WO2011005270A1

WO2011005270A1 - Peracid/peroxide composition, process for accurately making the same, and method for use as an evaporating film anti-microbial solution and as a photosensitizer

Info

Publication number: WO2011005270A1
Application number: PCT/US2009/057695
Authority: WO
Inventors: Jeffry Golden; Paul Brister; Joan Stader; Charles Martin
Original assignee: Jeffry Golden; Paul Brister; Joan Stader; Charles Martin
Priority date: 2009-07-08
Filing date: 2009-09-21
Publication date: 2011-01-13
Also published as: AU2009349654A1; EP2451483A1; CA2767493A1

Abstract

A method is provided for the microbicidal treatment of a surface such as sanitization, disinfection, sterilization, and decontamination of a surface or object by use of an anti-microbial composition comprising an aqueous solution of peracetic acid and hydrogen peroxide with acetic acid, water soluble polymer containing lactam, and phosphate ester surfactant and little or no stabilizer, and according to the method enhanced microbicidal efficacy is obtained when the composition is applied onto a surface as a thin film wetting the surface so that a shorter contact time for a desired fractional reduction in microbial population is obtained Still further, the compositions comprise photosensitizer for light-activated anti-microbial efficacy.

Description

PERΛCJD/PEROXIDE COMPOSITION, PROCESS FOR ACCURATELY MAKING THE SAME, AND METHOD FOR USE AS AN EVAPORATING FILM ANTIMICROBIAL SOLUTION AND AS A PHOTOSENSITIZER

Cross-Rcfcrence to Related Applications

[00011 This application is a continuation-in-part of a pending application serial number 1 1/329,433, filed on January 1 1 , 2006, based on a provisional application serial number 60/642,819, filed on January 1 1 , 2005, published as a publication number US 2007/0229225 (Get 12, 2006), Martin et al, "Peracid/ Peroxide Composition and the Use Thereof as an Anti- Microbial and a Photosensitizer."

Statement Regarding Federally Sponsored Research or Development

|0002] This work was part of a project supported by the Technical Support Working Group under contract DAAD05-02-C-0017. The Federal Government retains Government Purpose Rights, including the right to use, modify, perforin, display, release, or disclose technical data in whole or in part, in any manner for any government purpose whatsoever, and to have or authorize others to do so in the performance of a Government Contract.

Appendix

[0003] Not Applicable.

BACKGROUND OF THE INVENTION

1. FIELD OF THE INVENTION

|0004| The invention relates to a method for microbicidal treatment such as saniti/ation, disinfection, sterilization, and decontamination of a surface by use of such compositions as an anti-microbial thin film and also as a photosensitizer for light-activated killing. Further, the invention relates to a process for accurately making storage-stable embodiments of the anti-microbial compositions. This invention still further relates to aqueous anti-microbial compositions, made by the provided process, the compositions comprising peracetic acid, hydrogen peroxide, acetic acid, phosphate ester surfactant, water-soluble polymer containing lactam, and optionally, small amounts of minors and liltle or no additional stabilizer.

2. DESCRIPTION OF RELATED ART

|0005] Compositions comprising aqueous solutions of peracetic acid (peracetic acid) and hydrogen peroxide (HP) as microbicidal active ingredients are well known to have excellent microbicidal efficacy. When used as dilute solutions or as Use Dilutions of concentrated solutions, such compositions can be highly effective sporicidcs, disinfectants, bactericides, virucides, fungicides, tuberculocidcs, sanitizers, decontaminants, and mold killers. Such compositions are applied onto surfaces as a wiped, sprayed, or brushed on liquid, as a sprayed, drifted, or electrostatically attracted aerosol, or by immersion such as dipping. By conventional methods, a surfeit of anti-microbial is applied to the surface to thoroughly wet the surface and maintain a wet surface for at least a required period of time, the contact time, to obtain a desired fractional reduction in the targeted microbial population. The desired fractional reduction is commonly expressed as minus the logarithm of the ratio of the surviving microbial population and the initial microbial population and is referred to as the "logs of killing". Regulatory approval of a product as a sanitizer, disinfectant, sterilant, or decontaminant and approval of efficacy claims made on the label for such a product generally involve the validated achievement of a required number of logs of killing within the contact time stated in the label claim for a specific organism or type of organism.

|0006] ft is advantageous that the contact time be as short as possible. Advantages of a reduced contact time are the sooner availability for use of the surface or object being treated, or increased productivity of the person, or machine performing the treatment or subsequent related tasks such as post treatment wiping or rinsing, or more reliable achievement of microbicidal efficacy.

|0007| A commonly used approach to shorten the contact time is to use an antimicrobial composition with greater concentration of active ingredients so that the product of concentration (C) and contact time (T_c), the so-called ^>!CT_C" product, is adequate to achieve the required logs of killing with a desired T₀. However, use of compositions with greater concentration of active ingredients has the disadvantages of greater cost, greater corrosivity, greater release of volatile organic compounds, potential hazards, and/or toxicity, constraints on shipping, storage, and disposal, and additional hazard warnings and requirements for use of personal protection equipment.

[0008| In the microbicidal efficacy testing and development of directions for use of the compositions and Use Dilutions of the compositions of Martin et al, it was found that excellent microbicidal efficacy is achieved with the application of a thin layer of the composition, especially when it is used as a photosensitizes The objectives of the compositions of Martin et al include low cost and low logistical burden, and so, the compositions of Martin et al arc used typically with an application rate of about 40 to 150 ml/nr (that corresponds to u layer thickness of about 40 to 150 μm) for non-porous surfaces and up to about 300 ml W for porous surfaces such as textiles and carpets. In the testing of the compositions with standard methods (for eκample, the Germicidal Spray Test, the AOAC Sporicidal Activity Test, ct al.) for microbicidal efficacy in the case without light-activated killing, contact times typically much shorter than the time for evaporation of the thin layer (t_e) were used, i.e., T_c « t_e. For the photosensitized case, initial testing also was performed with T_c « t_e.

|0009j However, to obtain regulatory approval as a decontaminant, a modified carrier test called the Surface Sterilization Test (SST) was developed in which a thin layer is applied by spraying a carrier such as a glass Petri dish or aluminum weighing dish having a circular patch or carrier of dried inoculum of test organism or spores. In the early stages of testing and development of the SST, a large variability in the microbicidal efficacy was found. The variability was found to correlate with relative humidity, with the amount of material sprayed onto the carrier, and with the type of dish. Further, study of the evaporation rate of a thin layer of the compositions also depended on the type of dish. It turned out that the dependence on the type of dish was because of the flatness of the dish and how level it sat on a lab bench. With the glass dish having a slightly upward convex bottom and the aluminum dish having a slightly concave bottom, the excess applied liquid flows to the depression at the perimeter of the bottom of the glass dish but puddle at the center of the aluminum dish. From this it was surmised that the sprayed layer thickness for the glass Petri dish carriers at the inoculum was consistently less than the uniform thickness layer expected for a level, flat-bottomed dish. As expected, it was seen that acceptable efficacy only resulted with complete wetting of the inoculated area and that the evaporation time depends on the relative humidity and the thickness of the film that remains after the excess liquid has flowed away, but surprisingly, it was found that the efficacy depended non-linearly on the ratio T_c/t_c. As a consequence, it is found that a greater CT₀ can be obtained with an evaporating layer of the composition of the instant invention for which T_c/t_c is a substantial fraction of unity than for an essentially non-evaporating or slowly evaporating layer of the composition.

|0010| As shown by our testing and as expected by common sense, a necessary condition for good microbicidal efficacy in an uncon fined space is that the inoculated surface is completely wet so that the microbicidal composition contacts the target microbes. To ensure that there is an adequate amount of microbicidal composition present on the surface for the necessary contact time, a surfeit of microbicidal composition is applied by common practice because application of a thinner film is likely to lead to film defects of imperfect wetting or dry spots resulting from surface tension effects or patches that day more quickly and so, the required CT₀ is not obtained in such places. Though the addition of a substantial amount of thickeners or gels to the composition or the embodiment of the composition as a foam may hold the active ingredients in contact with surface, with such compositions, even with a collapsing foam, the benefits of increased concentration of the active ingredients in an evaporating thin layer are not accrued. Moreover, such use of thickeners and film formers lead to increased viscosity that make application of a thin film by aerosol spraying or wiping more difficult. Further, such additives and amounts result in undesirable amounts of residue.

[001 1 ) In contrast to the case of a surface in an unconfined space, there may not be a requirement of thorough wetting for a surface in a confined space because evaporated active ingredients can contact the microbes as a vapor or as a condensate and good microbicidal efficacy can be obtained in spite of the lack of a film entirely wetting the contaminated surface. However, vapor or condensate for microbicidal efficacy docs not provide anti-corrosive ingredients to protect the surface from the corrosive active ingredients. This is in contrast to the application of a liquid anti-microbial composition that contains an anti -corrosive ingredient. Thus, the method for microbicidal treatment of a surface of the instant invention applies to the case where the surface is in a space, either confined or not confined, an example of an unconfined space being the outdoors, and where the relative humidity, RH, is sufficiently less than 100% so that the applied thin layer significantly evaporates during the contact time.

|0012| In comparative testing of compositions comprising peracetic acid, hydrogen peroxide, acetic acid, phosphate ester^' surfactant, and, optionally, water-soluble polymer that differed only by the choice of water-soluble polymer or the absence of water-soluble polymer, it has been shown by the instant invention that compositions comprising water-soluble polymer having a lactam, such as the compositions provided by Martin et al. result in superior microbicidal efficacy to compositions with other polymers or no polymer.

[0013| This result is surprising, because it has been reported extensively that the amount of hydrogen peroxide that complexes with the polyvinyl pyrrolidone (PVP) containing lactam is only about 40% by weight of polymer. Thus, for a composition containing about 4 % hydrogen peroxide and 0.1 % w/w of PVP, the complexed amount of hydrogen peroxide is only about 0.04 % by weight of the composition and only about 1 % of the hydrogen peroxide. Yet, the combination of- phosphate ester anionic surfactant and water soluble polymer containing lactam in the microbicidal composition is found to be particularly well-suited to the method for microbicidal treatment with an evaporating film and outperforms other polymer and surfactant combinations.

[0014| Prior ait teaches the use of rheological modifiers, in particular polymer, of which PVP is one, and further that such stabilizers may be anti-corrosive and even for 'stabilizing', but only Martin et al teaches the selection of polymer containing lactam and surfactant for their ability to form adducts/complexes, and to improve microbicidal efficacy. For example, US 6,080,712 to Revell et al teaches use of aliphatic alcohol cthoxylates as thickeners. US 6,436,445 to Hci et al teaches polymer thickeners, e.g., methyl cellulose and many related polymers, and synthetic petroleum-based water soluble polymers, which include PVP among many others. US 5,294,644 to Login teaches use of lactams for complexing and for thickener for phosphate esters and for obtaining a highly polar and hydrophobic pyrrolidone moiety for anionic interactions, but not for improved microbicidal efficacy. US 6,403,547 to Grippaudo et al teaches a process of cleaning carpets with a composition comprising pcroxygen bleach and an N-vinyl polymer (0.01 to 10% preferably 0.05-2%).

|0015| Grippaudo teaches a composition further with a surfactant, preferably an anionic surfactant (or a zwitterionic surfactant or a mixture thereof, most preferably a sarcosinate surfactant) and organic and inorganic acid, with preferred organic acids being acetic acid or citric acid or a mixture thereof and preferred inorganic acids being sulfuric acid or phosphoric acid or a mixture thereof. Particularly preferred inorganic acid is sulfuric acid. Typical levels of such acids, when present, are from 0.01 % to 1 .0% by weight, preferably 0.05% to 0.08%, and more preferably from 0.1 % to 0.5% by weight of the total composition. A preferred peroxygen bleach is hydrogen peroxide. Suitable preformed peroxyacids include diperoxydodecandioic (DPDΛ). magnesium perphthalatic acid, et al, (but Grippaudo et al. does not mention peracctic acid), and surfactants (anionic, nonionic, zwitterionic, amphoteric, and cationic and mixtures thereof). Suitable anionic surfactants include sarcosinate surfactants, alkyl sulfate surfactants, alkul sulphonate surfactants, alkyl glycerol sulfate surfactants, and alkyl glycerol sulphonate surfactants (but Grippaudo et al. does not mention alkyl ethoxylate phosphate esters).

(0016| US 2004/0241 I 10 by Lee describes a jelly-type tooth bleaching patch that uses hydrogen peroxide or other peroxides (including tetra sodium pyrophosphate' peroxide) as bleach and PVP-pcroxidc + stabilizers (including stannate). Various polymer-peroxide combinations arc described, including polyvinyl pyrrolidone-vinyl acetate-hydrogen peroxide (PVP-VA-HP), polyvinyl pyrrol idone-acrylic acid-hydrogen peroxide (PVP-AA-HP), as coating forming agents, which may be aided by use of compounds such as methyl cellulose inter alia. US 6,462,008 B l to Ortiz teaches detergent compositions comprising photobleach delivery systems in which hydrophobic photobleaches arc combined with certain water-soluble polymers, which include copolymer of PVP and polyvinylimidazole (PVPVI), and most preferably PVP with an average molecular weight of from 20,000 to 60,000. US 6,472,360 to Beggs et al teaches a multi-part thickenable non-spray of at least two liquid partial compositions each having a viscosity of 20 mPa-s (cP) or less, one part containing peroxygen bleach, and after mixing, fϊnal composition having a viscosity of 50 mPa-s (cP) or greater. US 6, 183,807 to Gulzman ct al. teaches use of anionic surfactants including alcohol alkoxylates have ethylene oxide (EO), propylene oxide ( PO), and butylenes oxide (BO) blocks, with straight chain primary aliphatic alcohol alkoxylates being particularly useful as sheeting agents. By Gutzman et al, alcohol ethoxylates found to be useful are those having the general formula R— (EO)m— (PO)n, wherein m is an integer of about 2- 10 and n is an integer from about 2-20. R can be any suitable radical such as a straight chain alkyl group having from about 6-20 carbon atoms. Gutzman et al. further teaches that compounds such as mono, di and trialkyl phosphate esters may be added for the suppression of foam, with such phosphate esters being produced from aliphatic linear alcohols, there being from 8 to 12 carbon atomics in the aliphatic portions of the alkyl phosphate esters, and alkyl phosphate esters possessing some antimicrobial activity in their own right to add to the overall antimicrobial activity of a composition. US 6.165,483, US 6,238,685, and US 6,627,593 to Hei et al. teach antimicrobial compositions having active oxygen compounds including hydrogen peroxide, isolated peracids, such as peracelic acid inter alia, and anionic surfactants including alkyl, aryl, or alkaryl phosphate esters inter alia, and further. US 6,436,445 to Hei et al teaches the use of water soluble thickener, which may include PVP, although other polymers that have non-Newtonian viscosity are preferred in contrast to PVP that has Newtonian viscosity, to give viscous solutions. US 6,514,556 to Hilgren et al. also teaches peiacid and peroxide with surfactant and thickener, with non-ionic surfactants and natural gums, polysaccharide-bascd, ccllulosic polymers, polyacrylates, and liydrocolloid thickeners being preferred. US 6.5 18,307 to McKenzie et al teaches a method for control of microbial populations in the gastrointestinal tract of animals that uses a peracid composition having a wetting agent, stabilizing agent, and/or a defoaming agent. Among the taught defoaming agents are phosphate esters. US 5, 130, 124 to Merianos et al. teaches a stabilized, aqueous, film- forming antimicrobial composition of hydrogen peroxide that is stabilized in an aqueous-polyol solvent system containing PVP. US 5,200, 189 to Oakes et al. teaches alkyl mono- di-, and triphosphate esters to suppress foam and that may be antimicrobial in their own right. US 5,344,652 to Hall II et al. teaches a hydrogen peroxide and peraectic acid microbicidal composition with a wetting agent containing polyphosphonic acid compounds that may also act as an anti-corrosive. [00 I 7| However, none of the prior art teaches the combination of water-soluble polymer containing lactam and phosphate ester surfactant in a very dilute pcracetic acid solution for use as an evaporating thin film microbicidal treatment. In the prior art, the polymer, when used as a thickener, results in a substantial increase in viscosity, which is in contrast to the thin film application to a surface required by the instant invention and provided by the compositions of Martin et al. For example, the compositions used with the instant invention have viscosity about 10 to 50 % greater than water in contrast to the thickened compositions of the prior art that have viscosity in the range of several times to many times that of water. Moreover, though alkyl phosphate ester surfactant has some antimicrobial properties, there is no motivation to combine with water soluble polymer containing lactam for the purpose of obtaining improved microbicidal efficacy in an evaporating thin film treatment. Still further, when such compositions in the prior art are used for photoactive processes, the polymer taught as a thickener is specified as one of high molecular weight, which is not desirable for the microbicidal treatment method of the instant invention, nor is it desirable for the process to make a htorage stable composition or for the resulting composition of the instant invention.

|0018| Thus, by the instant invention, an improved method is provided for the antimicrobial treatment of a surface or object. Moreover, when the anti-microbial liquid is applied with a wipe or comparable applicator that is wet with the composition and so forms an evaporating thin layer that completely wets the surface according to the instant invention, and the wiping dislodges or removes some of the microbes from the surface, the results of the combination of removal of microbes and microbicidal action is superior efficacy with a short T₁. and a further reduction of the microbial population on the surface. For such a purpose, a wipe that is packaged as a pre-wetted wipe is particularly attractive for its convenience and the speed that it enables with the reduced T_c. For such a pre-wetted wipe, the anli-microbial composition in the form of a ready-to-use ("RTU") solution is especially useful and desirable.

|0019| Ready to use ("RTU") formulations of anti-microbial compositions are desired for several reasons. These include convenience, ease of use, safety, ship-ability, and broader market applications. Because excellent microbicidal efficacy can be obtained with concentrations of active ingredients that are relatively small, namely, hydrogen peroxide less than 8 % weight by weight (w/w) and peracetic acid less than I % vv/w, RTU compositions comprise very dilute solutions of peracetic acid. Such very dilute solutions avoid the handling of more concentrated solutions to prepare a "Use Dilution" solution, and they are easier to store and transport. The very dilute solutions further avoid the common prohibition against shipping by air a concentrate that contains more than 8% hydrogen peroxide. Very dilute RTU compositions are attractive because they pose low risk, greater ease of use, can be used in non-professional settings such as home use, and can be shipped without the constraints that may be applied to more concentrated compositions such as risk mitigation measures such as extensive personal protective equipment, spill containments and counteπneasures. mixing equipment and protected and ventilated storage locations that enable the storage, handling, and mixing of more concentrated compositions.

