WO2013160629A1

WO2013160629A1 - Anti-microbial mat

Info

Publication number: WO2013160629A1
Application number: PCT/GB2012/050899
Authority: WO
Inventors: Alexander Edward TURNER
Original assignee: At Promotions Ltd
Priority date: 2012-04-24
Filing date: 2012-04-24
Publication date: 2013-10-31

Abstract

There is provided a mat for protecting a work surface, said mat comprising an outer surface that supports an anti-microbial coating and a decorative layer, (i) wherein the anti-microbial coating comprises a polymer formed at a curing temperature of less than 600°C and contains anti-microbial particles distributed within said coating, (ii) wherein the anti-microbial coating and/or the decorative layer define an outermost surface that is exposed to contact by a user of the mat, (iii) and wherein the anti- microbial particles provide anti-microbial protection across the entire surface of said outermost surface. Also provided are corresponding processes for producing the mat.

Description

ANTI-MICROBIAL MAT

The present invention relates to mats having anti-microbial coatings, and to processes for producing such mats. The present invention also relates to decorated mats having anti-microbial coatings, and to processes for producing such decorated mats.

A class of widely used products is mats which are of the type which are used on a work surface to protect the work surface. Typical of such mats are mouse mats, desk mats, counter mats and coaster mats. In use, the mats come into regular contact with the human body, such as the hands of persons using the mats. This permits the transfer of microbes from a human body to a mat, and from a mat to a human body. Thus, mats of this type can facilitate the spread of microbes, including pathogenic microbes. This is undesirable and can be detrimental to people's health. There is therefore a need for mats which do not suffer from the above-described problems, and which can be used to prevent the unwanted spread of microbes.

Mats are often decorated on their surface, for example with a decorative pattern or with an image such as a photographic image. There is therefore also a need for decorated mats that do not suffer from the above-described problems, and which can be used to prevent the unwanted spread of microbes. In particular, it would be advantageous to provide a decorated mat wherein the present of a decoration does not compromise the prevention of the unwanted spread of microbes. The present invention addresses one or more of the above-described problems by providing anti-microbial mats, and processes for producing said mats, according to the present claims.

In one aspect, the invention provides a mat for protecting a work surface, said mat comprising an outer surface that supports an anti-microbial coating and a decorative layer, (i) wherein the anti-microbial coating comprises a polymer formed at a curing temperature of less than 600°C and contains anti-microbial particles distributed within said coating, (ii) wherein the anti-microbial coating and/or the decorative layer define an outermost surface that is exposed to contact by a user of the mat, (iii) and wherein the anti-microbial particles provide anti-microbial protection across the entire surface of said outermost surface.

The term "mat" relates to mats of the type which are used on a work surface to protect the work surface, and includes such mats as mouse mats, desk mats, counter mats and coaster mats.

Mats that do not comprise an anti-microbial agent are known in the art. Mats for use according to the present invention may be of any such type. The mat may be produced in a usual manner for that type of mat, such as (for example) by lamination, welding, moulding and cutting to size and shape. A coating is then applied in accordance with the present invention.

The mat of the present invention may be used for any suitable work surface, such as (for example) a desk, table or counter.

The mat comprises an outer surface. The outer surface may be found on the uppermost side (during normal use) of the mat before any coating process of the invention has been applied - the outer surface may include the external surface provided by the body of a mat.

The outermost surface of the mat represents a surface (following coating according to the present invention) that is exposed to contact by a user of the mat (for example when the mat is touched by the user during normal use).

A mat may be constructed of a polymer material, and thus may comprise (or consist of) a plastics material and/or a rubber material. By way of example, a mat may comprise one or more of the following polymer materials: polyvinyl chloride (PVC), mark-resistant PVC (MRPVC), polypropylene, polyester, or any other suitable plastic or plastics as known in the art. A mat may comprise a material such as paper or board. Alternatively, a mat may comprise a ceramic. By way of example, the mat may be made from bone china, porcelain, ceramics or stoneware. As a further alternative, the mat may also be made of glass. The mats of the present invention have an anti-microbial coating. A coating is a layer of material that is applied onto a surface of the mat.

The anti-microbial coating may be a clear, colourless, transparent or translucent coating. Alternatively, the coating may be a coloured coating, for example to produce a coloured mat in a corporate colour of a company.

The anti-microbial coating of the mat comprises a polymer and is cured onto the outer surface of the mat at a curing temperature of less than 600°C, for example less than 400°C or less than 300°C. This class of polymer is well known to a skilled person. "Cured" and "curing" refers to the chemical process of curing, via which process a composition (typically containing monomers, or small polymers) hardens (for example, due to the formation of cross-linking) when exposed to heat, air, infrared radiation, ultraviolet radiation, or chemical additives. Thus, the coating may be produced by curing a coating mixture to form a hardened coating.

