Anti-microbial fiber and fibrous products

Abstract

An anti-microbial sheet or film and various products made partially or wholly therefrom comprised of 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 products. The products 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 products comprise high tenacity polymers (e.g. PET) in one portion and hydrolysis resistance polymers (e.g. PCT) in another portion with the additives.

What is claimed is:  
     
         1 . An anti-microbial product in the form of a wide plastic sheet, comprising: 
 a first layer of a plastic polymer matrix and an anti-microbial/anti-fungal inorganic additive dispersed therein, the thickness of the layer being approximately 1.5 to 3 times the nominal particle size of the additive; and    at least one further plastic polymer layer adjacent to and providing support to the first layer.    
     
     
         2 . The product of  claim 1 , wherein the additive is one selected from the group consisting of copper, zinc, tin and silver.  
     
     
         3 . The product of  claim 2 , wherein the additive is a zeolite of silver.  
     
     
         4 . The product of  claim 1 , wherein the additive comprises approximately 1 micron cubes and the first layer thickness is approximately 2 microns thick.  
     
     
         5 . The product of  claim 1 , wherein the at least one further layer has dispersed therein a second additive selected from the group consisting of pigments, anti-odor compounds, UV resistant, anti-stain, flame retardant or flame resistant, hydrophilic, and hydrophobic materials.  
     
     
         6 . The product of  claim 5 , wherein the second additive is a hydrolysis resistant polymer providing resistance to long term washings in boiling water and strong soaps.  
     
     
         7 . The product of  claim 5 , wherein the second additive is a pigment providing uniform colors that do not fade significantly over long-term use and washing.  
     
     
         8 . The product of  claim 1 , the first layer being sufficiently dimensioned such that particles of the additive are held close to the outer surface of the first layer while affording resistance to removal therefrom under production and usage conditions of the product.  
     
     
         9 . The product of  claim 1 , wherein the at least one further layer comprises: 
 at least one further layer of a plastic polymer matrix and an anti-microbial/anti-fungal inorganic additive dispersed therein; and    a thicker support layer disposed adjacent to and between the first layer and the at least one further layer of plastic polymer matrix and additive dispersed therein.    
     
     
         10 . The product of  claim 1 , further comprising: 
 at least one edge layer of a plastic polymer matrix and an anti-microbial/anti-fungal inorganic additive dispersed therein, the edge layer adjacent to both the first layer and the at least one further layer.    
     
     
         11 . The product of  claim 1 , wherein the plastic polymer of the first layer is selected from the group consisting of polyolefin, polyethylene, polypropylene, poly 1,4 cyclohexylene dimethylene terephthalate, PETG, co-PET, Styrene, Halar®, PTT, 3GT, polyamide, polycaprolactone, PET, Polycarbonate, PVC, and EVA.  
     
     
         12 . The product of  claim 1 , wherein the plastic polymer of the at least one further layer is comprised of a thermoplastic resin selected from the group consisting of polyethylene, polypropylene, poly 1,4 cyclohexylene dimethylene terephthalate, PET, PETG, co-PET, Styrene, Halar®, PTT, 3GT, polyamide, acrylic, PET, Polycarbonate, PVC, and an ionomer, EVA or styrene stiffened ionomer, and an impact resistant strength layer of nonwoven material.  
     
     
         13 . The product of  claim 1 , wherein the concentration of the additive varies as a gradient within a section of the first layer.  
     
     
         14 . The product of  claim 1 , wherein the concentration of the additive varies regionally within a section of the first layer.  
     
     
         15 . The product of  claim 1 , formed as a flat film.  
     
     
         16 . The product of  claim 15 , consisting of part of work surface, floor, or wall.  
     
     
         17 . The product of  claim 1 , formed as an article exhibiting a rigid, shaped contour.  
     
     
         18 . The product of  claim 17 , consisting of part of a food storing, conveying or serving article. consisting in part of an article for storing or conveying clothing or personal items.  
     
     
         19 . The product of  claim 1 , formed as a profiled article wherein the additive is on the inner or outer surface of the profile.  
     
     
         20 . The product of  claim 19 , selected from one of piping, tubing, and gutters.  
     
     
         21 . The product of  claim 19 , consisting of part of a household or industrial appliance, fixture or utility.  
     
     
         22 . The product of  claim 1 , formed as an injection molded article.  
     
     
         23 . The product of  claim 22 , consisting of part of a hand-held device or utensil.  
     
     
         24 . An anti-microbial product in the form of a wide plastic sheet, comprising: 
 a first layer of a plastic polymer matrix and an anti-microbial/anti-fungal inorganic additive dispersed therein, the thickness of the layer being sufficiently thin such that substantially all particles of the additive are held close to the outer surface of the first layer while affording resistance to removal therefrom under production and usage conditions of the product; and    at least one further plastic polymer layer adjacent to and providing support to the first layer.    
     
     
         25 . An anti-microbial product in the form of a wide plastic sheet, comprising: 
 a first layer of a plastic polymer matrix and an anti-microbial/anti-fungal inorganic additive dispersed therein, the thickness of the layer being sufficiently thin such that substantially all particles of the additive have portions available at the outer surface of the first layer; and    at least one further plastic polymer layer adjacent to and providing support to the first layer.    
     
     
         26 . An anti-microbial product in the form of a wide plastic sheet, comprising: 
 a first layer of a plastic polymer matrix and an anti-microbial/anti-fungal inorganic additive dispersed therein, the thickness of the layer being less than the maximum dimension of the particles of the additive; and 
 at least one further plastic polymer layer adjacent to and providing support to the first layer.