[002Oj There are several desirable characteristics of microbicidal compositions that depend on the concentrations of the active ingredients of the composition and on the concentrations of additional components that are necessary to obtain the desired characteristics. Of particular interest are the following characteristics:

( 1 ) microbicidal efficacy (ME)

(2) rheological properties such as ability to wet a surface, especially when applied as a thin film by spraying or wiping, e.g., with a wet wipe, spray-ability, ability to penetrate porous materials, and in regard to the instant invention, the ability to consistently and completely coat a surface for CT₀ enhancement as an evaporating thin film

(3) speed, i.e., a small contact time to obtain a desired level of ML:

(4) storage stability

(5) material compatibility, i.e., low corrosivity

(6) efficiency, which can be quantified by the amount of the microbicide that must be applied to obtain a desired level of ME (7) aesthetic features, i.c, attributes such as acceptable odor and little or no environmentally non-persistent residue after use, and in particular, after drying

(8) robustness, which is effectiveness in the presence of organic materials and soil (^■'organic load") on environmental surfaces, and

(°) shippable within regulatory constraints for transport by commercial means of various modes.

(00211 Storage stable, commercially available compositions with hydrogen peroxide and peracetic acid can be categorized by their concentration of peracetic acid. Relatively concentrated products have peracetic acid concentration greater than about 25 %, with about 30- 35% being typical. There are less concentrated products with peracetic acid concentration of about 15%. Still less concentrated are products with peracetic acid of about 5%. Although all of these compositions may be called dilute solutions of peracetic acid, they are corrosive and are diluted still further with water to make "Use Dilution^" solutions for their use as microbiαdes.

(0022 J One reason for such concentrated commercial embodiments is that for the microbicidal treatment of a given surface area, the quantity of concentrate material to be shipped is substantially less than for the Use Dilution or an RTU embodiment with concentration equivalent to the Use Dilution. Another reason is that Use Dilutions and RTU solutions comprising compositions with peracetic acid concentration less than about I % have not exhibited sufficient storage stability for regulatory approval and practical commercial shel f life because small changes in the concentrations of hydrogen peroxide or acetic acid in such compositions, especially by loss, reaction with the container, or degradation, can lead to a relatively large fractional reduction in the peracetic acid concentration, and moreover, the peracetic acid is reactive and is also susceptible to decomposition and reactions with the container, so, as a result, the composition may no longer be in compliance with regulatory requirements for active ingredient concentrations.

|0023| The prior art does not offer a storage stable RTU composition comprising a very dilute solution comprising hydrogen peroxide in concentration in the range of 2 to 8 % weight/weight (vv/w) and peracetic acid in concentration in the range of 0.05 to about 0.74 % W''w as active ingredients, which has all of the desired characteristics listed above. Furthermore, there is no such storage stable R I U composition in the prior art for use as a photosensitizer for very rapid photo-activated and photo-killing. Further, in addition to storage stability, RTU compositions as very dilute solutions still may be corrosive, and they may be subject to regulatory constraints on the mode of shipping and packaging volumes, though lesser constrains than for more concentrated compositions.

|0024j Much prior art has been directed to overcoming these undesirable properties and providing storage stable and reduced corrosivity compositions with peracetic acid concentration greater than about 1 % vv/vv that can be shipped in commercially useful amounts and modes. In contrast to these more concentrated compositions, Martin et al teaches an RTU embodiment as a very dilute solution that has all of the desired characteristics except that no method for making a stable storage RTU microbicidal composition is given.

|0025| Peracetic acid (also known as peroxyacetic acid) in aqueous solution is necessarily found as a component with hydrogen peroxide, and acetic acid. Peracetic acid can be formed by reaction of acetic acid and hydrogen peroxide, which, in a reverse reaction are the products of hydrolysis of peracetic acid. Peracetic acid and hydrogen peroxide can be very reactive with trace constituents even in very dilute solutions. Furthermore, while solutions of peracetie acid, hydrogen peroxide, acetic acid, and water can be prepared that have the constituent proportions that correspond to a chemical equilibrium between the formation and hydrolysis reactions, such solutions arc generally unstable, especially in the presence of trace amounts of contaminants in the solution or because of interaction between constituents of the solution and the container for the solution.

|0026) Compositions with peracetic acid concentration < 1 %, and especially those with concentration < 0.5%, generally have poor storage stability in contrast to more concentrated compositions. The formation reaction and hydrolysis reaction rates generally depend on the concentration of hydrogen ion [H⁺]. Concentrated peracetic acid solutions have low pH, i.e., abundant [H¹]. and so, chemical equilibrium or near equilibrium can readily be obtained for compositions for which the formation rate is in balance with the rates of hydrolysis and other destruction/loss reactions. However, in the case of a very dilute peracetic acid solution, or more

I I concentrated compositions that are buffered to raise pH, the formation and hydrolysis reaction rates may become slow. AJso, reactions involving other ingredients to the composition, which are added to achieve certain desired properties, may greatly alter the reaction rates and the rate of approach to equilibrium. Such ingredients include sequcstrants, stabilizers, chelators, which are added as stabilizers to one or more of the components used to make the dilute solution, anti- corrosives, surfactants (surface active agents), or rheological modi Here such as polymer, or they may be inadvertent additives as contaminants such a.s transition metals, halides, and organics. The effect of one or more of these additional components can make unstable a very dilute peracetic acid solution that is initially prepared at or near equilibrium. The consequence is poor storage stability.

(0027J The prior art describes several different approaches to obtain storage stability for dilute solutions. These approaches include ( I) compositions comprising concentrates wherein component losses and degradation amount to an acceptably small fraction of the active ingredients, i.e., the ingredients that are the principal active microbicidal ingredients, (2) compositions that comprise binary components wherein ingredients that might react and lead to poor storage stability are put in separate components for mixture prior to use within the pot-life of the mixture, (3) the use of stabilizers and sequestrants to sufficiently overcome the effects or prevent reactions with trace components such as mono- and divalent metal ions and organic contamination that can react with the active ingredients or components necessary for equilibrium and adversely affect storage stability, and (4) use of very clean ingredients that have sufficiently low concentration of trace metals, organic contamination, salts, etc, so that reactions that lead to degradation occur acceptably infrequently so that the desired storage li fetime is achieved.

|()028| These approaches to obtain storage stability have disadvantages of one or more undesirable attributes for the characteristics listed above. More concentrated compositions are more corrosive and have poor material compatibility, and further, there are severe constraints or prohibitions against shipping higher concentration solutions. The use of stabilizers and/or sequestrants may lead to undesirable residue or environmental impact. Further, handling the concentrate for mixing requires appropriate personal protective equipment (PPE), adequate ventilation, and spill mitigation means that are by far more extensive than those required for handling and use of a dilute solution. Binary compositions involve mixing and may involve concentrate that is corrosive or has unacceptable constraints on shipping. The use of very clean ingredients may contribute greatly to stability, but as a sole approach is insufficient for stability of ver>' dilute compositions.

10029] Another approach for storage stability is the addition of stabilizer, e.g., sequestrant that 'captures' trace quantities of metals and metallic ions. Storage stability is commonly limited because of the degradation of the active ingredients by interactions with trace quantities of mono- and divalent ions, especially those of transition metals, by interactions with trace quantities of halides and/or with trace quantities of organic contamination, and also because of interactions of one or more of the components of the aqueous solution with the container for the composition. One or more stabilizer compounds are commonly added to sequester the metallic species and an anti-corrosive compound may be added to reduce the interaction of the composition with its container. ' Several examples have been given above. An additional example is aliphatic alcohol ethoxylate wetting agent which has an EO number of greater than 4 in an amount from 0.1 to 5 % w/w (US 5.489,706 to Revell). The sequestrant may also be an anti-corrosive compound. Further, an anti-corrosive compound commonly is also desirable so that the anti-microbial composition will not damage items that it contacts for microbicidal treatment.

|0030| Still another approach is the use of very pure, sometimes called "ultra pure" water, such as de-ioni/.cd, reverse osmosis, and filtered water, and 'clean' ingredients in the production of the pcracctic acid and hydrogen peroxide solution so that only an insignificant concentration of undesirable chemical species is present that may lead to degradation or decomposition of the active ingredients or acetic acid that participates in the equilibrium reactions of such compositions (tor example, US 5,508.046 to Cosentino).

10031 1 Λ different approach to reduce the corrosive effects and the shipping constraints and to obtain storage stability is the formulation of the composition as an equilibrium or near-equilibrium solution with sufficiently small concentrations of active ingredients to reduce shipping constraints and to employ a sufficient amount of stabilizer to obtain storage stability (see for example, US 5.656.302 to Cosentino). However, when such compositions arc very dilute solutions, they are difficult to make with accurately achieved and storage stable concentrations of the active ingredients, in particular, the concentration of the peracetic acid. Accurately achieved concentrations and storage stability are of special importance when such very dilute solutions are incorporated in products packaged as pre-vvetted wipes, which include pre-saturated wipes.

[0032] Generally, the minimum requirement for storage stability is a relative change of less than 10% in the concentration of the microbicidal active ingredients in the course of a year. In some jurisdictions a larger change during the approved shelf-life of the product is permitted, e.g.. a relative change in peracetic acid of up to about 30% and relative change in hydrogen peroxide of up to about 10% in a year or longer, e.g., in three years.

|0033| Storage stable compositions in the prior art and in commercially available products have a concentration of peracetic acid that typically is greater than 1 % w/w and contain stabilizer with concentration greater than about 0.5%. e.g., inorganic phosphate (US 5.077,008 to Kralovic. US 5,624,634 to Brougham, US 5,767,308 to Thiele). polymeric molecularly dehydrated phosphates (US 2,590,856 to Greenspan), pyro-phosphate (US 4.320, 102 to Dalton). ortho-phosphate, phosphonate, phosphonic acid (US 5,130,053 to Fcascy), including organic phosphonic acids (US 4,051 ,058 and 4,051 ,059 to Bowing, US 6,028, 104 to Schmidt) or their salts, an example being I -Hydroxy Ethylidene-l , l-Diphosphonic Λcid (H EDP) CAS No. 2809- 21 -4, or ethylenediami netetracetic acid (EDTA) or its sodium salt, or pyridine carboxylatc (see for example, US 5,656,302 to Cosentino. Zhao, et al., and Dul'neva ct al.). For typical dilute solutions with peracetic acid concentration in the range of about 5 to 15 % w/w, a Use Dilution comprising a 5-fold to 100-fold or greater dilution will have stabilizer concentration that is less than 0. 1 %. However, for a very dilute composition with peracetic acid concentration less than I % w/w, especially one that is an RTU solution, a stabilizer concentration greater than about VA % may lead to an unacceptable amount of residue, in particular when the stabilizer is a phosphate or phosphonate compound that may have adverse environmental impact. Thus, the prior art does not provide very dilute RTU compositions that are storage stable for one or more years and that have low stabilizer content, i.e., less than about % % w/w. [0034J Martin ct al teaches the benefits of dilute anti-microbial compositions comprising an aqueous solution of peracctic acid and hydrogen peroxide with anionic surfactant and water soluble polymer containing PVP with a lactam ("PVP/lactam"). The benefits include superior efficacy by comparison with compositions not containing anionic surfactant and PVP/lactam, good material compatibility, i.e., low corrosivity, and use as sterilant, disinfectant, saniti/er. and decontaininant. The composition comprises a photυsensitizer for light-activated killing of microbes and also an effective microbicide without the light activation. As a concentrate nominally comprising about 24% hydrogen peroxide and 1 .2% peracctic acid, a 6- fold dilution made by mixing one part of the concentrate with 5 parts of water results in a Use Dilution solution with about 4.2% active ingredients that has been shown to be a superior sterilant. disinfectant, sanitizer, sporicides, bactericide, virucides. fungicide, mold-killer, photosensiti/er disinfectant, and photosensitizer sporicidal decontaminant.

|0035] As a very dilute RTU composition according to Martin et al comprising about 4 to 5% hydrogen peroxide and about 0.2 to 0.3% peracetic acid with an equilibrium amount of acetic acid, microbicidal properties that are comparable or superior to the Use Dilution are obtained. However, it is found that the use of any of the common stabilizers described above, for example, phosphonate, inorganic phosphate stabilizer, phosphonie acids or their salts, HEE)P, ED^'I A, et al. in an amount greater than about 0.5% w/vv leads to an adverse interaction of the stabilizer with the anionic surfactant and polymer containing PVP with a lactam. The adverse interaction leads to the formation of a flocculent or precipitate and a loss in the microbicidal efficacy, anti-corrosion, and wetting/thin film-forming benefits of the composition containing the anionic surfactant and polymer. As a consequence, the preparation of a very dilute RTU composition of Martin et al cannot use stabilizer such as phosphonate or inorganic phosphate stabilizer with concentration of about 0.5% or greater to obtain storage stability.

[0036] The preparation of a storage stable, very dilute RTU composition of Martin et al has previously posed a challenge because small errors in the proportions of the hydrogen peroxide and acetic acid ingredients can lead to unacceptably large errors in the equilibrium concentration of peracetic acid. Moreover, the incompatibility and undesirability of inorganic phosphate, phosphonate, phosphonie acid stabilizer and the like at concentration greater than 0.5% makes the composition susceptible to minor trace amounts of metal ion contamination. The preparation is also made complicated by the prior ait's lack of or conflicting quantitative knowledge of the effect of a trace quantity acid catalyst and stabilizer on the rates for the reactions that determine and influence the chemical equilibrium of the composition. Further, slow interactions of the ingredients with container material and loss of one or more component compounds can shift the equilibrium or quasi-equilibrium concentrations of the components of the composition to values that are outside of the regulatory acceptable limits. Such interactions may include evaporation and permeation, and may be exacerbated by "vented" or incompletely sealing caps.

|0037] Still further, the prior art does not disclose unambiguous equilibrium constant values and does not teach ingredient proportions for the reliable and consistent preparation of storage stable, very dilute RTU compositions. Λn accurate value of the equilibrium concentration quotient K₀ for very dilute compositions was not known because compositions of the prior ail contain stabilizers and acid that apparently alter the equilibrium balance between peracetic acid formation and hydrolysis, so, the compositions of the prior art appear to have different values of K_c (see, for example, US 5,767,308 to Thiele, Uul'neva et al., and Zhao et al).

[0038J Dilute aqueous peracetic acid solutions comprise mixtures of peracetic acid (CH₃COOOH. a.k.a. PAA), water (H₂O), acetic acid (CH₃COOH, a.k.a. AcOH), and hydrogen peroxide (H₂Oi. a.k.a. HP). Commonly, such solutions also contain a small amount of acid catalyst: the most common being sul furic acid. The acetic acid + hydrogen peroxide react as a "forward" reaction (also, the "formation" reaction) with reaction rate K | to form peracetic acid and water, which undergo a hydrolysis reaction as a "reverse" reaction with reaction rate K.₂, i.e.,

CHiCOOH + H₂O₇ o CH ,COOOH + H₇O .

[0039| The equilibrium constant Ko for the reactions is the product of the equilibrium concentration quotient, K₀. and the activity constant quotient, Y_M, i.e.. |0040| Effective reaction rates k| and k₂ can be defined that include the effect of dependence of the activity coefficients on concentration so that the ratio of the effective reaction rates is equal to the equilibrium concentration quotient, i.e., r Ic₂ [HP][AcOH] where [x] is the molar concentration of species "x", PAA means peracetic acid, HP means hydrogen peroxide, and K_c will vary with the ionic strength of the solution.

[ 0041 ] Ideally, equilibrium means that the ingredients to the reaction are in proportions so that the concentrations of the individual reactants do not change in time. In practice, there are additional reactions so that ideal equilibrium is not achieved, or there are differences in concentration from equilibrium so that equilibration proceeds, but a condition of near-equilibrium exists for which the temporal changes are sufficiently slow that the composition meets practical use. storage, and regulatory requirements.

[0042] However, a storage stability challenge is posed by equilibrium or near- equilibrium very dilute aqueous compositions with a water mole fraction that is greater than or equal to about 0.91 and with peracetic acid concentration less than 1 % w/w and more concentrated dilute solutions for which the ratio of peracetic acid concentration and hydrogen peroxide is less than about 0. 15, because small changes or errors in the concentration of hydrogen peroxide and/or acetic acid can lead to large changes in the concentration of peracetic acid. Such errors in concentration may result from the difficulty of accurately measuring peracetic acid concentration in a very dilute solution having a concentration of hydrogen peroxide that is much greater than the concentration of peracetic acid. Changes in concentration may result from degradation of one or more ingredients, especially the degradation of hydrogen peroxide by reactions catalyzed by transition metal ions or halide ions, and it may also result from a loss of water and other constituents from the composition, for example, by evaporation or permeation. Moreover, the peracetic acid is reactive and it is also susceptible to decomposition and reactions with the container and impurities. Thus, the storage stability of such compositions has been elusive, especially for compositions containing little or no slabili7er. As a consequence, the prior art has not adequately provided such storage stable compositions and methods for their preparation.

