was stirred at 60°C for 2 hours
so as to support silver. Subsequently, it was washed well, dried at 120°C, and
then calcined at 720°C for 4 hours. The powder after calcining was lightly ground,
thereby giving a silver-based inorganic antimicrobial agent of the present
invention. When the compositional formula of this silver-based inorganic
antimicrobial substance was measured, the compositional formula was
Ag0.17Na0.07H1.36Zr1.85(PO4)30.11H2O.
The median diameter (µm) of this silver-based inorganic antimicrobial
substance, the standard deviation of the median diameter, the maximum particle
diameter (µm), and the minimum inhibitory concentration (MIC, µg/mL) for E. coli
were measured, and the results are given in Table 1.
[0066]
Example 3

0.09 mol of the zirconium phosphate synthesized in Synthetic Example 3
was added to 45O mL of a 1 N aqueous solution of nitric acid in which 0.045 mol of
silver nitrate had been dissolved, and the mixture was stirred at 60°C for 2 hours
so as to support silver. Subsequently, it was washed well, dried at 120°C, and
then calcined at 720°C for 4 hours. The powder after calcining was lightly ground,
thereby giving a silver-based inorganic antimicrobial agent of the present
invention. When the compositional formula of this silver-based inorganic
antimicrobial substance was measured, the compositional formula was
Ag0.44Na0.1H0.86Zr1.9(PO4)3.0.12H2O.
The median diameter (µm) of this silver-based inorganic antimicrobial
substance, the standard deviation of the median diameter, the maximum particle
diameter (µm), and the minimum inhibitory concentration (MIC, µg/mL) for E. coli
were measured, and the results are given in Table 1.
[0067]
Comparative Example 1
After 0.1 mol of oxalic acid dihydrate, 0.2 mol of zirconium oxychloride
octahydrate, and 0.05 mol of ammonium chloride were dissolved in 30O mL of pure
water, 0.3 mol of phosphoric acid was added thereto while stirring. The pH of this
solution was adjusted to 3.5 using a 20% aqueous solution of sodium hydroxide,
and the solution was then stirred at 98°C for 14 hours. Subsequently, the
precipitate thus obtained was washed well and then dried at 120°C, thus
synthesizing a zirconium phosphate.
0.09 mol of the zirconium phosphate synthesized above was added to 450
mL of a 1 N aqueous solution of nitric acid in which 0.004 mol of silver nitrate had
been dissolved, and the mixture was stirred at 60°C for 2 hours so as to support
silver. Subsequently, the precipitate thus obtained was washed well and dried at
120°C, and the powder after drying then lightly ground, thereby giving a
comparative silver-based inorganic antimicrobial agent. When the compositional
formula of this comparative silver-based inorganic antimicrobial substance was
measured, the compositional formula was
Ag0.07Na0.45(NH4)0.48Zr2(PO4)3.0.11H2O.

The median diameter (µm) of this comparative silver-based inorganic
antimicrobial substance, the standard deviation of the median diameter, the
, maximum particle diameter (µm), and the minimum inhibitory concentration (MIC,
ug/mL) for E. coli were measured, and the results are given in Table 1.
[0068]
Comparative Example 2
After 0.1 mol of oxalic acid dihydrate and 0.2 mol of zirconium oxychloride
octahydrate were dissolved in 30O mL of pure water, 0.3 mol of phosphoric acid
was added thereto while stirring. The pH of this solution was adjusted to 3.6
using a 20% aqueous solution of sodium hydroxide, and the solution was then
stirred at 98°C for 14 hours. Subsequently, the precipitate thus obtained was
washed well and dried at 120°C, thus synthesizing a zirconium phosphate.
0.09 mol of the zirconium phosphate synthesized above was added to 450
mL of a 1 N aqueous solution of nitric acid in which 0.015 mol of silver nitrate had
been dissolved, and the mixture was stirred at 60°C for 2 hours so as to support
silver. Subsequently, the precipitate thus obtained was washed well, dried at
120°C, and then calcined at 770°C for 4 hours. The powder after calcining was
lightly ground, thereby giving a comparative silver-based inorganic antimicrobial
agent. When the compositional formula of this comparative silver-based
inorganic antimicrobial substance was measured, the compositional formula was
Ag0.07Na0.45(NH4)0.48Zr2(PO4)30.11H2O.
The median diameter (µm) of this comparative silver-based inorganic
antimicrobial substance, the standard deviation of the median diameter, the
maximum particle diameter (µm), and the minimum inhibitory concentration (MIC,
µg/mL) for E. coli were measured, and the results are given in Table 1.
[0069]
Comparative Example 3
After 0.1 mol of oxalic acid dihydrate, 0.2 mol of zirconium oxychloride
octahydrate, and 0.05 mol of ammonium chloride were dissolved in 30O mL of pure
water, 0.3 mol of phosphoric acid was added thereto while stirring. The pH of this
solution was adjusted to 3.6 using a 20% aqueous solution of sodium hydroxide,

