FORM 2
THE PATENTS ACT 1970
[39 OF 1970]
&
THE PATENTS (AMENDMENT) RULES, 2006
COMPLETE SPECIFICATION
[See Section 10; rule 13]
“LONG-PERFORMING ANTIMICROBIAL ACTIVE SURFACES OF DIFFERENT MOCs”
Melzer Chemicals Pvt. Ltd., of Plot no. A-11 & A-11/B, MIDC Kurkumbh, Taluka: Daund, Pune -413802, Maharashtra, India, [Nationality: Indian],
The following specification particularly describes the invention and the manner in which it is to be performed:

PRIORITY INFORMATION
[0001] This patent application is a patent of addition and is an improvement over a patent application titled “SILVER ANTIMICROBIALS”, having application number 202121030579 and filed on 07/07/2021.
TECHNICAL FIELD
[0002] The present subject matter described herein, in general relates to chemical reaction-product recognized as previously declared well-stabilized colloidal dispersion of submicron size pure silver particles and becoming technical antimicrobial active ingredient, having microbe-elimination characteristics; and thereafter referred also as antimicrobial active agent working also against pathogenic microbial species. From this, further usable products meant for creating long-lasting antimicrobial surfaces of different Material of Construction (MOC) are derived, which is present subject. It is also directed towards the usage-methods of these products for achieving long-lasting antimicrobial performance with a convenient application-usage technique, as also for deriving certain usage-benefits from such surfaces. For instance, the application technique may include but not restricted to transfer of antimicrobial active agent through a mist generated from the formulated product having its novel characteristics, on different surfaces of different MOCs, including surfaces of different polymers; and ensuring antimicrobial activity from newly derived surfaces thereof, also displaying other speciality properties like but not limited to elimination of generation of foul odor from the surface, wash-resistance of the active surface thereby retaining its antimicrobial properties, weather-resistance of the active surface preventing early deterioration, and in cases of surfaces of polymer MOC the retention of its original modulus of elasticity, tensile strength, though surface-conductivity may get increased to certain level due to active agent on surface; thereby all providing usage-value-addition for such surfaces of different MOCs, as being one example.
[0003] Further, many plastic products are in daily usages, but which though do not support microbial growth by their constituents, but transmit microbial presence from their surfaces to spread infections, such as surfaces of polymer products derived from PE (LLDPE, LDPE, HDPE ) PP (covering Atactic, syndiotactic polypropylenes) and PS (covering polystyrenes like GPPS, HIPS ), surfaces of products manufactured from natural rubber, Nitrile rubber, SBR, EPDM, EVA and others also show the presence of microbes in big number on them. Many such

rubber products are in direct as also indirect food contact. Their surfaces need to have safe antimicrobial profile. Way and methods of deriving such antimicrobial safe surfaces of different MOCs by usage of newly derived microbially active products form the present subject.
BACKGROUND
[0004] In today’s world, in the absence of ‘hygienic protection’, surfaces in closed spaces of living interiors pose significant challenges to individual occupants due to the presence of unwanted and harmful microbial species that get settled on such surfaces. This is especially more so in closed large spaces where huge population assembles, some of whom may be carriers of harmful microbial species without their having knowledge about it and thus those become unidentified spreaders of infections. Commonly seen surfaces in direct as also indirect contact but devoid of antimicrobial property become further breeding ground leading to massive growth of unwanted microbial species, thereby escalating many concerns including those of hygiene of population assembled or living in closed spaces. The entire closed space also starts emitting foul misty odour generated by microbes, which lead to respiratory problems first and then its severity. Further, in high-traffic areas such as Railway stations, Bus stations, Airports, hospitals, theatres, schools and offices, where people get exposed to potentially dangerous microbial species present on the surfaces they come in contact with and also pick up those, without their knowing about it; thereby the risk of transmission of infectious diseases escalates exponentially in absence of ensuring antimicrobial safeguards. The closed spaces may include cabins of trains, buses, passenger taxis, and cars, as also modern aircrafts most often built by using plastic components, where (a) occupants of the said space change frequently and in large numbers, (b) where the occupants remain confined in such closed spaces for sufficiently long duration and hence they may face higher risks of catching infections from others and from the contact-surfaces and spread of infections thereafter, that (c) it is impossible to re-treat almost all the surfaces of such facilities to acceptable hygiene status every time the occupants in such closed spaces get replaced by newer ones, and (d) thus, ensuring a certain level of antimicrobial profile of MOC with respect to contact-surfaces for an extended period is highly desirable, that (e) such essential safeguard needs to be easily achievable/available, affordable and safe to everyone, that (f) it needs to be ensured ‘as possible to derive’ on surfaces from multiple MOCs simultaneously present together, that (g) those measures transferred on the surfaces should not create unknown adverse effects on masses getting exposed to such surfaces, that (h) the repeated

re-production of antimicrobial surfaces at whatever frequency by repeated application of hygiene solutions is not always possible, and that (i) achieving antimicrobial or hygiene status at regular intervals of the concerned surfaces of different MOCs by repeated operations on them is difficult, and hence (j) if at all it is to be attempted, the repetitive application of the safe-guard measures also needs to be minimized, thereby implying that once created antimicrobial surface needs to show long duration-activity.
[0005] Thus, once microbe resistant surface is created of different MOCs, the said safe-guard measure on the surfaces not only needs to be functionally effective for the longest period possible, but additionally, antimicrobial action must occur within the shortest exposure time on a range of microbial species equally effectively; and by ensuring safety of the occupants in close contact with the surfaces. On most painted interior surfaces, as one example, rapid proliferation of microorganisms starts since paint film holds abundant quantities of minerals, and once moisture settles on it, it provides establishing nourishing conditions for the microorganisms to grow. Without the ability to inhibit the growth of bacteria and other harmful microbial species, painted surfaces quickly become contaminated, also contributing to the spread of (unwanted) infections. Commonly used antimicrobials in paints maintain the integrity of dry film from microbial attack on film but do not act beyond, thus are paint-preservatives. Specialized hygiene coatings where a dry film of the same on the painted surface is expected to act against microbes are being manufactured, however those too seem to hold limitations regarding their sustainable performance. Present subject addresses this short-fall. Though on moulded plastics, micro-organisms may not last for long, those also act as propagators of microbes to other surfaces in vicinity where microbes can dwell and grow. Moreover, the lack of hygienic properties diminishes the durability of painted surfaces of polymer-based items, as also of other surfaces, as they are prone to staining, discoloration, and degradation over time due to microbial activity occurring on their surfaces.
[0006] In cases of surface of polymers as moulded articles, bacterial species also dwell on it by depositing its metabolites. So, the challenge is to eliminate the bacterial species before such micro-deposit adheres permanently on the surface created from plastics. When the surface is fibrous, the cross-wave vacant spaces provide much larger surface area for the dust to remain enclosed and with it the microbes, thereby no longer freshness of the surfaces can be expected. Additionally, fibre itself gets microbial attack, leading to deterioration of its properties. The

surface of woven and non-woven fibre articles are as good as other surfaces, on which microbial growth can always be present.
[0007] Another critical issue arises from the difficulty in maintaining cleanliness and hygiene standards in closed environments like home, hospitals, schools, offices, theatres, transport-vehicles and huge aircrafts and the like, where human traffic is high as also environment is challenging. For example, in aircraft, where food service is common and spills onto carpeted floors are not uncommon, thorough cleaning of all surfaces during busy routine-usage of aircraft is impractical. Here there is continued exposure to microbial species, as and how earlier ones on the surface get killed by using contact-disinfectants. That means a challenge exists that the active ingredient of the disinfectant should not remain behind in traces too on the surface on which it was used, at the same time, it should not become ineffective in the process of eliminating unwanted microbial species from the surface, which is crucial. Simultaneously it needs to be considered that for achieving highest degree of ‘disinfected’ status of all surfaces requires following an elaborate procedure towards it, but that only minimally required surface clean-up ends into nullity of the purpose. Surfaces without hygienic protection require frequent and rigorous cleaning protocols to mitigate the risk of contamination. Such disinfection process therefore needs to be avoided. Even after having followed best possible cleaning measures, persistent presence of microorganisms continues, mainly because such surfaces lack protective measure. Usual surfaces of from synthetic MOC present an ongoing challenge in achieving optimal hygiene levels. Additionally, the absence of hygienic protection exacerbates the need for regular maintenance and replacement of /re-attendance on surfaces, resulting in increased maintenance costs and operational disruptions plus the cost of replacement.
[0008] The economic challenges associated with maintaining hygienic surfaces cannot be overlooked. Implementing hygienic protection often requires investments. Those could by way of using specialized paints or coatings with antimicrobial additives in them. Such paints are costlier. Ongoing expenses for cleaning, maintenance and potential repainting/replacements further strain cost-budgets, particularly for businesses and institutions with limited resources. Under such circumstances, common household is always strained towards the best to achieve at affordable-spent. Balancing the imperative for hygiene with economic feasibility is crucial for people across various sectors. Additionally for very large establishments, administrative overheads of monitoring and adhering to required hygiene-protocol add to the financial burden.

