Anti-microbial fiber and fibrous products

Abstract

An anti-microbial and/or anti-fungal synthetic fiber and laminate 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 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.

1 . A laminate, comprising: 
 a tough extruded core of thermoplastic resin such as ionomer, EVA or styrene stiffened ionomer; and    at least one impact resistant strength layer of nonwoven material being made from a bi-component staple fiber or blend of PET staple fiber and binder staple fiber or blend of PET staple fiber and bi-component staple fiber, and having a combination of PET fibers and PETG or other copolymer or homopolymer fibers as binding agent for PET.    
     
     
         2 . The laminate of  claim 1 , wherein the thermoplastic components being miscible or mechanically compatible to allow for homogenization and incorporation into the extruded thermoplastic core thereby providing for complete recyclability of scrap material.  
     
     
         3 . A stiff, moldable laminate, comprising: 
 a layer of tough thermoplastic resin;    a nonwoven fabric layer;    a tough extruded core of thermoplastic resin;    at least one impact resistant strength layer of nonwoven material constructed from a bicomponent staple fiber or blend of PET staple fiber and binder staple fiber or blend of PET staple fiber and bicomponent staple fiber, the nonwoven layer using a combination of PET fibers and PETG or other copolymer or monopolymers fibers which act as a binding agent for PET.    
     
     
         4 . The laminate of  claim 3 , wherein the staple fiber is 4-15 denier and 38 to 76 mm in length.  
     
     
         5 . The laminate of  claim 4 , wherein the thermoplastic components are miscible or mechanically compatible to permit homogenization and incorporation into the extruded thermoplastic core.  
     
     
         6 . A laminate of a binding agent which is a thermoplastic binder fiber or a bi-component binder fiber which is thermally activated to bind and stiffen a nonwoven fabric into which it is incorporated.