In certain embodiments, the curing process requires heat. The heat required for the curing process may be provided by, for example, infrared radiation (such as in an infrared oven), or by convection (such as in a convection oven). Alternatively, curing may be effected by air in a process of air curing. In certain embodiments, the curing process may be carried out at a low heat, wherein "low heat" is defined as a temperature of 100°C or lower (for example, 90°C or lower, 80°C or lower, 70°C or lower, 60°C or lower, 50°C or lower, 40°C or lower, or 30°C or lower). Thus, in one embodiment, the anti-microbial coating is produced by applying a coating mixture to a mat followed by curing of the coating mixture at a temperature conducive to coating formation. A "coating mixture" comprises the ingredients that cure to form a coating on a mat. In one embodiment, the anti-microbial coating comprises (or consists of) a polymer that has been cured at a temperature of less than 250°C.

The coating of the present invention comprises (or consists of) a non-glass layer (or non-glass coating). In one embodiment, the anti-microbial coating is resistant to damage when the mat is cleaned. By way of example, the coating may be resistant to damage such as when the mat is cleaned by being wiped (e.g. by hand), washed in a washing machine, dry cleaned, or in any other suitable and appropriate manner. Examples of such coatings include polyurethane lacquers/paints, epoxy resins and polymeric blocked aliphatic diisocyanate epoxy resins.

The coating may be a spray coating (such as is applied by spraying). Alternatively, the coating may be a dip coating (such as is applied by dipping). The coating may be a clear coating or a coloured coating.

For example, the coating may comprise (or consist of) one or more of: a polyurethane (lacquer or paint), an epoxy (resin), a polyester, an acrylic, or mixtures thereof. An epoxy may be a thermosetting copolymer that is formed by the reaction between an epoxide and a polyamine. The coatings may be provided as, for example, a water- based coating mixture or a solvent-based coating mixture.

The polymer of the coating may be provided in a coating mixture as a water-based polymer or as a solvent-based polymer.

In one embodiment, the polymer may be provided in a coating mixture that contains 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10% polymer. In one embodiment, the coating comprises a cured polyurethane and/ or a cured epoxy (resin). For example, the coating may comprise (or consist of) polyurethane. In one embodiment, the coating comprises (or consists of) an epoxy coating.

By way of further example, the coating may comprise (or consist of) a polymeric blocked aliphatic diisocyanate epoxy coating, or an aliphatic (acrylic) polyurethane coating. A typical epoxy (resin) composition may comprise (or consist of):

polyisocyanate (e.g. an aliphatic diisocyanate based polyisocyanate), for example 5-

30 wt.%;

propylene glycol or ether acetate (e.g. a propylene glycol monomethyl ether acetate), for example 10-40 wt.%);

xylene (CAS No. 1330-20-7), for example 1-15 wt.%;

an organic solvent (e.g. solvent naphtha), for example 1-10 wt.%;

an epoxy resin (for example, 5-20 wt.%);

Where wt.% values are indicated, said composition components add up to 100%.

An example of an epoxy (resin) composition comprises (or consists of):

methyl ethyl ketoxime-blocked aliphatic diisocyanate based polyisocyanate <30 wt%; propylene glycol monomethyl ether acetate (CAS No. 108-65-6) <40 wt%;

xylene (CAS No. 1330-20-7) <15 wt%;

aromatic 100 (solvent naptha) (CAS No. 64742-95-6) <10 wt%;

epoxy resin <20 wt%.

Where wt.% values are indicated, said composition components add up to 100%.

By way of specific example, reference is made to DuraGlaze, which is a polymeric blocked aliphatic diisocyanate epoxy resin.

Thus, the coating may comprise (of consist of) DuraGlaze.

A further example of an epoxy coating is Slotogard, which may be obtained from Schloetter Co Ltd, Abbey Works, New Road, Pershore, Worcs, UK.

A yet further example of an epoxy coating comprises (or consists of):

an ethanol component (e.g. 2-(2-butoxyethoxy)ethanol), e.g. 5-5 wt.%;

an organic solvent component (e.g. xylene), e.g. 15-25 wt.%;

a butanol component (e.g. N-butanol), e.g. 1-5 wt.%;

epoxy resin (e.g. number average molecular weight <700), e.g. 25-50 wt.%;

wherein said composition components add up to 100%). An example of a suitable epoxy coating is Ceraglaze S 1475, which may be obtained from Neogene LLP, Watford, Hertfordshire, United Kingdom.

