Anti-microbial fiber and fibrous products

Abstract

An anti-microbial and/or anti-fungal synthetic fiber and various 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. 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 . An anti-microbial fabric, comprising: 
 a multi-layer filter article comprising a plurality of layers wherein at least one layer is made at least in part of a multi-component fiber of thermoplastic polymers, said 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% of the fiber by weight, wherein the thickness of the sheath in microns is approximately twice 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 said fiber further comprises an anti-odor agent.  
     
     
         5 . The fabric of  claim 1 , wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be upstream relative to any fluid flow traversing or otherwise contacting the fabric.  
     
     
         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 comprising a plurality of layers wherein at least one layer is made of a bi-component fiber, said 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% of the fiber by weight, said additive 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 said fiber further comprises an anti-odor agent.  
     
     
         16 . The fabric of  claim 12 , wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be upstream relative to any fluid flow traversing or otherwise contacting the fabric.  
     
     
         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 comprising a plurality of layers, wherein at least one layer is made at least in part of: 
 one or more units of 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% of the fiber by weight, and  
 other fibers that are free of said anti-microbial additive that are blended with said binder fiber the fabric having a form as made by heating to said melting temperature of the binder fiber and enabling melt and flow of the binder fiber with formation of nodes attaching some of the other fibers to each other, thereby providing a fiber blend that can be used to produce an anti-microbial finished fabric able to withstand significant wear and washings and maintain effectiveness of said anti-microbial additives.  
   
     
     
         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 said article further comprises an anti-odor agent.  
     
     
         27 . The fabric of  claim 23 , wherein said at least one layer including the binder fiber is on a side of the fabric that is adapted to be upstream relative to any fluid flow traversing or otherwise contacting the fabric.  
     
     
         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 that are free of said anti-microbial additive are cotton.  
     
     
         35 . The fabric of  claim 23 , wherein the binder fiber is made of PETG.  
     
     
         36 . An anti-microbial medical fabric, comprising: 
 a multi-layer fabric comprising a plurality of layers, wherein at least one layer is made at least in part of multi-component fibers of thermoplastic polymers, each fiber 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% of the fiber by weight, wherein the thickness of the sheath in microns is approximately twice the nominal particle size in microns of the additive.    
     
     
         37 . The medical fabric of  claim 36 , forming at least part of a wound care dressing or a burn dressing.  
     
     
         38 . The medical fabric of  claim 37 , wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be placed on the skin of a patient.  
     
     
         39 . The medical fabric of  claim 38 , wherein said at least one layer is comprised of an absorbent material.  
     
     
         40 . The medical fabric of  claim 36 , forming at least part of a medical wipe.  
     
     
         41 . An anti-microbial medical fabric, comprising: 
 a multi-layer fabric comprising a plurality of layers, wherein at least one layer is made at least in part of bi-component fibers, each 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, said sheath including an additive ranging from 0.1% to 20% of the fiber by weight said additive being selected from the group consisting of pigments, compounds creating a hydrophilic surface, and anti-microbial, anti-fungal and anti-odor materials.    
     
     
         42 . The medical fabric of  claim 41 , forming at least part of a wound care dressing or a burn dressing.  
     
     
         43 . The medical fabric of  claim 42 , wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be placed on the skin of a patient.  
     
     
         44 . The medical fabric of  claim 43 , wherein said at least one layer is comprised of an absorbent material.  
     
     
         45 . The medical fabric of  claim 41 , forming at least part of a medical wipe.  
     
     
         46 . An anti-microbial medical fabric, comprising: 
 a multi-layer fabric comprising a plurality of layers, wherein at least one layer is made at least in part of: 
 a binder fiber made from low temperature polymer with a melting or softening temperature below 200° C.,  
 an anti-microbial additive of an inorganic compound made from a metal chosen from the group consisting of copper, zinc, tin and silver that is added to the binder fiber, the additive ranging from 0.1% to 20% of the fiber by weight, and  
 fibers that are free of said anti-microbial additive that are blended with said binder fiber and heated to said melting temperature, thereby providing a fiber blend that can be used to produce an anti-microbial finished fabric able to withstand significant wear and washings and maintain its effectiveness.  
   
     
     
         47 . The medical fabric of  claim 46 , forming at least part of a wound care dressing or a burn dressing.  
     
     
         48 . The medical fabric of  claim 47 , wherein said at least one layer including the fiber is on a side of the fabric that is adapted to be placed on the skin of a patient.  
     
     
         49 . The medical fabric of  claim 48 , wherein said at least one layer is comprised of an absorbent material.  
     
     
         50 . The medical fabric of  claim 46 , forming at least part of a medical wipe.  
     
     
         51 . The medical fabric of  claim 46 , further comprising PETG as a carrier for a plurality of color pigments for said fabric.  
     
     
         52 . The medical fabric of  claim 51 , wherein the PETG had an anti-microbial and/or a colorant added thereto prior to melting at a low temperature.