Addressing these challenges requires innovative economical solutions to ensure optimal safe indoor environment quality; and for promoting public health and well-being.
[0009] Anticipating hygiene-needs of enclosed spaces with consistently high occupancy and an elevated risk of infection-spread through contact surfaces, specialized hygiene paints entered into market. These paints are designed for use in both domestic settings and critically sensitive establishments where conditions are conducive to the growth of pathogenic species and where potential threat for spread of secondary infections exists. However, it has been commonly observed that consumers always want to spend just the minimum for getting their living space decorated as per their taste and mainly by their affordability-index, whereby a consumer purposefully neglects using high-end hygiene paints, even when the consumer know that such paints can perhaps take good care of health and thus giving the entire family a healthy interior surrounding. Designing truly functional hygiene paint is also a technical challenge. Consumers with such priorities also require an affordable method to achieve hygienic interior finish.
[0010] Once their chosen paint finish has been applied as fitting into their budget, they can benefit from specially formulated antimicrobial hygienic solutions that can be easily transferred onto the painted surface at the end of painting process, which could be another effective solution. This approach provides a cost-effective means of attaining a hygienic surface by following specific application methods of antimicrobial formulation. Such specially formulated antimicrobial needs to adhere firmly to the newly applied paint film and must ensure long-lasting antimicrobial performance of the surface. Similar strategies can be implemented in various settings such as offices, hospitals, schools, theatres, and other places where conventional paints are applied, and where microbial challenges are prevalent. Generally, it is known that microbes cannot grow on the surface of silver due to the electrochemical potential of the surface of silver. Therefore, over the past decade, several commercial paints have been introduced based on silver, in which silver in multiple forms has been being used, like ionic compounds of silver, ionizable salts, ionic silver adsorbed on neutral carriers or the nano particles of silver.
[0011] There have also been specialized paints, which are used as hygiene coatings, containing ionizable silver, and those have been introduced to protect the indoor surfaces years back. Most often, final active film of coatings of such specialized paints are of thickness between 20 to 60

microns, commonly 25-40 microns. In such formulations of paints, silver in ionic form in best possible optimized dosage, due to high cost of such compounds, is being used. The paints film is expected to act against microbes mainly where silver in whatever form in the film provides contact-probability for the microbes. Nevertheless, no scientific study has reported so far on ‘quantified contact probability for expected kill of microbes per unit area of paint film’, though it is essential. The present subject gives this quantification.
[0012] However, conventional methods of incorporating silver directly into paint formulations in whatever form, but mainly as silver salts, like silver phosphate glass;’ or ‘silver ions on titanium dioxide or alumina’ have not been proven to be effective in providing long-lasting antimicrobial properties of the surface so-derived from hygiene-paint. While silver is known for its antimicrobial properties, the direct mixing of silver, either as ionic salt or as adsorbed on neutral carrier into paint seems to be leading to uneven distribution in paint mass or getting excessively covered by far larger paint-mass. Thus, this seems to result into limited efficacy of such added silver antimicrobial over the time from manufacture of paints.
[0013] Once the technology of building nano particles of silver became available, since nano particles provide much larger surface area and since on silver nano-particles microbes fail to grow, because nano particles exhibit both Electrostatic Charge (EC) and Electromagnetic (EM) effects, those of silver are also being used as forming the base-antimicrobial active ingredient in hygiene paints.
[0014] In general, it has been observed that dosing of silver nanoparticles in paints did not change the situation regarding expected sustainable performance of hygiene coatings. Additionally, insect-repellent coatings manufactured by dosing appropriate quantum of pesticides in them, but as being controlled by regulatory norms on pesticides, have shown expected functional performance to eliminate insects dwelling on painted surfaces, and therefore thought to be contributing to avoidance of certain health issues originating from presence of insects. But those face lot of inherent usage-restrictions since continued exposure in closed space to insecticides present in paint-film can lead to far serious health problems for the occupants.
[0015] The ambiguity has persisted whether mouldable polymer when dosed with any of the silver composition or copper composition as antimicrobial active ingredient protects moulded

articles of the polymer from its slow microbial degradation or is meant to create antimicrobial surface. Mostly, such active ingredient remains in core of polymer-thickness, with no known proportion on the surface of the article for creating its surface displaying pronounced antimicrobial profile. Therefore, arguments continue that added antimicrobial may be acting only as a barrier and surface remains far short of becoming truly antimicrobial surface, where the rate of anti-action needs to be sufficiently high. The latter is an important parameter towards hygiene considerations, but generally the test results on article’s antimicrobial performance are derived and shown to be suitable by providing quite high exposure time to microbes and high kill-rate observed accordingly.
[0016] Hence there’s indeed a pressing need of providing solution of the problems related to collapse of hygiene or shortfalls existing in achieving hygiene in relation to surfaces of polymers and rate of kill of microbes. Offering one or more novel compositions becoming as ‘solution’ are essential, in which seamless integration of active antimicrobial agents could be achieved as becoming suitable for different MOCs commonly used in living spaces. Also, on the surfaces in commercial transport machines, like cabin of cars, aircrafts, where polymers dominate as MOC, safety from spread of infections through the contact with such surfaces. needs to be ensured by making such surfaces antimicrobial and acting sufficiently fast. However, such ‘solution’ must remain safe to human and effective with usage-longevity. There is not only a need for the one or more novel compositions but also a method of applying the novel compositions on all such surfaces preferably in presence of each other. This necessitates extensive research and experimentation to identify the novel composition of antimicrobial-end-product suitable for treating all surfaces of multiple MOCs together which are already in usage, along with a method for applying such antimicrobial on them, which would enhance the antimicrobial efficacy of presently utilised parts from different MOCs by preserving their integrity and functionality for as long time as possible., till newer parts having desirable antimicrobial profile replace them.
[0017] Generating antimicrobial polymer MOCs showing excellent antimicrobial surface characteristics also form the subject of present application. It is generally being assumed that on the surface of articles derived from most polymers, there is no likelihood of microbial growth. As surface energy lowers from around 46 dynes/cm for some polymers to around 20 dynes/cm for other, adhesion of a foreign body on surface also decreases. Surface

energy quantifies the disruption of intermolecular bonds that occurs when a surface is created. Since surface energy is also defined as the work per unit area done by force for creating newer surface, from the context of adhesion of microbes on polymer, it means microbes may carry out a process, to be called as ‘work’, which can lead to a newer surface. Such new surface would allow adhesion of microbes. Material responsible for allowing microbes to adhere to a surface is metabolic fluid deposited by microbes. Once such metabolic deposit occurs on a polymer surface, it becomes difficult to remove and continues as ‘stains’ seen on the polymer surface. It suggests that polymers need to have antimicrobial surface. Present application states two methods of creating antimicrobial active polymer surface.
[0018] First one is already elaborated as by following spray-mist deposition and drying of specially formulated antimicrobial product so deposited. The sprayable hygiene solution needs to have surface energy between 30 to 50 dynes/cm, more preferably between 35 to 45 dynes/cm. Apart from this, present application states having derived antimicrobial additive/s which can be suitably loaded in polymers by following corresponding method, and such dosed polymer-base leading to offer surface of the polymer-articles as being antimicrobial, that means effective to curb (kill) the presence of microbes on the surface (in spite that polymer would also hold the said additive in its core-thickness in some proportion apart from what remains on newly obtained surface of polymer’s articles.) Additive/s for the purpose of deriving antimicrobial surface of polymer MOCs have been derived from sub-micron-size pure silver particles of predominantly one shape. More particularly, antimicrobial additive is designed from usage of pure sub-micron-size silver particles as being compatible not with one of the polymers but is suitable for its usage in most common polymers such as HDPE, PE, ABS, Polycarbonate, Polyamide, PP, PET, HIPS, Polystyrene and others. Present application states and shows that blending of an antimicrobial additive into polymer MOCs is possible by melting the polymer, and hence additive needs to have high-temperature stability, that its blending into polymers needs to be smooth, uniform, almost free of defects and the whole composition of blended polymer then becoming effective towards eliminating microbial presence on the newly obtained surface of polymers. Further, present application states that antimicrobial additive so created ensures that there is no alteration in original mechanical properties of polymer’s casts when polymer is dosed with the additive at its designated percentage. However, the composition of the additive to be used in polymers may as well hold other functionally active materials in

appropriate small quantum, such as anti-caking agent, slip agent, anti-shrinkage agent, de-aerating agent, impact modifier and alike, as becoming appropriate for deriving functional advantage by which each of those is being recognized.