Further examples of a polyurethane coating are Uraflex, and Polysil SCW 700 Series, which may both be obtained from Schloetter Co. Ltd, Abbey Works, New Road, Pershore, Worcs, UK.

The coating may comprise an organic coating, such as a Transparent Stoving Finish (TSF). By way of example, a TSF may be a blend of polyurethane and epoxy resin.

A typical TSF may comprise (or consist of):

2-methoxy-l-methylethyl (CAS No. 108-65-6) 5-15%;

N-butyl acetate (CAS No. 123-86-4) 5-15%;

xylene (CAS No. 1330-20-7) 25-50%;

ethylbenzene (CAS No. 100-41 -4) 5-15%;

epoxy resin (number average molecular weight <700) (CAS No. 25068-38-6) 1-5%; Where wt.% values are indicated, said composition components add up to 100%.

Commercially available examples of TSFs are available from Neogene LLP, Watford, Hertfordshire, United Kingdom, such as TSF product code S I 805.

The coating may comprise (or consist of) a polyester coating. An example of a polyester coating is Polysil SCW 800 Series, which may be obtained from Schloetter Co Ltd, Abbey Works, New Road, Pershore, Worcs, UK.

In one embodiment, the coating comprises (or consists of) 2,5,8, 1 l-tetramethyl-6- dodecyn-5,8 diol ethoxylate (CAS No. 1691 17-72-0). Such a coating provides excellent adhesion of inks to treated films and paper. A suitable commercially available example of such a coating is DigiPrime® 5000 from Michelman International Belgium SPRL, Zoning Industriel, B-6790, Aubange, Belgium (Product code DP5000). Further example coatings suitable for use with the mats of the present invention are MG381 Extender Base, and ZC521 Thinners from Fujifilm Specialty Ink Systems Ltd, Broadstairs, Kent, United Kingdom. MG381 is an Extender Base (Clear Ink) and is defined as a Screen Printing Ink. When used as a coating it is thinned out using ZC521 Thinners, which is a Screen Printing Ink Thinner.

In one embodiment, the coating is a coating obtained by curing at a low temperature (i.e. a "low heat", as defined above). Examples of coatings that may be obtained by curing at a low temperature are DigiPrime® 5000, and MG381 Extender Base (which may be used with ZC521 Thinners).

Thus, in one embodiment, the coating comprises a coating selected from DigiPrime® 5000, and MG381 Extender Base (optionally used with ZC521 Thinners).

Other coating materials may be employed and are well known to a skilled person.

The anti-microbial coating is not a glass layer. For example, the anti-microbial coating of the present invention is not one that is obtained by glazing, which refers to heating a coating mixture at a temperature greater than 650°C (for example, 1210°C).

The coatings for use in the present invention may be coatings that are applied by printing (e.g. silk screen printing or flexographic printing).

The coating may for example be applied by silk screen printing or flexographic printing. The anti-microbial may be mixed with a coating mixture with a ratio of 0.3% to 0.5%. Coatings, inks or varnishes such as Sericol MG, Digiprime 5000, Cavendish UV over varnish ATD005, Cavendish vinyl primer AT0006 or the Emicote 2 water based primer may be used. Such coatings may then be cured either by hot air, infrared (radiation) drying, ultraviolet (radiation) drying, or on a rack at room temperature depending upon the specific properties of the carrier coating, ink or varnish being used. Once assembled, the printed, coated and laminated materials may be cut or welded to shape, for example using a platen press, HF welder, plotter or other suitable machine.

The mats of the invention comprise a decorative layer. A decorative layer comprises a decoration which covers all or part of a surface (typically at least part of an outer surface) of the mat, and may provide an aesthetic effect for the user.

The decorative layer may be a pattern or an image such as a photographic image. The decorative layer may be coloured. Thus, by way of example, the decorative layer may comprise patterns, texts, logos, advertisements, or other designs (e.g. corporate branding or trademarks), or combinations thereof. The decorative layer may comprise an image or images, such as pictures or photographic images.

The decorative layer may cover part of a surface of the mat. Alternatively, the decorative layer may cover all of a surface of the mat. A decorative layer may be applied to an outer surface of a mat.

