Process for producing anti-microbial effect with complex silver ions

~ ~ ~ 9 ~ 2 FIELD OF THE INVENTION 3 The invention relates to methods of forming anti-microbial metal coatings, 4 foils and powders which provide a sustained release of anti-microbial metal species when in contact with an alcohol or electrolyte.

7 BACKGROUND OF THE INVENTION 8 The need for an effective anti-microbial coating is well established in the 9 medical community.

Physicians and surgeons using medical devices and appliances ranging from orthopaedic pins, plates and implants through to wound dressings and urinary 11 catheters must constantly guard against infection.

An inexpensive anti-microbial coating 12 also finds application in medical devices used in consumer hr~lthc~re and personal hygiene 13 products as well as in biomedical/biotechnical laboratory equipment.

The term "medical 14 device", as used herein and in the claims is meant to extend to all such products.

The anti-microbial effects of metallic ions such as Ag, Au, Pt, Pd, Ir (i.e.

16 the noble metals), Cu, Sn, Sb, Bi and Zn are known (see Morton, H.E., Pseudomonas in 17 Disinfection, Sterili~tion and Preservation, ed. S.S.

Block, Lea and Febiger, 1977 and 18 Grier, N., Silver and Its Compounds in Disinfection, Sterilization and Preservation, ed. S.S.

19 Block, Lea and Febiger, 1977).

Of the metallic ions with anti-microbial properties, silver is perhaps the best known due to its unusually good bioactivity at low concentrations.

This 21 phenomena is termed oligodynamic action.

In modern medical practice both inorganic and 22 organic soluble salts of silver are used to prevent and treat microbial infections.

While 23 these compounds are effective as soluble salts, they do not provide prolonged protection 24 due to loss through removal or complexation of the free silver ions.

They must be - 2 ~ ~ 4~g reapplied at frequent intervals to overcome this problem.

Reapplication is not always 2 practical, especially where an in-dwelling or implanted medical device is involved.

3 Attempts have been make to slow the release of silver ions during treatment 4 by creating silver containing complexes which have a lower level of solubility.

For example, U.S.

Patent 2,785,153 discloses colloidal silver protein for this purpose.

Such 6 compounds are usually formulated as creams.

These compounds have not found wide 7 applicability in the medical area due to their limited efficacy.

The silver ion release rate 8 is very slow.

Furthermore, coatings from such compounds have been limited due to 9 adhesion, abrasion resistance and shelf life problems.

The use of silver metal coatings for anti-microbial purposes has been 11 suggested.

For in~t~nce, see Deitch et al., Anti-microbial Agents and Chemotherapy, Vol.

12 23(3), 1983, pp. 356 - 359 and Mackeen et al., Anti-microbial Agents and Chemotherapy, 13 Vol. 31(1), 1987, pp. 93 - 99.

However, it is generally accepted that such coatings alone 14 do not provide the required level of efficacy, since diffusion of silver ions from the metallic surface is negligible.

16 A silver metal coating is produced by Spire Corporation, U.S.A. under the 17 trade mark SPI-ARGENT.

The coating is formed by an ion-beam assisted deposition 18 (IBAD) coating process.

The infection resistant coating is stated to be non-leaching in 19 aqueous solutions as demonstrated by zone of inhibition tests, thus enforcing the belief that silver metal surfaces do not release anti-microbial amounts of silver ions.

21 Given the failure of metallic silver coatings to generate the required anti22 microbial efficacy, other researchers have tried novel activation processes.

One technique 23 is to use electrical activation of metallic silver implants (see Marino et al., Journal of 24 Biological Physics, Vol. 12, 1984, pp. 93 - 98). Electrical stimulation of metallic silver ~ ~ ~ 3 ~ 4 5 5 is not always practical, especially for mobile patients.

Attempts to overcome this problem 2 include developing in situ electrical ~;ullell~ through galvanic action.

Metal bands or 3 layers of different metals are deposited on a device as thin film coatings. A galvanic cell 4 is created when two metals in contact with each other are placed in an electrically S conducting fluid.

One metal layer acts as an anode, which dissolves into the electrolyte.

6 The second metal acts as a cathode to drive the electrochemical cell.

For example, in the 7 case of alternating layers of Cu and Ag, the Cu is the anode, releasing Cu+ ions into the 8 electrolyte.

The more noble of the metals, Ag, acts as the cathode, which does not ionize 9 and does not go into solution to any large extent.

An exemplary device of this nature is 10described in U.S.

Patent 4,886,505 issued Dec. 12, 1989, to Haynes et al.

The patent 11 discloses sputtered coatings of two or more different metals with a switch affixed to one 12 of the metals such that, when the switch is closed, metal ion release is achieved.

13Previous work has shown that a film composed of thin l~minAtPs of 14 alternating, different metals such as silver and copper can be made to dissolve if the 15 surface is first etched.

In this instance, the etching process creates a highly textured 16surface (see M.

Tanemura and F.

Okuyama, J.

Vac.

Sci.

Technol., 5, 1986, pp 2369-2372).

17 However, the process of making such mllltil~min~ted films is time concuming and 18 expensive.

19Electrical activation of metallic coatings has not presented a suitable solution 20 to the problem.

It should be noted that galvanic action will occur only when an electrolyte 21 is present and if an electrical connection between the two metals of the galvanic couple 22 exists.

Since galvanic corrosion occurs primarily at the metallic interface between the two 23 metals, electrical contact is not sustained.

Thus a continuous release of metal ions over 24 an extended period of time is not probable.

Also, galvanic action to release a metal such as silver is difficult to achieve.

As indicated above, the metal ions exhibiting the greatest 2 anti-microbial effect are the noble metals, such as Ag, Au, Pt and Pd.

There are few 3 metals more noble than these to serve as cathode m~teri~lc so as to drive the release of a 4 noble metal such as Ag at the anode.

A second approach to activating the silver metal surface is to use heat or 6 chemicals. U.S.

Patents 4,476,590 and 4,615,705, issued to Scales et al. on October 16, 7 1984 and October 7, 1986, respectively, disclose methods of activating silver surface 8 coatings on endoprosthetic implants to render them bioerodible by heating at greater than 9 180~C or by contacting with hydrogen peroxide.

Such treatments are limited in terms of the substrate/devices which can be coated and activated.

11 There is still a need for an efficacious, inexpensive anti-microbial material 12 having the following properties:

13 - sustained release of an anti-microbial agent at therapeutically active levels;

14 - applicable to a wide variety of devices and m~teri~ - useful shelf life; and 16 - low m~mm~ n toxicity.

17 Metal coatings are typically produced as thin films by vapour deposition 18 techniques such as spulLeling.

Thin films of metals, alloys, semiconductors and ceramics 19 are widely used in the production of electronic components.

These and other end uses require the thin films to be produced as dense, crystalline structures with minim~l defects.

21 The films are often annealed after deposition to enhance grain growth and recryst~ tion 22 and produce stable properties.

Techniques to deposit metal films are reviewed by R.F.

23 Bunshah et al., "Deposition Technologies for Films and Coatings", Noyes Publications, 24 N.J., 1982 and by J.A.

Thornton, "Influence of Apparatus Geometry and Deposition Conditions on the Structure and Topography of Thick Sputtered Coatings", J.

Vac.

Sci.

2 Technol., 11(4), 666-670, 1974.

3 U.S.

Patent No. 4,325,776, issued April 20, 1982 to Menzel discloses a 4 process for producing coarse or single crystal metal films from certain metals for use in integrated circuits.

The metal film is formed by depositing on a cooled substrate (below 6 90~C) such that the metal layer is in an amorphous phase.

The metal layer is then 7 annealed by heating the substrate up to about room temperature.

The end product is stated 8 to have large grain diameter and great homogeneity, permitting higher current dçnciti~s 9 without electromigration failures.

Silver salts such as those of nitrate, proteins, acetate, lactate and citrate have 11 been suggested for use in anti-microbial coatings for medical devices.

Silver nitrate is 12 used in burn wound dressings in many hospitals.

These salts are known to have better 13 anti-microbial efficacy than silver metal.

The mechanism by which these compounds are 14 effective is the instant ionization/dissociation to produce the Ag+ ion.

The availability of the Ag+ ion is reduced significantly within or in contact with bodily fluids or tissues.

Due 16 to the high chloride content of such fluids, the silver is precipitated or tied up as insoluble 17 silver chloride (Ksp = 1.7 x 10-1~M).

As a consequence, excessive amounts of silver must 18 be present within any media cont~ining precipitants (chiefly chloride) in order to produce 19 the same efficacy from a silver salt as would be observed in water.

21 SUMMARY OF THE INVENTION 22 The inventors set out to develop an anti-microbial metal coating.

They 23 discovered that, contrary to previous belief, it is possible to form metal coatings from an 24 anti-microbial metal material by creating atomic disorder in the materials by vapour deposition under conditions which limit diffusion, that is which "freeze-in" the atomic 2 disorder.

The anti-microbial coatings so produced were found to provide sustained release 3 of anti-microbial metal species into solution so as to produce an anti-microbial effect.

4 This basic discovery linking "atomic disorder" to enhanced solubility has broad application.

The inventors have demonstrated that atomic disorder so as to produce 6 solubility can be created in other m~teri~l forms, such as metal powders.

The invention 7 also has application beyond anti-microbial metals, encompassing any metal, metal alloy, 8 or metal compound, including semiconductor or ceramic m~teri~l.c, from which su~t~inPd 9 release of metal species into solution is desired.

For instance, m~tPri~l.c having enh~nl~ed or controlled metal dissolution find application in sensors, switches, fuses, electrodes, and 1 1 batteries.

12 The term "atomic disorder" as used herein includes high concentrations of:

13 point defects in a crystal lattice, vacancies, line defects such as dislocations, interstitial 14 atoms, amorphous regions, grain and sub grain boundaries and the like relative to its normal ordered crystalline state.

Atomic disorder leads to irregularities in surface 16 topography and inhomogenieties in the structure on a nanometre scale.

17 By the term "normal ordered crystalline state" as used herein is meant the 18 crystallinity normally found in buLk metal materials, alloys or compounds formed as cast, 19 wrought or plated metal products.

Such materials contain only low concentrations of such atomic defects as vacancies, grain bound~ri~s and dislocations.