SUMMARY
[0019] Before the present system(s) and method(s), are described, it is to be understood that this application is not limited to the particular system(s), and methodologies described, as there can be multiple possible embodiments which are not expressly illustrated in the present disclosure. It is also to be understood that the terminology used in the description is for the purpose of describing the particular implementations or versions or embodiments only and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to a method of creating an antimicrobial surface using a hygienic solution. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[0020] In one implementation, creation of an antimicrobial surface using a hygiene solution having an antimicrobial base of silver is disclosed. The hygiene solution comprises: an antimicrobial base, wherein the antimicrobial base is a dispersion formed by colloidal silver particles (Ag0) of sub-micron size; an oxygenated solvent, wherein the oxygenated solvent in the hygiene solution is 2-9% by weight of total hygiene solution. Further, the hygiene solution comprises one or more binders. Binders are chosen from a range of acrylic polymers, modified acrylic polymer preferably aliphatic in nature, modified polyamide, aliphatic PUD. Binders are chosen by the properties of film towards tensile strength, flexural strength, scratch resistance. The composition needs to be VOC-free. Furthermore, it must have such surface activity that it becomes feasible to generate uniform sprayable mist of entire solution, for which SAA free of APEO is used in the range of 0.05 to 0.15% w/w. SAA could as well be sulfosuccinates. Ideal surface tension of such aqueous antimicrobial solution could be in range of 35-50 dynes/cm, more specifically around 42 dynes/cm. The mist to be applied is transferred on the surface, it is having almost uniform droplet size, preferably of 0.5 micron as is the nozzle diameter of spray gun shows. In case hygiene surface is to be derived as a paint-finish, hygiene mist is being applied when a previous newly applied coating composition of a durable paint on the surface is in a partially dried state but approaching dry-to-touch status. The paint could be of low, mid or high PVC. The hygiene mist is allowed to get integrated into the partially dried coating composition on the surface, when the coating beneath is getting hard dried, within about 8-10 hours, depending on properties of binders chosen. Finally, air-dried deposit of active silver particles but having no measurable film thickness renders antimicrobial activity, by leaving a

number of Silver particles (Ago), well-imparted and remaining bound to final surface, thereby it becoming antimicrobial active surface. In an embodiment, hygiene solution holds an oxygenated solvent or mixture of solvents from 2-9 % of the whole composition of antimicrobial hygiene solution, wherein the oxygenated solvents may be from higher alcohols, glycols and water and their mutual ratio varying as per binder as also by substate-characteristics receiving the generated mist, but the ratio may vary from 5:95 to 20: 80 , latter being the content of water in the mixture of solvent. In an embodiment hygiene solution by using water may be diluted up-to 93%
[0021] In yet another declaration, active particles of colloidal dispersion of sub-micron-size pure silver particles are being used, sub-micron size silver particles are derived by following thermal process, for creating a powder antimicrobial composition for its usage as an antimicrobial additive in mouldable commercially available polymers as granules of NYLON, HDPE, PP, PET, HIPS, Polystyrene, ABS, Polycarbonate. This is done by directly milling antimicrobial powder designed for the purpose or through master batch (MB) products produced separately of each polymer and getting dosed in respective polymers at the desired dosage by corresponding calculations on content getting transferred in final composition of each polymer. The said content is such that polymer’s mechanical properties are least affected. Such dosing finally leads moulded polymers displaying antimicrobial actions on their surfaces. Each polymer is dosed with the additive at certain percentage derived empirically, since the additive remains distributed in entire polymer-matrix of moulded articles and just not on surface of articles of each end-polymer. There is no known way of finding the distribution of active silver particles remaining on surface to those present in core. Antimicrobial additive as powder contains neutral carrier or a mixture of them such as magnesium or aluminon silicate. Carrier of active silver particles does not mean only a vehicle of holding such particles in well-distributed form. The carrier is chosen carefully so that it allows silver particles of the particular shape, in this case of triclinic shape, remain active. That those silver particles are not getting adsorbed on the surface of particles of each carrier. Best carrier is sulphate-free. Its preferred particle shape is also triclinic. Particle size of carriers is between 1 to 5 microns. Antimicrobial additive is also loaded with anti-shrinkage agent. Such loading is between 0.02% to 0.5% of total weight of additive, main ingredients like synthetic silicon dioxide (SiO2) (smoked silicon, silicone gel, zeolite) or natural and mineral SiO2 (clay, diatomite, quartz, talc). Synthetic

materials have the advantage of being free of dust, while natural materials carry it and introduce amorphicity.in polymers. Antimicrobial additive for different polymer MOCs also holds as a component anti-caking agent. It holds dual function. It allows air-release from molten polymer, eliminating chances of surface defect on casts when a polymer cools. During processing of a molten polymer MOC and when an additive like antimicrobial having in its different components too is dosed in molten polymer, a number of factors reduce the clarity of the end-product of polymer, including the use of recycle plastic. This necessitated using only a lowest possible percentage content of other compositional functional materials, for maintaining or increasing grain clarity and quality of moulded end-plastic-product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The foregoing detailed description of embodiments is better understood when read in conjunction with the appended drawings. For the purpose of illustrating of the present subject matter, an example of a construction of the present subject matter is provided as figures, however, the invention is not limited to the specific method of creating a hygiene film on a surface, disclosed in the document and the figures.
[0023] The present subject matter is described in detail with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identify the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer to various features of the present subject matter.
[0024] Figure 1 illustrates a method for creating an antimicrobial surface using a hygiene solution, in accordance with an embodiment of the present subject matter.
[0025] Figure 2 illustrates a method for creating an antimicrobial material of construction (MOC), in accordance with an embodiment of the present subject matter.
[0026] The figures depict an embodiment of the present disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION
[0027] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words “generating,” “applying”, “allowing,” “depositing” and other forms thereof, are intended to be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. Although any system and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, system and methods are now described. The disclosed embodiments are merely examples of the disclosure, which may be embodied in various forms.
[0028] Various modifications to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to other embodiments. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments described but is to be accorded the widest scope consistent with the principles and features described herein.
[0029] The need of present invention arose from the seriousness of above-summarised difficulties as also overall observations that any active antimicrobial dosed into the mass-composition of different MOCs does not necessarily and always give sustainable antimicrobial surface of MOC, which can continue to kill microbes settled on the surface of the MOC as is held to be the intention behind. Therefore, the invention pertains to nearly all conceivable technical and commercial variations in compositions achievable on a Material of Construction (MOC), (b) for fulfilling intended purposes and meeting usage standard; that (c) each of the one or more novel compositions are used to create active antimicrobial surfaces. Thus, the present composition can be applied to differing compositions of paints or moulded articles of different polymers and their derived surfaces by newer application usage-method. (d) ensuring the safety of the derived antimicrobial surface for human use, both during its creation and application; (e) considering environmental compatibility and assessing the suitability of the antimicrobial and its application method from an environmental perspective; (f) achieving a sufficiently rapid microbial kill-rate on the derived surface through the use of antimicrobial formulations; (g)