[0043] Regulatory requirements for the storage stability of products comprising peracctic acid-hydrogen peroxide solutions constrain the concentration of the active ingredients to remain, for the duration of the shelf-life of the product, within a range that is defined by a lower certified limit and an upper certified limit. The value of the range depends on the jurisdiction of the regulatory agency. Typically, for compositions with hydrogen peroxide between about 1 % and 8 % vv/vv. the allowable range in hydrogen peroxide concentration may be ±10 % w/ w of the nominal value, and the allowable range for the pcracetic acid concentration may be in a range from 15 % to i-30% w/w of the nominal value.

[0044| Although some prior art teaches compositions with peracetic acid concentration less than 1 %, such very dilute compositions do not exhibit acceptable storage stability for one year or more. An example of such a very dilute composition is provided by Cosentino (5,656,302. Table 1 ), which has an initial equilibrium concentration quotient K₀ of about 1 .4 and comprising about 0.055 % w/w peracetic acid, about 1 % w'w hydrogen peroxide, and about 5 % w/w of acetic acid, but this composition contains about 0.5% or greater concentration of phosphonic acid stabilizer and within a few days of mixture, the peracetic acid concentration is found to rise substantially and K₀ to rise to nearly 2. In the course of 193 days, the peracetic acid concentration has nearly doubled to more than 0.9 % w/w, and K_^- is greater than 2. Therefore, the composition of Cosentino's example in his Table I does not represent a storage stable equilibrium, nor docs it have IC_C of about 1 .4 at room temperature. Thus. Cosentino does not provide for a storage stable very dilute composition with little or no stabilizer and also having phosphate ester surfactant in combination with water soluble polymer containing lactam.

[0045] Moreover, the prior art does not provide a process for making a composition with sufficient accuracy so that the concentrations in a composition produced in a batch can be selected and obtained so that upon transferring the batch material to product packages, for example, smaller containers, that the shift in composition can be offset with the effects of evaporation, permeation, and interactions of the composition with the container. |0046| Prior art teaches formation of peracetic acid and water as products of the reaction of acetic acid and hydrogen peroxide or acetic anhydride and hydrogen peroxide. Once formed in aqueous solution, the equilihrium is a balance of the forward formation reaction and reverse reaction of hydrolysis of pcracetic acid.

[0047| Crommclynck (US 4,297,298) teaches a method of making a dilute, storage stable solution containing a rated concentration between I and 20% by weight of an aliphatic carboxylic peracid. In his method, the composition made by preparing a concentrated solution of aliphatic peracid from the corresponding carboxylic acid or anhydride and hydrogen peroxide in a concentration of between 60 and 90% in the presence of the substantially minimal amount of strong acid catalyst necessary to obtain equilibrium of the system in a maximum period of 48 hours; and diluting the concentrated solution of aliphatic peracid, prepared in the preparing step, with a solution containing at least one of the reagents used in the said preparing step in an amount and concentration sufficient to bring the concentration of the aliphatic peracid at least to the rated concentration of the mixture. This method involves very concentrated initial reagents and substantial dilution by which it is very difficult to accurately achieve peracetic acid concentration much less than I % w/w. Moreover, the concentrated initial reagents are not compatible with a prior addition of surfactant and polymer, and so the anti-corrosive benefit to reduce the interactions of hydrogen peroxide, acetic and peracetic acids with the blending vessel are not obtained.

|0048| Le Rouzic ct al (US 4,743,447) teaches very dilute compositions with 0.01 to 0.04 % peracetic acid. 1 -8 % hydrogen peroxide, preferably about 3 %, and an equilibrium amount of acetic acid (0.5 to 1 .5 %). These compositions are made by direct reaction of hydrogen peroxide and acetic acid. However, the accurate preparation of such compositions is problematic. Moreover, Le Rouzic teaches the optional use of a non-ionic surfactant, and so, a different equilibrium is to be expected for a composition containing anionic phosphate ester surfactant as for the compositions of the instant invention.

|0049| Brougham et al (US 5,349,083) teaches a process for the production of a dilute solution of a lower aliphatic peracid having an equilibrium composition by contacting hydrogen peroxide with a lower aliphatic acid each at each initial high concentrations in an aqueous reaction mixture thereby to rapidly form a reaction mixture rich in the lower aliphatic pcracid and diluting the reaction mixture with water and with any required quantities of lower aliphatic acid and/or hydrogen peroxide to reproduce the equilibrium composition of the dilute solution, the process being characterized in that the reaction mixture rich in lower aliphatic pcracid is diluted before it has itself reached equilibrium. However, accurate achievement of the desired final concentrations by Brougham's process requires knowing the equilibrium composition and accurately making the necessary dilutions. Brougham's prescription is to predetermine an equilibrating 'model' system and making measurements. This process does not provide for account of batching reactions other than the "forward" formation reaction and the "reverse" hydrolysis reaction. In particular, account is not made of the ancillary batching reactions of decomposition of peracetic acid to acetic acid and oxygen, degradation reactions between the ingredients and the containing vessel, and evaporation, and in particular at an elevated batch temperature. Thus, Brougham's process is not readily used to make a very dilute solution with high accuracy.

[0050] DaSilva et al (US 5,358,867) teaches a process for the accelerated production of stable very dilute peracetic acid solutions in equilibrium. DaSilva's process is an alternative to make dilute equilibrium, storage stable solutions of peracetic acid to the process wherein such compositions are made from mixtures of aqueous hydrogen peroxide and acetic acid, or by dilution of more concentrated peracetic acid solutions, which takes a long time because of the low concentrations of the active participating materials. By DaSilva, the process can be accelerated by employing a two step procedure in which a concentrated peracetic acid solution is diluted with water and partially hydrolyzed in the first step, and then the hydrolysis reaction is quenched by addition of hydrogen peroxide in the second step. As with the Brougham process, the DaSilva process does not provide for account of the ancillary batching reactions.

|00511 According to DaSilva, stable solutions, in equilibrium, of peracetic acid in low concentrations are considered to be those which contain between 0.05 and 2.5% by weight peracetic acid; 1 .0 and 7.0% by weight hydrogen peroxide; 0.01 and 1.5% by weight, often from 0.2 to 1.5% by weight and sometimes up to 1 .0% by weight catalyst; 0.01 and 1 .0% by weight stabilizer; 0.05 and 5.0% by weight wetting surfactant and the necessary quantities of water and acetic acid. Mineral, sulphonic or phosphonic acids and the derivatives thereof are considered as suitable catalysts. Pyridine carboxylates and derivatives thereof are considered as suitable stabilizers and, finally, alkylaryl sulphonatcs and the derivatives thereof as suitable wetting surfactants. DaSilva's Example 1 is a solution with about 2.2 % peracetic acid and an apparent K_c of about 1.77, and Example 2 is a solution with about 0.13 % peracetic acid and an apparent K_t of about 3.773. No prescription is given to determine the specific equilibrium compositions, the value of K_c, or to account for the ancillary batching reactions.

[0052| Malonc et al (US 5,565,23 1 ) teaches that a peracetic acid solution can be prepared by any of the methods known in the art, which generally comprise reacting acetic acid or acetic anhydride solution with hydrogen peroxide, optionally at elevated temperature, and in the presence of strong acid catalyst, together with any desired stabilizers, such as dipicolinic acid and or an organic phosphonic acid such as ethyl enehydroxy-di phosphonic acid. Λs Malone et al is about effective disinfection of sugar solutions with peracetic acid solutions, means are not provided for achieving accurate very dilute equilibrium peracetic acid solutions, which are not necessary for M alone' s objects.

[0053| Cosentino (US 5,656,302) teaches stable, shippable microbicidal compositions including between about 0.2 to 8% hydrogen peroxide, about 0.2 to 1 1 % peracetic plus acetic acid, 0 to about 1 .0% sequestrant such as organic phosphonic acid or its salt and water, and surfactant between 0 and about 1 % with the ratio of total acid to H₂O₂ being between about 1 .0 and 1 1. Several examples are given, but the examples are for compositions with water mole fraction less than 0.9 except for the very dilute solution of Table I . The data of this table are seen by inspection to show that the peracetic acid concentration nearly doubles in 193 days, and so, the composition docs not represent a stable equilibrium or near-equilibrium composition, (^■'urther, in spite of the high precision of the data presented by Cosentino, a process for accurately making the composition is not provided.

SUMMARY OF THR INVENTION 100541 Λ method is provided for the microbicidal treatment of a surface such as sanitation, disinfection, sterilization, and decontamination of a surface or object by use of an microbicidal composition comprising a very dilute aqueous solution of peracetic acid, hydrogen peroxide, acetic acid, water soluble polymer containing lactam, phosphate ester surfactant, and little or no stabilizer, and according to the method enhanced microbicidal efficacy is obtained when the composition is applied onto a surface as a thin film wetting the surface and subsequently is an evaporating film so that a shorter contact time for a desired fractional reduction in microbial population is obtained because of the increase in the concentration of the microbicidal active ingredients as the water in the composition evaporates from the thin film. The composition may be applied as a wiped, sprayed, or brushed on liquid, as a sprayed, drifted, or electrostatically attracted aerosol, or by immersion such as dipping.

[0055] The method for the microbicidal treatment of a surface comprises the step of applying a very dilute peracetic acid solution as a microbicidal composition to form a thin layer that wets the said surface; and the additional steps of contacting the said surface with the said microbicidal composition for a contact time. T_c. that is greater than about 20 % but less than or equal to 1 00% of the evaporation time, t_e, of the thin layer. i.e., 0.2 <— < 1.0 , and during the contact time the thin layer is evaporating; and after the contact time, the optional step of illuminating the wet said surface with light for photosensitized microbicidal effect; the optional step of rinsing the surface with clean water to substantially remove residue; the optional step of drying the said wet surface with a sterile wipe: and the optional step of air drying the said wet surface.

|0()56| When t_c < T_c, the method is extended so that after applying the microbicidal composition and contacting the surface for about 100% of the evaporation time, the steps of applying and contacting are repeated one or more times unti l the cumulative exposure time that is the product of the evaporation time and the number of application steps, N_app, is at least equal to the desired contact time, i.e.. N_:ippt_c > l^' _c.

100571 In another aspect, the invention is a process for accurately making a batch of a storage stable embodiment of the compositions for use in the above method of microbicidal treatment of a surface, whereby according to the process ingredients comprising a relatively concentrated solution of peracetic acid, hydrogen peroxide, and acetic acid, a relatively concentrated solution of hydrogen peroxide, glacial acetic acid, phosphate ester surfactant, water soluble polymer containing lactam, little or no additional stabilizer, and optionally small amounts of acid catalyst such as sulfuric acid and minors such as fragrance and colorants are combined in a specified order and in precise amounts to form a more dilute solution with peracetic acid at concentration greater than the desired final concentration of peracetic acid and reacted at elevated temperature to obtain with accuracy an equilibrium or near-equilibrium very dilute composition with concentrations of active ingredients that are storage stable within regulatory limits for more than one year.

|0058| The process accurately makes a batch of a storage stable microbicidal composition comprising a very dilute peracetic acid solution with the resulting composition having an equilibri um concentration quotient of about

1 1

K₁ « 1 .4cxp 240.7 - - at a temperature T given in degrees Kelvin and T is

J 203.2,

between about 283 and about 328 degrees Kelvin and the mole fraction of water of the said resulting composition is greater than about 0.9. According to the process, in the first step.

( 1 ) the target concentrations are selected, these being the concentrations of hydrogen peroxide, peracetic acid, polymer, and surfactant in the resulting composition at a selected batching temperature in the range of about 40° C" to about 55° C.

The following steps are:

(2) calculating the target equilibrium concentration of acetic acid in the said resulting composition;

(3) selecting an initial concentration of peracetic acid,

(4) determining by calculation that includes the decomposition of some of the peracetic acid into acetic acid and oxygen and the evaporation of some of the water during the batch process, and optionally, the degradation of some of the peracetic acid, acetic acid, and hydrogen peroxide, the amount of a diluted solution of a more concentrated solution of known composition, designated the peracetic acid stock solution, comprising peracetic acid, hydrogen peroxide, acetic acid, acid catalyst, and water, the amount of glacial acetic acid of known concentration, the amount of an aqueous solution of hydrogen peroxide of known concentration, designated the hydrogen peroxide stock solution, the amounth of surfactant, polymer, and minors, and the amount of de-ionized/reverse osmosis filtered water to be added to the batch to obtain the target concentrations;

(5) heating about 75 % to about 100 % of the amount of de-ionizcd/reverse osmosis filtered water in a clean, passivated hlending vessel to the said selected batching temperature and continuously mixing the contents of the said vessel to limit the spatial temperature variation of the said contents to less than about 5° C;

(6) adding the determined amount of water soluble polymer to and mixing with the said heated .water; then

(7) adding the determined amount of surfactant to and mixing with the contents of the vessel; then

(8) adding the determined amounts of hydrogen peroxide solution and glacial acetic acid to and mixing with the contents of the vessel; then

(9) adding the determined amount of peracetic acid solution to and mixing with the contents of the vessel; then

( 10) adding the remainder of the said determined amount of water to and mixing with the contents of the vessel; then

( 1 1 ) maintaining the contents of the vessel at the batching temperature with less than about 5 ⁰C spatial or temporal variation in the temperature of the said contents for a batching time in the range of about 2 to 4 equilibration times: then ( 12) measuring the concentrations of^" hydrogen peroxide, peracetic acid, and optionally acetic acid;

( 13) the optional step of adjusting the composition of the blended mixture to obtain the target concentrations;

( 14) the optional step of adding one or more said minor ingredients to and mixing

«

w ith the contents of the vessel;

( 1 5) cooling the contents of the contents of the vessel to a desired temperature or to ambient temperature in a time that is much less than an equilibration time, and optionally adding one or more said minor ingredients to and mixing with the contents of the vessel; then

( 16) the optional step of storing the resulting composition in the vessel, or transferring the said contents to another or several vessels, or transferring the said contents to product packages, or transferring the said contents as an ingredient in one or more products.

[0059| In another aspect, the instant invention provides the compositions made by the above process and comprising very dilute peracetic acid solutions that are storage stable R l^'U microbicidal compositions that can be used in the microbicidal treatment of a surface by the method of the instant invention. Further, the compositions made by the above process comprise photosensitizcr for light-activated anti-microbial efficacy.

[0060J The storage stable, very dilute RTU compositions so made can be used for microbicidal treatment by a variety of application methods such as liquid or aerosol spraying or misting, wiping, pouring, or by immersion of objects into the composition, or, still further, as a photosensitizcr, for application as a liquid or aerosol into a volume or onto a surface for subsequent illumination by light, especially ultraviolet light. Anti-microbial uses include use as a sanitizer, disinfectant, sterilant. virucidc. fungicide, moldicide, bactericide, dccontaminant, and sporicide. The microbicidal compositions also may be used as ingredients in other products to obtain microbicidal efficacy for a liquid aqueous composition. Further, the storage stable, very dilute RI U compositions may be incorporated with application means such as the prc-wetted wipes, e.g., partially or fully prc-saturated wipes, carriers, or applicators, or added at the time of use to such application means. Moreover, the microbicidal composition can be useful for additional purposes such as cleaning, washing, deodorizing, and as preservative. In another aspect, the composition also can be further diluted just prior to use as a sanitizer, sanitizer- cleaner, or other microbicidal application.

[00611 Desirable characteristics of the RTU solution include the following:

( 1 ) microbicidal efficacy when applied as a thin film on a surface.

(2) the consistent formation of a thin layer, i.e., a thin film, that thoroughly wets and coats the surface and has enhanced microbicidal effect as an evaporating thin film,

(3) an acceptably minimal and easily removable residue of non-volatile components after evaporation of the film formed by application of the microbicidal composition,

(4) insignificant interference of the microbicidal composition with the removal and collection of soil and pathogens from the surface by the wipe during the wiping action,

(5) storage stability of the RTU solution upon application to the wipe and during packaging and while packaged with the wipe, especially in the context of the relatively large surface area per mass of a wipe for a given package size, and

(6) accurate concentration of the constituents of the very dilute RTU composition after batching so that the regulatory agency allowed range of concentration for an active ingredient can be well exploited to accommodate changes in composition of the very dilute RTU composition during the shelf li fe of a pre-wettcd wipe product item.

|0062] The composition can be applied by various means, for example, by aerosol spraying, pouring, painting, brushing, etc. or be applied with a wipe, such as a partially-saturated or saturated pre-wetted wipe, or a wipe wetted just prior to use. Further, the composition may be used as a microbicidal bath for immersion of objects to be treated, or used as a mist, fog, or aerosol spray to kill airborne microbes and/or be used as a fumigant.

