Anti-microbial fiber and fibrous products

Abstract

An anti-microbial and/or anti-fungal synthetic fiber and various filter 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. In one embodiment, binder fibers are used which are mixed with other fibers.

What is claimed is:  
     
         1 . An anti-microbial fabric, comprising: 
 a multi-layer filter article, said article being made at least in part of a multi-component fiber of thermoplastic polymers, 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.  
   
     
     
         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 an anti-odor agent is added to the fiber.  
     
     
         5 . The fabric of  claim 1 , wherein at least one layer has the anti-microbial fiber, said layer being on the intended upstream side of the other layers.  
     
     
         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, said article being made of a bi-component 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% 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.  
   
     
     
         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 an anti-odor agent is added to the fiber.  
     
     
         16 . The fabric of  claim 12 , wherein at least one layer has the anti-microbial fiber, said layer being on the intended upstream side of the other layers.  
     
     
         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, 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.  
   
     
     
         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 an anti-odor agent is added to the fiber.  
     
     
         27 . The fabric of  claim 23 , wherein at least one layer has the anti-microbial fiber, said layer being on the intended upstream side of the other layers.  
     
     
         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 which are free of anti-microbial additive are cotton.  
     
     
         35 . The fabric of  claim 23 , wherein the binder fiber is made of PETG.