Processes for producing antitoxic fibers and fabrics

Abstract

The invention provides a novel method for producing an antitoxic nonwoven fabric by molecularly grafting the antitoxic molecule thereto. The method comprises immersing a fibrous media comprising a material having a melt flow index of less than 150 MFI in a stable antitoxin solution comprising an antitoxin, preferably triiodide. The wet media is processed through rollers, thereby forcing the antitoxic molecule (e.g., iodine) to penetrate the media. The wet media is dried, and the fabric isolated therefrom. The invention further provides products incorporating the antitoxic media formed by this molecularly grafting method, including a wound dressing, surgical drape, privacy curtain, facemask, gown, article of protective clothing, shoe covering, hair covering, air filter, medical tape, and wipe.

What is claimed is: 
     
         1 . A process for producing an antitoxic fabric comprising:
 a. providing a fibrous media comprising a material having a melt flow index of less than 150 MFI;   b. forming a concentrated stable antitoxin solution comprising triiodide;   c. fully immersing said media in said antitoxin solution to form a wet media;   d. processing the wet media through rollers, thereby forcing the iodine to penetrate the media; and   e. drying the wet media and isolating the fabric therefrom.   
     
     
         2 . The process of  claim 1 , wherein the antitoxin solution further comprises an active agent selected from the group consisting of iodine, bromine, chlorine and hydrogen peroxide. 
     
     
         3 . A wound dressing, surgical drape, privacy curtain, facemask, gown, article of protective clothing, shoe covering, hair covering, air filter, medical tape, or wipe comprising the antitoxic fabric formed according to the process of  claim 1 . 
     
     
         4 . The process of  claim 1 , wherein the antitoxin solution comprises a concentration of at least 2000 ppm iodine. 
     
     
         5 . The process of  claim 1 , wherein the antitoxin solution comprises a concentration of at least 2500 ppm iodine. 
     
     
         6 . The process of  claim 1 , wherein the fibrous media is a 50/50 blend of polypropylene and synthetic cellulose acetate. 
     
     
         7 . The process of  claim 1 , wherein the fibrous media is a 50/50 blend of polypropylene and alginate fibers. 
     
     
         8 . An antitoxic layer comprising the antitoxic fabric formed according to the process of  claim 1 . 
     
     
         9 . A wound dressing comprising the antitoxic fabric formed according to the process of  claim 6 . 
     
     
         10 . The process of  claim 8 , wherein the fibrous media is a nonwoven spunbond media characterized by an MFI of 30-40. 
     
     
         11 . The antitoxic layer of  claim 8 , wherein the fibrous media comprises polypropylene. 
     
     
         12 . A surgical mask or privacy curtain comprising the antitoxic fabric formed according to the process of  claim 1 , wherein the fibrous media comprises polypropylene, and wherein the antitoxin solution has a concentration of at least 2500 ppm iodine. 
     
     
         13 . The process of  claim 1 , wherein the antitoxic solution comprises a concentration of at least 25,000 ppm iodine. 
     
     
         14 . A medical tape comprising the antitoxic fabric formed according to the process of  claim 1 , wherein the fibrous media is spunbond, the medical tape further comprising an adhesive liner.