(0063) Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0064| The above and other objects and features of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompanying drawings, in which:

(0065) Fig. I shows the evaporation time for a uniform liquid layer as a function of relative humidity for various initial layer thickness (bottom) 12.5 μm to (top) 75 μm, for air current conditions that are typical of a ventilated interior room (v~ 0.3 m/s and X - 0.3 m);

[00661 F'g- 2 shows the evaporation time for a uniform liquid layer as a function of relative humidity for various initial layer thickness (bottom) 25 μm to (top) 100 μm, tor air current conditions that are typical of a container undergoing decontamination outdoors in a 7 mph wind (v ~ 3.2 m/s, X ~ 1.0 m);

[0067) Fig. 3 shows the concentration of hydrogen peroxide in the remaining liquid layer of the composition of Example 1 (initial concentration is 4.4 % w/w) as a function of the evaporated fraction of the initial layer, wherein the boxes are experimental measurements and the curve is a theoretical prediction;

|0068| Fig. 4 shows the ratio (solid curve) of the concentration of hydrogen peroxide in the remaining liquid layer and its initial concentration as a function of the evaporated fraction, (percent) and the ratio (dotted curve) of the concentration of peracetic acid in the remaining liquid layer and its initial concentration as a function of the evaporated fraction (percent), wherein the diamonds correspond to the experimental measurements of hydrogen peroxide;

(0069) Fig. 5 shows the time integrated product of concentration and time (CT) for an evaporating liquid layer of the composition of Example 1 as a function of T_c/t_e (in percent), which is set equal to the evaporated fraction (ξ in %), wherein it is seen that the CT is enhanced about a factor of 1 .25 for ς = 25%, about a factor of 2 for ξ = 50% and about a factor of 3.3 for ς -70%;

[0070] Fig. 6 shows the log reduction in R. coli on the bottom surface of a 14 mm diameter well of a polystyrene 24 well plate after a 30 second treatment by 40 μL of microbicide at various concentrations of active ingredients, wherein the initial film thickness of microbicide is approximately 1 50 μm, and the evaporation time is greater than 5 minutes, so very little evaporation occurs and consequently, very little enhancement of active ingredient concentration occurs, wherein the absicissa shown in the figure is the weight percentage of hydrogen peroxide in the composition, wherein the ratio of peracetic acid and hydrogen peroxide is 1 :20, and wherein the dashed line is the limit of detection of the measurement (LOD = 6.94 logs reduction);

[0071 | Fig. 7 shows the log reduction plotted as a function of contact time (minutes) for B. sublilis spores dried on a glass Petri dish and treated with microbicide (comprising 4 % w/w hydrogen peroxide and 0.2 % w/w peracetic), wherein the dotted curve is a regression tit that includes the point at 5 minutes, which corresponds to the limit of detection (LOD - 7.28 logs reduction) and wherein the dashed line is a 2" order polynomial fit to the data points, each of which represents the mean of several tests;

(00721 Fig. 8 shows the log reduction of Bacillus atrophaeus spores (bar 1 ) 4.43 logs, resulting from a I minute contact time of the composition of Example 1 compared to compositions that differ by replacement of the PVP polymer containing lactam with (bar 2) 2.76 logs, PPG, (bar 3) 2.66 logs, PEG, and (bar 4) 2.78 logs, no polymer;

[0073J Fig. 9 shows the concentration quotient K₀ plotted as a function of the mole fraction of water X_w., wherein the data points shown with "x" are experimentally measured values from the data of Revel] et al., Martin et al., and DaSilva et al. for X_w < 0.91 , and the composition of the instant invention for X_w > 0.91 , wherein curve 1 is a 4^th order polynomial fit to the data, wherein curve 2 is a polynomial fit and curve 3 is a local polynomial regression to the data of Cosentino et al. wherein curve 4 is an extrapolation of the data of Sawaki et al. , and wherein curve 5 is a curve representing the evolution of the data of Cosentino et al, Table 1 from day 1 1 K₀ = 1 .394 to day 193 (K₀ ^■= 2.424);

|0074] Fig. 10 shows the concentration quotient for Cosentino^*.. Table 1 dilute formulation seen to vary significantly with time, wherein the composition does not appear to be storage-stable;

(0075| Fig. 1 1 shows the concentration quotient for Coscntino's Table 2 formulation is seen to vary significantly with time, wherein the composition does not appear to be storage- stable:

[0076| Fig. 12 shows a plot of the concentration quotient K_v vs water mole fraction X_w for the compositions of Cosentino's Table 2 showing a significant monotonic decrease of KL₀ with increasing X_w;

[0077] Fig. 13 shows a plot of the measured concentration of pcracetic acid as a function of time for batches at various temperatures ((boxes) 23°, (diamonds) 45°, and (circles) 55° C) allowing determination of the equilibration times (7.5, 1 .3, and 0.77 days, respectively);

(0078) Fig. 14 shows the concentration of pcracetic acid as a function of time shown for two batches, each started with the same initial ingredients, wherein one batch (upper curve) was made and stored just above room temperature (23° C) and the other batch (lower curve) was made and stored at 45° C;

|0079] Fig. 1 5 shows the w/w concentrations of (upper curve) acetic acid, (middle curve) hydrogen peroxide, and (lower curve) pcracetic acid as functions of time (hours) during a batch process at a temperature of about 55" C, wherein the curves are calculated values and agree with measurement data with a standard deviation of about 3 %; and |0080| Fig. 16 shows the predicted concentrations as a function of time shown for the post-batching equilibration and evolution of the batch of microbicidal composition at room temperature after batching for 60 hours at a temperature of about 55° C (as shown in Fig. 15), followed by a fast cool down with no added fragrance, and then storage in sealed containers.

DETAILED DESCRIPTION OF TIlE INVENTION

[0081 J The following description of the preferred cmbodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

Method for Microbicidal Treatment of a Surface

100821 The enhancement of CT_C during the evaporation of a thin film of a peracetic acid solution (which necessarily contain hydrogen peroxide, acetic acid, and water) that wets a surface, i.e., a layer of the liquid composition in contact with the surface and wetting the surface, can be explained by the increase in concentration in active ingredients that occurs as the layer evaporates. However, as these active ingredients become more concentrated and become more corrosive, it might be expected that they will react more with the material comprising the surface, with each other, and with the "mcrts" in the solution, such as surfactant, polymer, and stabilizers. Further, as their concentration increases, their evaporation rate also will increase significantly, and as a result, their concentrations will increase until the concomitant increasing and limiting reactions and evaporation stop further increase and even lead to decrease in their concentrations as the evaporation of the layer approaches the evaporation time, t₀. the time at which nearly all of the water in the initial layer is gone from the residual layer.

[0083J Surprisingly, it is found that for very dilute peracetic acid solutions that contain phosphate ester surfactant and water-soluble polymer, that the concentration of hydrogen peroxide increases by about a factor of 10, and the concentration of peracetic acid increases by at least a factor of 4, when 90 % of the water in an initial thin film has evaporated, i.e., when the evaporated fraction of the initial thin film. ξ. is about 0.9. Further, it is found that little corrosion occurs, even on reactive metal surfaces, and that an apparently contiguous film remains during the evaporation. Still further, evaporating films of such very dilute peracetic acid solutions that contain phosphate ester surfactant and water-soluble polymer containing lactam have superior microbicidal efficacy.

|0084| RTU microbicidal compositions and Use Dilutions (i.e., very dilute solutions that are made from more concentrated microbicidal compositions) that have hydrogen peroxide and peracetic acid as their principal active ingredients are typically very dilute aqueous peracetic acid solutions comprising at least peracetic acid, hydrogen peroxide, acetic acid and water. As very dilute solutions, the evaporation rates of the solutes, peracetic acid, hydrogen peroxide, and acetic acid are governed by Henry's Law, for which at the air-liquid interface of the solution the vapor pressure of a solute constituent is equal to the molar concentration of the constituent divided by the product of the relevant Henry's Law constant and the density of the solution (which density is close to I kg/liter for very dilute solutions), rather than Rauolt's Law. for concentrated solutions for which the vapor pressure is equal to the product of the saturation vapor pressure for a vapor of the constituent and the mole fraction of the solute in the solution. As a consequence, the solute vapor pressures are small in a very dilute solution, so the solute evaporation rates are small, and the evaporation of a thin film of such a very dilute peracetic acid solution is dominated by the evaporation of water. Moreover, even though the saturation vapor pressures of acetic acid and peracetic acid are about two-thirds that of water for temperatures in the range υf 10°-50° C, and the saturation vapor pressure of hydrogen peroxide is an order of magnitude smaller, their vapor pressures given by Henry's Law for very dilute solutions are very much smaller. Thus, when the thin film has evaporated to where ξ approaches about 2/3. the relative evaporation rates of the acetic acid and peracetic acid will be comparable to that of the water.

|0085| Knowledge of the evaporation time, t_c. for a given set of ambient conditions enables the best exploitation of the CT_C enhancement of the evaporating microbicidal composition. The evaporation time depends on the relative humidity, RH (in percent), the air speed over the liquid-air interface of the thin film, v°, the scale size for the air flow over the film, Λ^", the ambient temperature, T, and the initial thickness of the film, Δ₍₎. |0086| In a mildly convectivc atmosphere, the scale length for the vapor concentration gradient can be calculated as a function of viscosity μ. flow velocity v", mass density p_u, of the atmosphere and the diffusion coefficient D of the evaporating species. Boundary layer thickness c)^' and local vapor pressure of the evaporating species at the liquid film- atmosphere interlace provide a basis for calculating the concentration gradient Vc , which is such that

2 δ. where δ. =δ Dp₁, is the concentration boundary layer thickness [see, for example, μ

CusslerJ, and C₁, - c«- is the difference of the vapor concentration c, at the liquid-atmosphere interface and- the concentration c_a, in the atmosphere outside of the boundaiy layer.

|0087| Fick's law is used to calculate the flux, I ^", from the interface,

where .v is the distance from the interface. Note that integration of liqn.(2) and application of appropriate boundary conditions gives the result of Eqn ( I ) At the interface, the flux is

I |-₀ - -_ I IJ) VVrC - --—U/^■) ⁰S¹ T— . π ( Ji)

2 d_r

|0U88| The calculation of evaporation rate proceeds with a calculation of the volumetric loss rate from a film of thickness Δ(t). Consider an area of film /f; the corresponding liquid volume is V - AA(I). The rate of change is dV

-^- = Ϊ>,,_W Λ , (4) where v_ins is the liquid molecular volume of species s, M.

v... =^■ (5)

P_> N_β

and where M, is the molecular weight (e.g., M = 0.018 kg/mole for water), p_s is for the liquid mass density, and N_a is Avogadro's number. For an ideal gas, the number density, i.e. concentration c (or N) is calculated from p = NAT, where k is Bollzmann's constant, and R=N_ak is the ideal gas constant. Combining Eqns. (3-5) yields

where 7',.. = temperature in the air away from the layer, and Ta is the temperature at the air-liquid interface. Integration gives the time dependent thickness of the layer as.

A(O = A₁₁ - Kj and t_f A (7)

A^' where A₁, is the initial film thickness and t_e is the evaporation time.

[0089] The concentration boundary layer thickness of ό_c is calculated as a function of characteristic scale length .V of the surface over which the laminar flowing atmosphere has a convecti ve velocity of v .

1 /2

(8)

X 13 μ

Consequently, the concentration boundary layer thickness is given by,

For air, μ

and in indoor situations, a typical velocity may be estimated as the resull of ventilation, density delects of suspended aerosol, or, more typically, buoyancy as a result of thermal gradient. In outdoor situations, a typical velocity may be estimated as the mean wind speed. [00901 The buoyancy velocity for a room of height H_r and thermal difference AT is estimated as o h ^Δ7" // (10) where g(dTfl)' is a "reduced gravity¹', and ventilation flow is assumed to be small. In a typical office, U, - 2.4 m. J7^' ~ '/; ⁰K, so v" ~ 0.3 m/s, i.e., the air current is about one foot per second.

|00911 For ease of calculations, consider v" = 1 m/s, then Eqn. (9) gives <\/X as.

For water vapor in air, D = 2.6 x 10 ^•γ^~-5 nr/s at 20⁰C, and

δ_f =0.7if? ¹ AT^{1 2} =0.02163 X ^] \ (12) when i'" - 1 m/s.

|0092| For very dilute solutions, the evaporative loss of solutes is governed by Henry's Law,

where c, is the liquid solute concentration (typically in moles/kg) of solute species "s" and Kn is Henry's constant (e.g.. Ku ~ 745 mole/kg-bar for peracetic acid, Kn ~ 4900 molc'kg-bar for acetic acid, and K₁₁ - 1 . 1 x 10⁵ mole/kg-bar for hydrogen peroxide). For the solvent, the vapor pressure is given by Raoult's Law, which for very dilute solutions yields p => p, , the saturated vapor pressure of the solvent. For water, the saturated vapor pressure is p_κs Ton" (14)

and at T= 293 K, p_Λ._s - 2.318 kPa.

|0093| Relative humidity RH is given in percent and is defined as RH : P 100. ( 15)

P_n

At RH -- 50%; p = V₂ p_ns = 1 .1 59 kPa.

(0094] Thus, the characteristic evaporation time for water,

Where the subscript, "vv'^", denotes "water". The corresponding lbrm of Eqn. (7) for the layer thickness as a function of time is given by,

Δ(/) = Δ₀[ l -j- L ( 17) and the evaporation time for the thin film is given by.

', =Δ₀^, . ( 1 8)

(0095| Some examples of t_e can be calculated using Eqn. 18 for the evaporation of a microbicidal composition comprising 4% w/w hydrogen peroxide, 0.2 % vv/vv peracelic acid, and less than 5 % w/w acetic acid from a treated surface. For typical conditions on the wall in an office, e.g., v" = 0.3 m/s, X - 2.4 m. RJtI - 50%, then

r_c,₀ «3.04 x l 0⁷ s/m. ( 19)

If Aa = 30 μm, then t_c ~ 91 2 s (~ 1 5 min); for a layer initially twice as thick, t,. ~ 30 min. For a typical disinfectant or sanitizcr application onto a counter top, an area of about 1 -2 square feet might be sprayed or wiped. In this case a typical scale length is about X— 0.3 m, then /,- = 9 8 min. As a further example, consider a 6 cm diameter Petri dish in a fume hood with v" - 0.5 m/s. If the composition is applied by spraying 0.21 ml into the X - 6 cm dish, and a layer (film) results with initial thickness Δ(t=0) = 75 μm. For RH - 50%. Eqn(7) yields ^, »4.9 min. The commonly observed value is approximately 5 minutes. With a flow rate of about v° » 10 m/s such as might be achieved with a fan or an intentional flow of gas to accelerate the evaporation, the corresponding evaporation time is /_, * I . I min. It is seen from these examples that in many common circumstances, the evaporation time t_c is in the range of about one to 30 minutes for RH

~ 50 %.

IOO96| Of particular interest are thin films with initial thickness Δ(t—O) in the range of about 12.5 μm to about 75 μm or in the range of about 50 μm to about 150 μm. I he first range is typical of the layer applied by a pre-vvetted wipe such being especially useful for the disinfection or sanitizing of interior surfaces in healthcare, residential, commercial, and food preparation settings, and the like. For this initial thickness range. Fig. 1. shows the evaporation time, t_c, for a uniform liquid layer as a function of relative humidity, RJf, for various initial layer thickness (bottom) 12.5 μm to (top) 75 μm, for air current conditions that are typical of a ventilated interior room (v~ 0.3 rn/s and X ~ 0.3 m).

|0097| The second range of initial thickness is typical of the layer applied by spraying as an aerosol as being especially useful for larger scale indoor and outdoor applications such as mold remediation, decontamination of biological warfare and bio-terrorism agents, agriculture and food production settings, and the settings listed above. For part of this range, Fig. 2. shows the evaporation time, t_e, for a uniform liquid layer as a function of relative humidity, RH, for various initial layer thickness (bottom) 25 μm to (top) 100 μm, for air current conditions that are typical of a container undergoing decontamination outdoors in a 7 inpli wind (v ~ 3.2 rn/s, X - 1 .0 m).

[0098| It is found that the active ingredient concentrations increase with evaporation of a thin film by a time (t) dependent factor F(t) that is approximately given by,

Where, g|ξ(t)j is a function that depends on the evaporated fraction of the initial layer,

^_{) =} , -_^L. , (21 )

Δ(/ = 0) and that accounts for the limiting reactions and shift from Henry's Law to Rauolt's Law. This function is near unity until ξ(t)— » 1 , then g decreases rapidly and limits F(t) to a moderate finite value.

[0099) Measurements have been made to determine the change in concentration of the principal active ingredients (hydrogen peroxide and peracetic acid) with the evaporation of microbicidal compositions that are each a very dilute peracetic acid solution comprising about 0.23 % w/w peracetic acid, about 4.4 % w/w hydrogen peroxide, about 4.9 % w/w acetic acid, 0.1 % w/w phosphate ester surfactant, dc-ionized/reverse osmosis (DI'RO) filtered water, and 0.1 % W/ W polymer selected from the group of lactam containing polyvinyl pyrrolidone (P VP), polyethylene glycol (PEG), and polypropylene glycol (PPG), or with no polymer, minor amounts of stabilizer and sulfuric acid, and with a balance of water. The evaporation was performed in a polystyrene Petri dish to minimi/e any corrosion reactions between the liquid and the dish. It is found that in all cases, the concentration increases according to Hqn. (20), with the maximum measured increase being about a factor of 1 1 when ξ(t) = 0.95. This is seen in Fig. 3. where the concentration of hydrogen peroxide in the remaining liquid layer is plotted as a function of the evaporated fraction of the initial layer. The boxes are experimental measurements and the curve is a theoretical prediction with g(ξ) = I .

|00100] Fig. 4 shows the ratio (solid curve, per Eqn. (20)) of the concentration of hydrogen peroxide in the remaining liquid layer and its initial concentration as a function of the evaporated fraction, ξ (percent), and the ratio (dotted curve, theoretical estimate) of the concentration of peracetic acid in the remaining liquid layer and its initial concentration as a function of the evaporated traction (percent). The diamonds correspond to the experimental measurements of hydrogen peroxide. Measurement of the peracetic acid in the layer proved to be very challenging. The measurement for the determination of < 1 % w/w peracetic acid content in a solution with hydrogen peroxide > 8 % w/w is made difficult by the disparate volumes of tit rant required that lead to imprecise end-point determination and the associated loss of peracetic acid because of reactions in a large volume of diluent. Measurement by high performance liquid chromatography (UPLC) was complicated by the large peroxide peak interfering with the peraeetic acid determination and by the limited dynamic range of the detector. Consequently, the measured increase in peracetic acid by about a factor of 4.5 for ξ - 0.9 to 0.95 should be considered a lower bound on the actual peracetic acid concentration. Based on an approximate weighting factor to account for the increase in evaporation of peracetic acid as ξ→ 1. an estimate of the enhancement in peracetic acid concentration is shown as the dotted line in Fig. 4.