21 The term "diffusion" as used herein implies diffusion of atoms and/or 22 molecules on the surface or in the matrix of the material being formed.

The terms "metal" or "metals" as used herein are meant to include one or 2 more metals whether in the form of substantially pure metals, alloys or compounds such 3 as oxides, nitrides, borides, sulphides, halides or hydrides.

4 The invention, in a broad aspect extends to a method of forming a modiffed material cont~ining one or more metals.

The method comprises creating atomic disorder 6 in the material under conditions which limit diffusion such that sufficient atomic disorder 7 is retained in the material to provide release, preferably on a sustainable basis, of atoms, 8 ions, molecules or clusters of at least one of the metals into a solvent for the material.

9 Clusters are known to be small groups of atoms, ions or the like, as described by R.P.

Andres et al., "Research Opportunities on Clusters and Cluster-Assembled Materials", J.

11 Mater.

Res.

Vol. 4, No. 3, 1989, P. 704.

12 Specific preferred embodiments of the invention demonstrate that atomic 13 disorder may be created in metal powders or foils by cold working, and in metal coatings 14 by depositing by vapour deposition at low substrate temperatures.

In another broad aspect, the invention provides a modified material 16 comprising one or more metals in a form characterized by sufficient atomic disorder such 17 that the m~tr,ri~l, in contact with a solvent for the material, releases atoms, ions, molecules 18 or clusters cont~ining at least one metal, preferably on a suct~in~hle basis, at an enhanced 19 rate relative to its normal ordered crystalline state.

In preferred embodiments of the invention, the modified m~tr,ri~l is a metal 21 powder which has been mechanically worked or compressed, under cold working 22 conditions, to create and retain atomic disorder.

23 The term "metal powder" as used herein is meant to include metal particles 24 of a broad particle size, ranging from nanocrystalline powders to flakes.

~ The term "cold working" as used herein indicates that the material has been 2 mechanically worked such as by milling, grinding, hammering, mortar and pestle or 3 compressing, at temperatures lower than the recrystallization temperature of the material.

4 This ensures that atomic disorder imparted through working is retained in the material.

S In another preferred embodiment, the modified material is a metal coating 6 formed on a substrate by vapour deposition techniques such as vacuum evaporation, 7 sputtering, magnetron sputtering or ion plating.

The material is formed under conditions 8 which limit diffusion during deposition and which limit annealing or recrystallization 9 following deposition.

The deposition conditions preferably used to produce atomic disorder in the coatings are outside the normal range of operating conditions used to produce defect 11 free, dense, smooth films.

Such normal practices are well known (see for example R.F.

12 Bunshah et al., supra).

Preferably the deposition is conducted at low substrate temperatures 13 such that the ratio of the substrate temperature to the melting point of the metal or metal 14 compound being deposited (T/Tm) is maintained at less than about 0.5, more preferably at less lS than about 0.35, and most preferably at less than 0.30.

In this ratio, the temperatures are in 16 degrees Kelvin.

The preferred ratio will vary from metal to metal and increases with alloy or 17 hll~uliliy content.

Other preferred deposition conditions to create atomic disorder include one 18 or more of a higher than normal working gas pressure, a lower than normal angle of incidence 19 of the coating flux and a higher than normal coating flux.

The temperature of deposition or cold working is not so low that substantial 21 annealing or recrystallization will take place when the material is brought to room temperature 22 or its intended temperature for use (ex. body temperature for anti-microbial materials).

If the 23 temperature differential between deposition and temperature of use (I~T) is too great, 24 annealing results, removing atomic disorder.

This ~T will vary from metal ~ 2 ~ 3~.

to metal and with the deposition technique used.

For example, with respect to silver, 2 substrate temperatures of -20 to 200~C are preferred during physical vapour deposition.

3 Normal or ambient working gas pressure for depositing the usually required 4 dense, smooth, defect free metal films vary according to the method of physical vapour deposition being used.

In general, for sputtering, the normal working gas pressure is less 6 than 10 Pa (Pascal) (75 mT (milliTorr)), for magnetron sp~lttering, less than 1.3 Pa (lOmT), 7 and for ion-plating less than 30 Pa (200 mT).

Normal ambient gas pressures vary for 8 vacuum evaporation processes vary as follows: for e-beam or arc evaporation, from 9 0.0001 Pa (0.001 mT) to 0.001 Pa (0.01 mT); for gas scattering evaporation (pressure plating) and reactive arc evaporation, up to 30 Pa (200 mT), but typically less than 3 Pa 11 (20 mT).

Thus, in accordance with the method of the present invention, in addition to 12 using low substrate temperatures to achieve atomic disorder, working (or ambient) gas 13 pressures higher than these normal values may be used to increase the level of atomic 14 disorder in the coating.

Another condition discovered to have an effect on the level of atomic 16 disorder in the coatings of the present invention is the angle of incidence of the coating 17 flux during deposition.

Normally to achieve dense, smooth coatings, this angle is 18 main~in~d at about 90~ +/- 15~.

In accordance with the present invention, in addition to 19 using low substrate temperatures during deposition to achieve atomic disorder, angles of incidence lower than about 75~ may be used to increase the level of atomic disorder in the 21 coating.

22 Yet another process parameter having an effect on the level of atomic 23 disorder is the atom flux to the surface being coated.

High deposition rates tend to 24 increase atomic disorder, however, high deposition rates also tend to increase the coating Z ~ 5 temperature.

Thus, there is an optimum deposition rate that depends on the deposition 2 technique, the coating m~tçri~l and other process parameters.

3 To provide an anti-microbial m~teri~l, the metals used in the coating or 4 powder are those which have an anti-microbial effect, but which are biocompatible (non5 toxic for the intended utility).

Preferred metals include Ag, Au, Pt, Pd, Ir (i.e. the noble 6 metals), Sn, Cu, Sb, Bi, and Zn, compounds of these metals or alloys cont~ining one more 7 of these metals.

Such metals are hereinafter referred to as "anti-microbial metals").

Most 8 preferred is Ag or its alloys and compounds.

Anti-microbial materials in accordance with 9 this invention preferably are formed with sufficient atomic disorder that atoms, ions, 10 molecules or clusters of the anti-microbial material are released into an alcohol or water 11 based electrolyte on a sllct~in~ble basis.

The terms "sustainable basis" is used herein to 12 differentiate, on the one hand from the release obtained from bulk metals, which release 13 metal ions and the like at a rate and concentration which is too low to achieve an anti14 microbial effect, and on the other hand from the release obtained from highly soluble salts 15 such as silver nitrate, which release silver ions virtually instantly in contact with an alcohol 16 or water based electrolyte.

In contrast, the anti-microbial m~teri~l~ of the present invention 17 release atoms, ions, molecules or clusters of the anti-microbial metal at a sufficient rate 18 and concentration, over a sufficient time period to provide a useful anti-microbial effect.

19 The term "anti-microbial effect" as used herein means that atoms, ions, 20 molecules or clusters of the anti-microbial metal are released into the electrolyte which the 21 material contacts in concentrations sufficient to inhibit bacterial growth in the vicinity of 22 the m~teri~l The most common method of measuring anti-microbial effect is by 23 measuring the zone of inhibition (ZOI) created when the m~tçri~l is placed on a bacterial 24 lawn. A relatively small or no ZOI (ex. less than 1 mm) in(lic~tes a non-useful anti . _ 3 7 ~ 3~ ~55 microbial effect, while a larger ZOI (ex. greater than 5 mm) indicates a highly useful anti2 microbial effect.

One procedure for a ZOI test is set out in the Examples which follow.

3 The invention extends to devices such as medical devices formed from, 4 incorporating, carrying or coated with the anti-microbial powders or coatings.

The antimicrobial coating may be directly deposited by vapour deposition onto such medical 6 devices as catheters, sutures, implants, burn dressings and the like.

An adhesion layer, 7 such as tantalum, may be applied between the device and the anti-microbial coating.

8 Adhesion may also be enhanced by methods known in the art, for example etching the 9 substrate or forming a mixed interface between the substrate and the coating by simultaneous sputtering and etching.

Anti-microbial powders may be incorporated into 11 creams, polymers, ceramics, paints, or other matrices, by techniques well known in the art.

12 In a further broad aspect of the invention, modified m~teri~ are prepared 13 as composite metal coatings cont~ining atomic disorder.

In this case, the coating of the 14 one or more metals or compounds to be released into solution con~titlltes a matrix containing atoms or molecules of a different material.

The presence of different atoms or 16 molecules results in atomic disorder in the metal matrix, for instance due to different sized 17 atoms.

The different atoms or molecules may be one or more second metals, metal alloys 18 or metal compounds which are co~ or sequentially deposited with the first metal or metals 19 to be rele~ce~ ~ltern~tively the different atoms or molecules may be absorbed or trapped from the working gas atmosphere during reactive vapour deposition.

The degree of atomic 21 disorder, and thus solubility, achieved by the inclusion of the different atoms or molecules 22 varies, depending on the materials.

In order to retain and enhance the atomic disorder in 23 the composite material, one or more of the above-described vapour deposition conditions, 24 namely low substrate temperature, high working gas pressure, low angle of incidence and high coating flux, may be used in combination with the inclusion of different atoms or 2 molecules.

3 Preferred composite m~teri~l~ for anti-microbial purposes are formed by 4 including atoms or molecules cont~ining oxygen, nitrogen, hydrogen, boron, sulphur or halogens in the working gas atmosphere while depositing the anti-microbial metal.

These 6 atoms or molecules are incorporated in the coating either by being absorbed or trapped in 7 the film, or by reacting with the metal being deposited.

Both of these mech~nicm~ during 8 deposition are hereinafter referred to as "reactive deposition".

Gases cont~ining these 9 element~, for example oxygen, hydrogen, and water vapour, may be provided continuously or may be pulsed for sequential deposition.

11 Anti-microbial composite materials are also preferably prepared by co- or 12 sequentially depositing an anti-microbial metal with one or more inert biocompatible 13 metals selected from Ta, Ti, Nb, Zn, V, Hf, Mo, Si, and Al.