Images and logos may be printed on the surface of paper, board, plastic or other suitable material. Similar printing technologies may be adopted as described in above. Once printed, the materials may, for example, either have a clear laminate to protect the print, or a varnish. Where a laminate is used, the laminate may be coated with a coating or varnish containing, for example, silver chloride coated titanium dioxide powder. Where a varnish or coating is used to protect the print, this may contain, for example, silver chloride titanium dioxide powder. Where varnishes are not required, for example with an all over print on the surface of PVC, paper or board, the silver chloride coated titanium dioxide particles may be mixed into the printing inks themselves, for example in similar ratios to those used when dispersed in the varnishes or coatings. The printing inks, varnishes or coatings may be cured in the same way as described above. The printed and/or coated substrates may then be laminated, cut or welded as described above. If printing paper, the product may equally be constructed by injection moulding a back layer behind the printed and treated sheet. The mat may be constructed of material which is partially or fully transparent. Thus, in one embodiment, the decorative layer is formed on the underside of a partially or fully transparent mat, such that the decorative layer is visible to a user through the topside of the mat.

The decorative layer may be formed on the mat by any suitable technique known in the art, for example dye sublimation or printing (e.g. silk screen printing, flexographic printing, offset litho digital offset or direct inkjet printing). Examples of suitable techniques for producing decorative layers include:

Dye sublimation - a sublimation paper (comprising a desired image such as a photograph) is prepared using, for example, organic inks (as described below in more detail). The sublimation paper is cut to a desired shape and placed on a coated mat, before being subjected to heat (in order to set or cure the ink). This results in the inks becoming absorbed into the coating, to form a diffuse layer within said coating. By way of example, the inks may become gaseous and permanently dye the coating.

Colour coating - a coating mixture (for example, Transparent Stoving Finish) is mixed with coloured inks (for example, from Neogene, as described below in more detail) before being applied to a mat and subjected to heat curing to form a coloured coating.

Screen printing - screen printing inks (for example, as described below) are screen printed or pad printed onto an uncoated mat and heat- or air-cured. A coating is then applied on top of the decorative layer (as described above).

WoW mats - an uncoated mat is sprayed with a coloured thermochromic ink and heat cured to form a decorative layer that in use reacts with heat to change colour. The decorative layer may be a matt layer. A coating (as described above) is then applied on top of the decorative layer.

Decal mats - decal inks (for example, as described below) are printed onto Waterslide Decal Paper. When dry, the decal paper may be cut to the desired shape and transferred, using warm water, onto an uncoated mat to form decorative layer. A coating (as described above) is then applied on top of the decorative layer.

By way of example, a decorative layer (for example, an image or logo) may be formed by printing on an upper surface or a lower surface of a mat of a suitable material, as described above, for example a plastic. The plastic top is then laminated to a foam base, which may be, for example, EPDM, EVA or an expanded PVC. If desired, the base may have a low-tack adhesive applied to provide grip to the work surface on which the mat is to be placed when in use.

Alternatively, the decorative layer may be an integral part of the mat itself. For example, the decorative layer may comprise a colour that is present throughout the mat. Any ink suitable for use on any of the above-described materials from which a mat may be made may be used with the present invention.

An example of an ink suitable for use in a dye sublimation process is an organic (aqueous) ink. By way of example, the organic ink is an ink that is applied (e.g. sets or cures) at a temperature of up to 250°C, for example at a temperature of up to 222°C, or in the temperature range of 180-220°C.

Examples of such inks are available from Sawgrass Europe, Jubilee House, Hillsborough, Sheffield, S6 ILZ, United Kingdom. Examples may include Rotech Cyan, Magenta, Yellow, Black, Black Plus, Light Cyan, Light Magenta, and Light Black.

A further example of an ink suitable for use in dye sublimation is an ink-jet ink for transfer printing that is applied (e.g. sets or cures) at a temperature of up to 250°C, for example at a temperature of up to 220°, or in the temperature range 180-220°C. Examples of such inks are available from Sensient Imaging Technologies SA, Specialty Inks and Colors, ZI Riond-Bosson 8, 1110 Morges 2, Switzerland. An example of such an ink has the name S4 Subli Blue 770 (article No. 648770W). An example of an ink suitable for use in a screen printing process is a screen and pad printing ink that is applied (e.g. sets or cures) at a temperature of up to 120°C, for example at 100°C or less (e.g. at air temperature such as 40°C or 30°C or less). Such an ink may be based on epoxy resins and on solvents. An example of an ink suitable for use in a screen printing process may comprise one or more of: 4-hydroxy-4- methylpentan-2-one (e.g. 5-15 wt.%), solvent naphtha (heavy) (e.g. 5-10 wt.%); butyl glycolate (e.g. 5-10 wt.%); cyclohexanone (e.g. 5-10 wt.%). An ink suitable for use in a screen printing process may further comprise one or more of: 2-methoxy-l- methylethyl acetate (e.g. 5-10 wt.%); (2-methoxymethylethoxy)propanol (e.g. 1-10 wt.%)); solvent naphtha (light) (e.g. 1-5 wt.%); naphtha (hydrotreated heavy) (e.g. 1-5 wt.%)); dehydrogenated gum rosin (e.g. 1-5 wt.%). Examples of such inks are available from Pad Print Limited, 14 Enterprise Court, Park Farm North, Wellingborough, NN8 6UW. An example of such an ink has the name Glass Ink GL (product No. 3321).