1001011 Based on the curves of Fig. 4. a prediction of the increase in the product of concentration, C, and contact time, T_c, i.e., the CT_C product, can be made. This is shown in Fig. 5, where the time integrated product of concentration and time (CT₀) for an evaporating liquid layer of the above composition with PVP polymer is shown as a function of T_c/t_c (in percent), which is set equal to the evaporated fraction (ξ in %), since by Hqns. 17 and 21. ξ - l/t_e. The solid curve shown in the figure is for hydrogen peroxide, the dashed curve is for peracetic acid, and the dotted curve corresponds to a constant concentration. It is seen that the CT_C is enhanced by about a factor of 1 .25 for ξ - 25%, about a factor of 2 for ξ = 50% and about a factor of 3.3 for c -^:70%. With the enhancement, the T_c necessary to achieve a desired log reduction, i.e.. microbicidal efficacy level, is reduced by a factor that is the inverse of the enhancement in comparison with the T_c without the enhancement.

[00102] Typically, the log reduction in a microbial population by microbicidal treatment is proportional to CT_C. This is illustrated in Fig. 5, where the log reduction in E. coli on the bottom surface of a 14 mm diameter well of a polystyrene 24 well plate after a 30 second treatment by 40 μl. of microbicidal composition with PVP polymer, described above, at various dilutions to vary the concentrations of the active ingredients. The initial film thickness of microbicide is approximately 150 μm. and lhe evaporation time is much greater than 5 minutes, so very little evaporation occurs and consequently, very little enhancement of active ingredient concentration occurs. The abscissa shown in the figure is the weight/weight percentage of hydrogen peroxide in the composition. The ratio of peracetic acid and hydrogen peroxide is 1 :20. Because the treatment time, i.e., T_c - 30 sec, is the same for all dilutions, it is seen that the log reduction decreases linearly with CT_C. The dashed line is the limit of detection of the measurement (LOD = 6.94 logs reduction). (00103] In contrast is the case for the treatment of Bacillus spores with a spray applied thin layer that is evaporating with time. Fig. 7 shows the log reduction plotted as a function of contact time (minutes) for B. subtilis spores dried on a glass Petri dish and treated with the microbicidal composition with PVP polymer (the active ingredients comprising 4 % wΛv hydrogen peroxide and 0.2 % w/w pcracetic) The dotted curve is a regression fit that includes the point at 5 minutes, which corresponds to the limit of detection (LOD = 7.28 logs reduction). The dashed line is a 2"^d order polynomial fit to the data points, each of which represents the mean of several tests. The dotted curve is misleading because the point at 5 minutes is at the LOD, and so distorts the curve. Instead, the dashed curve should be considered to be representative of the temporal dependence. It is seen that the log reduction is not a linear function of time, but instead the rate of microbicidal effect increases with time. Observation shows that the evaporation time for the spray applied microbicidal composition with initial layer thickness Λ(t=O) of about 50 μm is about 5 to 6 min, which agrees with the predicted t_e shown in Fig. I for the RH - 40 % that is typical of the laboratory in which the tests were conducted. So, the abscissa of Fig, 7 can be converted to ξ(t) by dividing the time by t_t. - 5.5 min. .Also shown in Fig. 7 is a dot-dashed curves that represents the log reduction as a linear function of contact time. Comparison of the ratio of the 2ⁿ order fit curve and the linear function with the enhancement predicted by the curves in Fig. 5, yield the results shown in Table I below. It is seen that there is reasonable agreement of the experimental values with the predicted values.

Table 1. Comparison of Experimental and Predicted Enhancement

[00104| The enhancement in concentration of the active ingredients in an evaporating thin film alone does not lead to enhanced microbicidal efficacy. It is also necessary that the thin film continues to wet the surface as it evaporates. Film defects such as dry spots, for example, those formed by surface tension effects that pull the liquid away from the defect, arc areas where the microbicidal composition may no longer be in contact with the target microbe. Thus, the film forming characteristics of the composition are important. Moreover, as taught by Martin et al, the distribution of the actives within the solution may affect the microbicidal efficacy. For example, the formation of adducts and complexes of the active ingredients with the polymer and surfactants, and the association of the polymer and surfactant can affect the efficacy. Thus, the choice of polymer and surfactant has been found to be critical. Further, it is found that these ingredients also play an important role as anti-corrosives, in film-forming and other rheological properties, and in storage stability. It is also clear that it is desirable that the composition have sufficiently low viscosity so that is can be readily applied as an aerosol spray or by wiping onto a surface as a thin film. Compositions for which the polymer and/or surfactant lead to a viscosity substantially greater than water will not flow and readily form a thin film. In a preferred embodiment, the viscosity at about room temperature of the compositions of the instant invention is less than about 2 mPa-s (cP). and in a more preferred embodiment, the viscosity is less than about 1.5 mPa-s (cP), and in a still more preferred embodiment, the viscosity is less than about 1 .3 mPa-s (cP). By comparison, the viscosity of water at room temperature is about 1 .003 mPa-s (cP).

|00105| A study was performed with the microbicidal compositions described above that varied only by the choice of polymer. In this study, an inoculum of Bacillus atrophaeous spores were dried on a Petri dish and the microbicidal compositions were applied by aerosol spray. After spray application, dry nitrogen gas flowed over the Petri dishes for about Vi minute to accelerate the evaporation of the microbicidal compositions. The apparent evaporation time was about one minute. At one minute, catalase and sodium thiosulfate neutralizer solution was applied to stop microbicidal action. The spore challenge level was approximately 1 .9 to 2.2 x H)⁷ spores and the nominal recovery was about 1 x 1 C)⁷ spores. Experimental controls included comparison test with neutralization, with no polymer, and with the various polymers, also phosphate buffered saline (PBS) controls, titer determination, and recovery fraction determination. The recovered samples were plated and enumerated on days 1 , 2 and 3.

|00106| The results of the comparative study are seen in Fig. 8. The log reduction of Bacillus atrophaeus spores by the microbicidal composition with PVP, (bar I ) 4.43 logs, is compared to compositions that differ by replacement of the PVP polymer containing lactam with PPG (bar 2). 2.76 logs, (bar 3) PEG, 2.66 logs, and no polymer (bar 4). 2.78 logs. The microbicidal composition with PVP polymer containing lactam is found to be superior by about 1.6 logs.

f00107| The applicability of the method of microbicidal treatment of a surface in a confined space may be limited because the evaporation of an applied thin layer will slow and may essentially stop because of the increase in RH as water evaporates from the layer. An example is given by decontamination or disinfection of a confined space for which the microbicidal composition is applied to the entire or the majority of the interior surface.

|0()108| In contained spaces such as a typical office, tactical shelter, or vehicle interior, thin layers with thickness greater than about 15 to 50 μm will lead to significant rise in RH. I^'his can be calculated by consideration of the volume of the space V₁, and its treated (wetted) surface area So. Note that for water at 25^° C, p_ΛS = 17.34 Torr, i.e., /?„, - 0.0228 atm, which corresponds to 22.8 l/m³. This is approximately 0.95 moles, as 1 mole = 22.4(T/273) liters (where T is the temperature in ⁰K), or approximately 17 g/m^J of water vapor. In this case, RH - 50% corresponds with approximately 8 Vz g/m³ of water. The equivalent film thickness A_f on area So is

RT S₁^p_n { 100 J where R = 8.3 1 molcs/K and p_ws is in Pa, M_w = 0.018 kg, and p_w = 1 x 1 0^J. For water at T =293 K (25°C), /Vv = 2.3 x 1 0³ Pa.

|OO I O9) As an example, consider a space with dimensions of 3 x 3 x 4 m and the thin film is applied to the entire interior surface. In this case. Si₁ = 66 m², and V₀ - 36 m³, then /I₁, =3. 12 x 1 C^)'5 (1 -/?/// 1 (K)) m. When RII is 50% initially, then a layer with Δ_t - 15.6 μm evaporating entirely will lead to RII = 100%, when liquid absorption into porous materials and other "'losses" arc negligible.

fOOl 10] The volumetric rate of evaporation slows as RH increases, and it is described by the following equation,

where V_x is a volume of the thtn film, /T₀ is the area on a surface that corresponds to the volume, and τ_e| ~ τ_M by Eqn. 16, but with RH - 0.

[001 1 1 ] The rate of mass evaporation, in , is obtained by multiplying bqn. 23 by the density, p, which gives. ή—_aά≡Ld EL)- _o ³ A^, /^>» .^Λ£-_ e (, EL) ₍₂₄)

^H τ_Λ { 100 J ^y* 2 δ_n T_{0 fK}R \ 100 J

RT dt ^{' w}

Consequently, the rate of change in the partial pressure of water is given by,

Define the humidity complement parameter, T - 1 - RJII] OO, then,

M _ 3 D_w 5₀

Ψ (26) dt 2 S_^ V_n

The solution to Hqn (26) is

And the characteristic exponentiation time for the decrease in Ψ ^~ I -RJ UlOl) is given by, a-' =^- . ^' (28)

(001 121 As an example, consider the space with dimensions of 3 x 4 x 3 m. if t)_m - 0.02163. X= 1.2 m. v" = 0.2 m/s, and Av =

2.6 x K)^"5 m²/s. S₀ ^~- 66 m², V₀ = 36 then a =^■ 1.35 x 10^'3, and a ' - 741 s - 12.35 min. If Λ^'- 0.5 m, then the time for Ψ to decrease by half is 0-.- - 0.693 a ¹ = 514 s ( = 8.56 min). Thus, for use of the method of microbicidal treatment of a surface with an evaporating film, the benefits of the instant invention are best obtained when t_c < a^{" 1}.

|00113] Calculations, observations, and extensive experience with microbicidal efficacy testing gxiidc the selection of the key parameters and conditions for obtaining the benefits of the method for microbicidal treatment of a surface of the instant invention. In preferred embodiments of the method, the application of the microbicidal composition forms a layer a thickness such that the desired T_c is greater than about 20 % of the evaporation time t_c, i.e.. T_cZt₁. > 0.2, and in a more preferred embodiment, T_c/t_t. > 0.5. For indoor use in typically ventilated rooms, when RH is in the range of about 30 % to about 60 %, an initial layer thickness in the range of about 10 μm to about 40 μm will have T₁. in the range of about 1 .3 to about 7.5 minutes. In this case, in a preferred embodiment for sanitizing treatment with T_c ~ 30 sec, a layer with initial thickness of 10 μm to 25 μm will result in an enhancement factor for the log reduction in the range of about 1 .25 to about 1 .5. Also for this indoor case, in a preferred embodiment for disinfecting treatment with T_c of about 2 minutes, a layer with an initial thickness of about 25 μm to about 40 μm will have t_c in the range of about 2.5 to about 7.5 min, and so result in an enhancement factor for the log reduction in the range of about 1 .2 to about 4. In a preferred embodiment for sporicidal disinfection treatment with T_c of about 5 minutes, a layer with an initial thickness of about 50 μm will have t_t. in the range of about 5.5 to about 9.5 min, and so result in an enhancement factor for the log reduction in the range of about 1 .7 to about 4. (001 14| For aerosol spray application, the amount of microbicidal composition applied to the surface to form a layer of a desired initial thickness can be selected by adjusting the spray applicator spray parameters such as flow rate, droplet size, and distance between the sprayer nozzle and the surface to be treated, and, for hand pumped sprayers, additionally selecting the number of pump actuations. In a preferred embodiment, the sprayer is a hand held, hand pumped aerosol sprayer that delivers about 25 μl to about 100 μl per pump actuation.

[001151 I'^or pre-wetted wipe applications, especially wipes packaged as pre-wettcd wipes, the amount of microbicidal composition applied to the surface can be selected by the choice of the saturation ratio, i.e., the ratio of the mass of the microbicidal composition to the mass of the wipe, the si/e of the wipe, the efficiency of transfer, which is the ratio of the mass of microbicide transferred to the surface and the mass of microbieide initially in the wipe, and the area to be treated. Further, as known in the art, the transfer efficiency further may depend on the • wipe material and its physical and chemical properties, morphology, which may depend on manufacturing method as well as its construction, and on its absorptive properties. In a preferred embodiment, the saturation ratio is in the range of about 0.5 to about 10. In a more preferred embodiment, the saturation ratio is in the range of about 1 to about 3, and the efficiency of transfer is in the range of 40 % to about 75 %. Another important use parameter is the ratio of treated area to wipe area. In a preferred embodiment, the ratio of treated area to wipe area is in the range of about 1 to about 4. The smaller value corresponds to thicker initial film thickness as is desirable for sporicidal disinfection treatment and longer T₀, and the larger value corresponds to a thinner initial film thickness as is desirable for sanitizing treatment and shorter T₀.

[00116| The formulation of the microbicidal composition is important to the success of the method of treatment. In a preferred embodiment, the microbicidal composition comprises hydrogen peroxide in concentration in the range of about 0.4 to 8 % by weight, peracetic acid in concentration in the range of about 0.02 to about 0.55 % by weight, acetic acid in concentration less that about 8 % by weight, phosphate ester surfactant in concentration in the range of about 0.01 to about 0.5 % by weight, water soluble polymer containing lactam in concentration in the range of about 0.01 to about 0.5 % by weight, less than 0.2 % by weight of stabilizers in the group consisting of inorganic phosphates, phosphonatcs, organic phosphonic acids or their salts, ethylenediaminetetracetic acid or its sodium salt, less than about 1 ppm of mono- and divalent metal ions, less than about 1 ppm of halitle ions, less than 0.5% by weight of minors selected from the group of fragrance, colorant, and aesthetic enhancements, and a balance of water.

[001 17| In a more preferred embodiment, the microbicidal composition comprises hydrogen peroxide in concentration in the range of about 3.5 to 5 % by weight, pcracetic acid in concentration in the range of about 0. 15 to about 0.35 % by weight, acetic acid in concentration less that about 5.5 % by weight, phosphate ester surfactant in concentration in the range of about 0.05 to about 0.3 % by weight, water soluble polymer containing lactam in concentration in the range of about 0.05 to about 0.3 % by weight, less than 0.2 % by weight of stabilizers in the group consisting of inorganic phosphates, phosphonates, organic phosphonic acids or their salts, ethylenediaminetetracetic acid or its sodium salt, less than about 1 ppm of mono- and divalent metal ions, less than about 1 ppm of halide ions, less than 0.5% by weight of minors selected from the group of fragrance, colorant, and aesthetic enhancements, and a balance of water.

|001 18| Another important parameter is the choice of surfactant and polymer. In a preferred embodiment, the polymer is a homopolyincr or copolymer of polyvinyl pyrrolidone and exemplary surfactants are anionic phosphate surfactants not limited to OC-40 manufactured by Hercules, Inc. of Wilmington, DE. This family of surfactants is characterized by the R terminal lipophilic alkyl hydrocarbon chain in range of C9 thru C l 3, a hydrophilic PRO polyoxyethylene chain in a range of PEO-3 to PFO-9 and a Z terminal mono and diester phosphate. The lactam-containing polymer and anionic surfactant are essential to obtain the desired characteristics of the composition, although they arc present in small percentage by weight. These ingredients arc selected so that the combination of anionic surfactant and lactam- containing polymer aid in providing microbicidal efficacy, especially for CT_C enhancement in an evaporating thin film of the composition. The anionic surfactant and polymer are further selected for their rheological properties so that the composition will form a good film when sprayed or applied by wiping, and yet, the polymer and surfactant do not greatly increase the viscosity or surface tension of the composition so as to preclude good transfer efficiency when applied as an aerosol spray, Further, the surfactant itself has some microbicidal efficacy and also has very good properties as an anti-corrosive, which is very important so that the composition has good material compatibility characteristics, i.e.. does not adversely affect the material of the surface to which it is applied. The polymer-surfactant interaction provides for effective dispersion in the pH range and has sequestrant properties that contribute to the equilibrium stability of hydrogen peroxide and peracetic acid. The unique aqueous soluble polymer- surfactant interaction provides a film forming capability to the formulation and further provides an anti-corrosive effective on metal surfaces. Another advantage of the polymer and surfactant combination is the essentially thorough sequestration of metals and metal ions so that the reactions of the metals and metal ions with the active ingredients are effectively eliminated so that, except for minor and acceptably small rates of degradation of the hydrogen peroxide, peracetic acid, and/or acetic acid, the metals and metal ions do not play a significant role in the chemistry, use. or efficacy of the composition. Further, the combination promotes stabilization of dielectric properties of the formulations when utilized in electrostatic spray applications. When the surfactant and polymer are each present in the microbicidal composition in concentration less than about 0.5 % w/w, acceptably little residue for most uses remains after evaporation of the composition. In a preferred embodiment, the polymer has a molecular weight in the range of about 4000 to about 20,000, and is present in a by-weight concentration in the range of 0.05% to about 0.5%. In a more preferred embodiment, the surfactant is present in the range of about 0.05% to about 0.5%. In a preferred embodiment with lower residue, the concentration of polymer and surfactant arc each less than 0.3 % w/w.

|001 19J With the preferred surfactant and polymer, the composition has a low corrosion rate on most materials. The principal anti -corrosive in the composition is the anionic surfactant. In a preferred RTU embodiment with about 4.4 % w/w hydrogen peroxide, about 0.23 % w/w peracetic acid, about 4.9 % w/w acetic acid, about 0. 1 % PVP polymer, and about 0.1 % w/w tridecyl alcohol ethoxylatc phosphate ester anionic surfactant, and less than about 0.1 % w/w stabilizer and sulfuric acid, and optionally less than about 0.4 % w/w fragrance, it is found that a typical initial immersion corrosion rate on reactive metals, copper for example, is about 4 mils/cm²-yr. This corresponds to a material loss of about 4 μg/cm² per hour of immersion. Such a corrosion rate is sufficiently low so that this RTU microbicidal composition is not classed as a corrosive and subject to the Department of Transportation shipping constraints as a Class 8 UN/DOT material. However, for spray or wipe applications, the immersion test results are not easily extrapolated to the use as an evaporating microbicide. So, tests have been performed in which various test articles and materials were repeatedly sprayed with the microbicidal composition, which was allowed to air diy between sprayings. The composition was applied at a rate of about 50 - 100 ml/m², and the spraying and drying cycle was repeated 20 times. Other than light surface tarnish on reactive metals, notably the transition metals, copper, nickel, magnesium, and zinc, there was no significant corrosion or mass loss. For materials other than some of the reactive metals, there was no observable adverse aesthetic change. For absorptive materials, a very slight swelling and a slight weight gain were observed. Surprisingly, even though the concentration of the solutes in the composition increases dramatically during the evaporation, no significant deleterious material effects occur.

