Antimicrobial Fabrics

Abstract

The disclosure features a fabric comprising polymer fibers and an antimicrobial system. The antimicrobial system comprises a sequestering agent and an agent binding the sequestering agent on surfaces of at least some of the polymer fibers. In some implementations, at least some of the sequestering agent remains on polymer fiber-surfaces after 50 cycles of laundering.

What is claimed is: 
     
         1 . A fabric comprising:
 polymer fibers, and   an antimicrobial system comprising a sequestering agent and a binding agent binding the sequestering agent on surfaces of at least some of the polymer fibers, at least some of the sequestering agent remaining on the surface of the at least some of the polymer fibers after 50 cycles of laundering.   
     
     
         2 . The fabric of  claim 1 , wherein the polymer fibers comprise micro-denier fibers and comprise a polymer selected from among polyester, polypropylene, polyamide, nylon, and combinations thereof. 
     
     
         3 . The fabric of  claim 1 , wherein the fabric has at least one raised surface. 
     
     
         4 . The fabric of  claim 3 , wherein the raised surface comprises a grid or reverse grid pattern or a jacquard pattern. 
     
     
         5 . The fabric of  claim 1 , wherein the binding agent comprises an acrylate or polyurethane. 
     
     
         6 . The fabric of  claim 1 , wherein the antimicrobial system comprises an antimicrobial agent having oxidizing property. 
     
     
         7 . The fabric of  claim 1 , wherein the fabric comprises 100% polymer fibers. 
     
     
         8 . The fabric of  claim 1 , wherein the polymer fibers constitute 50 wt % or more of the fabric. 
     
     
         9 . The fabric of  claim 8 , comprising cotton and wherein the polymer and fiber weight ratio is 50:50. 
     
     
         10 . A fabric comprising:
 polymer fibers comprising a polymer, and   an antimicrobial system comprising a sequestering agent dispersed within the polymer of at least some of the polymer fibers.   
     
     
         11 . The fabric of  claim 10 , wherein the sequestering agent is dispersed randomly throughout a cross-section of the at least some of the polymer fibers. 
     
     
         12 . The fabric of  claim 10 , wherein the polymer fibers comprise extrusion of the polymer and the sequestering agent dispersed throughout an entire cross section of the fibers. 
     
     
         13 . The fabric of  claim 10 , wherein the polymer fibers comprise a polymer core and a sheath over the core, the sequestering agent being substantially in the sheath. 
     
     
         14 . A fabric comprising:
 yarns comprising a polymer; and   an antimicrobial system comprising a sequestering agent dispersed within the polymer of at least some of the yarns.   
     
     
         15 . The fabric of  claim 14 , wherein the sequestering agent is dispersed randomly throughout a cross-section of the at least some of the yarns. 
     
     
         16 . The fabric of  claim 14 , wherein the yarns are co-spun and comprise the polymer and the sequestering agent. 
     
     
         17 . The fabric of  claim 14 , wherein the yarns comprise a core comprising the polymer and a sheath over the core, the sequestering agent being substantially in the sheath. 
     
     
         18 . A curtain comprising the fabric of  claim 1 ,  10 , or  14 . 
     
     
         19 . A blanket comprising the fabric of  claim 1 ,  10 , or  14 . 
     
     
         20 . The blanket of  claim 19 , wherein the fabric comprises a knit with terry sinker loop and at least one raised surface in velour finish. 
     
     
         21 . The blanket of  claim 20 , wherein the raised surface comprises a grid or reverse grid pattern or a jacquard pattern. 
     
     
         22 . A bedding sheet comprising the fabric of  claim 1 ,  10 , or  14 , wherein the fabric is woven or knitted. 
     
     
         23 . A mattress cover comprising the fabric of  claim 1 ,  10 , or  14 . 
     
     
         24 . A pillow case comprising the fabric of  claim 1 ,  10 , or  14 . 
     
     
         25 . A set of fabric articles of bedding comprising a blanket, a pillow case, and a mattress cover, at least one of which comprises the fabric of  claim 1 ,  10 , or  14 . 
     
     
         26 . The set of fabric articles of bedding of  claim 25  comprising a bedding sheet. 
     
     
         27 . The set of fabric articles of being of  claim 26  comprising a privacy curtain. 
     
     
         28 . A method comprising:
 applying an antimicrobial system to a fabric comprising polymer fibers, the antimicrobial system comprising a sequestering agent and a binding agent.   
     
     
         29 . The method of  claim 28 , wherein the antimicrobial system is applied in the form of a slurry. 
     
     
         30 . The method of  claim 28 , wherein the binding agent comprises an acrylate or polyurethane. 
     
     
         31 . The method of  claim 28 , wherein the fabric comprises 100% polymer fibers. 
     
     
         32 . The method of  claim 28 , wherein the fabric comprises 50 wt % or more polymer fibers. 
     
     
         33 . The method of  claim 28 , wherein the fabric comprises cotton and the polymer fibers and cotton have a weight ratio of 50:50. 
     
     
         34 . The method of  claim 28 , comprising forming at least one raised surface of the fabric before or after the antimicrobial system is applied. 
     
     
         35 . The method of  claim 34 , wherein the at least one raised surface comprises a grid or reverse grid pattern or a jacquard pattern. 
     
     
         36 . The method of  claim 28 , wherein the antimicrobial system comprises an antimicrobial agent applied after the sequestering agent and the binder. 
     
     
         37 . The method of  claim 28 , wherein the antimicrobial agent is applied during a laundering cycle. 
     
     
         38 . A method comprising:
 coextruding a polymer material and an antimicrobial system comprising a sequestering agent to form coextruded fibers; and   forming a fabric comprising the coextruded fibers.   
     
     
         39 . The method of  claim 38 , wherein coextruding comprises forming the coextruded fibers with a core-sheath construction, the sequestering agent being substantially within the sheath. 
     
     
         40 . The method of  claim 38 , wherein coextruding comprises forming the coextruded fibers with the sequestering agent dispersed throughout a cross-section of the coextruded fibers. 
     
     
         41 . A method comprising:
 co-spinning a polymer material and an antimicrobial system comprising a sequestering agent to form co-spun yarns; and   forming a fabric comprising the co-spun yarns.   
     
     
         42 . The method of  claim 41 , wherein co-spinning comprises forming the co-spun yarns with a core-sheath construction, the sequestering agent being substantially within the sheath. 
     
     
         43 . The method of  claim 41 , wherein co-spinning comprises forming the co-spun yarns with the sequestering agent dispersed throughout a cross-section of the co-spun yarns. 
     
     
         44 . A method comprising:
 1) providing a fabric article comprising the fabric of  claim 1 ,  10 , or  14  having a predetermined enhanced level of antimicrobial protection,   2) subjecting the fabric article to frequent industrial laundering cycles including contact with an aqueous solution of hydrogen peroxide, thereby to recharge antimicrobial protection provided by the fabric article to at least a predetermined minimum acceptable level, and   3) repeating step 2) for at least 50 industrial laundering cycles.   
     
     
         45 . The method of  claim 44 , wherein the multiple industrial laundering cycles comprises at least 100 industrial laundering cycles.