Anti-microbial fiber and fibrous products

• US 6,946,196 B2
• Filed: 01/30/2004
• Issued: 09/20/2005
• Est. Priority Date: 05/27/1999
• Status: Expired due to Term

• Current Assignee: Foss Manufacturing Company , LLC (Mohawk Industries Incorporated)
• Original Assignee: Foss Manufacturing Company Incorporated
• Inventors: Foss, Stephen W.
• Primary Examiner(s): DIXON, MERRICK L
• Application Number:
  US10/768,840
• Publication Number:
  US 20040209059A1
• Time in Patent Office: 599 Days
• Field of Search: 428/370, 428/373, 428/374, 428/220, 428/323, 428/332, 428/401, 428/375, 428/324, 428/372, 36/88, 361/03, 361/04, 36/43, 36/73, 361/81, 36/44, 361/53, 361/54
• 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

Anti-microbial and/or anti-fungal footwear components formed from various thermoplastic polymers and additives in fibers 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 include 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. In certain embodiments, high tenacity polymers (e.g. PET) are employed 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-layer footwear component, including:

a first layer comprising multi-component fibers of thermoplastic polymers, each of the multi-component fibers further 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% by weight of fiber, the thickness of the sheath in microns being approximately two times the nominal particle size in microns of the additive; and

second layer proximate the first layer providing support thereto.

2. The footwear component of claim 1, forming a footwear component selected from the group consisting of an insole, midsole, box toe, counter, and lining.

3. The footwear component of claim 1, wherein the anti-microbial fiber is used in the layer which is nearest the foot of a wearer.

4. The footwear component of claim 1, further comprising a support layer of latex attached to the layer containing the anti-microbial fiber.

5. A multi-layer laminate, comprising:

two internal layers having high porosity therebetween, one of which is bonded to the other with lateral fibers traversing parts of both layers, one or both of the two internal layers including multi-component fibers of thermoplastic polymers, each 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% by weight of fiber, the thickness of the sheath in microns being approximately two times the nominal particle size in microns of the additive, 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.

6. The laminate of claim 5, formed as an insertable/removable insole for a shoe or the like.

7. An anti-microbial footwear component, including:

a first layer comprising bi-component fibers, each of the bi-component fibers further comprising

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% 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; and

second layer proximate the first layer providing support thereto.

8. The footwear component of claim 7, forming a footwear component selected from the group consisting of an insole, midsole, box toe, counter, and lining.

9. The footwear component of claim 7, wherein the anti-microbial fiber is used in the layer which is nearest the foot of a wearer.

10. The footwear component of claim 7, further comprising a support layer of latex attached to the layer containing the anti-microbial fiber.

11. 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 including bi-component fibers of thermoplastic polymers, each 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 an additive 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, 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.

12. The laminate of claim 11, formed as an insertable/removable insole for a shoe or the like.

13. A multi-layer footwear component, including:

a first layer further including

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% by weight of the fiber, and

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; and

second layer proximate the first layer providing support thereto.

14. The footwear component of claim 13, formed as footwear component selected from the group consisting of an insole, midsole, box toe, counter, and lining.

15. The footwear component of claim 13, wherein the anti-microbial fiber is used in the layer which is nearest the foot of a wearer.

16. The footwear component of claim 13, further comprising a support layer of latex attached to the layer containing the anti-microbial fiber.

17. 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 including a binder fiber comprising a 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% by weight of the fiber, and 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, 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.

18. The fabric of claim 17, as an insertable/removable insole for a shoe or the like.