An example of an ink suitable for use in a colour coat process are paints or inks that are applied (e.g. set or cure) at a temperature of up to 200°C, for example at a temperature of up to 180°C, such as in the temperature range of 160-180°C. Examples of such inks are from Neogene.

An example of an ink suitable for use in a decal mat process is Covercoat yellow, available from Dove Screen Services Limited, Trinity Road, Uttoxeter, Staffordshire, ST14 8SP (product No. DS8001). The coated mats of the invention comprise an anti-microbial coating. The antimicrobial properties are derived from the presence in the coating of an anti-microbial particle that comprising or consisting of at least one anti-microbial agent.

The particles have sufficiently small dimensions to ensure substantially homogenous distribution throughout the anti-microbial coating. The particle may include a carrier, for example an inert particle meaning that it does not interfere with or otherwise adversely affect the integrity (e.g. strength and/ or appearance) of the anti-microbial coating and/ or the outermost surface. Simply for illustrative purposes, one example of a carrier is a titanium dioxide particle. Alternative carriers are well known to a skilled person. The anti-microbial agent may be coated onto or impregnated into an anti-microbial particle.

When incorporated within an anti-microbial coating component of the present invention, the anti-microbial particle retains an anti-microbial property after the curing process - in other words, the anti-microbial property of the particle is not destroyed during the curing process. Similarly, when incorporated within a decorative layer component of the present invention, the anti-microbial particle retains an antimicrobial property after the application process employed (which may, for example, include a heating or pressure application step) - in other words, the anti-microbial property of the particle is not destroyed during application of the decorative layer to the mat.

An anti-microbial agent is a substance that is able to kill or inhibit the growth of microorganisms (also known as microbes), for example bacteria, viruses, fungi and protozoa. Thus, the application of anti-microbial particles to a mat in accordance with the present invention enables the killing, colonisation inhibition, or growth inhibition of microorganisms (such as pathogenic or disease-causing microorganisms) that may contact said mat. This advantageously reduces or prevents the spread of microorganisms and therefore reduces or prevents the incidence and spread of diseases caused by microorganisms.

In one embodiment, the anti-microbial particle consists of or comprises an antibacterial agent.

More than one different type of anti-microbial agent, for example two, three, four or five anti-microbial agents may be employed in the context of the present invention and thus applied to the same mat. In this regard, use of multiple different antimicrobial agents may be employed to increase the range of microorganisms to be targeted.

The same or different anti-microbial agent(s) may be employed in the anti-microbial coating component, and in the decorative layer component of the present invention. Any suitable and appropriate anti-microbial agent may be employed for preventing or hindering the spread of any relevant infection, for example, bacterial infections, microbial infections, and viral infections. In use, the anti-microbial agent may exert its effect by destabilising microbial cell membrane/ cell wall integrity, by suppressing nucleic acid or protein synthesis, by suppressing cell division, and/ or by starving the microbes of nutrients that they would require to thrive and proliferate.

The anti-microbial agent or agents used in the present invention may be effective against one or more of Clostridium difficile, methicillin-resistant Staphylococcus aureus (MRSA), Listeria monocytogenes, Salmonella species, enteritis-causing microorganisms, Escherichia coli, Bacillus cereus, Aspergillus niger, Pseudomonas aeruginosa, Klebsiella pneumonia, Saccharomyces cerevisiae, and Penicillium purpurogenum. Preferred microbial targets of the present invention are gastro- intestinal disease-causing bacteria.

In one embodiment, the anti-microbial agent is an anti-bacterial agent.

The anti-microbial agent (e.g. silver chloride coated titanium dioxide) may be added as an ingredient to, for example, PVC, polypropylene or polyester substrates when they are extruded.

The anti-microbial particles are typically incorporated into the anti-microbial coating by a pre-mixing step prior to application of the coating mixture to the mat. The anti- microbial coating may then be formed by curing said mixture - the curing temperature and conditions are selected to ensure adequate coating formation has been achieved, whilst ensuring that the anti-microbial agent retains adequate anti-microbial activity. Said pre-mixing step ensures that the anti-microbial particles are distributed throughout the coating.