Altern~tively, the composite 14 materials may be formed by co-, sequentially or reactively depositing one or more of the anti-microbial metals as the oxides, carbides, nitrides, borides, sulphides or halides of these 16 metals and/or the oxides, carbides, nitrides, borides, sulphides or halides of the inert 17 metals.

Particularly preferred composites contain oxides of silver and/or gold, alone or 18 together with one or more oxides of Ta, Ti, Zn and Nb.

19 The invention also extends to the preparation of anti-microbial silver materials which form complex silver ions other than Ag+, Ag2+ and Ag3+, in contact with 21 an alcohol or a water based electrolyte.

The complex silver ions are found to have a 22 surprisingly greater anti-microbial efficacy than does the Ag+ ion released from the silver 23 salts of the prior art.

Exemplary complex silver ions include Ag(CN)2-, AgCN(aq~(ion pair), 24 Ag(NH3)2+, AgCl2-, Ag(OH)2-, Ag2(0H)3-, Ag3(0H)4 and Ag(S2o3)23. Silver coatings, ~ 2 ~ ~ 6 ~ powders, flakes and foils prepared with atomic disorder in accordance with the present 2 invention are exemplary of silver materials which release complex silver ions having anti3 microbial efficacy.

Alternatively the silver m~teri~l~ may be prepared as solutions, 4 ointments, paints or suspensions cont~ining the complex silver ions.

Such silver m~teri~lc have wide application, for example as coatings for medical devices, in topical anti6 microbial compositions, in anti-fouling paints or coatings and as coatings for anti-microbial 7 filters.

8 Thus, in accordance with a broad aspect of the invention, there is provided 9 a method of producing an anti-microbial effect in an alcohol or a water based electrolyte comprising, preparing a silver material such that it forms complex silver ions other than 11 Ag+, Ag2+ and Ag3+ in an amount so as to produce an anti-microbial effect in contact with 12 an alcohol or water-based electrolyte that is greater than that produced by an equivalent 13 amount of silver as Ag+; and bringing the silver material in contact with the surface, 14 alcohol or electrolyte to be treated so as to cause the release of the complex silver ions.

16 DESCRIPTION OF THE PREFERRED EMBODIMENTS 17 As above stated, the present invention has application beyond anti-microbial 18 materials.

However, the invention is disclosed herein with anti-microbial metals, which 19 are illustrative of utility for other metals, metal alloys and metal compounds.

Preferred metals include Al and Si, and the metal elements from the following groups of the periodic 21 table: IIIB, IVB, VB, VIB, VIIB, VIIIB, IB, IIB, IIIA, IVA, and VA (excluding As) in 22 the periods 4, 5 and 6, (see Periodic Table as published in Merck Index 10th Ed., 1983, 23 Merck and Co.

Inc., Rahway, N.J., Martha Windholz).

Different metals will have varying 24 degrees of solubility.

However, the creation and retention of atomic disorder in accordance with this invention results in enhanced solubility (release) of the metal as ions, atoms, 2 molecules or clusters into an applop-iate solvent i.e. a solvent for the particular material, 3 typically a polar solvent, over the solubility of the m~teri~l in its normal ordered crystalline 4 state.

The medical devices formed from, incorporating, carrying or coated with the 6 anti-microbial material of this invention generally come into contact with an alcohol or 7 water based electrolyte including a body fluid (for example blood, urine or saliva) or body 8 tissue (for example skin, muscle or bone) for any period of time such that microorganism 9 growth on the device surface is possible.

The term "alcohol or water based electrolyte" also includes alcohol or water based gels.

In most cases the devices are medical devices 11 such as catheters, implants, tracheal tubes, orthopaedic pins, insulin pumps, wound 12 closures, drains, dres~ingc, shunts, connectors, prosthetic devices, pacem~k~r leads, needles, 13 surgical instruments, dental prostheses, ventilator tubes and the like.

However, it should 14 be understood that the invention is not limited to such devices and may extend to other devices useful in consumer healthcare, such as sterile packaging, clothing and footwear, 16 personal hygiene products such as diapers and sani~aly pads, in biomedical or biotechnical 17 laboratory equipment, such as tables, enclosures and wall coverings, and the like.

The 18 term "medical device" as used herein and in the claims is intended to extend broadly to 19 all such devices.

The device may be made of any suitable material, for example metals, 21 including steel, ~luminllm and its alloys, latex, nylon, silicone, polyester, glass, ceramic, 22 paper, cloth and other plastics and rubbers.

For use as an in-dwelling medical device, the 23 device will be made of a bioinert material.

The device may take on any shape dictated by 3 ~ its utility, ranging from flat sheets to discs, rods and hollow tubes.

The device may be 2 rigid or flexible, a factor again dictated by its intended use.

4 Anti-Microbial Coatin~s The anti-microbial coating in accordance with this invention is deposited as 6 a thin metallic film on one or more surfaces of a medical device by vapour deposition 7 techniques.

Physical vapour techniques, which are well known in the art, all deposit the 8 metal from the vapour, generally atom by atom, onto a substrate surface.

The techniques 9 include vacuum or arc evaporation, sputtering, magnetron sputtering and ion plating.

The deposition is conducted in a manner to create atomic disorder in the coating as defined 11 hereinabove.

Various conditions responsible for producing atomic disorder are useful.

12 These conditions are generally avoided in thin film deposition techniques where the object 13 is to create a defect free, smooth and dense film (see for example J.A.

Thornton, ~).

14 While such conditions have been investigated in the art, they have not heretofore been linked to enhanced solubility of the coatings so-produced.

16 The preferred conditions which are used to create atomic disorder during the 17 deposition process include:

18 - a low substrate temperature, that is m~in~ining the surface to be coated 19 at a temperature such that the ratio of the substrate temperature to the melting point of the metal (in degrees Kelvin) is less than about 0.5, more preferably less than about 0.35 and 21 most preferably less than about 0.3; and optionally one or both of:

22 - a higher than normal working (or ambient) gas pressure, i.e. for vacuum 23 evaporation: e-beam or arc evaporation, greater than 0.001 Pa (0.01 mT), gas scattering 24 evaporation (pressure plating) or reactive arc evaporation, greater than 3 Pa (20 mT); for 16 sputtering: greater than 10 Pa (75 mT); for magnetron sputtering: greater than about 1.3 2 Pa (10 mT); and for ion plating: greater than about 30 Pa (200 mT); and 3 - m~int~ining the angle of incidence of the coating flux on the surface to be 4 coated at less than about 75~, and preferably less than about 30~ The metals used in the coating are those known to have an anti-microbial 6 effect.

For most medical devices, the metal must also be biocompatible.

Preferred metals 7 include the noble metals Ag, Au, Pt, Pd, and Ir as well as Sn, Cu, Sb, Bi, and Zn or alloys 8 or compounds of these metals or other metals.

Most preferred is Ag or Au, or alloys or 9 compounds of one or more of these metals.

The coating is formed as a thin film on at least a part of the surface of the 11 medical device.

The film has a thickness no greater than that needed to provide release 12 of metal ions on a sll~t~in~ble basis over a suitable period of time.

In that respect, the 13 thickness will vary with the particular metal in the coating (which varies the solubility and 14 abrasion resistance), and with the degree of atomic disorder in (and thus the solubility of) the coating.

The thickness will be thin enough that the coating does not interfere with the 16 dimen~ional tolerances or flexibility of the device for its intended utility.

Typically, 17 thicknesses of less than 1 micron have been found to provide sufficient sustained anti18 microbial activity.

Increased thicknesses may be used depending on the degree of metal 19 ion release needed over a period of time.

Thicknesses greater than 10 microns are more expensive to produce and normally should not be needed.

21 The anti-microbial effect of the coating is achieved when the device is 22 brought into contact with an alcohol or a water based electrolyte such as, a body fluid or 23 body tissue, thus releasing metal ions, atoms, molecules or clusters.

The concentration of 24 the metal which is needed to produce an anti-microbial effect will vary from metal to metal.

Generally, anti-microbial effect is achieved in body fluids such as plasma, serum 2 or urine at concentrations less than about 0.5 - 1.5 ,ug/ml.

3 The ability to achieve release of metal atoms, ions, molecules or clusters on 4 a s-l~t~in~ble basis from a coating is dictated by a number of factors, including coatingcharacteristics such as composition, structure, solubility and thicknrss, and the nature of 6 the environment in which the device is used.

As the level of atomic disorder is increased, 7 the amount of metal ions released per unit time increases.

For inct~nce, a silver metal film 8 deposited by magnetron sputtering at T/Tm < 0.5 and a working gas pressure of about 0.9 9 Pa ~7 mTorr) releases approximately 1/3 of the silver ions that a film deposited under similar conditions, but at 4 Pa (30 mTorr), will release over 10 days.

Films that are 11 created with an intermediate structure (ex. lower pressure, lower angle of incidence etc.) 12 have Ag release values intermediate to these values as determined by bioassays.

This then 13 provides a method for producing controlled release metallic coatings in accordance with 14 this invention.

Slow release coatings are prepared such that the degree of disorder is low while fast release coatings are prepared such that the degree of disorder is high.

16 For continuous, uniform coatings, the time required for total dissolution will 17 be a function of film thickness and the nature of the environment to which they are 18 exposed.

The relationship in respect of thickness is approximately linear, i.e. a two fold 19 increase in film thicknrss will result in about a two fold increase in longevity.

It is also possible to control the metal release from a coating by forming a 21 thin film coating with a modulated structure.

For in~t~nce, a coating deposited by 22 magnetron spuL~eling such that the working gas pressure was low (ex. 2 Pa (15 mTorr)) 23 for 50% of the deposition time and high (ex. 4 Pa (30 mTorr)) for the rem~ining time, has 24 a rapid initial release of metal ions, followed by a longer period of slow release.

This type 18 ~f coating is extremely effective on devices such as urinary catheters for which an initial rapid 2 release is required to achieve immediate anti-microbial concentrations followed by a lower 3 release rate to sustain the concentration of metal ions over a period of weeks.

4 The substrate temperature used during vapour deposition should not be so low that annealing or recrystallization of the coating takes place as the coating warms to ambient 6 temperatures or the temperatures at which it is to be used (ex. body temperature).

This 7 allowable ~T, that the temperature differential between the substrate temperature during 8 deposition and the ultimate temperature of use, will vary from metal to metal.

