Antimicrobial and antifungal polymer fibers, fabrics, and methods of manufacture thereof

• US 9,908,987 B2
• Filed: 08/12/2014
• Issued: 03/06/2018
• Est. Priority Date: 08/12/2013
• Status: Active Grant

• Current Assignee: Stephen W. Foss
• Original Assignee: PurThread Technologies, Inc.
• Inventors: Foss, Stephen W., Chamberlain, Stanley, Frick, Lloyd
• Primary Examiner(s): Pak, Hannah
• Application Number:
  US14/457,546
• Publication Number:
  US 20150044449A1
• Time in Patent Office: 1,302 Days
• CPC Class Codes: A01N 25/10 Macromolecular compounds
• CPC Class Codes: A01N 59/16 Heavy metals; Compounds thereof
• CPC Class Codes: A01N 59/20 Copper
• CPC Class Codes: C08J 2367/02 Polyesters derived from dicarboxylic acids and dihydroxy compounds; C08J2367/06 takes precedence
• CPC Class Codes: C08J 2377/02 Polyamides derived from omega-amino carboxylic acids or from lactams thereof C08J2377/10 takes precedence
• CPC Class Codes: C08J 2377/06 Polyamides derived from polyamines and polycarboxylic acids C08J2377/10 takes precedence
• CPC Class Codes: C08J 3/128 Polymer particles coated by inorganic and non-macromolecular organic compounds
• CPC Class Codes: C08J 3/203 Solid polymers with solid and/or liquid additives
• CPC Class Codes: C08K 2003/2241 Titanium dioxide
• CPC Class Codes: C08K 2003/3045 Sulfates
• CPC Class Codes: C08K 2201/013 Additives applied to the surface of polymers or polymer particles
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 3/30 Sulfur-, selenium- or tellurium-containing compounds
• CPC Class Codes: D01D 1/00 Treatment of filament-forming or like material working of plastics or substances in a plastic state, in general B29
• CPC Class Codes: D01F 1/04 Pigments
• CPC Class Codes: D01F 1/06 Dyes
• CPC Class Codes: D01F 1/103 Agents inhibiting growth of microorganisms
• CPC Class Codes: D01F 6/60 from polyamides from polyamino acids or polypeptides D01F6/68
• CPC Class Codes: D01F 6/62 from polyesters
• CPC Class Codes: D01G 13/00 Mixing, e.g. blending, fibres; Mixing non-fibrous materials with fibres
• CPC Class Codes: D10B 2331/04 : polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component

Abstract

High-melting antimicrobial polymer fibers and antimicrobial fabrics comprising such fibers are prepared by preparing a masterbatch of polymer pellets (e.g., PET), silver and copper salts, and a compounding agent which provides free flowing polymer pellets which can be prepared in advance, with a long shelf life. Polymer masterbatches prepared by the methods of the invention can produce limited color or off-white antimicrobial fibers and fabrics using conventional melt spinning manufacturing methods. Fabrics incorporating fibers of the present invention are potent inhibitors of Athlete'"'"'s foot fungi, gram negative and gram positive bacteria, and drug resistant pathogens.

Claims

1. A polymer composition comprising:

(a) a first population of high-melting polymer particles;

(b) about 1 to about 26 wt.% of a silver salt having the formula Ag_aX_bY_cZ_d;

(c) about 0.1 to about 2.6 wt.% of a copper salt having the formula Cu_aX_bY_cZ_d; and

(d) about 0.15 to about 3 wt.% of a compounding agent;

Ag is Ag(I) or Ag(II), and a is 1 to 4;

each X is sulfur, and b is independently 1 to 4;

each Y is oxygen, and c is independently 2 to 8;

each Z is independently H;

C₁-C₁₄ alkyl;

C₃-C₈ cycloalkyl;

C₁-C₈ alkyl substituted by C₃-C₆ cycloalkyl;

C₁-C₈ alkyl optionally substituted by C₆-C₁₀ aryl;

C₆-C₁₀ aryl;

C₆-C ₁₀ aryl substituted by C₁-C₁₄ alkyl, C₃-C₈ cycloalkyl, C₁-C₈ alkyl substituted by C₃-C₆ cycloalkyl, or halogen;

d is 0 or 1;

wherein a mixture of the silver salt, copper salt, and compounding agent is disposed over the surface of the high-melting polymer particles.

2. The polymer composition of claim 1, wherein the high-melting polymer particles comprise a polyethylene terephthalate polymer, Nylon 6, or Nylon 6,6.

3. The polymer composition of claim 1, wherein the compounding agent is one or more compounds selected from the group consisting of polydimethylsiloxane, hydroxyl terminated polydimethylsiloxane, amorphous silica, aliphatic hydrocarbons, aliphatic petroleum distillates, and liquefied petroleum gas.

4. The polymer composition of claim 2, wherein the compounding agent comprises a mixture of polydimethylsiloxane, hydroxyl terminated dimethylsiloxane, and amorphous silica.

5. The polymer composition of claim 1, further comprising a pigment and an optical brightener.

6. The polymer composition of claim 5, wherein the pigment is titanium dioxide.

7. The polymer composition of claim 1, wherein the polymer composition has not been subjected to heating in excess of about 110°

C.

8. A polymer mixture comprising the combination of the polymer composition of claim 1 with a second population of high-melting polymer particles, whereby the polymer mixture has the following composition:

(i) about 0.05 to about 0.50 wt. % silver salt having the formula Ag_aX_bY_cZ_d;

(ii) about 0.01 to about 0.1 wt. % copper salt having the formula Cu_aX_bY_cZ_d;

(iii) about 0.01 to about 0.1 wt. % compounding agent ; and

(iv) high-melting polymer particles from the first and second populations of high-melting polymer particles.

9. The polymer mixture of claim 8, wherein the high-melting polymer particles from the first and second populations of high-melting polymer particles comprise a polyethylene terephthalate polymer.

10. The polymer mixture of claim 8, further comprising about 0.0002 to about 0. 025% NaIO₄.

11. The polymer mixture of claim 8, further comprising a pigment and an optical brightener.

12. The polymer mixture of claim 11, wherein the pigment is titanium dioxide.

13. The polymer mixture of claim 8, in the form of a melt spun fiber.

14. The polymer mixture of claim 9, in the form of a melt spun fiber.

15. A method of making the polymer composition of claim 1 comprising coating a mixture of the compounding agent, silver salt, and copper salt over the surface of the high-melting polymer particles.

16. The method of claim 15, wherein the high-melting polymer particles comprise a polyethylene terephthalate polymer.

17. The method of claim 15, wherein said coating comprises:

(1) coating the first population of high-melting polymer particles with the compounding agent; and

(2) adding the silver salt and copper salt to the coated high-melting polymer particles, thereby forming a mixture of the silver salt, copper salt, and compounding agent disposed over the surface of the high-melting polymer particles.

18. The method of claim 17, wherein the high-melting polymer particles comprise a polyethylene terephthalate polymer, nylon 6, or nylon 6,6.

19. A method of making the polymer mixture of claim 8, comprising mixing the first population of high-melting polymer particles, having a mixture of compounding agent, silver salt having the formula Ag_aX_bY_cZ_d, and copper salt having the formula Cu_zX_bY_cZ_ddisposed over the surface thereof, with the second population of high-melting polymer particles.