The coating and/or the decorative layer of the present invention provide an outermost surface that is typically exposed to contact by a user (during normal use) of the mat. In one embodiment, said outermost surface has anti-microbial particles distributed across the entire surface thereof. Thus, the entire outermost surface of the mat may have anti-microbial properties due to the presence of the anti-microbial agent across the entire outermost surface.

In one embodiment, the decorative layer provides at least part of the outermost surface, and wherein said decorative layer comprises anti-microbial particles. In one embodiment, the decorative layer provides at least part of an outermost surface that is exposed to contact by a user (during normal use) of the mat, said outermost surface having anti-microbial particles distributed across the entire surface thereof.

In one embodiment, the decorative layer forms a diffuse layer within at least part of the anti-microbial coating. Thus, in one embodiment, a decorative layer is formed (for example, by dye sublimation) as an integral part of the coating. Thus, advantageously, the presence of the decorative layer does not compromise the anti-microbial agent from exerting its anti-microbial effect at the outermost surface of the mat. Accordingly, a decorative layer may be incorporated into the mat, which maintains optimal anti-microbial capacity at the outermost surface local to (e.g. in the immediate vicinity of) the decorative layer. This therefore negates the need for application of a separate/ subsequent anti-microbial coating at the outermost surface local to (e.g. in the immediate vicinity of) the decorative layer.

In one embodiment, the decorative layer provides an outermost surface that is exposed to contact by a user of the mat, said outermost surface having anti-microbial particles distributed across the entire surface thereof.

In one embodiment, the decorative layer is located beneath the anti-microbial coating, said anti-microbial coating providing the outermost surface. Thus, the decorative layer does not cover, block, or otherwise form a barrier to the anti-microbial agent. In one embodiment, the decorative layer is on top of the coating, and anti-microbial agent is distributed within the decorative layer. Thus, any part of the coating that is otherwise covered by the decorative layer advantageously retains anti-microbial properties due to the additional presence of anti-microbial agent distributed within the decorative layer.

In one embodiment, the coating comprises the decorative layer. Thus, in one embodiment, a decoration is formed in such a way that it becomes an integral part of the coating. By way of example, the decorative layer may be applied with the coating, thus being applied simultaneously with the anti-microbial agent. Thus, advantageously, the presence of the decorative layer does not prevent the antimicrobial agent from having access to the external surface of the mat.

In one embodiment, the anti-microbial agent comprises silver. In one embodiment, the anti-microbial agent comprises (or consists of) silver chloride. Silver chloride is known to have anti-microbial effects, which have been attributed to the anti-microbial properties of silver ions. Accordingly, other silver halides may be similarly employed.

Other anti-microbial agents are suitable for use in the present invention, for example anti-microbial agents containing metals other than silver. Non- limiting examples include anti-microbial agents comprising one or more of the following metals: mercury, copper, iron, lead, zinc, bismuth, gold, and aluminium. Chlorides and other halides of these metals may be similarly employed. The anti-microbial agent may be incorporated as part of a slow release anti-microbial particle. Thus, in one embodiment, the anti-microbial agent is provided in a form in which the active constituent is released at a controlled rate, thus increasing the lifetime of the anti-microbial agent and making it more effective. By way of example, anti-microbial agent may be coated onto titanium oxide particles, which act as a carrier and provides slow release properties. Other suitable metal oxide carrier particles may be similarly employed, and include one or more of sodium antimony oxide, zinc iron manganese titanium oxide, iron titanium oxide, manganese antimony oxide, and manganese titanium oxide.

In one embodiment, the anti-microbial agent comprises (or consists of) titanium oxide particles coated with silver chloride. Said coated particles advantageously have slow release properties. In one embodiment, the anti-microbial agent is stable (i.e. it retains anti-microbial efficacy) after having been heated to a temperature up to 600°C.

In one embodiment, the anti-microbial agent is provided in a separate layer that is specifically just for carrying the anti-microbial agent. In one embodiment, the anti-microbial agent is stable (i.e. it retains anti-microbial efficacy) after having been heated to a temperature up to 600°C. In one embodiment, the anti-microbial coating is a coating that is produced by curing at a temperature of 600°C or less. Accordingly, the anti-microbial agent employed for use in said coating is stable at the elected temperature.

In one embodiment, the coating is a coating that is produced by curing at a temperature of 180-220°C. Accordingly, the anti-microbial agent employed for use in said coating is stable at the elected temperature.

