Anti-microbial fiber and fibrous products

• US 20050019568A1
• Filed: 01/27/2004
• Published: 01/27/2005
• Est. Priority Date: 05/27/1999
• Status: Abandoned Application

• Current Assignee: Foss Manufacturing Company , LLC (Mohawk Industries Incorporated)
• Original Assignee: Foss Manufacturing Company Incorporated
• Inventors: Sawvell, Robert V., Foss, Stephen W.
• Application Number:
  US10/765,255
• Publication Number:
  US 20050019568A1
• 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. An anti-microbial fabric, comprising:

a multi-layer filter article comprising a plurality of layers wherein at least one layer is made at least in part of a multi-component fiber of thermoplastic polymers, said fiber including;

a core of thermoplastic polymer being at least 20% and less than 70% of the fiber by weight, and

a sheath being more than 30% of the fiber by weight and including (i) a thermoplastic polymer and (ii) an anti-microbial/anti-fungal inorganic additive being from 0.1% to 20% of the fiber by weight, wherein the thickness of the sheath in microns is approximately twice the nominal particle size in microns of the additive.

2. The fabric of claim 1, forming at least a part of an air filter.

3. The fabric of claim 1, forming at least a part of a water filter.

4. The fabric of claim 1, wherein said fiber further comprises an anti-odor agent.

5. The fabric of claim 1, wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be upstream relative to any fluid flow traversing or otherwise contacting the fabric.

6. The fabric of claim 1, forming at least part of a car wash material.

7. The fabric of claim 1, forming at least part of a filter or a batt in a car wash water recycle storage tank.

8. The fabric of claim 1, forming at least in part a mop head fabric.

9. The fabric of claim 1, forming at least in part a dust mask.

10. The fabric of claim 1, forming at least in part a humidifier evaporation surface media and/or a circulation/aeration system pad.

11. The fabric of claim 1, forming at least in part a boat bilge anti-microbial pad.

12. An anti-microbial fabric, comprising:

a multi-layer filter article comprising a plurality of layers wherein at least one layer is made of a bi-component fiber, said fiber including;

a core of a high tenacity polymer being at least 20% and less than 70% of the fiber by weight, and

a sheath of a hydrolysis resistant polymer being at least 30% of the fiber by weight, and including an additive ranging from 0.1% to 20% of the fiber by weight, said additive and being selected from the group consisting of pigments, compounds creating a hydrophilic surface, and anti-microbial, anti-fungal and anti-odor materials.

13. The fabric of claim 12, forming at least a part of an air filter.

14. The fabric of claim 12, forming at least a part of a water filter.

15. The fabric of claim 12, wherein said fiber further comprises an anti-odor agent.

16. The fabric of claim 12, wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be upstream relative to any fluid flow traversing or otherwise contacting the fabric.

17. The fabric of claim 12, forming at least part of a car wash material.

18. The fabric of claim 12, forming at least part of a filter or a batt in a car wash water recycle storage tank.

19. The fabric of claim 12, forming at least in part a mop head fabric.

20. The fabric of claim 12, forming at least in part a dust mask.

21. The fabric of claim 12, forming at least in part a humidifier evaporation surface media and/or a circulation/aeration system pad.

22. The fabric of claim 12, forming at least in part a boat bilge anti-microbial pad.

23. An anti-microbial fabric, comprising:

a multi-layer filter article comprising a plurality of layers, wherein at least one layer is made at least in part of;

one or more units of a binder fiber made from low temperature polymer with a melting or softening temperature below 200 degrees C.,

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 binder fiber, the additive ranging from 0.1% to 20% of the fiber by weight, and

other fibers that are free of said anti-microbial additive that are blended with said binder fiber the fabric having a form as made by heating to said melting temperature of the binder fiber and enabling melt and flow of the binder fiber with formation of nodes attaching some of the other fibers to each other, thereby providing a fiber blend that can be used to produce an anti-microbial finished fabric able to withstand significant wear and washings and maintain effectiveness of said anti-microbial additives.

24. The fabric of claim 23, forming at least a part of an air filter.

25. The fabric of claim 23, forming at least a part of a water filter.

26. The fabric of claim 23, wherein said article further comprises an anti-odor agent.

27. The fabric of claim 23, wherein said at least one layer including the binder fiber is on a side of the fabric that is adapted to be upstream relative to any fluid flow traversing or otherwise contacting the fabric.

28. The fabric of claim 23, forming at least part of a car wash material.

29. The fabric of claim 23, forming at least part of a filter or a batt in a car wash water recycle storage tank.

30. The fabric of claim 23, forming at least in part a mop head fabric.

31. The fabric of claim 23, forming at least in part a dust mask.

32. The fabric of claim 23, forming at least in part a humidifier evaporation surface media and/or a circulation/aeration system pad.

33. The fabric of claim 23, forming at least in part a boat bilge anti-microbial pad.

34. The fabric of claim 23, wherein the fibers that are free of said anti-microbial additive are cotton.

35. The fabric of claim 23, wherein the binder fiber is made of PETG.

36. An anti-microbial medical fabric, comprising:

a multi-layer fabric comprising a plurality of layers, wherein at least one layer is made at least in part of multi-component fibers of thermoplastic polymers, each fiber comprising;

a core of thermoplastic polymer being at least 20% and less than 70% of the fiber by weight, and

a sheath being more than 30% of the fiber by weight and including;

(i) a thermoplastic polymer and (ii) an anti-microbial/anti-fungal inorganic additive being from 0.1% to 20% of the fiber by weight, wherein the thickness of the sheath in microns is approximately twice the nominal particle size in microns of the additive.

37. The medical fabric of claim 36, forming at least part of a wound care dressing or a burn dressing.

38. The medical fabric of claim 37, wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be placed on the skin of a patient.

39. The medical fabric of claim 38, wherein said at least one layer is comprised of an absorbent material.

40. The medical fabric of claim 36, forming at least part of a medical wipe.

41. An anti-microbial medical fabric, comprising:

a multi-layer fabric comprising a plurality of layers, wherein at least one layer is made at least in part of bi-component fibers, each fiber including;

a core of a high tenacity polymer being at least 20% and less than 70% of the fiber by weight, and

a sheath of a hydrolysis resistant polymer being at least 30% of the fiber by weight, said sheath including an additive ranging from 0.1% to 20% of the fiber by weight said additive being selected from the group consisting of pigments, compounds creating a hydrophilic surface, and anti-microbial, anti-fungal and anti-odor materials.

42. The medical fabric of claim 41, forming at least part of a wound care dressing or a burn dressing.

43. The medical fabric of claim 42, wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be placed on the skin of a patient.

44. The medical fabric of claim 43, wherein said at least one layer is comprised of an absorbent material.

45. The medical fabric of claim 41, forming at least part of a medical wipe.

46. An anti-microbial medical fabric, comprising:

a multi-layer fabric comprising a plurality of layers, wherein at least one layer is made at least in part of;

a binder fiber made from low temperature polymer with a melting or softening temperature below 200°

C.,

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

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

47. The medical fabric of claim 46, forming at least part of a wound care dressing or a burn dressing.

48. The medical fabric of claim 47, wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be placed on the skin of a patient.

49. The medical fabric of claim 48, wherein said at least one layer is comprised of an absorbent material.

50. The medical fabric of claim 46, forming at least part of a medical wipe.

51. The medical fabric of claim 46, further comprising PETG as a carrier for a plurality of color pigments for said fabric.

52. The medical fabric of claim 51, wherein the PETG had an anti-microbial and/or a colorant added thereto prior to melting at a low temperature.