ANTIMICROBIAL OVERLAY SHEET AND METHOD
An overlay component has an antimicrobial melamine resin including an antimicrobial agent incorporated therein. The overlay component is useful for making melamine-surfaced laminate articles having a tough, mar-resistant surface exhibiting antimicrobial properties.
1 . An overlay component, comprising:
a paper article;
a melamine resin substantially impregnated in the paper article; and
a first antimicrobial agent disposed in the melamine resin.
2 . The overlay component of claim 1 wherein the first antimicrobial agent is triclosan.
3 . The overlay component of claim 1 wherein the first antimicrobial agent is a pyrithione compound.
4 . The overlay component of claim 1 wherein the first antimicrobial agent is a silver compound.
5 . The overlay component of claim 1 wherein the first antimicrobial agent is an isothiazolone compound or a quaternary ammonium compound.
6 . The overlay component of claim 1 wherein the first antimicrobial agent is an azole; poly (hexamethylene biguanide) hydrochloride; 3,4,4′-trichlorocarbanilide; titanium dioxide; barium metaborate monohydrate; ortho phenyl phenol; or diiodomethyl p-tolylsulfone.
7 . The overlay component of claim 1 wherein the first antimicrobial agent is present in the melamine resin at a concentration in the range of from about 0.1% to about 5.0% by weight.
8 . The overlay component of claim 1 wherein the first antimicrobial agent is present in the melamine resin at a concentration in the range of from about 0.3 to about 1.0% by weight.
9 . The overlay component of claim 1 wherein the paper article is provided in a sheet.
10 . The overlay component of claim 1 wherein the paper article is provided in a roll.
11 . The overlay component of claim 1 , further comprising:
a second antimicrobial agent disposed in the melamine resin.
12 . The overlay component of claim 11 wherein the first antimicrobial agent is triclosan and the second antimicrobial agent is selected from the group consisting of a pyrithione compound, a silver compound, an isothiazolone compound, and a quaternary ammonium compound.
13 . The overlay component of claim 11 wherein the first antimicrobial agent is a pyrithione compound and the second antimicrobial agent is selected from the group consisting of triclosan, a silver compound, an isothiazolone compound, and a quaternary ammonium compound.
14 . The overlay component of claim 11 wherein the first antimicrobial agent is one of triclosan or a pyrithione compound, and the second antimicrobial agent is selected from the group consisting of: the other of triclosan or a pyrithione compound, a silver compound, an isothiazolone compound, and a quaternary ammonium compound, an azole, poly (hexamethylene biguanide) hydrochloride, 3,4,4′-trichlorocarbanilide, titanium dioxide, barium metaborate monohydrate, ortho phenyl phenol, and diiodomethyl p-tolylsulfone.
15 . A method for manufacturing a laminate article having an antimicrobial melamine surface layer, comprising:
disposing an overlay component adjacent a substrate, wherein the overlay component includes:
a paper article,
a melamine resin substantially impregnated in the paper article, and
a first antimicrobial agent disposed in the melamine resin; and
applying heat and, optionally, pressure to bond the overlay component to the substrate.
16 . The method of claim 15 wherein the laminate article is a countertop, a tabletop, a desktop, or a flooring article.
17 . The method of claim 15 wherein the first antimicrobial agent is triclosan.
18 . The method of claim 15 wherein the first antimicrobial agent is a pyrithione compound.
19 . The method of claim 15 wherein the first antimicrobial agent is a silver compound, an isothiazolone compound or a quaternary ammonium compound.
20 . The method of claim 15 wherein the overlay component is provided in a sheet.
21 . The method of claim 15 wherein the overlay component is provided in a roll.
22 . The method of claim 15 wherein the overlay component further includes a second antimicrobial agent disposed in the melamine resin.