(00120] The method of microbicidal treatment by an evaporating thin film is well suited for the additional step of illumination with light for producing photochemical species and also obtaining direct photo-killing and inactivation of microbes. This additional step is enabled in a preferred embodiment when the microbicidal composition is also a photosensitizer. In a photosensitize!", it is important that the anionic surfactant not merely be photoabsorptive, but that it is photoreactive and beneficially promote the formation of microbicidal species, for example, ions and radicals. In a preferred embodiment, the anionic surfactant is photoreactive and is a phosphate ester. In a more preferred embodiment, the surfactant is an alkyl cthoxylate phosphate ester. With the compositions described above for preferred embodiments, a light fluence greater than or equal to about 45 mJ/cm² of light in the visible and ultraviolet parts of the spectrum provides for sporicidal and disinfecting efficacy. In a still more preferred embodiment, the light used for such photosensitized killing and photo-killing is in the spectral range of about 210 nm to about 400 nm. In this case, the destruction of Deoxyribonucleic acid (DNA) and/or Ribonuclei acid (RNΛ) and other nucleic acid compounds results when the lluencc is greater than or equal to about 30 mJ/cm². In a still more preferred embodiment, the light is greater than or equal to about 30 mJ/CTir in the spectral region of 210 nm to about 315 nm. Process for Accurately Making a very dilute, storage stable microbicidal composition

[0012 I J In a preferred embodiment of the method of microbicidal treatment of a surface with an evaporating microbicidal thin film of the instant invention, the microbicidal composition is a storage stable, very dilute peracetic acid solution. However, to make such a composition with sufficient storage stability so that the concentrations of the principal active ingredients, namely the concentration of hydrogen peroxide, [HPj (where the square brackets f] denote molar concentrations), and the concentration of peracetic acid, [PΛΛ], remain for one year or longer within relatively narrow ranges about the nominal values for each chemical to meet requirements for regulatory approval, it is necessary that the microbicidal composition resulting from the production process have [HPJ and [PAA] very close to selected target concentrations that may differ from the nominal values.

[00122| The target concentrations are selected so that the composition will remain in compliance within regulatory limits, in spite of anticipated changes in [PAA] and [HP]. An example of such limits are the Upper Certified Limit and Lower Certified Limit that are specified for a product that is registered with the U.S. Environmental Protection Agency (US EPA) under the Federal Insecticide, Fungicide, and Rodcnticide Act.

|00123| Because, in a preferred embodiment [HP]/[PAA] is in a range of about 10 to about 30, and [PAA] « [AcOIJ], the peracetic acid can be susceptible to a substantial secular temporal change that leads to [PAA] being outside the regulatory permitted limits. The change in [PAA] can result from equilibrium shift because of degradation and decomposition reactions, or other loss of hydrogen peroxide, acetic acid, or peracetic acid. It also can result from loss of water or other ingredients by evaporation or permeation into or through a container. Further, the change in equilibrium concentrations also may be the result of errors in manufacturing the target composition. |00124| Another contribution to change in [PAAJ is reaction of the constituents of the composition with a container, or in the case of pre-wcttcd wipes, by reactions between the constituents of the composition and the wipe material or impurities associated with the wipe material.

|U0125| One approach to reduce degradation of hydrogen peroxide, peracetic acid, and acetic acid is to use ingredients that have low impurity content. In particular, the use of water that has low content of mono- and di-valent metals, halides. and organics is essential as water is the majority ingredient of the very dilute solution. In a preferred embodiment, the water is de-ionized and reverse osmosis filtered (DI/RO) water with mono- and di-valent metals in concentration below one part per million (ppm), and with species such as iron, copper, manganese, /inc ions and the like each preferably in concentration less than 100 parts per billion (ppb). However, it is also important that the other ingredients, namely the peracetic acid stock solution, the glacial acetic acid, the hydrogen peroxide stock solution, the polymer containing lactam, the phosphate ester surfactant, and minor ingredients all have low concentrations, in a preferred embodiment less than about I O ppm, and in a more pre fared embodiment less than about 1 ppm. of impurities such as organics. halides, and mono- and di-valent metal ions. The use of such low impurity materials can contribute greatly toward minimi/ing the degradation of the major constituents of the composition, but this approach is not sufficient to ensure storage stability of very dilute peracetic acid solutions.

|00126| Another approach to obtain storage stability is to use stabilizers. So- called storage stable stock hydrogen peroxide solutions are available commercially with hydrogen peroxide concentration in the range of 30 to 70 % w/w and also containing up to about 500 ppm of stabilizers such as colloidal stannate compounds, stannic phosphate, thymol, sodium orthophosphate, organophosphonates, hydroquinone, and acetani lide. When the stock hydrogen peroxide solution is added to make the microbicidal composition, the stabilizer is diluted by about an order of magnitude, so in the resulting composition, stabilizer is present in relatively small amounts. Similarly for the peracetic acid stock solution, stabilizer is often present, and an acid catalyst is also typically present, for example, sulfuric acid in an amount up to about 1 % w/w. For a peracetic acid stock solution comprising about 15 % w/w peracetic acid, about 22 % \v/\v hydrogen peroxide, and about 1 6 % w/w acetic acid, stabilizer, acid, and a balance of water, addition to a batch to make the microbicidal composition will result in the stabili/er and sulfuric acid being diluted by more than an order of magnitude to less than about 0.1 % w/w of the resulting composition. Although the residual amount of stabilizer can significantly contribute to stabilization of the composition and can effectively sequester metals and their ions that would pose a threat to storage stability, stabilizer alone in such small concentration has not been sufficient to achieve storage stability of a very dilute peracetic acid solution.

|00127| Yet another approach is to blend the composition at equilibrium or near- equilibrium. This approach in combination with the use of low impurity materials and stabili/er can help greatly in slowing the rate of a secular temporal variation in the concentration of the principal active ingredients. The prior art prov ides a variety of prescriptions for determining equilibrium conditions, which include experimental modeling and parametric variation to select equilibrium concentrations, or use of excess acid content by comparison with the hydrogen peroxide or other formulations that exhibit apparent stability. However, such seemingly successful examples do not inform the- formulation of a very dilute peracetic acid solution that contains phosphate ester surfactant and polymer containing lactam.

|00128| The prior art docs not provide adequate information about the value of K₀ (see Eqn. 3, above), notwithstanding the recent results of Zhao et al and the much earlier results of Sawaki et al. This is seen in Fig. 9, which shows the value of K₀ as a function of water mole fraction, X_w, for microbicidal compositions with hydrogen peroxide and peracelic acid as the principal active ingredients. The values of K₀ are either reported values or based on manufacturer statements about the formulation of their composition. The data points shown with "x" are experimentally measured values from the data of US 5,489,706 to Revell et al., Martin et al., and DaSilva ct al. for X_w < 0.91 , and for the composition of the instant invention for X_w > 0.91. Curve 1 is a 4^th order polynomial fit to the data. Curve 2 is a polynomial fit and curve 3 is a local polynomial regression to the data of Cosentino et al. Curve 4 is an extrapolation of the data of Sawaki et al. Curve 5 is a curve representing the evolution of the data of Coscntino et al. Table 1 from day 1 1 (K₀ = 1 .394) to day 193 (K₀ = 2.424). It is apparent that the plateau seen for Xw > 0.91 . which includes the compositions of the instant invention is not anticipated by the prior art. In particular, as shown in Fig. 10, where K_c is plotted against time, the dilute composition of Cosentino et al, Table I , is seen to vaiy significantly with time. The composition does not appear to be storage-stable. Further, as shown in Fig. 1 1 , where K_c is plotted against time, the dilute composition of Cosentino et al, Table 2, is seen to vary significantly with time. The composition does not appear to be storage-stable. By plotting the data for the exemplary compositions of Cosentino et al, Table 2. as K₀ as a function of X_w, as shown in Fig. 12, it is seen that the curve does not have a plateau for X_w > 0.91 , in contrast to the results for the composition of the instant invention. Another composition with X_w ~ 0.93 is that of US 5,851 ,483 to Nicole for which a very dilute solution has K₀ ~ 1.9. This composition is claimed to be storage stable for more than a year, but its value of K_c differs that of the compositions of the instant invention, 'likely because of the stabilizers in the composition of Nicole and the lack of phosphate ester surfactant and polymer.

|OO I 291 In practice and in the non-ideal situation for which the reactions (see paragraph [0038]) are not independent of the other reactions and loss or degradation processes that may change the concentrations of the reactants, the relationship (see paragraph [0040J) for K₍ is not accurately achieved. It is found that theoretical predictions and empirical values for K_c deteπnined for solutions with peracetic acid concentration greater than about one percent differ significantly from the value determined for the compositions of the instant invention. Further, it is found that K₁- depends on the type and amount of stabilizer present in the solution [see, for example, US 5,767,308 to Thicle ct al, wherein various stabilizers are shown to result in different equilibration times, and so different reactions rates are inferred].

|00130] For compositions with X_w < 0.91. K_c is found in the range of about 1.6 to about 3.5 for solutions at about room temperature. Analysis of several commercial peracetic acid/hydrogen peroxide compositions reveals that the majority of compositions comprises equilibrium or near equilibrium solutions with K_c in the range of 2.9 to 3.5. Zhao et al also reports K₀ - 2.9. In contrast, however, Dul'ncva et al. report K₀ in the range of 2 to 2.2 and activation energies that are lower than those reported by Zhao.

(001311 Sawaki et al studied the variation of K₀ with Hammett's acidity function for concentrated solutions of peracetic acid, hydrogen peroxide, and acetic acid. They showed that K₀ increases slowly as a function of Hammett's acidity function. In particular, at very high concentration of peracetic acid; they hypothesised that because the concentration of water is low and the demand for water for hydration of the other species is high, that available 'free^' water is reduced. The result is an increased value in K₀. For lower concentration solutions, Sawaki et al pointed out that ion clustering and the formation of complexes make K^. no longer clearly dependent on the acidity function, and so useful extrapolation of their curve to very dilute solutions is precluded.

[00132) Knowing the value of FQ for very dilute peracetic acid solutions enables calculation of the equilibrium concentrations, p- [PAAJ. h= [HP], v= [AcOH], and \v= [HjO], for lossless equilibration by the reactions (see paragraph [0038J) for an initial mixture with starting constituent molar concentrations, po= [PAA jα, ho= [HPIo, vo^~ [ACOH]₀, and Wo= [H_?O]u, where the subscript, "0", denotes the quantity as a starting value. Further the weight/weight percentage (5 w/w) concentrations of peracetic acid, hydrogen peroxide, acetic acid, and water are related to the molar concentrations by P₀= p₍|M,_>/K)p. H₀= hoMi/l Op. V₀= voMJl Op. Wo= W_t)MvJ 1 Op, where M_s is the molecular weight of constituent ^4>s" in g/mole. and p is the density of the solution in g/'ml. When the solution contains a w/w percentage of inert ingredients, I, the water concentration is related to the other constituents by

W =\ 00 - / -(P + H + V) . (29)

(00133| For a lossless system, the equilibration reactions (see paragraph [0038J) can be stated as a set of differential equations,

^•—=- k_lhv + k,pw , (30b)

. at

With stoichiometric balance, p - p<> -Λ, w = \v_o -Δ, h = h₀ ⁾ Δ, v - v_o÷Δ. and Eqns. 29 and 30, with k (T)

K_c (T) - ' can be solved to yield,

[0U134] Concentrations calculated by Eqns. 31 a and 3 1 b are typically accurate within a few percent for solutions with T near room temperature and when losses are very small. However, at elevated temperatures, the calculated predictions may significantly depart from experimentally measured concentrations. Such inaccurate prediction at elevated temperature is undesirable because it makes difficult achievement of target concentrations that maximize the duration of storage stability within regulatory limits.

|00135| Preparing and equilibrating a batch of the microbicidal composition at an elevated temperature is known in the prior art as a way to reduce the equilibration time (for example, see, US 4,297,298 to Crommelynck ct al., US 5,565.231 to Malone et al., US 5,767,308 to Thiele, and US 5.886,216 to Pudas), and so, reduce the manufacturing time that may be up to about 3 equilibration/exponentiation times. The manufacturing time can be about a month for batching at room temperature, and in contrast, it can be about two and half days at T - 55°C. Since degradation and decomposition reactions and interactions with containers begin as soon as the ingredients are combined in the manufacturing process, reducing the manufacturing time is desirable so that the resulting composition can be packaged sooner as a composition with constituent concentrations that are within the regulatory acceptable limits, and can have a longer shelf life before degradation and decomposition reactions make it unacceptable. An additional advantage of reduced manufacturing time is that the manufacturing resources have a greater throughput. In particular, batching at sufficiently elevated temperature so that at least one or. better yet, two batches per standard work week can be prepared, equilibrated sufficiently, analyzed to meet release criteria, and packaged impacts manufacturing capacity and economic return on capital investment favorably even though batching at elevated temperature requires a blending tank that is maintained at the elevated temperature and may also require a means for rapidly cooling the tank to further reduce the time between the start of the batch and packaging or storage.

|00136| However, according to the prior art, there may be a disadvantage to batching at elevated temperature because of the decomposition of peracetic acid into acetic acid and oxygen, i.e..

ICH₁COOOH => 2CUiCOOH +O₇, . (32)

The reaction rate, kj, for Bqn. 32, recently reported by Zhao, Ct al for dilute peracetic acid solutions, can amount to a substantial fractional change in peracetic acid and acetic acid because of the larger amount of these constituents in dilute solutions. However, we have found that with the smaller concentrations of these constituents in very dilute solutions, that the decomposition of peracetic acid amounts to a few percent change in these constituents so long as the time at elevated temperature is a few clays or less. By Zhao's formula for k j,

^A ₁ = M₄ - ' \ i ' (33) where, according to Zhao et al,

[-30151.551 ^' , _{t Mc} ,. . , [ - 88377.82

K_: = 2.528 x 10° exp V- Λ and /c₄ = 1 .075 x IO ' ex

RT RT

and where [H ¹ J is the concentration of hydrogen ion, which can be estimated per Zhao et al. or determined by measurement of the pH = -log[H 'j. [0013VJ Nonetheless, the decomposition of peraeetie acid during elevated temperature batching of very dilute solutions cannot be ignored if the object is an accurately made composition with concentrations that are very close to target concentrations. Additionally, the evaporation of water from unsealed or open batch containers or tanks also must be taken into account. Such evaporation can be estimated by the use of Eqns. 24 and 9. For a covered but ventilated upright cylindrical tank with about 3 m diameter, stirred at a few rpni to obtain thermal mixing, a typical water evaporation rate, ψ, of a very dilute solution is on the order of about ψ ~ 0.5 - 1 \ 10^"4 per hour. So. in 60 hours of batching, the evaporated water loss amounts to about one half percent.

|()0138| Further, degradation of peracetic acid, hydrogen peroxide, and acetic acid also can be taken into account. Commonly, blending tanks are made of Austenitic stainless steel, in a preferred embodiment, the alloy is type 3 16 stainless steel. It is also common practice to passivate the tank. e.g.. by rinsing the interior tank wall with nitric or citric acid and then rinsing the tank with DI/RO water, and then, still further, rinsing it with a dilute hydrogen peroxide solution, for example, a 4 % solution. Experiments with elevated temperature batching very dilute peracetic acid solutions in well passivatcd Austenitic stainless stcci tanks were performed, and we discovered that there are additional advantages of adding the polymer containing lactam and then the phosphate ester surfactant to hot DI/RO water in the tank prior to adding the other constituents of the composition. One advantage is that the degradation of hydrogen peroxide by interaction with the tank wall material is less by a factor of a few, e.g., about 3 to about 5. and amounts, typically, to about 1 x 10^"5 percent per hour per m² of tank wall surface area. Other advantages arc that the polymer and surfactant are more easily dissolved and can, in the presence of metals and metal ions, especially mono- and di-valent species, in concentration less than about 1 ppm, in essence, thoroughly sequester metals and metal ions prior to the addition of the other ingredients so that the reactions of the metals and metal ions with the active ingredients are effectively eliminated and so that, except for minor and acceptably small rates of degradation of the hydrogen peroxide, peracetic acid, and/or acetic acid, the metals and metal ions do not play a significant role in the chemistry, use, or efficacy of the composition. For a production size tank of about 25 m³ capacity, and when the polymer and surfactant are added prior to the other ingredients, the degradation rate for hydrogen peroxide is about δ_h - 3 x 10^~4 percent per hour. It is found that the degradation rates for peracetic acid. δ_p, and acetic acid. δ_v are comparable or less by a factor of a few, i.e., δp. δ_v ~ ] x ] (T⁴ percent per hour.

[00139] Batches may also be prepared in plastic tanks that can be heated. In a preferred embodiment, a plastic blending tank is made of high density polyethylene (HDPR), or polypropylene, or a combination of stainless steel, plastic, and/or compatible metals that are known in the art. Also, the piping, pump components, mixing blade, and other components that may contact the microbicidal composition must be made of compatible materials. Generally passivation of a plastic tank is not necessary, but the tank must be well cleaned, for example by thoroughly washing and then rinsing the tank with DI/RO water^or other low impurity water. However, interaction with the tank may still occur at elevated temperature. This may occur because of interaction between the constituents of the composition and the material of the tank and/or with contaminants not removed by prior tank cleaning. I¹Or an HDPE plastic tank, cracking and crazing may eventually occur that reduce the lifetime of the tank. Further, a heated plastic tank may not be as durable as a metal tank. However, for smaller batches, for example batches of less than about 2 m³, the cost of a plastic tank may be much less than a comparable stainless steel tank. Small batches have conveniently been made in well cleaned HDPE plastic drums that are heated with thermostatically controlled electric blankets.

|00140) Knowing the evaporation rate, and decomposition and degradation rates, allows a prediction of concentrations during the equilibration process can be determined. For a system with loss reactions involving peracetic acid, hydrogen peroxide, and acetic acid that include degradation, decomposition, interactions with the container or tank, and evaporation of water, the equilibration reactions can be stated as a set of differential equations.

