Anti-microbial fiber and fibrous products

• US 20030170453A1
• Filed: 04/02/2003
• Published: 09/11/2003
• Est. Priority Date: 05/27/1999
• Status: Abandoned Application

• Current Assignee: Foss Manufacturing Company Incorporated
• Original Assignee: Foss Manufacturing Company Incorporated
• Inventors: Brown, Steven R., Cashin, Arthur H., Tefft, Alan, Goudreault, Kim, Keser, Dieter, Parlier, James M., Foss, Stephen W., Sawvell, Robert V. Jr., Goodwin, Gordon Jr.
• Application Number:
  US10/406,720
• Publication Number:
  US 20030170453A1
• Time in Patent Office: Days
• US Class Current: 428/373
• CPC Class Codes: A01N 2300/00 Combinations or mixtures of active ingredients covered by classes A01N27/00 - A01N65/48 with other active or formulation relevant ingredients, e.g. specific carrier materials or surfactants, covered by classes A01N25/00 - A01N65/48
• CPC Class Codes: A01N 25/34 Shaped forms, e.g. sheets, not provided for in any other sub-group of this main group
• CPC Class Codes: A01N 57/16 containing heterocyclic radicals
• CPC Class Codes: A01N 59/16 Heavy metals; Compounds thereof
• CPC Class Codes: A41B 17/00 Selection of special materials for underwear
• CPC Class Codes: A41B 2400/60 Moisture handling or wicking function
• CPC Class Codes: A41D 31/00 Materials specially adapted for outerwear
• CPC Class Codes: A41D 31/12 Hygroscopic; Water retaining
• CPC Class Codes: A61F 13/8405 Additives, e.g. for odour, disinfectant or pH control
• CPC Class Codes: A61F 2013/8414 with anti-microbic
• CPC Class Codes: A61L 15/46 Deodorants or malodour counteractants, e.g. to inhibit the formation of ammonia or bacteria
• CPC Class Codes: A61L 2/238 Metals or alloys, e.g. oligodynamic metals
• CPC Class Codes: A61L 2300/104 Silver, e.g. silver sulfadiazine
• CPC Class Codes: A61L 2300/404 Biocides, antimicrobial agents, antiseptic agents
• CPC Class Codes: B01D 2275/10 Multiple layers
• CPC Class Codes: B01D 39/1615 of natural origin
• CPC Class Codes: B01D 39/1623 of synthetic origin
• CPC Class Codes: B01D 46/00 Filters or filtering processes specially modified for separating dispersed particles from gases or vapours filtering elements B01D24/00-B01D35/00; filtering material B01D39/00; their regeneration outside the filters B01D41/00
• CPC Class Codes: B01D 46/0028 provided with antibacterial or antifungal means
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: B32B 2262/0276 : Polyester fibres
• CPC Class Codes: B32B 2262/0284 : Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
• CPC Class Codes: B32B 2264/10 : Inorganic particles
• CPC Class Codes: B32B 2305/20 : in the form of a non-woven mat
• CPC Class Codes: B32B 2305/70 : Scrap or recycled material
• CPC Class Codes: B32B 2307/558 : Impact strength, toughness
• CPC Class Codes: B32B 2307/7145 : Rot proof, resistant to bacteria, mildew, mould, fungi
• CPC Class Codes: B32B 2367/00 : Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2437/02 : Gloves, shoes
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/18 : characterised by the use of special additives
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/306 : comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: D01F 1/103 : Agents inhibiting growth of microorganisms
• CPC Class Codes: D01F 8/12 : with at least one polyamide as constituent
• CPC Class Codes: D01F 8/14 : with at least one polyester as constituent
• CPC Class Codes: D02G 3/449 : Yarns or threads with antibacterial properties filaments containing agents inhibiting growth of microorganisms D01F1/103
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/251 : Mica
• CPC Class Codes: Y10T 428/26 : Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/2904 : Staple length fiber
• CPC Class Codes: Y10T 428/2907 : with coating or impregnation
• CPC Class Codes: Y10T 428/2913 : Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/2915 : including textile, cloth or fabric
• CPC Class Codes: Y10T 428/2924 : Composite
• CPC Class Codes: Y10T 428/2929 : Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
• CPC Class Codes: Y10T 428/2931 : Fibers or filaments nonconcentric [e.g., side-by-side or eccentric, etc.]
• CPC Class Codes: Y10T 428/2933 : Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/298 : Physical dimension
• CPC Class Codes: Y10T 442/30 : Woven fabric [i.e., woven strand or strip material]
• CPC Class Codes: Y10T 442/3073 : Strand material is core-spun [not sheath-core bicomponent strand]
• CPC Class Codes: Y10T 442/3146 : Strand material is composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• CPC Class Codes: Y10T 442/3154 : Sheath-core multicomponent strand material
• CPC Class Codes: Y10T 442/444 : Strand is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• CPC Class Codes: Y10T 442/637 : Including strand or fiber material which is a monofilament composed of two or more polymeric materials in physically distinct relationship [e.g., sheath-core, side-by-side, islands-in-sea, fibrils-in-matrix, etc.] or composed of physical blend of chemically different polymeric materials or a physical blend of a polymeric material and a filler material
• CPC Class Codes: Y10T 442/638 : Side-by-side multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/64 : Islands-in-sea multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/641 : Sheath-core multicomponent strand or fiber material
• CPC Class Codes: Y10T 442/659 : Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/674 : Nonwoven fabric with a preformed polymeric film or sheet
• CPC Class Codes: Y10T 442/69 : Autogenously bonded nonwoven fabric
• CPC Class Codes: Y10T 442/692 : Containing at least two chemically different strand or fiber materials
• CPC Class Codes: Y10T 442/697 : Containing at least two chemically different strand or fiber materials
• CPC Class Codes: Y10T 442/699 : Including particulate material other than strand or fiber material