For the most 9 preferred metals of Ag and Au, preferred substrate temperatures of -20 to 200~C, more preferably -10~C to 100~C are used.

11 Atomic disorder may also be achieved, in accordance with the present 12 invention, by preparing composite metal materials, that is materials which contain one or 13 more anti-microbial metals in a metal matrix which includes atoms or molecules different 14 from the anti-microbial metals.

Our technique for preparing composite material is to co- or sequentially deposit16 the anti-microbial metal(s) with one or more other inert, biocompatible metals selected from 17 Ta, Ti, Nb, Zn, V, Hf, Mo, Si, Al and alloys of these metals or other metal elements, typically 18 other transition metals.

Such inert metals have a different atomic radii from that of the anti19 microbial metals, which results in atomic disorder during deposition.

Alloys of this kind can also serve to reduce atomic diffusion and thus stabilize the disordered structure.

Thin film 21 deposition equipment with multiple targets for the placement of each of the anti-microbial and 22 inert metals is preferably utilized.

When layers are sequentially deposited the layer(s) of the 23 inert metal(s) should be discontinuous, for example as islands within the anti-microbial metal 24 matrix.

The final ratio of the anti 19 .~ microbial metal(s) to inert metal(s) should be greater than about 0.2.

The most preferable 2 inert metals are Ti, Ta, Zn and Nb.

It is also possible to form the anti-microbial coating 3 from oxides, carbides, nitrides, sulphides, borides, halides or hydrides of one or more of 4 the anti-microbial metals and/or one or more of the inert metals to achieve the desired atomic disorder.

6 Another composite m~t~ l within the scope of the present invention is 7 formed by reactively co- or sequentially depositing, by physical vapour techniques, a 8 reacted m~tçri~l into the thin film of the anti-microbial metal(s).

The reacted material is 9 an oxide, nitride, carbide, boride, sulphide, hydride or halide of the anti-microbial and/or inert metal, formed in situ by injecting the appropriate reactants, or gases cont~ining same, 11 (ex. air, oxygen, water, nitrogen, hydrogen, boron, sulphur, halogens) into the deposition 12 chamber.

Atoms or molecules of these gases may also become absorbed or trapped in the 13 metal film to create atomic disorder.

The reactant may be continuously supplied during 14 deposition for codeposition or it may be pulsed to provide for sequential deposition.

The final ratio of anti-microbial metal(s) to reaction product should be greater than about 0.2.

16 Air, oxygen, nitrogen and hydrogen are particularly preferred re~ct~nt~.

17 The above deposition techniques to prepare composite coatings may be used 18 with or without the conditions of lower substrate temperatures, high working gas pressures 19 and low angles of incidence previously discussed.

One or more of these conditions is preferred to retain and çnh~nce the amount of atomic disorder created in the coating.

21 It may be advantageous, prior to depositing an anti-microbial in accordance 22 with the present invention, to provide an adhesion layer on the device to be coated, as is 23 known in the art.

For instance, for a latex device, a layer of Ti, Ta or Nb may be first 24 deposited to enhance adhesion of the subsequently deposited anti-microbial coating.

~ 5 ~ Anti-Microbial Powders 2 Anti-microbial powders, including nanocrystalline powders and powders 3 made from rapidly solidified flakes or foils, can be formed with atomic disorder so as to 4 ellh~nce solubility.

The powders either as pure metals, metal alloys or compounds such 5 as metal oxides or metal salts, can be mechanically worked or compressed to impart 6 atomic disorder.

This mechanically imparted disorder is conducted under conditions of 7 low temperature (i.e. temperatures less than the temperature of recryst~ tion of the 8 m~teri~l) to ensure that annealing or recryst~ tion does not take place.

The temperature 9 varies between metals and increases with alloy or impurity content.

Anti-microbial powders produced in accordance with this invention may be 11 used in a variety of forms, for instance in topical creams, paints or adherent coatings.

12 ~ltern~tively, the powder may be incorporated into a polymeric, ceramic or metallic matrix 13 to be used as a material for medical devices or coatings therefor.

14 15 Silver Materials Formin~ Complex Silver Ions 16 In accordance with the invention, silver materials are prepared which form 17 complex silver ions other than Ag+,Ag2+ and Ag3+, when the material is contacted with an 18 alcohol or a water based electrolyte.

Exemplary complex silver ions shown to demonstrate 19 an anti-microbial effect include Ag(CN)2-, AgCN(aq~(ion pair), Ag(NH3)2+, AgCl2-, Ag(OH)2-, Ag2(0H)3-, Ag3(0H)4- and Ag(S2o3)23-.

These silver materials forming complex silver ions 21 have wide application, for instance, as anti-microbial coatings for medical devices, as anti22 microbial powders for medical or ph~rmaçeutical use, as anti-fouling paints, coatings or 23 compositions, anti-microbial coatings for filters and the like.

It should be understood that the phrase "silver materials which form 2 complex silver ions other than Ag+, Ag2+ and Ag3+" as used herein and in the claims is 3 not intended to exclude silver materials which form one or more of Ag+, Ag2+ and Ag3+, 4 ions in addition to the complex silver ions when the material contacts an alcohol or a water based electrolyte.

The notation Ag+, Ag2+ and Ag3+- refers to these ions in solution and 6 includes solvated forms.

The term complex silver ions as used herein and in the claims 7 is not intended to include silver ions stabilized with strong oxidizing agents, such as 8 persulphate and periodate, to prevent the reduction of the silver ions.

9 The anti-microbial coatings, powders and foils of the present invention, when created with atomic disorder as above described, are exemplary of silver materials 11 which form complex silver ions other than Ag+ so as to cause an anti-microbial effect.

It 12 is believed that the complex silver ions which may be formed when such silver materials 13 contact an alcohol or water based electrolyte, are one or more of the negative ions 14 Ag(OH)2-, Ag2(OH)3- and Ag3(0H)4-.

Silver materials which form complex silver ions may also be prepared by 16 bringing a silver metal, compound or salt into an environment cont~ining excessive 17 amounts of a cationic, anionic or neutral species with which it is desired to complex silver.

18 For example, the negative complex silver ion AgCl2- can be generated by placing a silver 19 salt such as AgNO3 in an aqueous medium with an elevated concentration of the Cl- ion.

AgNO3/NaCl or AgCl/NaCl mixtures, solutions or suspensions can form the AgCl2- ion.

21 This AgCl2- ion may also be generated with mixtures of silver powder with NaCl.

22 Preferably the silver powder is one which is prepared in accordance with the present 23 invention so as to contain atomic disorder, but buL~ silver may also be activated in this 24 manner.

BuL~ silver powder, fine grain (<140 nm) and nanocrystalline (<20 nm) powders 5~ ._ may be used.

Similarly, the ion Ag(NH3)2+ can be formed in aqueous solution by adding 2 silver salts to excess ammonium hydroxide.

The ion Ag(S2o3)23 may be formed in 3 aqueous solution by adding silver salts to excess sodium thiosulphate.

The ion Ag(CN)24 may be formed in aqueous solution by adding excess potassium cyanide to silver cyanide.

S The silver m~teri~ls forming complex silver ions may be formulated for use 6 in many forms, including for example, powders, suspensions, solutions, ointments or 7 coatings.

For instance, a ph~rm~ceutical composition to generate the AgCl2- ion can be 8 formulated as a mixture of the salts AgNO3/NaCl or as a mixture of NaCl with a silver 9 powder, preferably one cont~ining atomic disorder.

These mixtures of the silver material 10 might be pre-formulated as a solution, suspension or ointment with a sterile aqueous or 11 saline solution and pharmaceutically acceptable carriers, ~iluent~, exipients and the like.

12 ~ltt.rn~tively the silver material might be provided as the mixtures of silver powder/NaCl 13 salt or AgNO3/NaCl, for later formulation by the end user.

14 The invention is further illustrated by the following non-limiting examples.

16 Example 1 17 A medical suture m~teri~l size 2/0, polyester braid was coated by magnetron 18 sputtering from 20.3 diameter (8 in.) planar silver and copper magnetron cathodes to form 19 an Ag-Cu-alloy on the surface to a thickness of 0.45 microns, using either argon gas working pressures of 0.9 Pa (7 mTorr) or 4 Pa (30 mT) at 0.5 KW power and a T/Tm ratio 21 of less than 0.5.

The total mass flow of gas was 700 sccm (standard cubic centimeters per 22 minute.) 23 The anti-microbial effect of the coatings was tested by a zone of inhibition 24 test.

Basal medium Eagle (BME) with Earle's salts and L-glut~min~ was modified with calf/serum (10%) and l.S % agar prior to being dispensed (15 ml) into Petri dishes.

The 2 agar cont~ining Petri plates were allowed to surface dry prior to being inoculated with a 3 lawn of Staphylococcus aureus ATCC# 25923.

The inoculant was prepared from Bactrol 4 Discs (Difco, M.) which were reconstituted as per the m~nllf~cturer's directions.

Immediately after inoculation, the m~teri~ or coatings to be tested were placed on the 6 surface of the agar.

The dishes were incubated for 24 h at 37~C.

After this incubation 7 period, the zone of inhibition was measured and a corrected zone of inhibition was 8 calculated (corrected zone of inhibition = zone of inhibition - diameter of the test material 9 in contact with the agar).

The results showed no zone of inhibition on the uncoated suture, a zone of 11 less than 0.5 mm around the suture coated at 0.9 Pa (7 mTorr) and a zone of 13 mm 12 around the suture coated at 4 Pa (30 mTorr).

Clearly the suture coated in accordance with 13 the present invention exhibits a much more pronounced and effective anti-microbial effect.

14 Example 2 16 This example is included to illustrate the surface structures which are 17 obtained when silver metal is deposited on silicon wafers using a magnetron spulleling 18 facility and different working gas pressures and angles of incidence (i.e. the angle between 19 the path of the sputtered atoms and the substrate).

All other conditions were as follows:

target was a 20.3 cm dia. planar silver magnetron cathode; power was 0.1 kW; deposition 21 rate was 200 A~/min; ratio of temperature of substrate (wafer) to melting point of silver 22 (1234~K), T/Tm was less than 0.3.