The present invention also provides processes for producing a mat as described above. In one aspect, the present invention provides a process for producing a mat having an integral anti-microbial coating, wherein the mat comprises an outer surface that supports an anti-microbial coating, and a decorative layer, said process comprising the steps of: providing a coating mixture that comprises anti-microbial particles, wherein said coating mixture forms the anti-microbial coating upon curing at a temperature of less than 600°C, applying said coating mixture to the outer surface of the mat, curing the coating mixture at a temperature of less than 600°C to form said anti-microbial coating, wherein the anti-microbial coating defines an outermost surface that is exposed to contact by a user of the mat, and wherein said anti-microbial particles provide anti-microbial protection across the entire surface of said outermost surface.

In one embodiment, the coating mixture is cured using ultraviolet radiation. The use of ultraviolet radiation may, in certain embodiments, be combined with the use of heat. In one embodiment, the coating mixture is cured at a temperature of 180-220°C.

In one embodiment, the coating mixture is cured at a temperature of less than 180°C, for example, 150° or lower, 140°C or lower, 130°C or lower, 120°C or lower, or 110°C or lower. In certain embodiments, the curing mixture may be cured out at a low heat, wherein "low heat" is defined as a temperature of 100°C or lower (for example, 90°C or lower, 80°C or lower, 70°C or lower, 60°C or lower, 50°C or lower, 40°C or lower, or 30°C or lower).

In one embodiment, the coating mixture is cured at room temperature (e.g. 20-30°C, for example, 25°C). In one embodiment, wherein the coating mixture is cured at room temperature, the coating mixture is cured using ultraviolet radiation.

The coating mixture may be cured for a period of time of between 1 and 30 minutes, for example, 5-25 minutes, 5-20 minutes, 10-20 minutes, or 10-15 minutes.

In one embodiment, the mat includes a decorative layer on or as part of the outer surface, said process comprising applying the coating mixture to said respective outer surface, wherein the anti-microbial coating is either clear, colourless, transparent or translucent so that the decorative layer remains visible after curing.

In one embodiment, the process as described above further comprises the steps of: providing a decorative mixture, and impregnating the decorative mixture into at least part of the anti-microbial coating of the mat, wherein the decorative mixture forms a diffuse decorative layer within at least part of the anti-microbial coating. Advantageously, the resulting mat demonstrates an uncompromised anti-microbial outermost layer. Such a process may be carried out using a technique such as dye sublimation.

In one embodiment, the process as described above further comprises the steps of: providing a decorative mixture comprising anti-microbial particles, and applying said decorative mixture to at least part of the anti-microbial coating of the mat, wherein the decorative mixture is applied as a decorative layer, and wherein the anti-microbial coating and/or the decorative layer define the outermost surface. Advantageously, the resulting mat demonstrates an uncompromised anti-microbial outermost layer. In one embodiment, the process comprises providing a mat having an integral antimicrobial coating, as described above.

In one aspect, the invention provides a mat obtainable by a process as described above.

The anti-microbial agent for use in the process of the invention may be any antimicrobial agent as described above. The temperature values/ranges described herein with reference to the mat aspect apply equally to the coating step of the process aspect.

Reference herein to "supports" simply indicates that an anti-microbial coating has been applied to the outer surface of the mat. Thus, the anti-microbial coating may directly contact the outer surface and/or may be separated therefrom by one or more intervening layers/coatings.

Reference to "outermost surface" when used in the context of anti-microbial coating and/ or decorative layer applied to the outer surface of the mat means the resulting exposed surface(s) that would come into contact with a user of the mat during normal use of the mat.

Embodiments of the invention will now be described solely by way of example and with reference to the accompanying drawings.

Referring to Figure 1 , there is shown a mat having a rigid PVC surface and/or base 1. The mat has a coating 2 (for example, of DigiPrime® 5000) which comprises an antimicrobial agent 3. Referring to Figure 2, there is shown a mat having an extruded PVC surface and/or base 1 having a coating 2 (for example, MG381 Extender Base with 20% ZC521 thinners) which comprises an anti-microbial agent 3. Examples

Example 1

A mat made of see-through PVC is provided. A DigiPrime® 5000 coating, comprising an image that will form a decorative layer, is applied to the underside of the mat, such that the printed image shows through. The topside of the mat is also coated with DigiPrime® 5000 with the anti-microbial agent (silver chloride) mixed in at the rate of 0.3% to 0.5% by weight. Example 2

A mat made of extruded PVC (soft & floppy) is provided. MG381 Extender Base and ZC521 Thinners are used (Thinners makes up 20% of the mix). The Extender Base contains the anti-microbial agent (silver chloride) mixed in at 0.3% to 0.5%. The coatings are applied to the mat and cured at a low heat using ultraviolet light.