ensuring the longevity of the MOC surface under typical handling conditions; and, most importantly, (h) providing a scientific explanation for the sustainable antimicrobial action and safety origins. Although these actions have often relied on empirical data, generated through repeated experiments and conclusions. However, there’s still a lack of a direct scientific explanation for instances where lower levels of antimicrobial effectiveness are observed. The invention thus includes creation of one or more novel formulated aqueous hygiene solution and creation of active antimicrobial surfaces from the hygiene solution by each solution’s application-usage method as per MOC of the surface.
[0030] The invention states that antimicrobial surface formed by applying aqueous active hygiene solution does not exhibit measurable film thickness built from deposition and adherence of active antimicrobial. However, despite lacking a visible layer, this modified surface retains sufficient strength to sustain its antimicrobial activity for an extended period unless it undergoes physical damage. The active antimicrobial surface created from the hygiene solution by the application process disclosed herein does not change or alter original properties of the surface. The source and rationale behind the sustained antimicrobial activity of the surface, generated through the application and usage of a hygiene solution, enable the adjustment of the expected percentage and rate of antimicrobial kill exhibited by the surface.
[0031] Referring now to Figure 1, a method 100 for creating an antimicrobial surface is disclosed in accordance with an embodiment of the present subject matter. The order in which the method 100 is described is not intended to be construed as a limitation, and any number of the described method-blocks can be combined in any order to implement the method 100 or alternate methods for creating an antimicrobial surface.
[0032] Additionally, individual blocks may be deleted from the method 100 without departing from the scope of the subject matter described herein. Furthermore, the method 100 can be implemented with any suitable chemical reactants, alternatives of the reactants or combination thereof. However, for ease of explanation, in the embodiments described below the method 100 may be considered to be implemented as described in the method 100 for creating an antimicrobial surface.
[0033] The method begins with generating a hygiene mist from a hygiene solution in order to create an antimicrobial surface. The antimicrobial surface may be created by a creating a

hygiene film, from the hygiene mist, on the surface. The hygiene film may be defined as a uniform and cohesive layer or coating that adheres to the surface. In one aspect, the surface may be a surface covered with a coating composition. The coating may be of a conventional paint. For example, interior painted walls or ceilings of schools, residences, theatres, and hospitals and the like. These surfaces include a broad variety of materials that are prone to microbiological contamination. By applying the hygiene mist to these surfaces, it creates a barrier that actively stops the growth and spread of viruses, bacteria, and other dangerous diseases. In one aspect, the hygiene film created on the surface has a negligible thickness such that avoiding any changes in appearance or texture of the surface. The hygiene mist sprayed on the surface may be transparent in nature and does not change the colour of the surface upon application.
[0034] In one aspect, at step 102, the hygiene mist is generated from a hygiene solution. In one aspect, the hygiene solution comprises an antimicrobial base, an oxygenated solvent, and one or more binders. It may be pertinent to note that, in an embodiment, the antimicrobial base comprises the plurality of colloidal Silver particles (Ag0). The Ag0 may also be understood to be ‘colloidal silver’. The Ag0 may be understood to be of sub-micron size in a neutral form. Further, the size of Ag0 may be less than 10-6 metre and greater than 10-9 metre. The Ag0 may not constitute Silver nano particles and only constitute colloidal particles that are sub-micron in nature. Thus, from the disclosed antimicrobial base, the Ag0 silver particles may not penetrate the human skin unlike the Silver nanoparticles and hence may be safe to use. In one implementation, antimicrobial base of colloidal dispersion of pure silver particles comprises silver particles around 1015 in number per ml of its solution as calculated. The silver particles proportion in the formulated hygiene solution may be maintained so as to derive particle-range of pure silver as 1012 in number per ml of formulation solution. More particularly it could be in the lowest range of around 1010 per ml. The number of silver particle depends on several factors related to achieving stability of the formulation free of agglomeration. In an embodiment, the antimicrobial base is a colloidal dispersion of pure silver particles (Ag0) of sub-micron size and with specific structural morphology of particles. The content of the antimicrobial may be from 500 to 9000 ppm i.e. the hygiene solution comprises 0.05% to 0.9% % of the antimicrobial base by weight of the hygiene solution.

[0035] In one aspect, the hygiene solution may include an oxygenated solvent. The oxygenated solvent may be an aqueous solvent, such as oxygen-enriched demineralized water. In an embodiment, the oxygenated solvent constitutes 2-9% by weight of the hygiene solution. The aqueous solvent is primarily composed of demineralized water with a conductivity lower than 2 micro-siemens to maintain hydrophilic status. The demineralized water in the hygiene solution may account for 75-90% by weight. Within this range, the oxygen-enriched water component may specifically constitute 5-13% by weight of the hygiene solution. Water being the main component, is non-toxic and poses minimal health risks compared to organic solvents which may contain volatile compounds detrimental to human health and the environment. Water as solvent offer excellent compatibility with a wide range of active ingredients, enabling efficient incorporation of the antimicrobial base having Silver particles (Ag0), into the hygiene solution. Additionally, water as solvent produce little to no odour, contributing to improved indoor air quality and user comfort. In one aspect, the hygiene solution is transparent in nature.
[0036] In one implementation, the hygiene solution may include one or more binders. A formulation of the one or more binders may be chosen based on specific nature of the MOC to be treated. In an embodiment, the formulation-composition of the hygiene solution disclosed herein may be suitable for one or more MOCs like concrete, ceramic, glass, stainless steel, plastic, and the like. The hygiene solution, when applied to a surface, demonstrates sustained antimicrobial performance, ensuring the overall hygiene of the surface. This allows for the use of a single formulated hygiene solution, even in scenarios where surfaces of different Materials of Construction (MOCs) are encountered simultaneously.
[0037] In one aspect, the one or more binders are responsible for holding together the Silver particles (Ag0) of the hygiene film on to the surface. In an embodiment, the surface may be a painted surface. This ensures that the antimicrobial properties of the silver particles (Ag0) are effectively transferred to the painted surface and remain intact over time to provide long-lasting protection against microbial contamination. The one or more binders may be chosen from: aqueous acrylic polymer of medium molecular weight, clear transparent acrylic, modified acrylic, styrene-acrylic polymer or polyurethane known as PUD, or a mix of multiple aqueous polymer-emulsions. In an embodiment, a concentration of the one or more binders in the hygiene solution may be preferably 5% by weight. In an embodiment, the one or more binders in the hygiene solution may be in the range of 3 to 12% by wt. In an embodiment, one or more

binders comprises one or more of acrylic emulsions, modified acrylic emulsions, latex emulsion, and PUD. The content of binder in hygiene solution may be from 3 to 12 % w/w hygiene solution by using water may be diluted up to 93%.
[0038] This specific concentration improves the stability of the hygiene formulation, helping to prevent the agglomeration or settling of active Silver particles (Ag0) and maintaining their dispersion within the solution or with the paint layer on the surface. The one or more binders in the hygiene solutions have been chosen such that they are compatible with any type of paint being used on the surface. There has been no reaction between the one or more binders and the paint of the surface that could lead to discoloration, resistance to environmental factors, and the like. The one or more binders helps encapsulate the active silver particles (Ag0) from the sprayed hygiene mist, ensuring their proper distribution and adhesion to the painted surface. The one or more binders forms an adhesion of the Silver particles (Ag0) such that the silver does not comes out even for example, the painted surface is washed, cleaned, and the like. The Silver particles (Ag0) being transferred constitute to non-migrant silver.
[0039] In an embodiment, a co-solvent in the hygiene solution formulation is chosen to hold the one or more binder and one or more additives together without separating out, which is one, or a combination of two or more, oxygenated organic compound fully miscible in water. In an embodiment, the one or more additives are chosen as spreading and levelling agents from the commercially available non-silicone products, having suitable HLB value. In an embodiment, a total dosage of the one or more additives is 0.005 to 0.2 % wt/wt of the formulation of the hygiene solution. In yet another embodiment the concentartion of the one or more additives may be 0.008 to 0.015 wt/wt of the hygiene solution.
[0040] In an embodiment, the hygiene solution is derived, from base silver solution having active silver particles 1010 to 1012 per ml. The hygiene solution being transparent solution containing the one or more binders and additives and being fully miscible in DM water. In an embodiment, the hygiene solution in its further diluted form is used for application on different surfaces. The dilution may be adjusted based on the desired number of silver particles available to act as antimicrobial agents when transferred onto the surface to be treated. However, it is essential that these particles ultimately bind to the surface in a sufficiently dense arrangement.