Argon gas pressures of 0.9 Pa (7 mTorr) (a normal 23 working pressure for metal coatings) and 4 Pa (30 mTorr) were used with a total mass gas 24 flow of 700 sccm.

Angles of incidence at each of these pressures were 90~ (normal 2 incidence), 50~ and 10~.

The coatings had a thickness of about 0.5 microns.

3 The resulting surfaces were viewed by sc~nning electron microscope.

As 4 argon gas pressure increased from 0.9 Pa (7 mTorr) to 4 Pa (30 mTorr) the grain size decreased and void volume increased significantly.

When the angle of incidence was 6 decreased, the grain size decreased and the grain boundaries became more distinct.

At 0.9 7 Pa (7 mTorr) argon pressure and an angle of incidence of 10~, there were indications of 8 some voids between the grains.

The angle of incidence had a greater effect on the surface 9 topography when the gas pressure was increased to 4 Pa (30 mTorr).

At 90~, the grain size varied from 60 - 150 nm and many of the grains were separated by intel~ laihl void spaces 11 which were 15 - 30 nm wide.

When the angle of incidence was decreased to 50~, the grain 12 si~ decreased to 30 - 90 nm and the void volume increased substantially.

At 10~, the 13 grain size was reduced to about 10 - 60 nm and void volumes were increased again.

14 The observed nanometre scale changes in surface morphology and topography are indications of atomic disorder in the silver metal.

While not being bound 16 by the same, it is believed that such atomic disorder results in an increase in the chPmic~l 17 activity due to increased internal stresses and surface roughnPss created by mi.cm~tched 18 atoms.

It is believed that the increased chemical activity is responsible for the increased 19 level of solubility of the coatings when in contact with an electrolyte such as body fluid.

The anti-microbial effect of the coatings was evaluated using the zone of 21 inhibition test as set out in Example 1.

Each coated silicon wafer was placed on an 22 individual plate.

The results were compared to the zones of inhibition achieved when solid 23 silver (i.e. greater than 99% silver) sheets, wires or membranes were tested.

The results 24 are summ~ri~ed in Table 1.

It is evident that the pure silver devices and the silver sputtered coating at 0.9 Pa (7 mTorr) do not produce any biological effect.

However, the 2 coatings deposited at a higher than normal working gas pressure, 4 Pa (30 mTorr), 3 demonstrated an anti-microbial effect, as denoted by the substantial zones of inhibition 4 around the discs.

Decreasing the angle of incidence had the greatest effect on anti S microbial activity when combined with the higher gas pressures.

7 Table I 8 Anti-miaobial effects of various silver and silver coated samples as d~ ;Pd using StaphJlrcrccc u,, 9 aureus 11 12 Sample Percent Angle of Working Gas Corrected Zone 13 Silver Deposition Pressure of Tnhihition 14 Pa (mTorr) (mm) 16 Silver Sheet17 rolled 99+ - - c0.5 18 19 Silver wire (.0045") 99+ - - cO.5 21 22 Silver memhmn~ 23 cast 99+ - - c0.5 24 Sputtered thin 26 film 99+ normal (90~) 0.9 (7) cO.5 27 28 Sputtered thin 29 film 99+ 50~ 0.9 (7) cO.5 31 Sputtered thin 32 film 99+ 10~ 0.9 (7) <0.5 33 34 Sputtered thin film 99+ normal (90~) 4 (30) 6.3 36 37 Sputtered thin 38 film 99+ 50~ 4 (30) 10 39 Sputtered thin 41 film 99+ 10 4 (30) 10 42 43 44 26 s ~ ~ Example 3 2 Silicon wafers were coated by magnetron sputtering using 20.3 cm dia.

3 planar silver and copper magnetron cathodes to produce an alloy of Ag and Cu (80:20) at 4 normal incidence at working gas pressures of 0.9 Pa (7 mTorr) and 4 Pa (30 mTorr), all 5 other conditions being identical to those set out in Example 2.

As in Example 2, when the 6 coatings were viewed by SEM, the coatings formed at high working gas pressure had 7 smaller grain sizes and larger void volumes than did the coatings formed at the lower 8 working gas pressures.

9 Coatings which were .~imil~rly formed as a 50:50 Ag/Cu alloy were tested for anti-microbial activity with the zone of inhibition test set out in Example 1.

The 11 results are summarized in Table 2.

Coatings deposited at low working gas pressure (0.9 12 Pa (7 mTorr)) showed minimal zones of inhibition, while the coatings deposited at high 13 working gas pressure (4 Pa (30 mTorr)) produced larger zones of inhibition, indicative of 14 anti-microbial activity.

16 17 Table 2 18 The anti-microbial effect of various sputter deposited silver-copper alloys as ~e~rmined using Sl, k~la~e~ 19 aureus 21 22 Sample Percent Angle of Working Gas Corrected 23 Silver DePO~;~;OD Pressure Zone of 24 (~) Pa (mTorr) Tnhihi~i~n (mm) 26 27 1 so normal (90~) 1.0 (7.5) c0.5 28 29 2 50 nonnal (90~) 4 (30) 16 31 3 50 10 4 (30) 19 32 Example 4 2 A coating in accordance with the present invention was tested to determine 3 the concentration of silver ions released into solution over time.

One cm2 silicon wafer 4 discs were coated with silver as set forth in Example 2 at 0.9 Pa (7 mTorr) and 4 Pa (30 mTorr) and normal incidence to a thickness of 5000 A~.

Using the method of Nickel et 6 al., Eur. J.

Clin.

Microbiol., 4(2), 213-218, 1985, a sterile synthetic urine was prepared and 7 dispensed into test tubes (3.5 ml).

The coated discs were placed into each test tubes and 8 incubated for various times at 37~C.

After various periods of time, the discs were removed 9 and the Ag content of the filtered synthetic urine was detPrminPd using neutron activation analysis.

11 The results are set forth in Table 3.

The table shows the comparative 12 amounts of Ag released over time from coatings deposited on discs at 0.9 Pa (7 mTorr) 13 or 4 Pa (30 mTorr).

The coatings deposited at high pressure were more soluble than those 14 deposited at low pressure.

It should be noted that this test is a static test.

Thus, silver levels build up over time, which would not be the case in body fluid where there is 16 constant turn over.

28 Table 3 2 C.."~ ."~ of silver in synthetic urine as a function of exposure time 4 Silver Co"~ ion ,ug/ml 6 Exposure Time Working Argon Working argon 7 (Days) gas pressure gas pressure 8 0.9 Pa (7mTorr) 4 Pa (30mTorr) 0 ND1 ND 11 12 1 0.89 1.94 13 14 3 1.89 2.36 16 lo 8.14 23.06 17 18 Note: Films were deposited at normal in~ Pnre (903 19 1 - ND (non ~lete~tP~'-) <0.46 ,ug/ml 21 Example S 22This example is included to illustrate coatings in accordance with the present 23 invention formed from another noble metal, Pd.

The coatings were formed on silicon 24wafers as set forth in Example 2, to a thickness of 5000 A~, using 0.9 Pa (7 mTorr) or 4 25Pa (30 mTorr) working gas pressures and angles of incidence of 90~ and 10~.

The coated 26 discs were evaluated for anti-microbial activity by the zone of inhibition test subst~nti~lly 27 as set forth in Example 1.

The coated discs were placed coating side up such that the agar 28 formed a 1 mm surface coating over the discs.

The medium was allowed to solidify and 29 surface dry, after which the bacterial lawn was spread over the surface.

The dishes were 30 incubated at 37~C for 24 h.

The amount of growth was then visually analyzed.

29 ' The results are set forth in Table 4.

At high working gas pressures, the 2 biological activity of the coating was much greater than that of coatings deposited at low 3 pressure.

Ch~nging the angle of incidence (decreasing) improved the anti-microbial effect 4 of the coating to a greater extent when the gas pressure was low than when it was high.

6 Table 4 7 Surface Control of St~! y~ ..s aureus by Sputter Deposited Palladium metal Sample Sputtering Angle of Anti-microbial Control 11 Pressure Deposition 12 Pa (mT) 14 1 0.9 (7) 90~(normal inridenre) More than 90% of surface covered by bacterial growth 16 18 2 0.9 (7) 10~(grazing inridenre) 20-40% of surface covered by bacterial growth 19 21 3 4 (30) 90~(normal inridrnre) Less than 10% surface covered by bacterial growth 22 23 2254 26 Example 6 27 This example is included to illustrate the effect of silver deposition 28 temperature on the anti-microbial activity of the coating.

Silver metal was deposited on 29 2.5 cm sections of a latex Foley catheter using a magnetron spulle~ g facility.

Operating conditions were as follows; the deposition rate was 200 A~ per minute; the power was 0.1 31 kW; the target was a 20.3 cm dia. planar silver magnetron cathode; the argon working gas 32 pressure was 4 Pa (30mTorr); the total mass gas flow was 700 sccm; and the ratio of 33 temperature of substrate to melting point of the coating metal silver, T/Tm was 0.30 or 34 0.38.

In this example the angles of incidence were variable since the substrate was round 35 and rough.

That is the angles of incidence varied around the circumference and, on a finer ~ ~ 3 ~ ~ 5 5 scale, across the sides and tops of the numerous surface features.

The anti-microbial effect 2 was tested by a zone of inhibition test as outlined in Example 1.

3The results showed corrected zones of inhibition of 0.5 and 16 mm around 4the tubing coated at T/Tm values of 0.38 and 0.30 respectively.

The sections of Foley 5 catheter coated at the lower T/Tm value were more efficacious than those coated at higher 6 T/Tm value.

8Example 7 9This example is included to demonstrate an anti-microbial coating formed 10by DC magnetron sputtering on a commercial catheter. A teflon coated latex Foley 11catheter was coated by DC magnetron sputtering 99.99% pure silver on the surface using 12the conditions listed in Table 5.

The working gases used were commercial Ar and 99/1 13wt% Ar/O2.

14The anti-microbial effect of the coating was tested by a zone of inhibition test.

15Mueller Hinton agar was dispensed into Petri dishes.

The agar plates were allowed to 16surface dry prior to being inoculated with a lawn of Staphylococcus aureus ATCC# 25923.

17The inoculant was prepared from Bactrol Discs (Difco, M.) which were reconstituted as 18per the m~mlf~cturer's directions.