and the solution was then stirred at 98°C for 14 hours. Subsequently, the
precipitate thus obtained was washed well and dried at 120°C, thus synthesizing a zirconium phosphate.
0.09 mol of the zirconium phosphate synthesized above was added to 450
mL of a 1 N aqueous solution of nitric acid in which 0.045 mol of silver nitrate had
been dissolved, and the mixture was stirred at 60°C for 2 hours so as to support
silver. Subsequently, the precipitate thus obtained was washed well, dried at
120°C, and then calcined at 770°C for 4 hours. The powder after calcining was
lightly ground, thereby giving a comparative silver-based inorganic antimicrobial
agent. When the compositional formula of this comparative silver-based
inorganic antimicrobial substance was measured, the compositional formula was
Ag0.44Na0.22H0.34Zr2(PO4)3.0.11H2O.
The median diameter (µm) of this comparative silver-based inorganic
antimicrobial substance, the standard deviation of the median diameter, the
maximum particle diameter (µm), and the minimum inhibitory concentration (MIC,
µg/mL) for E. coli were measured, and the results are given in Table 1.
[0070]

[0071]
Example 4: Evaluation of molding
The silver-based inorganic antimicrobial agent obtained in Example 1 was
added at 0.15% to a Nylon 6 resin manufactured by Ube Industries, Ltd., and the
mixture was subjected to injection molding at 280°C to give a 2 mm thick plate,
thus giving a molding a. The L/a/b color values of this molding a and its color
difference AE from that of a plate to which no antimicrobial agent had been added

were measured using a colorimeter. The results are given in Table 2.
Furthermore, an antimicrobial property test was carried out using this injection-molded plate by a test method in accordance with JIS Z2801 5.2, Plastic
Products, etc. The antimicrobial activity value thus obtained is also given in
Table 2.
Similarly, moldings b and c and comparative moldings d to f were prepared
using the silver-based inorganic antimicrobial agents of Examples 2 and 3 and the
comparative silver-based inorganic antimicrobial agents of Comparative Examples
1 to 3. The color values and the antimicrobial activity of these moldings were
also measured, and the results are given in Table 2.
[0072]

[0073]
Example 5: Polyester spinning test
The silver-based inorganic antimicrobial agent prepared in Example 1 was
added at 1O wt % to a polyester resin (MA2103, manufactured by Unitika Ltd.) to
give a master batch. This master batch was then mixed with polyester resin
pellets to give an antimicrobial resin containing 1 wt % of the silver-based
inorganic antimicrobial agent. The antimicrobial resin was subjected to melt
spinning using a multifilament spinning machine at a spinning temperature of
275°C and a windup speed of 400O m/minute, and a 24 filament antimicrobial
agent-containing polyester fiber was wound up in drum form to give an
antimicrobial agent-containing polyester fiber (antimicrobial fiber a). Filament
formation properties were evaluated with respect to filter pressure increase,
filament breakage, and the state of wear of a ceramic guide made of alumina

during this process. The results are given in Table 3.
Similarly, an antimicrobial agent-containing polyester fiber (antimicrobial
Tiber 'b) was obtained using the silver-based inorganic antimicrobial agent
prepared in Example 2, Furthermore, an antimicrobial agent-containing
polyester fiber (antimicrobial fiber c) was obtained using the silver-based
inorganic antimicrobial agent prepared in Example 3. Moreover, a comparative
antimicrobial agent-containing polyester fiber (comparative antimicrobial fiber d)
was obtained in the same manner as for antimicrobial fiber a using the
comparative silver-based inorganic antimicrobial agent prepared in Comparative
Example 1. Similarly, a comparative antimicrobial agent-containing polyester
fiber (comparative antimicrobial fiber e) was obtained using the comparative
silver-based inorganic antimicrobial agent prepared in Comparative Example 2,
and a comparative antimicrobial agent-containing polyester fiber (comparative
antimicrobial fiber f) was obtained using the comparative silver-based inorganic
antimicrobial agent prepared in Comparative Example 3.
The target polyester fiber was also prepared in the same manner but
without using a silver-based inorganic antimicrobial agent.
The antimicrobial agent-containing polyester fiber, etc. thus obtained was
scoured, and antimicrobial properties were evaluated. The results are given in
Table 3. The antimicrobial properties were evaluated in accordance with a
quantitative test of JIS L 1902"1998, and the test was carried out using
Staphylococcus aureus. When the microbiostatic activity was equal to or greater
than 2.2, it was evaluated as having antimicrobial properties.
[0074]