The closed packing of such silver particles is in the range 4,50,000 to 1,00,00,000. particles per sq. cm of surface receiving such solution.
[0041] In one implementation, surfaces such as painted surfaces, polymer articles, or moulded surfaces made from synthetic non-woven polyester fibres, as well as those composed of cotton, polypropylene, PET, and polyester blends, may achieve hygiene, antimicrobial, and durable properties when silver particles present in the hygiene solution are deposited at the required density per square centimetre. This deposition may not result in a measurable film thickness, nor does it visibly alter the surface finish. However, the surface demonstrates an antimicrobial efficacy of 99.9% to 99.999%, effectively eliminating bacteria and viruses upon contact, with antimicrobial activity persisting over an extended period. This continued efficacy remains intact, ensuring at least a 99% microbial kill as confirmed by test protocol ASTM G21/G24 and AATCC 100 TM even with continued usage unless the antimicrobial surface undergoes physical damage.
[0042] In an implementation, the hygiene solution may be transferred on surface of different MOCs by way of creating hygiene spray-mist of the hygiene solution. The hygiene mist may be generated using a misting process. The misting process may break down the hygiene solution into small droplets, dispersing the colloidal Silver particles (Ag0) throughout the air. The hygiene mist may be created using an atomization equipment. The term ‘atomization equipment’ may refer to an apparatus intended to disperse a liquid into tiny particles or droplets. This may involve a variety of tools, including sprayers, atomizers, nebulizers, and aerosol generators. The atomization equipment may include one of the techniques like pneumatic, centrifugal, ultrasonic, air compression, and mechanical mechanisms to produce the small droplets. The atomization equipment may be selected based on viscosity, droplet size, and dispersion pattern as required. In one aspect, the parameters such as pressure, flow rate, or nozzle settings of the atomization equipment may be adjusted to achieve the droplet size and dispersion pattern for optimal mist coverage. In an embodiment, the hygiene mist may be created using commercially available spay gun having an orifice at the spray nozzle and by applying pneumatic/hydraulic pressure on formulated antimicrobial silver solution. For example, the pressure may be 2 to 4 psi. The spray mist may be directed towards the surface of the object whereby its wastage by spread over other objects could be limited. Even when other objects in close vicinity receive such spray-mist, the surface of such objects exhibit sustainable

antimicrobial performance. Though hygiene spray mist formed using the hygiene solution is safe to the operator, care towards avoiding excessive inhalation needs to be taken.
[0043] In an embodiment, the hygiene mist may be applied on the surface of different MOCs such that the hygiene mist so applied first adheres on the surface, thus treated. In one aspect, the surface may be prepared before applying the created hygiene mist. For example, the surface may be cleaned to get rid of any impurities, dust, or dirt that can prevent the hygiene mist from sticking. To make sure there are no remainders, the surfaces may be scrubbed, cleaned, and dried. Additionally, in order to produce a homogeneous and smooth substrate for mist application, any surface flaws like holes or fractures may be repaired.
[0044] In an embodiment, at step 104, in one aspect, the created hygiene mist may be applied on the surface. For example, the hygiene mist may be applied during a transitional state of a coating composition like paint on the surface. For example, the coating of paint is in transition from wet to dry but is partially dried. During the transitional state, the paint layer may undergo significant changes in the physical and chemical properties. For example, a solvent present in the composition of paint layer may start to evaporate and lead to decrease in volume of liquid in the paint. As the solvent evaporates, the remaining components in the paint layer may become more concentrated, leading to an increase in viscosity. The painted surface may become slightly sticky allowing adherence to the surface and facilitating application of additional materials like the hygiene mist. The hygiene mist may be applied during the transitional period to effectively bond with the paint layer on the surface. This approach not only ensures thorough coverage and robust adherence of the hygiene mist on the surface but enhanced performance. In one aspect, the application of the hygiene mist may depend on the ambient temperature and humidity levels surrounding painted surface. The ambient temperature may refer to the temperature of the air surrounding the painted surface. The ambient temperature may influence the rate of evaporation of solvents in the paint. As higher ambient temperature may lead to fast drying and lower ambient temperature may lead to slow drying of the paint. The pace at which water-based paints and other materials evaporate is affected by humidity levels. Low humidity speeds up evaporation, while high humidity slows it down. In one aspect, the hygiene mist created from the hygiene solution does not react with the paint on the surface.

[0045] In an embodiment, at step 106, hygiene mist is allowed to integrate into the partially dried coating composition on the surface through adhesion. For example, after a certain amount of time when the coating composition of paint is completely dried, due to the application of the hygiene mist at a specific time (when partially dried) as discussed above the hygiene mist may be integrated into the coating composition on the surface.
[0046] At step 108, a number of Silver particles (Ag0) are imparted from the hygiene mist to per square centimetre of the surface based on the integration and thereby creating the antimicrobial surface. Thus, deposition of the hygiene mist of the formulation of active pure silver particles gives permanent antimicrobial surface. Thereby the whole film-surface becomes well-integrated with a huge number of silver, For example, in the range 45,00,000 to 1,50,00,000 particles per square cm area remaining closely packed on it. Due to this huge number of the silver particles (Ag0) being deposited at the surface the overall antimicrobial efficacy of the surface is enhanced. At Once deposited on the surface, the antimicrobial particles become activated, releasing antimicrobial agents that inhibit the growth and proliferation of microorganisms. This huge number of Silver particles (Ag0) being imparted cannot be achieved by the conventional method of mixing conventional Silver into the paint directly. This procedure not only increases the treated surface’s antimicrobial efficacy but also offers a flexible and adaptive method of preserving hygiene in a range of contexts, including residential dwellings and healthcare facilities.
[0047] In one aspect, the hygiene mist may be applied to the surface at or slightly above the room temperature and the surface may be at a lower temperature. Due to this temperature difference, the heat transfer may occur from the warmer hygiene mist to the colder target surface. The temperature gradient may accelerate the evaporation of the solvent component within the hygiene mist. The kinetic energies of the solvent molecules in the hygiene mist vary, for example some have enough energy to break free from the intermolecular interactions binding them together and enter the gas phase. Higher kinetic energy solvent molecules spread towards the cooler surface as the hygiene mist comes into touch with it and release energy upon impact, aiding in the evaporation process. Rapid evaporation is encouraged by the surface lower temperature because it lowers the vapor pressure needed for solvent molecules to change from the liquid to the gas phase. The solvent molecules evaporate and scatter into the ambient air, resulting in the suspended silver particles remaining on the surface. As long as the hygiene mist

and surface have different temperatures and there is still solvent in the hygienic mist that can
evaporate, the process will continue.
The temperature gradient, relative humidity, and the physical characteristics of the solvent (such as its boiling point and vapor pressure) all affect how quickly a solvent evaporates.
[0048] In one aspect, the hygiene solution, when sprayed in the form of hygiene mist, exhibits very low toxicity, making it safe for use in various settings. Even if the hygiene mist is inadvertently sprayed on other surfaces or objects within for example, a room, it poses minimal risk of harm or adverse effects. The hygiene mist’s minimal toxicity is due to the meticulous chemical selection and formulation of the hygiene solution. The use of water as a solvent in a specific proportion in the hygiene solution further contributes to the low toxicity and safety profile when sprayed in the form of hygiene mist.
[0049] In an alternative approach, an antimicrobial active surface is developed using non-woven polyester staple fibres, which are further processed into non-woven cloth. This non-woven composition may consist of a blend of cotton and various synthetic fibres in addition to polyester fibres. The creation process involves using a formulated antimicrobial solution containing appropriate binders and additives. Specifically, a binder is selected from a range of options, and the staple fibres are impregnated with the formulated solution and then heat-cured. Similarly, the non-woven cloth, comprising different fibre compositions, undergoes impregnation and subsequent curing. The impregnation process is achieved through either padding or exhaust methods. Additionally, after impregnation and curing, the non-woven cloth is exposed to a mist of the solution to further enhance its antimicrobial properties. In either of these pre-treatment processes, the hygiene solution needs to be suitable diluted and the pick-up of pure silver particles from the solution as antimicrobial active on staple fibres or on the non-woven cloth from them is critically monitored by a special monitoring method developed for the purpose, which is not intended to be disclosed here.
[0050] More particularly, in the formulated hygiene solution for such usage, the one or more binders may include one or more of polyaminoamide, mix of polyamonoamide, and acrylic in ratio 1:4 to 1:1, or aliphatice PUD and the like. In an embodiment, the concentration of binder in the active hygiene solution may be 1 to 5 % wt /wt, and that heat-curing temperature of the treated synthetics may be from 900 C to 1200 C. The time required for heat-curing may be 2 to