Immediately after inoculation, the coated m~teri~l~ to 19be tested were placed on the surface of the agar.

The dishes were incubated for 24 hr. at 2037~C.

After this incubation period, the zone of inhibition was measured and a corrected 21zone of inhibition was calculated (corrected zone of inhibition = zone of inhibition 22diameter of the test m~teri~l in contact with the agar).

23The results showed no zone of inhibition for the uncoated samples and a corrected 24zone of less than 1 mm for catheters sputtered in commercial argon at a working gas pressure of 0.7 Pa (5 mT). A corrected zone of inhibition of 11 mm was reported for the 2 catheters sputtered in the 99/1 wt% Ar/O2 using a working gas pressure of 5.3 Pa (40 mT).

3 XRD analysis showed that the coating spu~ ed in 1% oxygen was a crystalline Ag film.

4 This structure clearly caused an improved anti-microbial effect for the coated catheters.

6 Table 5 7 C-)n~litionc of DC Magnetron Sputtering Used for Anti-Microbial Coatings Samples Sputtered in Commercial Argon Samples Sputtered in 99/1 wt% Ar/O211 12 13 Power 0.1 kW Power 0.5 kW 14 Target 20.3 cm dia Ag Target 20.3 cm dia.

Ag 17 Argon Pressure: 0.7 Pa (5 m Torr) Ar/O2 Pressure: 5.3 Pa (40 m Torr) 18 19 Total Mass Flow: 700 sccm Total Mass Flow: 700sccm 21 Initial Substrate T~ r~ e. 20~C Initial Substrate Tr.. ~ . 20~C 22 23 Cathode/Anode Distance: 40 mm Cathode/Anode Distance: lOOmm 24 Film Thi~l~n~cc: 2500 A Film Thi~ CC. 3000 A 26 27 28 29 Example 8 31 This example demonstrates silver coatings formed by arc evaporation, gas scattering 32 evaporation (pressure plating) and reactive arc evaporation.

Evaporation of 99.99% silver 33 was performed onto silicon or ~lumin~ wafers at an initial substrate temperature of about 34 21~C, using the parameters as follows:

Bias: - 100 V 36 Current: 20 Amp-hrs 37 Angle of incidence: 90~ 32 Working Gas Pressure: 0.001 Pa (0.01 mT) (arc), 3.5 Pa (26 mT) Ar/H2 96:4 (gas 2 scattering evaporation), and 3.5 Pa (26 mT) ~2 (reactive arc evaporation) 3 No corrected ZOI was observed for wafers coated at vacuum (arc).

Pressure plating 4 with a working gas atmosphere containing Ar and 4 % hydrogen produced a 6 mm ZOI, while a working gas atmosphere of pure oxygen (reactive arc) produced an 8 mm ZOI.

6 Film thicknes.~e.s of about 4000 Angstroms were produced.

The results indicate that the 7 presence of gases such as hydrogen and/or oxygen in the arc evaporation atmosphere cause 8 the coatings to have improved anti-microbial efficacy.

Example 9 11 This example is included to illustrate composite m~teri~ to produce anti12 microbial effects. A set of coatings were produced by RF m~gn~tron sputtering zinc oxide 13 onto silicon wafers as outlined below.

The zinc oxide coatings showed no zone of 14 inhibition.

Coatings of Ag and ZnO were deposited to a total thickness of 3300 16 Angstroms by sequentially sputtering layers of Ag with layers of ZnO, according to the 17 conditions below, in a 75/25 wt% ratio.

The coatings were demonstrated to have no zone 18 of inhibition when the zinc oxide layers were about 100 Angstroms thick.

However, films 19 consisting of islands of very thin to discontinuous layers of ZnO (less than 50 Angstroms) in an Ag matrix (ie. a composite film) had a 8 mm corrected zone of inhibition.

21 The conditions used to deposit ZnO were as follows:

22 Traget 20.3 cm dia.

Zno; Working gas = argon; Working gas pressure = 4 Pa (30 mT);

23 Cathode-Anode distance: 40 mm; Initial Substrate Temperature: 21~C; Power: RF 24 magnetron, 0.5 kW.

2 t ~ 4~ ' "~_ The conditions used to deposit the Ag were as follows:

2 Traget 20.3 cm dia.

Ag; Working gas = argon; Working gas pressure = 4 Pa (30 mT);

3 Cathode-Anode distance = 40 mm; Initial Substrate Tempel~lu,e - 21~C; Power = DC 4 m~gnetron, 0.1 kW.

s 6 Example 10 7 This example demonstrates the effects of cold working and ~nne~ling silver 8 and gold powders on the anti-microbial efficacy demonstrated by a standard zone of 9 inhibition test.

Cold working of such powders results in a defective surface structure containing atomic disorder which favours the release of ions causing anti-microbial 11 activity.

The anti-microbial effect of this defective structure can be removed by ~nnP~ling.

12 Nanocrystalline silver powder (crystal size about 30 nm) was sprinkled onto 13 adhesive tape and tested. A zone of inhibition of 5 mm was obtained, using the method 14 set forth in Example 7. A 0.3g pellet of the nanocrystalline Ag powder was pressed at 275,700 kPa (40,000 psi).

The pellet produced a 9 mm zone of inhibition when tested for 16 anti-microbial activity.

Nanocyrstalline silver powder was mechanically worked in a ball 17 mill for 30 sec.

The reslllting powder was tested for anti-microbial activity, both by 18 sprinkling the worked powder on adhesive tape and applying to the plates, and by pressing 19 the powder into a pellet at the above conditions and placing the pellet on the plates.

The zones of inhibition observed were 7 and 11 mm respectively. A pellet that had been 21 pressed from the worked powder was annealed at 500~C for 1 hour under vacuum 22 conditions. A reduced zone of inhibition of 3 mm was observed for the annealed pellet.

23 34 2 ~ 3 ~ 4 5 5 ~ These results demonstrate that nanocrystalline silver powder, while having a 2 small anti-microbial effect on its own, has an improved anti-microbial effect by introducing 3 atomic disorder by mechanical working of the powder in a ball mill or by pressing it into a 4 pellet.

The anti-microbial effect was significantly decreased by annealing at 500~C.

Thus, 5 conditions of mechanical working should not include or be followed by conditions such as 6 high temperature, which allow diffusion.

Cold mechanical working conditions are preferred 7 to limit diffusion, for example by working at room temperature or by grinding or milling in 8 liquid nitrogen.

9Silver powder, l micron particle size, was tested in a manner similar to above.

10 The Ag powder sprinkled onto adhesive tape and tested for a zone of inhibition.

No zone of 11 inhibition was observed.

The powder was worked in a ball mill for 30 seconds and sprinkled 12 onto adhesive tape. A 6 mm zone of inhibition was observed around the powder on the tape.

13 When the Ag powder (as is or after mechanical working in the ball mill) was pressed into a 140.3 g pellet using 275,700 kPa (40,000 psi), zones of inhibition of 5 and 6 mm respectively 15 were observed. A pellet which was formed from the ball milled powder and which was 16 annealed at 500~C for 1 hour had significantly reduced anti-microbial activity.

Initially the 17 pellet had some activity (4.5 mm zone of inhibition) but after the pellet was tested a second 18 time, no zone of inhibition was observed. A control pellet which had not been annealed l9 continued to give a zone of inhibition greater than 4 mm even after 14 repeats of the test.

This 20 demonstrates that an annealing step, following mechanical working, limits the sustainable 21 release of the anti-microbial silver species from the powders.

22Nanocrystalline gold (20 nm crystals), supplied as a powder, was tested for 23 anti-microbial effect by sprinkling the powder onto adhesive tape and using the zone of 2 ~ inhibition test.

No zone of inhibition was recorded for the nanocrystalline gold powder.

2The gold powder was pressed into a 0.2 g pellet using 275,700 kPa (40,000 psi). A 10 3 mm zone of inhibition was observed.

When the pressed pellets were subsequently vacuum 4 annealed at 500~C for 1 hour and the zone of inhibition was found to be 0 mm.

5The results showed that solubility and thus the anti-microbial efficacy of 6 gold powders can be improved by a mechanical working process such as pressing a 7 nanocrystalline m~ten~l into a pellet.

The anti-microbial activity can be removed by 8 ann~ling Cold working is preferred.

9Other gold powders including a 2-5 micron and a 250 micron particle size 10 powder did not demonstrate an anti-microbial effect under the above mechanical working 11 conditions.

It is believed that the small grain size of the nanocrystalline gold powder was 12 an important cofactor which, with the mechanical working, produced the desired anti13 microbial effect.

14 15 Example 11 16This example is included to demonstrate a composite anti-microbial coating 17 formed by reactive sputtering (another example of composite films).

Example 7 18 demonstrates that an anti-microbial coating of silver can be obtained by sputtering in argon 19and 1% oxygen (0.5 kW, 5.3 Pa (40 mTorr), 100 mm anode/cathode distance, and 20~C 20 produced a zone of inhibition of 11 mm).

21When a working gas of argon and 20 wt% oxygen was used to sputter anti22 microbial coatings under the conditions listed in Table 6, the zones of inhibition ranged 23 from 6 to 12 mm.

This indicates that the provision of a reactive atmosphere during vapour 36 deposition has the result of producing an anti-microbial film over a wide range of 2 deposition process parameters.

4 Table 6 - Sputtering Conditions 6 Target 20.3 cm dia., 99.99% Ag 7 Working Gas: 80/20 wt% Ar/O2 8 Working Gas Pressure: 0.3 to 6.7 Pa (2.5 to 50 mTorr) 9 Total Mass Gas Flow: 700 sccm Power: 0.1 to 2.5 kW 11 Substrate Temperature: -5 to 20~C 12 Anode/Cathode Distance 40 to 100 mm 13 Base Pressure: less than 5 x 10-4 Pa (4 x 10-6 Torr) 14 16 Example 12 17 This example demonstrates that the coatings of this invention have an anti18 microbial effect against a broad spectrum of bacteria.

19 A total of 171 different bacterial samples encompassing 18 genera and 55 20 species were provide by the Provincial Laboratory of Public Health for Northern Alberta.

21 These samples had been quick frozen in 20% skim milk and stored at -70~C for periods 22 ranging from several months to several years.

