ANTIMICROBIAL MELAMINE RESIN METHOD
A melamine laminate article, having incorporated therein an isothjazolone antimicrobial agent, is formed by a high-pressure manufacturing process. The melamine resin is compounded with the antimicrobial as a finely divided powder diluted in a liquid forming a dispersion.
1 . A method for forming an antimicrobial laminate article, comprising:
supplying a melamine bath mixture including:
a melamine resin in an aqueous solution, and
an isothjazolone antimicrobial agent predispersed in a liquid dispersion;
immersing a substrate in the melamine mixture to substantially impregnate the substrate with the mixture; and
wherein the formed antimicrobial laminate article has a surface that substantially reduces or eliminates microbial growth thereon by virtue of the isothjazolone antimicrobial agent.
2 . The method according to claim 1 wherein the predispersed antimicrobial agent in the melamine bath mixture has a concentration of from about 0.1% to about 0.5% based upon the weight of melamine resin.
3 . The method according to claim 2 wherein the predispersed antimicrobial agent in the melamine bath mixture has a concentration of from about 0.3% to about 1.0% based upon the weight of melamine resin.
4 . The method according to claim 1 wherein the melamine resin is a melamine, a methylated melamine, a butylated melamine, or an isobutylated melamine.
5 . The method according to claim 1 further comprising heat curing the substrate under pressure.
6 . A method for manufacturing an antimicrobial laminate article, comprising:
adhering a melamine-formaldehyde impregnated printed paper sheet to a fiberboard, the melamine-formaldehyde impregnated printed paper sheet formed by:
(a) supplying a melamine bath mixture including a melamine compound in an aqueous solution, and an isothjazolone antimicrobial agent predispersed in a liquid dispersion, and
(b) immersing a substrate in the melamine mixture to substantially impregnate the substrate with the mixture;
adhering a melamine-formaldehyde impregnated overlay sheet to the printed paper sheet; and
heating the fiberboard, printed paper sheet and overlay sheet with pressure for from 15 seconds to several minutes at a temperature of from about 127° C. to about 290° C. and under a pressure of from about 1000 psi to about 5000 psi;
wherein the isothjazolone antimicrobial agent is disposed at or near a surface of the manufactured laminate article defined by the melamine-formaldehyde impregnated printed paper sheet, such that the surface has antimicrobial efficacy for the life of the manufactured laminate article.