4 minutes. The active antimicrobial silver particles firmly remain adhered on the treated surface for giving almost permanent antimicrobial finish, exhibiting more than 99.9 % kill of pathogenic microbial species. In an embodiment, such treated non-woven synthetic cloth may be pressure-moulded at certain temperature to acquire a permanent shape by fusion of the synthetics, having good tensile strength, modulus of elasticity and abrasion resistance, as also weather resistance and non-absorbency of moisture and a range of liquids. The pressure for the moulding depends on the thickness of the moulded shape, and so also curing temperature could be 110 0 C to 1250 C, and time for the fusion or curing could be 2 to 4 minutes. Said impregnation carried out with the active antimicrobial solution as also the method used for it become complex technical derivation in accordance with engineering-design aspects of the machine, and moulded article, and accordingly formulation of antimicrobial solution could be designed.
[0051] In another implementation, moulded articles made from synthetic fibres and their accompanying non-woven cloth are used to create robust, self-supporting panels designed to serve as integral components in construction projects. These panels are prefabricated to fit seamlessly into the intended structure. When multiple panels of appropriate size, shape, and thickness are assembled closely together, they form the interior finish of vehicles such as cars, buses, railway coaches, or aircraft. By utilizing a formulated antimicrobial solution during the manufacturing process and applying a spray mist over the entire surface, including synthetic flooring composed of staple polyester fibres and other mixed compositions, an antimicrobial-impregnated continuous surface is achieved. This method ensures that the assembled panels, which have been treated with the antimicrobial solution, contribute to creating a safe and hygiene environment within enclosed spaces. The hygiene mist of the formulated antimicrobial solution may have certain concentration for yielding active surface of closely packed particles of pure silver in certain number per square cm by calculations, thereby rendering far effective hygiene interior surfaces displaying sustainable, longer and persistent antimicrobial activity exhibiting more than 99.9% kill of pathogenic species for taking care of frequently changing occupants using such transportation machines and having come from untraceable background of likely direct or indirect exposure to pathogens. Thus, and likely to be their carriers too, from further spread of those unwanted infections to big number of further untraceable population.
[0052] In another implementation, the formulated antimicrobial solution is applied in mist form onto moulded polymers used as fitment parts in various interior applications, creating an

antimicrobial surface on these components. This includes synthetic flooring made from staple polyester fibres or a mixture of fibres, which are woven into sheets of specific thickness and finish. Synthetic carpets installed on the floors of cars, transportation vehicles, railways, aircraft, theatres, residential areas, and commercial spaces serve multiple functions, such as providing heat insulation and soundproofing. However, they often develop unpleasant odors due to the accumulation of microbial growth on residual dust, different humidity level, and organic matter embedded within the carpet fibres and structure. These conditions create an environment conducive to the growth of viruses and other harmful microorganisms. Thus, the complex microbial presence cannot be easily eliminated by vacuum cleaning. Also, in close spaces harsh anti-microbial agents may not be used, thus posing risk of asthma, breathing difficulties, as also further health hazard to occupants. Treating carpets with the formulated antimicrobial solution and applying additional mist sprays of the same solution as part of a periodic maintenance program has proven to be the simplest and most sustainable method for achieving prolonged and consistent antimicrobial activity. This approach provides assurance of maintaining high hygiene standards over an extended period.
[0053] In an embodiment, formulation of such antimicrobial solution requires the use a binder which self-dries. The binder may be chosen from aliphatic PUD or acrylic emulsion or modified acrylic polymer-solution, the dry film of which is water resistant. The binder may be from 2 to 6% wt /wt of aqueous formulation, which is chosen so as to avoid agglomeration of active antimicrobial pure silver particles, and further dosing of additives like anti-crease, anti-stain agents based on modified silanes, or polymer of silicones need to be done, and in percentage which does not affect re-coatability, the said percentage is in the range 0.002% to 0.05 by wt of binder chosen, as also the dose is dependent on nature of the binder.
[0054] In another embodiment, different plastics, that means MOCs of HDPE, Acrylics, PP, Polyester, HIPS, PET, Polycarbonate, Nylon either virgin or loaded by recycled grains, FRP, EVA, SBR, EPDM, Nitrile, Natural rubber PVC and alike are converted into antimicrobial MOCs by dosing an antimicrobial additive in each of them from which moulded articles displaying pronounced antimicrobial activity are derived. Additive for that purpose is designed from pure silver particles of sub-micron size having preferred/specially derived morphology. Additive is in powder form, which is stable at high temperature, exceeding melting temperature of polymers, which means temperature above 250 0 C. The dosage of additive could be within

0.5% to 2 % by weight of polymer, depending on numerous factors, related to performance expectations as also nature of plastic. Plastic may contain recycled component as best possible to load it for ensuring end-mechanical, thermal, functional properties aimed from the intended usages of plastics. Antimicrobial additive dosed in plastics by mastication at melt temperature disperses well in plastics. Also, it holds specially oriented lamellar extender in 80-92% content, along with dispersing additive for easy mastication of antimicrobial composition at melt temperature. Fig. 2 discloses a method for creating an antimicrobial material of construction (MOC), according to an embodiment. Fig. 2 illustrates a method for creating an antimicrobial material of construction (MOC). At step 202, a polymer is selected from a group that includes HDPE, Acrylics, PP, Polyester, HIPS, PET, Polycarbonate, Nylon, FRP, EVA, SBR, EPDM, Nitrile, Natural rubber, and PVC. In step 204, an antimicrobial additive comprising pure silver particles of sub-micron size is incorporated into the selected polymer at a concentration of 0.4% to 2% by weight. The antimicrobial additive is in powder form and is stable at temperatures exceeding 250°C. At step 206, the antimicrobial additive is dispersed uniformly within the polymer matrix through mastication at the polymer’s melt temperature. Finally, at step 208, the polymer with the dispersed antimicrobial additive is moulded into the desired shape, ensuring that the antimicrobial additive remains evenly distributed both in the core and on the surface, thereby creating the antimicrobial MOC.
[0055] During this process, additive as also plastic do not show any gaseous emission. When molten plastic is moulded into desired shape of utility value, antimicrobial additive remains well dispersed in core as also on surface of plastic, thereby making the whole as antimicrobial MOC. In an embodiment, powder flow agent may be present in 1% to 4% by weight of the carrier additive and the whole becomes also as a nucleating agent for molten polymers to orient themselves while solidification occurs. The moulding of the selected polymer is promoted into a desired shape without introducing warp and twist and strain in polymer resulting into fracture point. The antimicrobial additive remains dispersed in core and on the surface of the moulded polymer, thereby creating the antimicrobial MOC of the polymer.
[0056] Antimicrobial additive carries out nucleation of polymer from its molten mass, by observing certain path towards it. Design of the antimicrobial powder additive needs to ensure its working equally towards Isotactic, Syndiotactic as also Atactic Polymer crystallization, whereby end-moulded polymer does not develop any adiabetic stress, thereby affecting

mechanical properties of antimicrobial moulded plastic in the end. Pure Silver particles (Ag0) which are devoid of any ionic charge, work to achieve that. Further, molten polymer may be considered as at non-equilibrated state, in which additive has to perform towards self-induced nucleation of polymer for it to take up certain orientation, and its continuation thereafter to as much best extent, but which cannot be easily studied and monitored during such moulding process. However, its effects can be identified by modulus of elasticity, ductility, tensile strength and resultant Tg of end-polymer. It is being stated that microscopic kinetics of different processes towards nucleation also control these properties, and antimicrobial additive has to contribute towards it. Further, since antimicrobial additive is based on pure sub-micron size silver particles (Ag0 ), and since silver is good heat conductor, it establishes required kinetics of heat flow during nucleation and solidification of molten plastic in required end-shape, which in other way could be said as achieving hierarchical order of polymer-crystallization and co-operativity of additive involved in nucleation process.
[0057] In yet another implementation, additive may contain a constituent substance as being a carrier extender substance of Ag0 sub-micron-size particles, which substance is chemically neutral, stable to heat, non-absorbent of moisture, stable to weathering, safe by its toxicity profile and most preferably having lamellar shape of its crystals. Its D98 particle size may be from 10 to 30 microns. It may be in weight content from 85 to 92%, along with a powder flow agent present in .5 % to 7 % by weight of the additive. In an embodiment, powder flow agent presents in .5 % to 3 % by weight of the additive. Content of Ag0 sub-micron size particles may vary between 109 to 1012 in number per g of antimicrobial additive. Antimicrobial additive is preferably odourless, free flowing powder non-dusty, and devoid of imparting any colour to plastic. Best composition of the constituents of antimicrobial additive arrived at by empirical derivations gives far improved optical properties of moulded plastics (which are devoid of added colorant) due probably to lamellar nucleation of the polymer from its melt when additive is added and masticated in molten polymer, and therefore allowing uniformly oriented refraction/transmission of visible light from its film or up to 3 mm thick wall. Once loaded with antimicrobial additive, moulded polymer of each from such MOC shows smooth surface profile, without any blister, unevenness, dry powdery patch, cavity formation, shrinkage, fish eye, surface non-uniformity including roughness; and so also is the core of the polymer-article from antimicrobial-loaded MOC.