Fastidious org~ni~m~ which were unlikely 23 to grow under conditions used in standard Kirby-Bauer susceptibility testing were not used.

24 Each frozen sample was scraped with a sterile cotton swab to inoculate a 25 blood agar plate (BAP).

The plates were incubated overnight at 35~C.

The following 26 morning isolated colonies were subcultured onto fresh BAPs and incubated at 35~C 27 overnight.

The next day, the org~ni.~ms were subjected to Kirby-Bauer susceptibility 28 testing as described below.

29 Four to five colonies (more if colonies were small) of the same 30 morphological type were selected from each BAP subculture and inoculated into individual tubes con~ining approximately 5 mL of tryptic soy broth (TSB).

The broths were 2 incubated at 35~C for approximately 2 to 3 hours.

At this time, the turbidity of most of 3 the broth cultures either equalled or exceeded that of a 0.5 McFarland standard.

The more 4 turbid samples were diluted with sterile saline to obtain a turbidity visually comparable to 5 that of the standard.

To aid in the visual assessment of turbidity, tubes were read against 6 a white background with contrasting black line.

7 A small number of the organisms (Streptococcus and cbrynebacterium) did 8 not grow well in TSB.

The turbidity of these broths, after incubation, was less than that 9 of the 0.5 McFarland standard.

Additional colonies from the BAP subcultures were 10 inoculated to these tubes to increase the turbidity to approximate that of the standard.

11 Within 15 minutes of adjusting the turbidity of the bacterial suspensions a 12 sterile cotton swab was dipped into each broth.

Excess fluid was removed by rotating the 13 swab against the rim of the tube.

The inoculum was applied to a Mueller Hinton (MH) 14 agar plate by streaking the swab evenly in three directions over the entire agar surface.

15 Three 1 cm x 1 cm silver coated silica wafer squares were applied to each MH plate and 16 the plates were inverted and incubated overnight at 35~C.

The coatings had been ~pu~ered 17 under the following conditions, which through XRD analysis were shown to be silver/silver 18 oxide composite films:

19 21 Target: 20.3 cm dia., 99.99% Ag 22 Working gas: 80/20 wt % Ar/O2 23 Working gas pressure: 5.3 Pa (40 mT) 24 Total Mass Gas Flow: 700 sccm Power: 0.1 kW 26 Temperature of Deposition 20~C 27 Base pressure 2.7 X 10-4 Pa (2 x lo-6 Torr) 28 Cathode/anode distance 40 mm 38 ' BAP cultures of control organisms were provided by the Provincial 2 Laboratory and included: Staphylococcus aureus ATCC 25923; Pseudomonas aeruginosa 3 ATCC 27853; Escherichia coli: ATCC 25922; and Enterococcus faecalis ATCC 29212 to 4 check the quality of the MH agar.

These cultures were treated in a like manner to the test S organisms except that standard antibiotic discs rather than ~ilver coated wafers were 6 applied to the bacterial lawns on the MH agar.

These organisms demonstrated that the MH 7 agar was suitable for standard ZOI tests.

8After 16 to 18 hours of incubation at 35~C zones of inhibition around the 9 silver wafers or antibiotic discs were measured to the nearest rnm.

Corrected zones were 10 calculated by subtracting the size of the wafer (1 cm) from the size of the total zone.

11 Representative zone of inhibition results are shown in Table 7.

12 39 2 ~ 3~ ~5~ Table 7 2 The S~ ivi~y of a Broad Range of Microorganisms to Silver* Coated Silicon Wafers Organism Source Corrected Zone of 6 linhibition (mm) Staphylococcus, :d~ RC-455 blood 10 u~ Bacillus licheniformis R-2138 tibia 6 1 - cu~ ~terium sp R-594 leg 10 __ Listeria monocytogenes R-590 blood 5 6 F. ~,ùcocLusfaecalisSR-113 bone 5 51~ LLUJ bovis SR-62 blood 10 _4 ~ ' ;Lh.!l coli R-1878 urine 11 . _ Klebsiella ozonae R-308/90 abdomen 10 ~.s,ok~t~, cloacaeR-1682 unknown 8 _C Proteus vulgaris 3781 urine 4 " P,.".1~ ~ ;a stuartii U-3179 urine 8 ."g Citrobacterfreundii U-3122190 urine 7 ~0 J_ S' ~ .. ~lla tJ,.' ER-1154 urine 6 _ _ _ ~i Serraria ~ Le:SC~S R-850 sputum 6 C p ~ ,.".6 a U-3027 urine 10 ~6 J7 Y ' . -- I ' ~h ' ~ 90-lOB unknown 9 ~1.' A~,.. ~. caviae R-1211 woumd 5 ~.) ~_ B, I 'Irl c~71 ,h~lis R-2681 umknown 12 ~~ Silver ~C 46 Example 13 47 This example demonstrates the use of t~nt~ m as an adhesive layer for 48 coatings of this invention.

Tantalum is well known as a material which, in the form of an 49 interlayer, improves adhesion of thin films to substrates.

In this example test sections including a group of stainless steel (316) (1 x 1 cm) and silicon (1.7 X 0.9 cm) coupons 51 and sections of latex tubing (5 cm) were cleaned in ethanol and then half of the test 52 sections were coated (by sputtering) with a thin layer (approx. 100 Angstroms) of Ta Z~ r before an anti-microbial silver film was deposited on them.

The second group of the test 2 sections were only coated with the anti-microbial Ag film.

Coating conditions are listed 3 below.

While all test sections had similar anti-microbial activity, the Ta coated test 4 sections had much better adhesion properties than did the untreated test sections.

Adhesion properties were determined using ASTM method D3359-87, a standard test method for 6 me~uring adhesion.

7 Sputtering Condiffons 9 Target: 20.3 cm dia., 99.99% Ta Working Gas: 99/1 wt% Ar/O2 11 Working Gas Pressure: 1.3 Pa (10 mTorr) 12 Total Mass Gas Flow: 700 sccm 13 Power: 0.5 kW 14 Cathode/Anode Distance: 100 mm Substrate Temperature: 20~C 16 17 Target: 20.3 cm dia., 99.99% Ag 18 Working Gas: 99/1 wt% Ar/O2 19 Working Gas Pressure: 5.3 Pa (40 mTorr) Total Mass Gas Flow: 700 sccm 21 Power: 0.5 kW 22 Cathode/Anode Distance: 100 mm 23 Substrate Temperature: 20~C 24 26 Example 14 27 DC magnetron sputtering was used to deposit silver from a 20.3 cm dia., 28 99.98% pure cathode onto silicon and alumina wafers with commercial argon moisturized 29 with water as the working gas at a total mass gas flow of 700 sccm.

The argon was 30 moisturized by passing it through two flasks containing 3 litres of room temperature water 31 and one empty flask set up with glass wool to absorb any free liquid before the gas entered 32 the spu~ g unit.

33 The conditions of sputtering and the results of the standard zone of 34 inhibition test performed on the sputtered silver films are shown below.

Silver films which 41 normally had no anti-microbial properties when deposited using argon that had not been 2 treated with watcr yielded a corrected zone of inhibition of up to 8 mm when sputtered 3 using a argon/water vapour mixture as the working gas.

Table 8 6 Con(lition~ used for DC Magnetron Sputtering of Anti-Microbial Caotings Working Gas Working Gas Power Substrate Anode/Cathode Corrected Pressure Temperature Distance ZOI _ _ Pa (mT) r~ ~i,l Argon 1.3 (10) 0.5kW -lO'C 100 mm O mm _ ~ Ar passed through H~O 1.3 (10) 0.5kW _lODc 100 mm 8 mm 21 Example 15 22 This example is included to demonstrate the generation of silver complex 23 ions which are distinct from the Ag+ ion and which are highly efficacious in generating 24 an anti-microbial effect.

The example provides comparative diffusion and zone of inhibition (ZOI) data for various silver solutions.

26 Solutions were prepared to generate 10,000 ppm Ag as AgNO3, Ag(NH3)2+, 27 Ag(CN)2-, Ag(S2o3)23- and Ag(protein).

28 The silver solutions were prepared as follows:

29 1) Ag(S2o3)3-- 2.66 g of AgCl were dissolved in 150 ml of deionized water.

17.22 g of Na2(S2O3) were added and the volume was brought up to 200 ml with 31 deionized water.

32 2) Ag(CN)2- - Equal volumes of 12.5 g/L AgCN and 50g/L KCN were mixed.

33 3) Ag(protein) - Two silver protein samples were tested.

Silver protein powder ~0.5 34 g of Sigma S-6767, lot# 121H3437, 20% Ag) were added to 10 ml of deionized 42 $ water.

Silver protein powder (1.25 g of Sigma S-9017, lot # 33H3456, 8% Ag) 2 were added to 10 ml of deionized water.

3 4) Ag(NH3)2+ - Silver nitrate was added to ammonium hydroxide to form a black 4 precipitate.

To this solution was added dropwise additional ammonium hydroxide until the precipitate redissolved, leaving the complex silver ion Ag(NH3)2+ in 6 solution.

7 Also prepared were control solutions cont~ining the same concentrations of 8 nitrate, ammonia, cyanide and thiosulphate as was present in the test solutions.

The anti9 microbial effect of the test solutions was tested by a zone of inhibition test. A sensi disc (cellulose, 6mm diameter) containing 25 microlitres of each of the test solutions was 11 placed in the middle of a MHA (Difco media) plate.

The silver complexes or ions in the 12 sensi disc were allowed to diffuse for 4 hours on the MHA plate stored in a 37~C 13 incubator.

After 4 hours, the sensi disc was removed from the plate and analyzed for 14 silver content using neutron acivation analysis (NAA, University of Alberta Slowpoke Reactor Facility). A further set of plates were used to measure zones of inhibition against 16 S. aureus for each of the silver complexes or ions in the sensi discs.

Samples of the agar 17 were taken from the plates from two locations - the edge of the zone of inhibition and 18 underneath the discs.

The agar samples were analyzed for silver content by NAA.

The 19 control solutions were tested for anti-microbial effect and were found to cause no zone of inhibition.

The results are set forth in Table 9.