Anti-microbial efficacy

Results are presented below of tests carried out on surfaces rendered anti-microbial using silver chloride. The effectiveness of anti-microbial coatings of silver chloride is clearly demonstrated and applicable to the mats of the present invention.

The anti-microbial properties of mugs were tested in comparison to control samples lacking any anti-microbial agents. Results are presented as CFU cm^"2.

Claims

1. A mat for protecting a work surface, said mat comprising an outer surface that supports an anti-microbial coating and a decorative layer,

(i) wherein the anti-microbial coating comprises a polymer formed at a curing temperature of less than 600°C and contains anti-microbial particles distributed within said coating,

(ii) wherein the anti-microbial coating and/or the decorative layer define an outermost surface that is exposed to contact by a user of the mat,

(iii) and wherein the anti-microbial particles provide anti-microbial protection across the entire surface of said outermost surface.

2. The mat of claim 1, wherein the decorative layer provides at least part of the outermost surface, and wherein said decorative layer comprises anti-microbial particles.

3. The mat of claim 1, wherein the decorative layer is located between the outer surface of the mat and the anti-microbial coating; optionally wherein said decorative layer either includes or excludes anti-microbial particles.

4. The mat of claim 1, wherein the decorative layer forms a diffuse layer within the anti-microbial coating; optionally wherein said decorative layer either includes or excludes anti-microbial particles.

5. The mat of any preceding claim, wherein the outermost surface comprises substantially all exposed surface areas of the mat, and wherein the anti-microbial particles provide anti-microbial protection across the entire surface of said outermost surface.

6. The mat of claim 5, wherein the decorative layer is located between the base of the mat and the anti-microbial coating or wherein the decorative layer forms a diffuse layer within the anti-microbial coating;

optionally wherein said decorative layer either includes or excludes antimicrobial particles.

7. The mat of any previous claim, wherein the anti-microbial particles comprise metal oxide particles.

8. The mat of any previous claim, wherein the anti-microbial particles comprise a slow release agent that controls release of the anti-microbial agent component from the anti-microbial particles.

9. The mat of any previous claim, wherein the anti-microbial particles comprise a silver compound (e.g. silver chloride).

10. The mat of any previous claim, wherein the anti-microbial particles comprise metal oxide (e.g. titanium oxide) particles coated with a silver compound (e.g. silver chloride).

11. The mat of any previous claim, wherein the anti-microbial coating comprises a polymer formed by curing using ultraviolet light.

12. The mat of any previous claim, wherein the mat comprises (or consists of) a plastics material and/or a rubber material.

13. The mat of any previous claim, wherein the anti-microbial coating comprises a polymer formed at a curing temperature of 100°C or lower.

14. A process for producing a mat having an integral anti-microbial coating, wherein the mat comprises an outer surface that supports an anti-microbial coating, and a decorative layer, said process comprising the steps of:

providing a coating mixture that comprises anti-microbial particles, wherein said coating mixture forms the anti-microbial coating upon curing at a temperature of less than 600°C,

applying said coating mixture to the outer surface of the mat, and

curing the coating mixture at a temperature of less than 600°C to form said antimicrobial coating, wherein the anti-microbial coating defines an outermost surface that is exposed to contact by a user of the mat, and wherein said anti-microbial particles provide antimicrobial protection across the entire surface of said outermost surface.

15. The process of claim 14, wherein the coating mixture is cured using ultraviolet light.

16. The process of any of claims 14-15, wherein the mat includes a decorative layer on or as part of the outer surface, said process comprising applying the coating mixture to said respective outer surface, wherein the anti-microbial coating is either clear, colourless, transparent or translucent so that the decorative layer remains visible after curing.

17. The process of any of claims 14-16, further comprising the steps of:

providing a decorative mixture, and

impregnating the decorative mixture into at least part of the anti-microbial coating of the mat, wherein the decorative mixture forms a diffuse decorative layer within at least part of the anti-microbial coating.

18. The process of any of claims 14-17, further comprising the steps of:

providing a decorative mixture comprising anti-microbial particles, and

applying said decorative mixture to at least part of the anti-microbial coating of the mat, wherein the decorative mixture is applied as a decorative layer, and wherein the anti-microbial coating and/or the decorative layer define the outermost surface.

19. The process of any of claims 14-18, said process comprising providing a mat having an integral anti-microbial coating as defined in any of claims 1-13.

20. The process of any of claims 14-19, wherein the coating mixture is cured at a temperature of less than 100°C.

21. A mat having an integral anti-microbial coating obtainable by the process of any of claims 14-20.