[0058] In an embodiment, the antimicrobial polymer MOC of each may be derived from virgin polymer of each type or containing along with virgin polymer component also recycled polymer of each kind. The ratio of proportion may be 80:20 to 70:30, and that, both display distinguishing antimicrobial characteristics of the entire matrix of polymer as also of surface of moulded polymer derived from each. Each dosed polymer shows rheological behaviour of the melt not differing from original properties, almost same static heat stability as original polymer shows, almost identical extrusion characteristics of dosed polymer. Each polymer shows increase in tensile strength by 7 to 10%, but a marginal drop, from 0.5 % to 2%, in flexural strength, and far increase in light transparency noticeable from polymer’s cross-sectional thickness up to 3 mm. As also colour improvement, all caused by certain nucleating process getting initiated from silver containing antimicrobial additive, which seems to control thermodynamics and kinetics of polymer’s heat exchange and melt-diffusivity during cooling to solid form, initiating nucleation from well-equilibrated state of polymer melt. Primarily due to stack of a large number of intimately linked lamellae of particles of the antimicrobial additive. Almost all of them getting oriented parallel to each other. Further, each polymer dosed with antimicrobial additive so derived does not show any structural defect generally caused by grains of dry powders remaining undistributed in polymer melt.
[0059] In yet another implementation, additive works to create antimicrobial MBs of different polymer MOCs and such MBs of each polymer may be used in respectively identical polymer MOC for obtaining antimicrobial moulded articles. Content of Ag0 sub-micron size particles may vary between 108 to 1010 in number per g of antimicrobial additive. Additive can be loaded in each MOC polymer from 10 to 15% by weight, for creating respective MB of each MOC polymer. Such MB of each polymer can be loaded in the respective polymer MOC at 5 to 12% dosage for moulding it into desired shape and weight for obtaining usable end-antimicrobial plastic article. MBs can be in form of polymer-granules. Once loaded with antimicrobial MBs, moulded polymer of each from such MOC shows and other defects; and so also is the core of the polymer-article from antimicrobial-loaded MOC.
[0060] Moulded articles from antimicrobial polymer MOCs, derived either from usage of MBs or by direct use of antimicrobial additive displays antimicrobial activity as quantified by kill percentage of a range of bacteria, fungi and algae from plastic surface ( having smooth surface profile, without any blister, unevenness, dry powdery patch, cavity formation, shrinkage, fish

eye, surface non-uniformity including roughness and any other defects) as more than 99.9%, by following ASTM AATCC 100 Test Method as also anti-viral activity. Activity is retained over long usage of plastic, as evidenced by tests carried out on plastics during its usage, as also by challenging the plastic repeatedly in laboratory by well-quantified microbial load on it, against the blank run simultaneously.
[0061] In yet another implementation, specialised Antimicrobial MBs were prepared for the usage to manufacture PP and PET fibre, by designing antimicrobial additive in powder form suitable for extrusion of such fibre from the melt of polymer, fibre having high flexibility as also stretchability, from usage of sub-micron-size pure silver particles of specifically intended morphology as microbially active ingredient. In an embodiment, antimicrobial MBs were prepared for the usage to manufacture PP and PET fibre by incorporating corresponding MB into PP or PET melt of polymer at 5% to 10% by weight. Extruding the polymer into fiber such that the resulting fiber exhibits high flexibility and stretchability. Content of Ag0 sub-micron size particles may vary between 107 to 1010 in number per g of antimicrobial additive. Such fibre often holds recycled polymer of either kind in each, up to certain percentage, additionally though recycled polymer granules of either can also get mixed together during operations, and that, such mix of base-polymers is invariably transferred for extrusion of polymer-melt into fibre. Antimicrobial additive dosed in corresponding MB of polymer does not obstruct fibre-extrusion process. From MB, the additive is loaded in fibre around 0.5 % to 1.2% of total weight of fibre. Fibre then shows more than 99.9% kill of unwanted microbes coming in contact. Antimicrobial additive in MB, or the additive used directly in molten polymer, shows almost transparency of extruded fibre.
[0062] In yet another implementation, FRP (Fiberglass Reinforced Plastic) as also PVC (Polyvinyl Chloride) are converted into antimicrobial MOCs by using antimicrobial powder additive. Dosage of additive is from 10% to 20% by weight of polymer composite. Antimicrobial flexible PVC, using PVC of corresponding K value, is obtained by dosing additive through preferably polymeric, no-migratory plasticizer at dosage which retains from 0.8% to 2% by weight of additive in final PVC product, and displaying thereafter more than 99.9% kill percentage of a range of bacteria, fungi, algae as also virus from its surface. Flexible PVC needs to be cured at designated temperature. Rigid PVC loaded with antimicrobial powder

additive at 0.8 to 2% of final weight of MOC gives antimicrobial profile of surface of PVC showing more than 99.9% kill of a range of bacteria, fungi, algae as also virus.
[0063] In yet another implementation, a composition of antimicrobial additive is designed and prepared in powder form for the usage to obtain antimicrobial rubber products from SBR, Nitrile, Neoprene, EPDM, Natural Rubber, Thermoplastic polyurethane (TPU) and EVA, based on sub-micron size pure silver particles of specifically intended morphology as base antimicrobial ingredient. Blending powder additive into rubber processing oil and then its loading at 0.4 to 1% weight by weight of rubber followed by usual vulcanization imparts almost permanent antimicrobial profile to rubbers having smooth surface profile, without any blister, unevenness, dry powdery patch, cavity formation, shrinkage or surface non-uniformity including roughness; and so also is the core of rubbers, and all showing more than 99.9% kill of unwanted microbial species from the active surface.
[0064] In yet another implementation, antimicrobial additive is designed and prepared as a liquid in active hydroxylated organic compound containing sub-micron size pure silver particles of specifically derived morphology, content of Ag0 particles in it may vary between 108 to 1010 in number per g of antimicrobial additive, for manufacturing PE and PET fibre from corresponding polymer-melt. Liquid antimicrobial additive in certain calculated dose can be loaded into equalization tank for converting corresponding oligomer to polymer, and polymer gets enriched with antimicrobial at its formation. Molten polymer when extruded forms fibre holding antimicrobial in its composition in inseparable way, displaying superlative antimicrobial profile thereafter, with more than 99.9% kill of unwanted microbial species. Antimicrobial activity of such fibre is almost permanent without affecting its physical and chemical properties significantly.
EXPERIMENTAL DATA
1. Compositional constituents of sprayable hygiene antimicrobial products under and for application usages for deriving long lasting active antimicrobial surfaces are active antimicrobial ingredient, its carrier, binder of active ingredient, flow improver additive, anti-gelling agent and stabilizer.