-£ =k_}hv-k₂ pw- (δ_p - ψ)p - k_i p- , (34a)

— =- k_]hv + k-, pw- (δ_h - ψ)h , (34b) dt — =kjιv-k.,pw - ψw + ό_pp + ό_hh + S_vv , (34c) and — =- k_shv + k₁pw- (δ_ι - ψ^ + k^p⁷ , (34d) dt

These equations can be integrated as an initial value problem by any of several standard methods, to determine the temporal variation of the concentrations in the solution. Further, by being able to predict the secular temporal variation of the solution, a process for accurately batching the microbicidal composition is enabled. Still further, the predictive capability enables selection of post batching target concentrations and package performance criteria.

[001411 We have performed experiments with various starting concentrations, and measured the time evolution of the concentrations to determine the forward and reverse reaction rates and associated activation energies. Fig. 13 shows a plot of the concentration of peracetic acid as a function of time for various batching temperatures ((boxes) 23°, (diamonds) 45°, and (circles) 55° C). Measurement of the decay rates allows determination of the equilibration times (7.5, 1 .3, and 0.77 days, respectively).

[OO I42| In the preferred embodiments of the composition of the present invention it is found that K₁. is given by,

K_c «

at a temperature T given in degrees Kelvin and T is between about 283 and about 328 degrees Kelvin, Hn is approximately 2000 kJ/mole, R = 8.3 1 k.l/niole°K is the universal gas constant, and X_w is greater than about 0.9. Λs predicted by Cqn. 35, and as found experimentally. K_c increases about 10 % as T decreases from 55⁰C and room temperature. Furthermore, by knowing K₀, the equilibrium molar concentration o f acetic acid can be related to the concentrations of hydrogen peroxide and peracetic acid by Eqns. 29 and 35a to obtain,

|00143| The activation energies and coefficients for ki and k? for the compositions of a preferred embodiment, namely those comprising a very dilute peracetic acid solution containing PVP polymer and phosphate ester surfactant, are determined from the experimental data. The resulting expressions for the rates are,

- 58445 ]

k_χ =4.45x 10^s [H] exp- (36a)

~RT^~)

60445)

A₂ = 7. I x 10* [Hl exp- (36b)

RT

These rates differ from those reported by Zhao in both coefficients and activation energies.

{00144| The evolution of the batching process can be predicted for the batch preparation of the composition at a temperature T, by knowing good estimates of the reaction rates, degradation and decomposition rates, and the evaporation and/or permeation rates, and using the model of Eqns. 34, . Using this approach, we have found that conditions for accurately achieving target concentrations in the batching process, wherein the accuracy of the resulting composition and of the value of the rates is principally limited by the accuracy of analytic assay methods used to determine the concentrations. These are typically HPLC that is calibrated by comparison with standard solutions and/or titranietric assays such as 2-step titration methods commonly practiced in the art. In our experience, these methods have accuracy in the range of about ±2 % to about -t 8 % w/w as practiced in the conditions of a "manufacturing facility" setting.

|00145j Further, by experiment we have determined estimates of the rates for permeation and loss of water of such solutions in HDPE containers such as may be used for packaging the compositions as products. Knowing the rates for the interactions in a packaging container, and using the model of Eqns. 33-36. we have found that the evolution of the composition in the packaging container can be predicted. Consequently, the predictions can be used to select the target concentrations for the batch preparation of the composition.

|00146| We have found that in a preferred embodiment of the batch process that the starting or initial concentration of peracetic acid be greater than the target concentration by at least 15 % vv/vv, and that the initial concentrations of hydrogen peroxide and acetic acid be less than the target values. This permits adjustment of the concentrations part way through the batch process, for example by slight dilution by the addition of water, or, more preferably, by concentration adjustments by the addition of relatively small amounts of peracetic acid stock solution, and/or hydrogen peroxide stock solution, and/or glacial acetic acid, or a combination of relatively small additional amounts of one or more of these and a small dilution with Dl/RO tiltered water. The greater starting value of [PΛΛ] also provides a margin for account of measurement errors. Further, the stock peracetic acid solution may be a source of sulfuric acid and stabilizer, and so it may be advantageous to use a greater starting value of [FAAJ so that these minor ingredients are provided in the step of adding the initial peracetic acid to the batch. In a preferred embodiment, the starting value of [PAA] is at least 50 % greater than the target value, but less than about 6 times the target value.

[00147] The process accurately makes a batch of a storage stable microbicidal composition comprising a very dilute peracetic acid solution with the resulting composition having an equilibrium concentration quotient o f about

K , χ \ Acxp<— H₀ T i i \ > at a temperature T given in degrees Kelvin and T is

* \ R [ T 293.2 J] ^{l h b}

between about 283 and about 328 degrees Kelvin and the mole fraction of water of the said resulting composition is greater than about 0.9. According to the process, in the first step,

( I ) the target concentrations arc selected, these being the concentrations of hydrogen peroxide, peracetic acid, polymer, and surfactant in the resulting composition at a selected batching temperature in the range of about 40° C to about 55° C. The following steps arc:

(3) selecting an initial concentration of peracetic acid,

(4) determining by calculation that includes the decomposition of some of the peracctic acid into acetic acid and oxygen and the evaporation of some of the water during the batch process, and optionally, the degradation of some of the peracctic acid, acetic acid, and hydrogen peroxide, the amount of a diluted solution of a more concentrated solution of known composition, designated the peracetic acid stock solution, comprising peracetic acid, hydrogen peroxide, acetic acid, acid catalyst, and water, the amount of glacial acetic acid of known composition, which may contain a relatively small amount of water, the amount of an aqueous solution of hydrogen peroxide of know composition, designated the hydrogen peroxide stock solution, the amounts of surfactant, polymer, and minors, and the amount of de-ioni/ed/reverse osmosis filtered water to be added to the batch to obtain the target concentrations;

(5) heating about 75 % up to about 100 % of the amount of de-ioni/ed/reverse osmosis filtered water in a clean, passivated blending vessel to the said selected batching temperature and continuously mixing the contents of the said vessel to limit the spatial temperature variation of the said contents to less than about 5° C;

(6) adding the said determined amount of water soluble polymer to and mixing with the said heated water; then

(7) adding the said determined amount of surfactant to and mixing with the contents of the vessel; then

(8) adding the determined amounts of hydrogen peroxide stock solution and glacial acetic acid to and mixing with the contents of the vessel; then (y) adding the determined amount of peraeetic acid stock solution to and mixing with the contents of the vessel; then

( M ) maintaining the contents of the vessel at the batching temperature with less than about 5° C spatial or temporal variation in the temperature of the said contents for a batching time in the range of about 2 to 4 equilibration times; then

( 12) measuring the concentrations of hydrogen peroxide, peraeetic acid, and optionally acetic acid;

(13) the optional step of adjusting the composition of the blended mixture to obtain the target concentrations;

( 14) the optional step of adding one or more said minor ingredients to and mixing with the contents of the vessel;

( 15) cooling the contents of the contents of the vessel to a desired temperature or to ambient temperature in a time that is much less than an equilibration lime, and optionally adding one or more said minor ingredients to and mixing with the contents of the vessel; then

|()0148| In preparing the polymer and/or lhe surfactant prior to the above steps of their addition to the batch, the polymer and/or the surfactant may each be mixed with a quantity of DI/RO filtered water, which may be at elevated temperature, for example, approximately the temperature of the batch process. Such pre-mixing may lead to more ready pouring or pumping or other means of introduction of the polymer and/or surfactant to the batch, for example, reducing viscosity, or more convenient and thorough mixing. However, it is important that contaminants not be introduced into the polymer or surfactant.

|00149] In another aspect, the instant invention provides the compositions made by the above process and comprising very dilute peracetic acid solutions that are storage stable RTU microbicidal compositions that can be used in the microbicidal treatment of a surface by the method of the instant invention. Further, the compositions made by the above process comprise photosensitizer for light-activated anti-microbial efficacy.

|00150] A comparison of predictive calculation and experimental measurement is shown in Fig. 14. The concentration of peracetic acid as a function of time is shown for two batches, each started with the same initial ingredients. One batch (upper curve) was made and stored just above room temperature (23³ C). The other batch (lower curve) was made and stored at 45° G. Both batches were made in sealed HDPE containers, split into aliquots, and stored in sealed HDPE containers. Because the batching was performed in sealed containers, evaporation and water loss during the process were negligible. The increase in concentration with time is likely the result of water loss by permeation and/or absorption into the container. The difference in post-batching concentration of the two batches results from the increased decomposition of peracetic acid at elevated temperature and the difference in K_c. which is a function of temperature.

Compositions made by process

[00151 ] The microbicidal compositions made by the batch process of the instant invention comprise, at about room temperature, hydrogen peroxide in concentration in the range of about 2.0 to about 6 % by weight, peracetic acid in concentration in the range of about 0.05 to about 0.74 % by weight, acetic acid, phosphate ester surfactant in concentration in the range of about 0.025 to about 0.3 % by weight, water soluble polymer containing lactam in concentration in the range of about 0.025 to about 0.3 % by weight, acid catalyst in concentration in the range of 0 to about 1 000 ppm by weight, less than 0.2 % by weight of stabilizers in the group consisting of inorganic phosphates, phosphonatcs. organic phosphonic acids or their salts, ethylenediaminetetracetic acid or its sodium salt, less than about 1 0 ppm by weight of mono- and divalent metal ions, less than about 1 ppm by weight of halide ions, less than 0.5% by weight of minors selected from the group of fragrance, colorant, and aesthetic enhancements, and a balance of water. The combination of polymer and surfactant in the compositions of the instant invention provide, in the presence of metals and metal ions, especially mono- and di-valent species, in concentration less than about 1 ppm, essentially thorough sequestration of metals and metal ions so that the reactions of the metals and metal ions with the active ingredients are effectively eliminated and so that, except for minor and acceptably small rates of degradation of the hydrogen peroxide, peracetic acid, and/or acetic acid, the metals and metal ions do not play a significant role in the chemistry, use, or efficacy of the composition.

[00152| In a preferred embodiment, the initial starting concentration of peracetic acid is in the range of 0.75 to 1.15 % w/w so that after batching, the resulting post-batch composition has a concentration of peracetic acid in the range of 0. 17 to 0.29. The starting concentrations of hydrogen peroxide and acetic acid are below the post-batching target levels in amounts commensurate with the predictions of the results of integration of Eqns. 34. In a preferred embodiment, the surfactant is an alkyl ethoxylate phosphate ester. In a more preferred embodiment, the batching is carried out at a temperature in the range of 50° to 55° C, and the starting concentrations of 1 .09 % w/w pcraeetic acid, 4.07 % w/w hydrogen peroxide, 4.20 % w/w acetic acid, 0.1 % w/w of PVP polymer, 0. 1 % w/w rridecyl alcohol ethoxylate phosphate ester surfactant, about 50 -750 ppm of sulfuric acid, less than 200 ppm of stabili/.ers, and a balance of water having a low content of impurities, i.e., less than 1 ppm of organic compound impurities, halidcs, and mono- and divalent metal ions and metals. The resulting composition has target concentrations values that will equilibrate at about room temperature, namely T - 2O⁰C, to 0.23 % vv/w peracetic acid, 4.4 % w/w hydrogen peroxide, and about 4.9 % w/w acetic acid. Optionally, fragrance amounting to about 0.1 to about 0.4 % w/w concentration may be added to the post-batching composition. |00I53| In a preferred embodiment, the fragrance is compatible, i.e., of low reactivity, with the constituents of the composition so that the fragrance is not functionally degraded nor is the storage stability of the resulting composition significantly reduced.

Example 1

|00154| A composition was prepared by the above process with 3 days of batching at ^"1^" = 55° C and the initial concentrations of the more preferred embodiment described above by the combination of the following ingredients:

18.21 pounds stock hydrogen peroxide solution (35 % hydrogen peroxide, stabilizers, balance of water, Solvay Interox, Houston, TX)

18.64 pounds stock peracetic acid solution ( 15 % peracetic acid. 22 % hydrogen peroxide, 15 % acetic acid, stabilizer and acid minors, balance of water. BioSide HS 1 5, Enviro-Tech Chemical Services, Inc., Modesto, CΛ)

8.03 pounds glacial acetic acid (99.7 % acetic acid, balance water)

0.256 pounds PVP K- 15 polymer (International Specialty Products, Wayne, NJ)

0.256 pounds tridecyl alchohol ethoxylatc phosphate ester surfactant (Dextrol OC-40 surfactant made by Hercules, Inc., Wilmington, DE.)

21 1 .9 pounds DI/RO water

Analysis of the resulting compound by HPLC and also by titramctiϊc assay gave the following results for comparison with targeted and calculated: Table H. Com arison of redicted a easur d c ncentrations w/vv

Example 2

|00155| A batch of microbicidal composition was prepared by the process of the instant invention with 5 days of batching at 55° C and then storage in H DPE containers at room temperature. The target concentrations were:

Table 111. Comparison of predicted and measured concentrations (w/w %).

Starting Post-batching Target concentrations:

concentrations Measured Predicted

Peracetic acid: 0.98 % w/w 0.21 % w/w 0.21 % w/w

Hydrogen peroxide: 4. 10 % w/w 4.50 % w/w 4.50 % w/w Acetic acid: 4.20 % w/w 4.80 % w/w 4.88 % w/w

Time

Post-batching: Hydrogen peroxide 4.5 % Peracetic acid 0.2 ! %

3 months: Hydrogen Peroxide 4.4 % Pcracetic acid 0.22 %

6 months: Hydrogen Peroxide 4.4 % Peracetic acid 0.22 %

9 months: Hydrogen Peroxide 4.4 % Peracetic acid 0.22 %

12 months: Hydrogen Peroxide 4.3 % Pcracetic acid 0.22 %

Measurements at 3, 6, 9, and 12 months were made by titrametric assay by an independent laboratory Also, measurements of physical properties were performed. The pH of the composition is about 2. 1 and the viscosity is 1.126 mPa-s (cP) at 20° C and 0.74 mPa-s (cP) at 40° C. By comparison, the viscosity of water is about 1.003 and 0.653 mPa-s (cP), respectively. So, the viscosity of the composition is only about 12% greater than water.

Example 3

|00156] A batch was prepared with stalling concentrations of 1.003 % w/w peracetic acid, 4.262 % w/w hydrogen peroxide, and 4.58 % w/w acetic acid. The concentrations of PVP polymer and phosphate ester surfactant each were 0.1 % w/w. After 60 hours of batching, the concentrations were 0.24 % w/w, 4.60 % w/w, and 5.19 % w/w, respectively. In Fig. 1 5, the % w/w concentrations of (upper curve) acetic acid, (middle curve) hydrogen peroxide, and (lower curve) peracetic acid are shown as functions of time (hours) during the batch process at a temperature of about 55° C. The curves are calculated values and agree with measurement data with a standard deviation of about 3 %.

(OO I57| In Fig. 16, the predicted concentrations as a function of time are shown for the post-batching equilibration and evolution of the batch of microbicidal composition at room temperature afler batching for 60 hours at a temperature of about 55° C (as shown in Fig. 1 5), followed by a fast cool down with no added fragrance, and then storage in sealed containers Evaporation and permeation during storage amount to 3 %/year; peracctic acid, hydrogen peroxide, and acetic acid degrade/decompose at 9 %/year. 12 %/year, and 6 %/year, respectively. These values are based on experimental measurements of the composition in contact with synthetic textile wipe material.

|00158| Microbicidal efficacy tests have been performed with three lots of microbicidal composition prepared according to the process of the instant invention. The nominal active ingredient concentrations were selected so that they would be representative of the lower half of the range between the certified limits for the composition of Example 1. For these tests, the hydrogen peroxide concentration was about 4.2 % w/w, and the pcracetic acid concentration was 0.20 % w/w. The tests comprised several tests according to the AOAC Official Methods of Analysis and as required by the US HPA Disinfectant Technical Science Section ( DlSTSS) Guidelines. At least one of the lots of the composition used in the tests listed below was more than 60 days old at the time of testing. The tests included a .soil load (typically, 5 % soil), neutralization controls to demonstrate the success and reliability of the catalase/thiosulfate neutralization of the active ingredients at the end of the contact time, and experimental controls to determine recovered fraction of inoculum, titer concentration, and as applicable, to determine cytotoxicity, for example in the virucidal efficacy test. The tests that have been successfully passed when the composition was used as a ready-to-use microbicide with the listed contact times are listed in Table IV, below.