Abstract

An anti-microbial and/or anti-fungal synthetic fiber and various products made partially or wholly therefrom. The fiber comprises various thermoplastic polymers and additives in a mono-component form or a bi-component form in either a core-sheath or side-by-side configurations. The anti-microbial synthetic fibers comprise inorganic anti-microbial additives, distributed in certain areas to reduce the amount of the anti-microbial agents being used, and therefore the cost of such fibers. The fibers can incorporate anti-microbial additives so that they are not removed by repeated washing in boiling water and in dry clean cycles and become ineffective and conversely enhance access to the additives by washing or the like. The fibers comprise high tenacity polymers (e.g. PET) in one portion and hydrolysis resistance polymers (e.g. PCT) in another portion with the additives. The fibers can further be blended with non-anti-microbial fibers such as cotton, wool, polyester, acrylic, nylon etc. to provide anti-microbial finished fabrics. In one embodiment, binder fibers are used which are mixed with other fibers.

Claims

1. A multi-component fiber of thermoplastic polymers, comprising:

a. a first component of thermoplastic polymer having between 20-80% of the fiber by weight; and

b. a second component having between 80-20% of the fiber by weight and including (i) a thermoplastic polymer and (ii) an anti-microbial/anti-fungal inorganic additive, said first and second components are in a core-sheath configuration and the additive in said second component is from 0.1% to 20% by weight of fiber.

2. A fiber as defined in claim 1 wherein the additive is one selected from the group consisting of copper, zinc, tin and silver.

3. A fiber as defined in claim 2 wherein the additive is zeolite of silver.

4. A fiber as defined in claim 3 wherein said sheath is more than 30% of the cross section of the total fiber.

5. A fiber as defined in claim 4 wherein said additive particles are approximately 1 micron cubes and the sheath is approximately 2 microns thick.

6. A fiber as defined in claim 3 wherein the additives are 0.2 to 6.0% by weight of the multi-part fiber.

7. A multi-part fiber as defined in claim 4 wherein the zeolite of silver is dispersed in a carrier of PE, PET, or PBT.

8. A multi-part fiber as defined in claim 3 wherein the first and second components are blended with a fiber which is selected from the group consisting of cotton, wool, polyester, acrylic and nylon and which is free of anti-microbial agents.

9. A fiber as defined in claim 6, wherein the polymers are of at least one chosen from the group consisting of PE, PP, PET (polyester), PCT, PETG, Co-PET, Styrene, Halar®

, PTT, 3GT, and polyamide 6 or 6,6.

10. A fiber as defined in claim 1 wherein there is a second additive which is at least one chosen from the group consisting of pigments, anti-odor compounds, hydrophilic, and hydrophobic materials.

11. A fiber as defined in claim 7 wherein the fiber size ranges from 0.7 dTex to 25.0 dTex.

12. A fiber as defined in claim 9 wherein said fiber is cut staple in lengths from 1.0 mm to 180.0 mm.

13. A fiber as defined in claim 9 wherein the fiber is continuous filament.

37. The product of claims 1 or 14 or 27 forming at least a part of a multi-layer incontinent article.

38. The product of claim 37, wherein said article is a garment.

39. The product of claim 37, wherein said article is a linen.

40. The product of claim 37 wherein said article is a bed pack.

41. The product of claim 37 wherein said article is prepared of woven fabric, non-woven fabric, or knitted fabric.

42. The product of claim 37 wherein said article is a diaper.

43. The product of claim 37 wherein said article includes an absorbent pad.

44. The product of claim 37 including a wick layer and an absorbent layer.

45. The product of claim 44 wherein the layer which is intended to be against a wearer'"'"'s skin is made of anti-microbial fibers.