As being one embodiment towards designing stable sprayable hygiene antimicrobial product, previously declared aqueous colloidal dispersion of sub-micron size silver particles of specifically derived morphology, of different concentration of active silver particles in each as per application-usage-needs by MOC as also by factors related to compatibility, stability and commercials, is used for deriving active antimicrobial solution in sprayable form. Particle-morphology may be preferably triclinic, but the presence of spherical particles is acceptable. Particle size may be between 300 to 500 in nm, more particularly, the desired particle size of most silver particles is between 200 to 500 nm, more preferably D90 particle size is between 425 to 500 nm. Activity of solution is determined by content of silver available as is required for treating a surface of each type of MOC, by chemistry and characteristics of MOC, for its conversion into long-lasting antimicrobial active surface. Range of silver content in sprayable hygiene solution can be 100 to 800 ppm depending on the characteristics of surface of each MOC. Active antimicrobial composition contains binder, its content ranges from 1.2% to 8% of total composition by weight. In one embodiment, binder is PUD having active content between 17 to 28%, in another composition, binder is thermosetting acrylic clear emulsion, having 30-36% solids. Content of binder falls within the range 1.2% to 8% depending on the chemical nature of each, its surface tension and adhesion characteristics as also its contribution to overall viscosity and flow property of end-product. As one embodiment, PUD is chosen from aliphatic types and well-stabilized against weathering. Base of PUD can be acrylic or non-acrylic polyol and of molecular weight between 3000 to 6500, preferably as non-liner polymer. PUD can be self-drying or heat-curing type. Self-drying composition of PUD can as well be further cured by heat. In other embodiment, acrylic binder within molecular wt range of 4000-8000 could be pure acrylic, more of linear polymer having cross-linking groups well-built within it and also of self-drying nature. In yet another embodiment, binder composition is mix of PUD and acrylic polymer, in range of respectively 70:30 ratio to 40:60 ratio. Carrier solvent for deriving compatibility with the active antimicrobial agent is free of VOC, it is in range of 3% to max 11% of total liquid content but is mostly aqueous. Active silver content is then loaded in such binder composition already diluted at ambient temperature over a certain period of mixing for deriving the uniformity and ending with viscosity range limited to max 200 cps. As one

embodiment says, sprayable hygiene composition so arrived needs to have flow improver and coalescing agent for forming its continuous deposition on the surface under treatment (MOC), this additive is required in the range of 0.02 to 0.07% by weight of total composition. Coalescing additive, which is mostly organic hydroxy compound, its molecular weight range of 200-300 may as well be chosen which can also act as anti-gelling agent. Composition is further stabilized from unwanted coagulation, or settlement or separation, by thixotropic agent, which is added in 0.02 to 0.05% w/w of total composition. It is derived mainly from modified cellulosic polymer. End-composition so-derived can be used by spray application by further dilution, 1;1 to 1:5, preferably by sterile water.
2. Compositional constituents for antimicrobial additive/s for converting different plastics as also different rubbers as being MOCs into corresponding antimicrobial plastics and rubbers, and their surfaces to derive long-lasting antimicrobial properties are active silver particles of sub-micron size of specific morphology, selective carrier/s for them, SAA, anti-caking agent and anti-dusting agent.
In one embodiments from aqueous dispersion, silver particles are derived by spray-drying; in other those are derived by drying aqueous dispersion along with certain content of a carrier which is in powder form by spray-drying, where operation temperature of drying pan is maintained between 105 to 125 0 C, as depends upon rate of drying and equipment characteristics, also time required for it is directly related to equipment characteristics. Carrier content ranges from 8 to 15 % of the total by weight for achieving ease of operation, and thereafter total content of carrier in product/s as becoming 88-96% w/w is blended into mass so-obtained, also dosed at this stage is non-dusting additive which is one from modified silicones from 0.02 to 0.05% w/w. Carrier becomes nucleating agent for introducing graded polymer crystallization from each polymer’s molten mass, without allowing any shrinkage or defects to occur on the polymer in solid stage, and hence carrier chosen from lamellar shaped crystal orientation, carrier having MP above 2500 C, free of moisture and which is non-degradable at such temperature. Degree of lamellar particles against amorphous particles in total mass of carrier powder is more or equal to 60%. Its micron size is chosen between 10 to 40, more particularly below 30 microns. SAA is added into the formulation-blend to 0.5 % to 1.5% w/w of total mass of antimicrobial additive, whereas KPPP as SAA is dosed from 0.3 to 0.8% w/w. Silica based fluidity additive, an

anticaking additive is dosed to 0.01 to 0.05 % w/w. Entire powder is once again dried at temperature 105 to 110 0 C, sieved and packed.

I/We Claim:
1. A method of creating an antimicrobial surface using a hygiene-solution, wherein the method comprises:
generating a self-drying hygiene mist from the hygiene-solution, wherein the hygiene-solution comprises;
an active antimicrobial base, wherein the antimicrobial base is an aqueous dispersion formed by colloidal pure Silver particles (Ag0) of sub-micron size and having specific morphology of particles having capped them, wherein the hygiene-solution comprises 0.05% to 0.9% of the antimicrobial base by weight of the hygiene-solution, and wherein the Silver particles (Ag0) in the hygiene-solution are present at a concentration of 10¹⁰ to 10¹² particles per millilitre of the hygiene solution;
oxygenated solvent, wherein the oxygenated solvent in the hygiene-solution is 2-9% by weight of the hygienic-solution;
one or more binders comprising one or more of acrylic emulsions, modified acrylic emulsions, latex emulsion, and PUD, wherein the one or more binders in the hygiene-solution is in range of 3 to 12 % by weight of the hygiene-solution; and
water, wherein the water in the hygienic solution is up to 93% by weight of the hygienic solution;
applying the hygiene-solution from the generated hygiene mist on a surface, wherein the hygiene-mist is applied via spraying on surface to make the surface uniformly moist, wherein the surface is to be converted into hygiene surface, wherein the surface is at least one of a coated surface or plastic surface created from one or more MOUs, wherein the hygiene-mist comprising active ingredients are deposited and bound through adhesion upon drying onto the surfaces, and wherein the mist is applied when a coating composition on the surface is in partially dried state;
allowing the hygiene-mist to integrate into the partially dried coating composition on the surface through adhesion and then reaching to total dry state creating active long-lasting hygiene surface; and

depositing multiple Silver particles (Ag0) from the hygiene-mist to per square centimetre of the surface based on the integration and thereby creating long-lasting antimicrobial hygiene status of the surface, wherein the multiple particles of Ag0 transferred per square centimetre are in range of 45,00,000 to 1,50,00,000.
2. The method of claim 1 further comprises:
applying the coating composition to the surface, wherein the composition is a formulated composition of one or more characteristics features; and
allowing the coating composition to reach to partially dried state.
3. The method of claim 1, wherein the oxygenated solvents comprise of demineralized water and having a conductivity lower than 2 micro-siemens.
4. A method for creating an antimicrobial material of construction (MOC), comprising:
selecting a polymer from a group comprising of HDPE, Acrylics, PP, Polyester, HIPS, PET, Polycarbonate, Nylon, FRP, EVA, SBR; EPDM, Nitrile and Natural rubber and PVC;
incorporating an antimicrobial additive into the selected polymer at 0.4% to 2% by weight of the polymer, wherein the antimicrobial additive comprises pure silver particles (Ag0 ) of sub-micron size, and wherein the antimicrobial additive is in powder form and is stable at temperatures above 250°C;
dispersing the antimicrobial additive in the selected polymer by mastication at melt temperature; and
moulding the selected polymer with the dispersed antimicrobial additive into a desired shape, wherein the antimicrobial additive remains dispersed in core and on the surface of the moulded polymer, thereby creating the antimicrobial MOC.
5. A composition for the antimicrobial additive claimed in claim 4, comprising:
pure silver particles ( Ag0) of sub-micron size;
a carrier-extender substance for the silver particles, wherein the carrier substance has a D98 particle size of 10 to 30 microns and comprises 85% to 92% by weight of the additive; and

a powder flow-improving agent present in 0.5 % to 3% by weight of the additive, wherein the content of silver particles is between 109 to 1012 particles per gram of the additive.
6. A method for creating an antimicrobial master batch (MB), comprising: incorporating the antimicrobial additive of claim 5 into a polymer MOC at 10% to 15% by weight.
7. A method for creating an antimicrobial moulded article, comprising:
incorporating the MB of claim 6 into a corresponding polymer MOC at 10% to 20% by weight; and
moulding the polymer into a desired shape and weight as antimicrobial article.
8. A method for manufacturing an antimicrobial fibre, comprising:
preparing an antimicrobial MB for PP or PET fibre production by incorporating the MB of claim 6 into PP or PET at 5% to 10% by weight; and extruding the polymer into antimicrobial fibre.
9. The method of claim 8, wherein the resulting fibre exhibits high flexibility and
stretchability and other characteristic properties.
10. A method for creating antimicrobial FRP (Fiber Reinforced Plastic) or PVC (Polyvinyl
Chloride) long-performing antimicrobial articles, comprising:
incorporating an antimicrobial powder additive of claim 4 at 0.8% to 2% by weight of the polymer composite.