43 5 ~ Table 9 2 Anti-Microbial Effect of Ag+ Ion Compared to Silver Complex Ions 4 Test Solution ZOI Silver Content (ppm) (mm) In Disc Under Disc Ed~e of ZOI 87 Ag(N0)3 6 9000 100 1.8 g Ag(NH3)2 18 7300 221 1.7 11 Ag(CN)2- 70 1400 420 4.3 12 13 Ag(S203)23 36 * * * Ag(protein) 6 * * * 16 17 * Not mp~e~ d 18 19 The above results indicate that silver salts or compounds known to 20 dissociate to produce the Ag+ ion (ex. silver nitrate and silver proteins) have a limited anti21 microbial effect (6mm ZOI).

The anti-microbial effect is greater for silver compositions 22 which release silver complex ions other than Ag+ (ex.

Ag(NH3)2+, Ag(CN)2- and 23 Ag(S2o3)23-).

It is also apparent that the silver complex ions are able to diffuse further in 24 the agar medium than the Ag+ ion, thereby achieving an anti-microbial effect further from 25 the silver source.

26 Without being bound by the same, it is believed that the Ag+ ion is less 27 efficacious in its anti-microbial effect because it readily precipitates in the agar medium 28 with chloride ions known to be present.

The silver complex ions on the other hand 29 demonstrate a higher level of anti-microbial effect and more rapid diffusion.

The silver 30 complex ions are also believed not to precipitate with chloride ions to such an extent, 31 making them more suitable for use in industrial systems or with medical devices and the 32 like which come into contact with fluids cont~ining chloride ions.

33 44 2 ~ 3 ~ Example 16 2 This example provides comparative diffusion data and zone of inhibition 3 data for several silver anti-microbial coatings.

4 Three silver films were sputtered under the conditions set forth in Table 10.

6 TABLE 10 7 SpuUerin~ Conditions Film 1 Film 2 Film 3 8 Target (20.3 cm dia.) 99.99% Ag 99.99% Ag 99.99% Ag 9 Working Gas 99/1 wt% Ar/O2 99/1 wt% Ar/O2 99/1 wt% Working Gas Pressure 0.7 Pa 5.3 Pa 5.3 Pa 11 Total Mass Flow 700 sccm 700 sccm 700 sccm 12 Power 0.5 kW 0.5 kW 0.05 kW 13 Substrate Tr~ r.~ .r 21~C 21~C 21~C 14 Anode/Ca~ode Distance 100 mm 100 mm 100 mm 16 The coatings were tested for anti-microbial activity by a ZOI test, as set 17 forth in previous examples.

Silver content was measured by NAA after 4 hours diffusion 18 in the agar medium, as set forth in Example 15.

The comparative results are set out in 19 Table 11.

21 Table 11 22 Anti-Microbial Effect of Silver Coatings 23 24 Test Film Ag CZOI Silver Content (ppm) Species (mm) Under Film Edge of ZOI 26 27 Film 1 Ag+ 2 35 0.8 28 Film 2 AgXl 12 8.5 0.7 29 Film 3 Ag+ + AgXl 12 654 0.4 31 1 AgX is a silver complex ion or ion pair.

32 33 34 For Film 1, which releases predomin~ntly Ag+ ions, a small ZOI is produced, with the 35 silver being precipitated as AgCl below the film.

For Film 2, a much larger ZOI (6X) is 36 produced with 1/4 the amount of silver being precipitated under the wafer.

This suggests 4 ~ ~ I that a silver complex ion different than Ag+ is formed which diffuses more readily.

It is 2 believed that the diffusion is accelerated as a result of the nature of the complex silver 3 species.

Film 3 releases much more silver than Films 1 or 2, but the bulk of the silver is 4 in the form of Ag+ which precipitates as AgCl under the film.

However, the size of the 5 ZOI indicates that, in addition to Ag+, a complex silver ion with much greater mobility 6 than Ag+ is generated.

It is believed that one or more of the negative silver hydroxyl ions 7 Ag(OH)2-, Ag2(0H)3-, or Ag3(0H)4- are generated.

In that chloride is in the agar medium, 8 negative silver hydroxyl-chloro complexes may form.

Example 17 11 This example is included to demonstrate the preparation of complex ions of 12 silver cyanide, and the anti-microbial effect of such ions.

13 A silver cyanide bath typically used in electroplating was tested for anti14 microbial effect using 25 microlitres of bath on a sensi disc in a standard ZOI test.

The silver cyanide bath contained 37 g/L silver cyanide, 45 g/L potassium cyanide and 30 g/L 16 potassium carbonate.

The resulting ZOI covered the entire plate, indicating a corrected 17 ZOI greater than 94 mm.

The maximum amount of silver that was available in the AgCN 18 bath was 30,000 ppm.

From previous work it is known that this concentration as AgNO3 19 would not yield a ZOI greater than 6 mm.

The effect of the cyanide ion alone was determined by placing 25 microlitres of 45 g/L KCN on a sensi disc and repeating the ZOI 21 test. A corrected ZOI of 12.5 mm was produced. A solution of AgCN in ~ tilled water 22 (37 g/L) was simil~rly tested for a ZOI. A corrected ZOI of 14 mm was observed.

23 The molar ratio of silver ion to cyanide ion in the bath 0.37: 1.

This favours 24 the formation of a negative silver cyanide complex Ag(CN)2- or AgCN(aq) as an ion pair.

46 The above results demonstrate that these complex silver ions have anti-microbial efficacy 2 and increased mobility within an agar medium.

3 Thin strips of filter paper were treated with 50 microlitres of either a silver 4 nitrate solution (10,000 ppm Ag) or a potassium cyanide solution (6,400 ppm CN-).

The strips were subjected to a standard ZOI test on the MHA plate.

Silver nitrate control strips 6 gave a corrected ZOI of 8 mm, while the KCN control strips gave no ZOI.

When one of 7 each of the silver nitrate and potassium cyanide strips were placed on the MHA plate at 8 right angles to each other, the corrected ZOI was 30 mm from the silver nitrate strip and 9 22 mm from the potassium cyanide strip.

This result demonstrates that a complex silver ion resulting from the 11 combination of silver nitrate and potassium cyanide in the media has greater anti-microbial 12 efficacy than either solution alone.

13 14 Example 18 This example is included to demonstrate the anti-microbial efficacy of a 16 complex silver ion of silver chloride.

17 Silver chloride was pressed into a 0.2 g pellet at 413,550 kPa (60,000 psi) 18 and tested using a standard ZOI test on MHA plates.

An 8 mm zone resulted. A mixture 19 of 0.15 g AgCl and 0.05 g NaCl pressed into a pellet at 60,000 psi and .~imil~rly tested.

A 24 mm zone was observed.

21 The increased concentration of the available chloride ion favours the 22 formation of the complex silver ion AgCl2-, which is demonstrated above to have improved 23 anti-microbial efficacy over AgCl.

47 4 ~ ~ A silver nitrate solution (10,000 ppm Ag) was tested with sensi discs (25 2 microlitres) in a ZOI test. A 6 mm zone was observed.

The same concentration of 3 AgNO3 was tested on an agar plate which had been supplemented with 5% NaCl. A 20 4 mm zone was observed, indicating improved anti-microbial efficacy. A control plate of 5 agar supplemented with 5% NaCl did not inhibit bacterial growth (S. aureus).

6 It is believed that the higher concentrations of the chloride ion favoured the 7 formation of the complex silver ion Ag(C1)2-.

This species shows three times the anti8 microbial efficacy of Ag+ from silver nitrate.

Example 19 - Animal Testing - Irritation 11 A primary skin irritation study was performed on New Zealand White 12 (NZW) rabbits using gauze coated with an anti-microbial metal of this invention.

The 13 coating was deposited on a USP type VII gauze using the process conditions of Example 14 7 where the working gas was 99/1 wt% Ar/O2.

The coated gauze was placed on abraded and unabraded skin on the side of 16 a New 7e~1~nd White rabbit.

At 24 h the gauze was removed and the site was graded for 17 erythema and edema at 1, 24 and 48 hours after removal.

18 All ~nim~l.c survived to the end of the study.

No erythema, edema or 19 infection was observed on any animal.

It was concluded that the gauze did not produce local irritation when placed on the skin of male or female NZW rabbits.

21 22 Example 20 - Animal Testing - Sensitivity 23 The sensitivity of Hartley Guinea Pigs to USP type VII gauze coated with 24 an anti-microbial metal coating of the present invention was investigated.

The gauze was 4~ coated as per Example 7 using 99/1 wt% Ar/O2.

The split adjuvant technique was used 2 since the test material was not injectable and the application of dry ice to the induction 3 area most closely simulates the clinical situation.

4 There was no evidence that the coated gauze induced erythema or edema S and no infection was observed in any of the ~nim~ All anim~l~ survived the study.

6 Application of the coated gauze to the skin of male Hartley Guinea Pigs did 7 not result in local sensitivity when tested by the split adjuvant technique.

9 Example 21 This example is included to demonstrate that silver powder/NaCl mixtures 11 produce an anti-microbial effect from complex silver ions believed to be AgC12-.

12 Pellets of silver powder (1 micron) and NaCl (25%) were pressed at the 13 conditions set out below.

The anti-microbial effect was measured by a zone of inhibition 14 test with the pellets. A comparative control of pressed silver powder was also tested for 15 a zone of inhibition.

The results are shown in Table 12:

16 17 Table 12 18 Anti-Microbial Effect of Silver Powder/NaCI 19 Pellet C~ ,ssion ZOI 21 k~ (Ib.) 22 23 Ag + 25% NaCl 454 (1000) 26 mm 24 Ag + 25% NaCI 1361 (3000) 20 mm Ag + 25% NaCI 2268 (5000) 19 mm 26 Ag powder 454 (1000) <1 mm 27 28 29 All publications mentioned in this specification are indicative of the level 30 of skill of those skilled in the art to which this invention pertains.

All publications are 49 herein incorporated by reference to the same extent as if each individual publication was 2 specifically and individually indicated to be incorporated by reference.

3 The terms and expressions in this specification are used as terms of 4 description and not of limitation.

There is no intention, in using such terms and expressions, of excluding equivalents of the features illustrated and described, it being 6 recognized that the scope of the invention is defined and limited only by the claims which 7 follow.