Table IV. Summary of Microbicidal Efficacy of a Composition of a Preferred Embodiment

STERILAiNT

(45 minutes @ room temperature)

AOAC Sporicidal Activity Test

Bacillus subtilis

Clostridium sporogcncs

DISINF ECTANT Bactericidal (2 minutes)

AOAC Germicidal Spray Test

Enterobacier aerngenes

Listeria monocytogenes

Pseudomonas aeruginosa

Salmonella typhimurium

Staphylococcus aureus

Vibrio cholerae

Salmonella enterica

Acinetobacter baumanii

Campylobacter jejuni

E. co H Ol 57:117

E. coli ESBL

Enterococcits faecalis-V 'ancomycin Resistant (VRE)

Enterococcus hirae

Haemophilus influenzae

Klebsiella pneumoniae

Legionella pneumophila

Proteus vulgaris Serratia rnarcesvens

Shigella sonnei

Staphylococcus aureus -MRSA

Community Acquired- Staphylococcus aureus (CA-MRSA) Streptococcus pneumoniae- Penicilin Resistant (PRSP)

Streptococcus pyogenes

Tuberculocidal (5 minutes)

AOAC Tuberculocidal Activity (Method

Mycobacterium bo vis

Viricidal (2 minutes) D1S/TSS-7 ASTM E 1053-97

Avian Influenza A (H3N2)

Human Coronavirus (SARS)

Adenovirus

Influenza H5N 1

Herpes simplex, Type 1

Herpes simplex, Type 2

Human Immunodeficiency type - I (H IV- I )

Influenza Λ

Influenza B

Norovirus (F. CaI ici virus)

Poliovirus type-1

Reo virus

Respiratory syncytial vims (RSV)

Rhinovirus

Rotavirus

Sporicidal Activity of Disinfectant (7 minutes)

Standard Quantitative Disk Carrier Test

Clostridium difficile spores

Fungicidal/Mold Killing

(1 minute hard surfaces)

Fungicidal Germicidal Spray Method

Aspergillus niger

Candida albicans

Trichophyton mentagrophytcs

SAJMTIZER

nds @ half-strength) on hard, inanimate non-food contact surfaces:

Saniti/.er Test for Inanimate Non-Food Contact DIS/TSS- 10

Staphylococcus aureus Klebsiella pneumoniae

(30 seconds @ half strength on pre-cleaned. food contact surfaces:

Germicidal and DetergentSanitizing Action of Disinfectants

DIS/TSS-4

Escherichia coli

Staphylococcus aureus

[00159| The tested microbicidal composition is expected to have Use Sites that will include the following: Disinfectant for use on hard, non-porous surfaces m: Hospitals and Health Care Facilities such as Clinics, Dental Offices, Hospices, Hospitals, Laboratories, Nursing Homes, Physical Therapy, Physician's Offices. Radiology. Rehabilitation, and Transport Vehicles, Critical Care Areas such as Critical Care Unit (CCU), Emergency Room, Intensive Care Unit (ICU), Neonatal Intensive Care Unit (NICU). Operating Room, Pediatric Intensive Care Unit (PICXJ), Surgery, and Emergency Medical Services, and Other Sites such as Schools, Colleges, Correctional Facilities, Hospitality Establishments such as Hotels. Motels, Cruise Ships, 'Veterinary Clinics, Animal Life Science Laboratories, Funeral Homes and Morgues, Research Laboratories, Industrial Facilities, Pharmaceutical Production Facilities. Cosmetic Processing Facilities, Consumer Home Use, Dining Areas (non-food contact surfaces), Office Buildings, Recreational Facilities, Retail and Wholesale Establishments, Prisons, Animal Care Facilities, Veterinary Facilities, Farms, Livestock Quarters, Poultry Premises. Poultry Houses and Hatcheries, and vehicles including ships, planes, automobiles, trucks, ambulances, trains, and farm vehicles.

|00160| Typical items that can be treated by the tested microbicidal composition include the following: Hospital. Healthcare, and Critical Use Sites: May be used on hard non- porous surfaces of autoclaves, bed railings, blood glucose monitors, cabinets, caits, chairs, counters, exam tables, gurneys, isolettes, infant incubators and care cribs. Intravenous (IV) poles, phlebotomy trays, polyvinyl chloride (PVC) tubing, stethoscopes, stretchers, tables, bathrooms, sinks, faucets, toilet seats and rims, towel dispensers, hand railings, stall doors, bath tubs, showers, hampers, tiled walls, telephones, door knobs, vanities, floors, non-porous shelves, and display cases. Hard non-porous exlernal surfaces include the following: ambulance equipment, diagnostic equipment, dialysis machines, mammography equipment, patient monitoring equipment, respiratory equipment, ultrasound transducers and probes, patient support ami delivery equipment. The microbicidal composition is compatible with and in typical use will not harm aluminum, low density polyethylene (LDPE). HDPE, vinyl, painted surfaces, polycarbonate, polypropylene, polyurethane varnish, PV⁷C, silicone rubber, stainless steel, medical tubing, vinyl rubber, acrylic, brass, LCD screens, copper. Corian®. glass, laminate flooring and eountertops, nickel, polycarbonate, porcelain, glass, glazed tile, and many other materials.

|ΘO16t| Microbicidal efficacy tests have also been performed with compositions having lower concentrations of active ingredients than the composition of Examples I and 2 Tests with active ingredients being about 0.05 % w/w peracetic acid and hydrogen peroxide about 1.0 % w/w, which corresponds to a 4-fold dilution of the composition of Example 2. exhibited about 5.6 logs of killing of E. coli bacteria. Thus, in addition to comprising an RTU composition, the compositions of the instant invention may be diluted prior to use as an effective anti-microbial solution.

|00162] Further, the microbicidal compositions of Examples 1 and 2 have been found to be excellent tor mold killing and mold remediation because they kill provide about 5 logs of killing of Aspergillus niger spores on porous surfaces such as textiles, nylon and polyolefin carpet, painted drywall, and painted/sealed masonry with a contact time of about 10 minutes and an application rate that is in the range of about 150 to about 300 rriL/m² as sufficient to thoroughly wet the surface and contaminated pores of lhe material. For killing mold, it is further found that use of the composition in a step of cleaning the contaminated surface and removing deposits of mold and infested material, followed by the application of the composition by aerosol spraying, wiping, pouring, or other means, results in effective mold remediation. In an aspect of its use, the compositions provide significant reduction in odors associated with mold, bacteria, and other microbial infestations. It is also found that the compositions, when used as an aerosol spray, especially in conjunction with circulating or non-still air. dramatically remove undesirable odors. Use of the compositions containing fragrance results provides the aesthetic appeal of air- freshening.

(OO 163] Still further, it is found that the microbicidal compositions of the instant invention are excellent photosensitizes. With contact time T_c ^~ one minute, and a subsequent illumination of about at least about 30 niJ/cm" fluence of UV light, killing of Bacillus atrophaeous spores to the level of detection, typically, about 6-7 logs of killing are obtained. Similarly, with T_c = 3 rnin. and a fluence of at least about about 30 mJ/cm² of UV light, killing of Bacillus siibtilis spores to the level of detection, typically, about 6.5 logs of killing are obtained. Still further, the nucleic acid compounds, which include Deoxyribonucleic acid (DNA) and Ribonucleic acid (RNA), are substantially destroyed by such photosensitized UV treatment. The rapid and thorough killing and destruction of nucleic acid compounds arc desirable attributes for uses in response and remediation to biological contamination alter a bio-terrorism event or resulting from a natural disaster, such as a Hood, and for tactical use by military forces or emergency or law enforcement rcsponders. Effective killing is also obtained with the composition being used as a photosensitizer with a contact time of about 1 to about 3 minutes and the subsequent illumination by at least about 45 mJ/ciir fluence of visible light, although treatment without UV does not substantially destroy nucleic acid compounds. The teachings of this specification are representative examples, and as will be obvious to those practiced in the art, there arc many variations in concentration and combinations -of surfactants and polymers and peroxide and peracid compounds that will exhibit the photoactive behavior that enhances microbicidal efficacy.

1001641 As various modifications could be made to the "exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the invention, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above- described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.

Claims

CLAIMS What is claimed:

1. A method for the microbicidal treatment of a surface comprising the steps of: applying a microbicidal composition to form a thin layer that wets said surface, wherein said microbicidal composition comprises:

hydrogen peroxide in concentration in a range of about 0.4 to 8 % by weight,

peracetic acid in concentration in a range of about 0.02 to about 0.55 % by weight,

acetic acid in concentration less that about 8 % by weight,

phosphate ester surfactant in concentration in a range of about 0.01 to about 0.5 % by weight,

water soluble polymer containing lactam in concentration in a range of about 0.01 to about 0.5 % by weight,

less than 0.2 % by weight of stabilizers selected from a group comprising inorganic phosphates, phosphonatcs, organic phosphonic acids or their salts, ethylenediaminetetracetic acid or its sodium salt,

less than about 1 ppm of mono- and divalent metal ions,

less than about 1 ppm of halide ions, and

a balance of water; and

contacting said surface with said microbicidal composition for a contact time that is greater than about 20 % but less than or equal to 100% of an evaporation time of said thin layer, during said contact time said thin layer evaporating.

2. The method of Claim I , wherein said microbicidal composition further comprises less than 0.5% by weight of minors selected from a group comprising fragrance, colorant, and aesthetic enhancements.

3. The method of Claim 1 further comprising:

illuminating said surface with light for photosensitized microbicidal effect.

4. The method of Claim 1 further comprising:

rinsing said surface with clean water to substantially remove residue

5. The method of Claim 1 further comprising:

air-drying said surface.

6. The method of Claim 1. wherein the step of applying said microbicidal composition is by a wipe that is wetted with said microbicidal composition just prior to use.

7. The method of Claim I , wherein the step of applying said microbicidal composition is by a packaged pre-wetted wipe with a ratio of a mass of said microbicidal composition and a mass of said wipe is in a range of 0.25 to about K).

8. The method of Claim 1 wherein in the step of contacting said surface with said microbicidal composition said contact time is about 100% of the evaporation time of said thin layer, and wherein the steps of applying said microbicidal composition and contacting said surface with said microbicidal composition are repeated one or more times.

9. The method of Claim 3, wherein said surface is illuminated by ultraviolet light with a fluence of about 30 mJ/crn' or greater for said photosensitized microbicidal effect.

10. The method of Claim I . wherein said thin layer has an initial thickness up to 1 50 μm.

1 1. The method of Claim 1 , wherein said thin layer has an initial thickness in a range of about 10 μm to 100 μm.

12. The method of Claim 1 , wherein said contact time is in a range of 25 % to 70 % of the said evaporation time.

13. A process for accurately making a batch of a microbicidal composition, wherein said batch of microbicidal composition comprises:

hydrogen peroxide in concentration in a range of about 2.0 to 6 % by weight, peracetic acid in concentration in a range of about 0.05 to about 0.74 % by weight, an equilibrium quantity of acetic acid,

phosphate ester surfactant in concentration in a range of about 0.025 to about 0.3 % by weight,

water soluble polymer in concentration in a range of about 0.025 to about 0.3 % by weight, and

a balance of water,

the resulting microbicidal composition having an equilibrium concentration

1 I

quotient of about K_c « 1.4 exp 240.71 ₇- - at a temperature T given in degrees

L \ T 293.2

Kelvin, wherein T is between about 283 and about 328 degrees Kelvin, and the mole fraction of water of the resulting microbicidal composition is greater than about 0.9,

said process comprising the steps of:

selecting target concentrations of hydrogen peroxide, peracetic acid, polymer, and surfactant in the resulting microbicidal composition at a selected batching temperature in a range of about 40° C to about 55° C;

calculating a target equilibrium concentration of acetic acid in the resulting microbicidal composition; and

selecting an initial concentration of peracetic acid

14. The process of Claim 13, wherein said water soluble polymer contains lactam.

1 5. The process of Claim 1 3, wherein said hatch of microbicidal composition further comprises:

acid catalyst in concentration in the range of 0 to about 1000 ppm by weight, less than 0.2 % by weight of stabilizers selected from a group comprising inorganic phosphates, phosphonates, organic phosphonic acids or their salts, ethylenediaminetctracetic acid or its sodium salt,

less than about 1 ppm by weight of mono- and divalent metal ions,

less than about 1 ppm by weight of halide ions, and

less than 0.5% by weight of minors selected from the group of fragrance, colorant, and aesthetic enhancements.

16. The process of Claim 1 5. further comprising:

determining by calculation that includes decomposition of peracetic acid into acetic acid and oxygen and an evaporation of water during the process, an amount of a diluted solution of a more concentrated solution of known composition comprising peracetic acid, hydrogen peroxide, acetic acid, acid catalyst, and water, an amount of glacial acetic acid, an amount oϊ an aqueous solution of hydrogen peroxide, amounts of surfactant, polymer, and minors, and an amount of de-ionized/reversc osmosis filtered water to be added to the batch to obtain said target concentrations.

17. The process of Claim 16, further comprising:

heating about 75 % to about 100% of the said amount of dc-ionized/reversc osmosis filtered water in a clean, passivated blending vessel to said selected batching temperature and continuously mixing contents of said vessel to limit spatial temperature variation of said contents to less than about 5 ⁰C.

1 8. The process of Claim 1 7, further comprising:

adding the determined amount of water soluble polymer to and mixing with said heated water; adding the determined amount of surfactant to and mixing with the contents of said vessel:

adding the determined amounts of hydrogen peroxide solution and glacial acetic acid to and mixing with the contents of said vessel;

adding the determined amount of peracetic acid solution to and mixing with the contents of said vessel; and

adding the determined amount of water to and mixing with the contents of said vessel.

19. The process of Claim 18, further comprising:

maintaining the contents of said vessel at said batching temperature with less than about 5 °C spatial or temporal variation in the temperature of the contents for a batching time in a range of about 2 to 4 equilibration times.

20. The process of Claim 19, further comprising:

measuring concentrations of hydrogen peroxide, and peracetic acid.

21. The process of Claim 20, further comprising:

cooling the contents of the contents of said vessel to a desired temperature or to ambient temperature in a time that is much less than an equilibration time.

22. The process of Claim 18, further comprising a step of:

adjusting the microbicidal composition of the blended mixture to obtain said target concentrations;

23. The process of Claim 18, further comprising a step of:

adding one or more said minors to and mixing with the contents of said vessel;

24. The process of Claim 2 I . further comprising a step oϊ: storing the resulting microbicidal composition in said vessel, or transferring the contents to another vessel, or transferring the contents to a product package, or transferring the contents as an ingredient in one or more products.

25. The process of Claim 13 wherein the selection of said target concentrations is made so that during the year following the making of the batch, the concentration of peracctic acid in the resulting microbicidal composition remains within an upper limit and a lower limit that are within + 30 % wΛv of said target concentration and the concentration of hydrogen peroxide in the resulting microbicidal composition remains within an upper limit and a lower limit that are within ± 10 % wΛv of said target concentration.

26. A microbicidal composition comprising:

phosphate ester surfactant in concentration in a range of about 0.025 to about 0.3 % by weight.

water soluble polymer in concentration in a range of about 0.025 to about 0.3.% by weight, and

a balance of water,

the resulting microbicidal composition having an equilibrium concentration quotient of about 1.4exp-< 240.7— \ > at a temperature T given in degrees Kelvin wherein T is between about 283 and about 328 degrees Kelvin, and the mole fraction of water of the said resulting microbicidal composition is greater than about 0.9.

27. The microbicidal composition of Claim 26, wherein said soluble polymer contains lactam.

28. The microbicidal composition of Claim 26, further comprising:

acid catalyst in concentration in a range of 0 to about 1000 ppm by weight, less than 0.2 % by weight of stabilizers selected from a group comprising inorganic phosphates, phosphonates. organic phosphonic acids or their salts, ethylenediaminetetracetic acid or its sodium salt,

less than about 1 ppm by weight of mono- and divalent metal ions,

less than about I ppm by weight of halide ions, and

less than 0.5% by weight of minors selected from a group comprising fragrance, colorant, stabilizer, and aesthetic enhancements.

29. The microbicidal composition of Claim 26, wherein the resulting microbicidal composition is made by a process for accurately making a batch of the microbicidal composition, the said process comprising the steps of:

selecting target concentrations of hydrogen peroxide, peracetic acid, polymer, and surfactant in the resulting microbicidal composition at a selected batching temperature in a range of about 40 "C to about 55 ⁰C;

calculating target equilibrium concentration of acetic acid in the resulting microbicidal composition; and

selecting an initial concentration of peracetic acid, determining by calculation that includes decomposition of peracetic acid into acetic acid and oxygen and an evaporation of water during the batch process, an amount of a diluted solution of a more concentrated solution of known composition comprising from about 8% to about 25% w/w peracetic acid, about 10% to about 35% w/w hydrogen peroxide, from about 8% to about 28% w/w acetic acid, and water, an amount of glacial acetic acid, an amount of an aqueous solution of hydrogen peroxide, amounts of surfactant, polymer, and minors, and an amount of dc- ionizcd/reverse osmosis filtered water to be added to the batch to obtain the target concentrations.

30. The microbicidal composition of Claim 29, wherein said process further comprising:

heating from about 75 % to about 100 % of an amount of de-ionized/reverse osmosis filtered water in a clean, passivatcd blending vessel to the selected batching temperature and continuously mixing the contents of said vessel to limit the spatial temperature variation of the contents to less than about 5 °C;

adding the determined amount of water soluble polymer to and mixing with said heated water;

- adding the determined amount of surfactant to and mixing with the contents of said vessel;

adding the determined amount of pcracetic acid solution to and mixing with the contents of said vessel:

adding the remainder of the deteπnincd amount of water to and mixing with the contents of said vessel;

maintaining the contents of said vessel at the batching temperature with less than about 5 ⁰C spatial or temporal variation in the temperature of the contents for a batching time in a range of about 2 to 4 equilibration times:

measuring the concentrations of hydrogen peroxide, and peracetic acid; and cooling the contents of said vessel to a desired temperature or to ambient temperature in a time that is much less than an equilibration time,

31 . The microbicidal composition of Claim 30, wherein said process further comprises:

adjusting the composition of the blended mixture to obtain the target concentrations; and adding one or more said minors to and mixing with the contents of said vessel;

32. The microbicidal composition of Claim 30, wherein said process further comprises a step of:

storing the resulting microbicidal composition in said vessel, or transferring the contents to another vessel, or transferring the contents to a product package, or transferring the contents as an ingredient in one or more products.

33. The microbicidal composition of Claim 26, wherein said microbicidal composition has a concentration of peracetic acid that remains within ± 30 % w/w of a desired nominal value in a range of about 0.05 and 0.74 % w/w and a concentration of hydrogen peroxide that remains within ± 10 % w/w of a desired nominal value in a range of about 1 and 6 % w-'w for at least one year when stored within a temperature range of I 0 to 30 ⁰C.

34. A use of the microbicidal composition of Claim 26 as a photosensiti/.er for ultraviolet light activated microbicidal effect.