46. The product of claim 37 wherein said article is underwear.

47. The product of claim 37 wherein said article is pajamas.

48. The product of claims 1 or 14 or 27 forming at least part of a multi-layer air filter.

49. The product of claim 48 wherein an anti-odor agent is added to the fiber.

50. The product of claim 48 wherein at least one layer has the anti-microbial fiber, said layer being on the intended upstream side of the other layers.

51. The product of claims 1 or 14 or 27 forming at least part of a multi-layer wound care or burn dressing.

52. The product of claim 51 wherein at least one layer has the anti-microbial fiber, said layer being on the intended skin side of the other layers.

53. The product of claim 52 wherein at least one other layer is of an absorbent material.

56. The product of claims 1 or 14 or 27 forming at least part of a multi-layer footwear component.

57. The product of claim 56 wherein said component is an insole, midsole, box toe, counter, lining.

58. The product of claim 57 wherein the anti-microbial fiber is used in the layer which is nearest the foot of a wearer.

59. The product of claim 58 wherein there is a support layer of latex attached to the layer containing the anti-microbial fiber.

60. The product of any of claims 1 or 14 or 27 forming at least part of a multi-layer laminate of high porosity between two internal layers thereof, one of which is bonded to the other with lateral fibers traversing parts of both layers, one or both of such layers incorporating anti-microbial agents, and means for acquiring moisture vapor into the laminate and trapping it there, one of the internal layers having higher strength properties than the other and the other having a higher moisture retention capacity.

61. The product of claim 60 as an insertable/removable insole for a shoe or the like.

62. The product of any of claims 1 or 14 or 27 forming at least part of a multi-layer partition or as a fabric for office, hospital, waiting area, classrooms, busses, cars, and the like and also curtains, upholstery, carpets and bedspreads.

63. The product of any of claims 1 or 14 or 27 forming at least part of a car wash material.

64. The product of any of claims 1 or 14 or 27 forming at least part of a filter or a batt in a car wash water recycle storage tank.

65. The product of any of claims 1 or 14 or 27 forming at least in part institutional and home furnishings, including bed sheets, pillow cases, mattress pads, blankets, towels, drapes, bedspreads, pillow shams, carpets, walk-off mats, napkins, linens, wall coverings, upholstered furniture, liners, mattress ticking, mattress filling, pillow filling, carpet pads, and upholstery fabric.

66. The product of any of claims 1 or 14 or 27 forming at least in part athletic clothing, athletic wear liners and component fabrics.

67. The product of any of claims 1 or 14 or 27 forming at least in part a mop head fabric.

68. The product of any of claims 1 or 14 or 27 forming at least in part a medical wipe.

69. The product of any of claims 1 or 14 or 27 forming at least in part a dust mask.

70. The product of any of claims 1 or 14 or 27 forming at least in part a humidifier evaporation surface media and/or a circulation/aeration system pad.

71. The product of any of claims 1 or 14 or 27 forming at least in part a boat bilge anti-microbial pad.

72. The product of any of claims 1 or 14 or 27 forming at least in part a laundry bag.

73. The product of any of claims 1 or 14 or 27 forming at least in part a piece of apparel.

74. The product of any of claims 1 or 14 or 27 forming at least in part a nautical fabric.

75. The product of any of claims 1 or 14 or 27 forming at least in part a layer of a wide stiff plastic sheet

14. A bi-component fiber, comprising:

a. a first component of a high tenacity polymer having between 20-80% of the fiber by weight and constituting a core;

b. a second component of a hydrolysis resistant polymer having between 80-20% of the fiber by weight and constituting a sheath surrounding the core, and including an additive; and

c. the additive in said second component ranging from 0.1% to 20% by weight of the fiber and being selected from the group consisting of pigments, compounds creating a hydrophilic surface, and anti-microbial, anti-fungal and anti-odor materials.

15. The fiber as defined in claim 14, wherein said first component of high tenacity polymer is PET providing strength to the fiber, and said second component of hydrolysis resistant polymer is PCT providing a hydrolysis resistant surface with good wrinkle resistance, and resistance to long term washings in boiling water and strong soaps.

16. The fiber as defined in claim 15, wherein the core is constructed to have a high modulus with properties of tenacity and elongation similar to cotton.

17. The fiber as defined in claim 15 wherein the core is constructed to have a low modulus with properties similar to wool.

18. The fiber as defined in claim 15, wherein the core is constructed to have an intermediate modulus fiber with properties between cotton and wool.

19. The fiber as defined in claim 14 wherein the additive is hydrophilic to create a fiber that, in a garment, appears to wick body moisture away from the skin and evaporate to create comfort to a wearer.