[0075]
As is clear from Table 3, the antimicrobial polyester fiber employing the
antimicrobial agent of the present invention showed less increase in filter pressure,
fewer filament breakages, and little guide wear during spinning, and had excellent
processability when fiber spinning. It can also be seen to have high antimicrobial
properties.
[0076]
From these results, the silver-based inorganic antimicrobial agent of the
present invention has excellent processability such as spinning properties and
also has excellent discoloration resistance when added to a plastic product.
Furthermore, it has been confirmed that the silver-based inorganic antimicrobial
agent of the present invention has a high antimicrobial effect toward various types
of microbes compared with existing silver-based inorganic antimicrobial agents.
Industrial Applicability
[0077]
Since the novel silver-based inorganic antimicrobial agent of the present
invention is a uniform and fine particulate, it has excellent processability and,
moreover, it has excellent resistance to discoloration of a plastic product and
excellent antimicrobial properties. It is therefore possible to use it as an
antimicrobial agent having high suitability in applications where processability is
important, such as application to fine fibers, paints, etc.

WE CLAIM :
1. A silver-based inorganic antimicrobial agent represented by Formula [1]
below
AgaMbZrc(PO4)3nH2O [1]
Wherein : M is at least one type of ion selected from an alkali metal ion, such
as herein described, a hydrogen ion, and an ammonium ion, a, b, and c are positive
numbers and satisfy 1.5 2. The silver-based inorganic antimicrobial agent as claimed in claim 1,
wherein the silver ions are supported on a zirconium phosphate represented by
Formula [2] below
Mb1Zrc(PO4)3.nH2O [2]
Wherein : M is at least one type of ion selected from an alkali metal ion, such
as herein described, a hydrogen ion, and an ammonium ion, b1 and c are positive
numbers and satisfy 1.5 3. The silver-based inorganic antimicrobial agent as claimed in claim 2,
wherein the zirconium phosphate, so employed, is prepared by a wet synthetic
method using greater than 1.5 but less than 2 moles of phosphoric acid or a salt
thereof relative to 1 mole of a zirconium compound, such as herein described.
4. The silver-based inorganic antimicrobial agent as claimed in any one of
claims 1 to 3, wherein the alkali metal ion is a sodium ion or potassium ion.

5. The silver-based inorganic antimicrobial agent as claimed in any one of
claims 1 to 4, wherein a is at least 0.01 and no greater than 1, b is at least 0.1 and
less than 3, and c is greater than 1.75 and less than 1.99.
6. The silver-based inorganic antimicrobial agent as claimed in any one of
claims 1 to 5, which has a median diameter of 0.1 to 5 µm.
7. The silver-based inorganic antimicrobial agent as claimed in any one of
claims 3 to 6, wherein the wet synthetic method is a process in which an aqueous
solution comprising a zirconium compound, such as herein described, and
phosphoric acid or salt thereof is adjusted so as to have a pH of no greater than 4,
and then heated at a temperature of at least 70°C.
8. The silver-based inorganic antimicrobial agent as claimed in any one of
claims 1 to 7, which is calcined at a temperature of at least 550°C but no higher than
1,000°C.
9. The silver-based inorganic antimicrobial agent as claimed in any one of
claims 1 to 7, wherein M is at least one type of ion selected from an alkali metal ion,
such as herein described, and a hydrogen ion.
10. An antimicrobial product comprising the silver-based inorganic
antimicrobial agent as claimed in any one of claims 1 to 9.


ABSTRACT

SILVER-BASED INORGANIC ANTIMICROBIAL AGENT AND
ANTIMICROBIAL PRODUCT THEREOF
A silver-based inorganic antimicrobial agent represented by Formula [1] below
AgaMbZrc(PO4)3nH2O [1]
Wherein : M is at least one type of ion selected from an alkali metal ion,
such as herein described, a hydrogen ion, and an ammonium ion, a, b, and c are
positive numbers and satisfy 1.5 than 2.
The present invention is also directed to an antimicrobial product comprising the
said silver-based inorganic antimicrobial agent.