20. The fiber as defined in claim 14 wherein the additive is pigment to provide uniform colors that do not fade significantly over long-term use and washing.

21. The fiber as defined in claim 14 wherein the fiber size ranges from 0.7 dTex to 25.0 dTex.

22. The fiber as defined in claim 14 wherein said fiber is cut staple in lengths from 1.0 mm to 180.0 mm.

23. The fiber as defined in claim 14 wherein the fiber is continuous filament.

24. The fiber as defined in claim 14 wherein the additive is zeolite of silver.

25. The fiber as defined in claim 14 wherein said sheath is more than 30% of the cross section of the total fiber.

26. A fiber as defined in claim 14 wherein said additive particles are approximately 1 micron cubes and the sheath is approximately 2 microns thick.

27. An anti-microbial fiber, comprising:

a. a binder fiber made from low temperature polymer with a melting or softening temperature below 225 degrees C.;

b. an anti-microbial additive of an inorganic compound made from a metal chosen from the group consisting of copper, zinc, tin and silver added to the homopolymer fiber, the additive ranging from 0.1 to 20% by weight of the fiber; and

c. untreated fibers which are free of anti-microbial additive being blended with said binder fiber, said blend of fibers having been heated to its melting temperature, thereby providing a fiber blend which can be used to produce an anti-microbial finished fabric able to withstand significant wear and washings and maintain its effectiveness.

28. The fiber as defined in claim 27, wherein said low temperature homopolymer is selected from the group consisting of PETG, PE, PP, Co-PET and amorphous PET.

29. The fiber as defined in claim 28, wherein said inorganic compound of said anti-microbial additive is zeolitic of silver which is dispersed in PE, PET or PBT before being added.

30. The fiber as defined in claim 29, wherein said additive is added directly to said low temperature homopolymer with predispersion.

31. The fiber as defined in claim 27, wherein the non-anti-microbial fiber is selected from the group consisting of cotton, wool, polyester, acrylic and nylon.

32. The fiber as defined in claim 27 wherein said low temperature homopolymer is PETG, said anti-microbial additive being zeolite of silver, and said non-anti-microbial fiber being cotton.

33. The fiber as defined in claim 32 wherein said PETG polymer with said zeolite of silver additive is blended with said cotton up to 10% by weight to produce a fiber particularly suitable for a bed sheet.

34. The fiber as defined in claim 32, wherein said binder fiber is activated in a drying cycle of a final bleaching operation, whereby said PETG melts and wets the surface of said cotton fibers to carry the anti-microbial characteristics to the entire bed sheet with an added benefit of increasing strength and reducing pilling.

35. The fiber as defined in claim 27, wherein the fiber size ranges from 0.7 dTex to 25.0 dTex, and the fiber is cut staple in lengths from 1.0 mm to 180.0 mm.

36. The fiber as defined in claim 27, wherein the fiber is a continuous filament in a wrap spun application and said non-anti-microbial fiber is spun around an anti-microbial filament.

54. The product of claim 27 forming at least part of a fabric wherein PETG is used as the carrier for color pigments for said fabric.

55. The product of claim 54 wherein the PETG has been melted as a low temperature and has had an anti-microbial and/or a colorant added thereto prior to melting

76. A laminate comprising:

a tough extruded core of thermoplastic resin such as ionomer, EVA or styrene stiffened ionomer and at least one impact resistant strength layer of nonwoven material.

the needle punched nonwoven being made from a bi-component staple fiber or blend of PET staple fiber and binder staple fiber or blend of PET staple fiber and bi-component staple fiber, and having a combination of PET fibers and PETG or other copolymer or homopolymer fibers as binding agent for PET.

77. A laminate as defined in claim 76 wherein the thermoplastic components being miscible or mechanically compatible to allow for homogenization and incorporation into the extruded thermoplastic core thereby providing for complete recyclability of scrap material.

78. A stiff,moldable laminate, comprising:

a layer of tough thermoplastic resin;

a nonwoven fabric layer;

a tough extruded core of thermoplastic resin;

at least one impact resistant strength layer of nonwoven material constructed from a BiComponent staple fiber or blend of PET staple fiber and binder staple fiber or blend of PET staple fiber and BiComponent staple fiber, the nonwoven layer using a combination of PET fibers and PETG or other copolymer or monopolymers fibers which act as a binding agent for PET.

79. A laminate as defined in claim 78, wherein the staple fiber is 4-15 denier and 38 to 76 mm in length.

80. A laminate as defined in claim 79, wherein the thermoplastic components are miscible or mechanically compatible to permit homogenization and incorporation into the extruded thermoplastic core.

81. A laminate of a binding agent which is a thermoplastic binder fiber or a bi-component binder fiber which is thermally activated to bind and stiffen a nonwoven fabric into which it is incorporated.