Documents:

03775-kolnp-2007-abstract.pdf

03775-kolnp-2007-claims.pdf

03775-kolnp-2007-correspondence others.pdf

03775-kolnp-2007-description complete.pdf

03775-kolnp-2007-form 1.pdf

03775-kolnp-2007-form 3.pdf

03775-kolnp-2007-form 5.pdf

03775-kolnp-2007-international publication.pdf

03775-kolnp-2007-international search report.pdf

03775-kolnp-2007-pct priority document notification.pdf

03775-kolnp-2007-pct request form.pdf

03775-kolnp-2007-translated copy of priority document.pdf

3775-KOLNP-2007-(23-05-2012)-ABSTRACT.pdf

3775-KOLNP-2007-(23-05-2012)-AMANDED CLAIMS.pdf

3775-KOLNP-2007-(23-05-2012)-AMANDED PAGES OF SPECIFICATION.pdf

3775-KOLNP-2007-(23-05-2012)-DESCRIPTION (COMPLETE).pdf

3775-KOLNP-2007-(23-05-2012)-ENGLISH TRANSLATION.pdf

3775-KOLNP-2007-(23-05-2012)-FORM-1.pdf

3775-KOLNP-2007-(23-05-2012)-FORM-2.pdf

3775-KOLNP-2007-(23-05-2012)-FORM-3.pdf

3775-KOLNP-2007-(23-05-2012)-OTHERS.pdf

3775-KOLNP-2007-(23-05-2012)-PA.pdf

3775-KOLNP-2007-(23-05-2012)-PETITION UNDER RULE 137-1.pdf

3775-KOLNP-2007-(23-05-2012)-PETITION UNDER RULE 137-2.pdf

3775-KOLNP-2007-(23-05-2012)-PETITION UNDER RULE 137-3.pdf

3775-KOLNP-2007-(23-05-2012)-PETITION UNDER RULE 137.pdf

3775-KOLNP-2007-ASSIGNMENT.pdf

3775-KOLNP-2007-CLAIMS-1.1.pdf

3775-KOLNP-2007-CORRESPONDENCE OTHERS 1.1.pdf

3775-KOLNP-2007-CORRESPONDENCE OTHERS 1.2.pdf

3775-KOLNP-2007-CORRESPONDENCE.pdf

3775-KOLNP-2007-EXAMINATION REPORT.pdf

3775-KOLNP-2007-FORM 13.pdf

3775-kolnp-2007-form 18.pdf

3775-KOLNP-2007-FORM 3-1.1.pdf

3775-KOLNP-2007-FORM 3.pdf

3775-KOLNP-2007-FORM 5.pdf

3775-KOLNP-2007-GPA.pdf

3775-KOLNP-2007-GRANTED-ABSTRACT.pdf

3775-KOLNP-2007-GRANTED-CLAIMS.pdf

3775-KOLNP-2007-GRANTED-DESCRIPTION (COMPLETE).pdf

3775-KOLNP-2007-GRANTED-FORM 1.pdf

3775-KOLNP-2007-GRANTED-FORM 2.pdf

3775-KOLNP-2007-GRANTED-SPECIFICATION.pdf

3775-KOLNP-2007-OTHERS.pdf

3775-KOLNP-2007-PA.pdf

3775-KOLNP-2007-REPLY TO EXAMINATION REPORT.pdf

3775-KOLNP-2007-REPLY TO EXAMINATION REPORT1.1.pdf

3775-KOLNP-2007-TRANSLATED COPY OF PRIORITY DOCUMENT.pdf


Patent Number 254738
Indian Patent Application Number 3775/KOLNP/2007
PG Journal Number 50/2012
Publication Date 14-Dec-2012
Grant Date 13-Dec-2012
Date of Filing 05-Oct-2007
Name of Patentee TOAGOSEI CO., LTD.
Applicant Address 1-14-1, NISHI-SHIMBASHI, MINATO-KU, TOKYO
Inventors:
# Inventor's Name Inventor's Address
1 SUGIURA KOJI C/O TOAGOSEI CO., LTD., 1-1, FUNAMI-CHO, MINATO-KU, NAGOYA-SHI, AICHI
2 ONO YASUHARU C/O TOAGOSEI CO., LTD., 1-1, FUNAMI-CHO, MINATO-KU, NAGOYA-SHI, AICHI
PCT International Classification Number A01N 59/16
PCT International Application Number PCT/JP2006/308771
PCT International Filing date 2006-04-26
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2005-133328 2005-04-28 Japan