Fibers with improving anti-microbial performance

Abstract

Fibers and fabrics with improved anti-microbial activity in after laundering, and a method of producing the same, are described. One embodiment includes a method for generating a synthetic fiber, the method comprising creating a mixture, the mixture comprising a polymer, an anti-microbial agent, and a dispersion liquid, and extruding the mixture to form a synthetic fiber.

1 .- 28 . (canceled) 
     
     
         29 . A synthetic fiber having anti-microbial activity, the synthetic fiber comprising:
 a base polymer;   a dispersion additive embedded within the synthetic fiber; and   an anti-microbial agent dispersed generally uniformly throughout the synthetic fiber;   wherein the dispersion additive facilitates combination of the base polymer with the anti-microbial agent so as to prevent the anti-microbial agent from separating from the base polymer during laundering of a fabric containing the synthetic fiber; and   wherein dissolution of at least a portion of the embedded dispersion additive, during laundering, imparts the synthetic fiber with striations that expose a quantity of the anti-microbial agent to pathogens.   
     
     
         30 . The synthetic fiber of  claim 29 , wherein the anti-microbial agent comprises silver and/or copper and/or zinc and/or gold in metallic form, salt form or ionic form. 
     
     
         31 . The synthetic fiber of  claim 29 , wherein the dispersion additive is a dispersion liquid. 
     
     
         32 . The synthetic fiber of  claim 31 , wherein the dispersion liquid is selected from the group consisting of an anti-stat, an anionic anti-stat oil, a phosphate ester, a wax, and a vegetable oil. 
     
     
         33 . The synthetic fiber of  claim 29 , wherein the synthetic fiber is from 0.5 to 20 denier. 
     
     
         34 . The synthetic fiber of  claim 29 , wherein the synthetic fiber is from 1.0 to 3.0 denier. 
     
     
         35 . The synthetic fiber of  claim 29 , wherein a tenacity of the synthetic fiber is greater than  4  grams per denier. 
     
     
         36 . The synthetic fiber of  claim 29 , wherein the synthetic fiber is at least a portion of an air jet spun yarn. 
     
     
         37 . The synthetic fiber of  claim 29 , wherein the fabric containing the synthetic fiber is at least a portion of a sheet, pillow case, privacy curtain, isolation gown, medical scrubs, doctor coat, or blanket. 
     
     
         38 . The synthetic fiber of  claim 29 , wherein the base polymer includes polyester. 
     
     
         39 . The synthetic fiber of  claim 29 , wherein the base polymer includes nylon. 
     
     
         40 . The synthetic fiber of  claim 29 , further comprising a metallic anti-microbial coating that comprises:
 a solution containing copper, silver, gold or zinc; and   a binder.   
     
     
         41 . A synthetic fiber having anti-microbial activity, the synthetic fiber comprising:
 a base polymer;   a dispersion additive embedded within the synthetic fiber;   an anti-microbial agent dispersed generally uniformly throughout the synthetic fiber and combined with the base polymer so as to prevent the anti-microbial agent from separating from the base polymer during laundering of a fabric containing the synthetic fiber; and   one or more striations in the synthetic fiber, formed where portions of the embedded dispersion additive have dissolved during laundering, the one or more striations exposing a quantity of the anti-microbial agent to pathogens.   
     
     
         42 . The synthetic fiber of  claim 41 , wherein the anti-microbial agent comprises silver and/or copper and/or zinc and/or gold in metallic form, salt form or ionic form. 
     
     
         43 . The synthetic fiber of  claim 41 , wherein the dispersion additive is a dispersion liquid selected from the group consisting of an anti-stat, an anionic anti-stat oil, a phosphate ester, a wax, and a vegetable oil. 
     
     
         44 . The synthetic fiber of  claim 41 , wherein the base polymer includes polyester. 
     
     
         45 . The synthetic fiber of  claim 44 , further comprising a metallic anti-microbial coating that comprises:
 a solution containing copper, silver, gold or zinc; and   a binder.   
     
     
         46 . A method of generating a washable fabric exhibiting anti-microbial activity, the method comprising:
 mixing an anti-microbial agent and a dispersion additive with a base polymer to form a mixture, wherein:
 the dispersion additive generally uniformly disperses the anti-microbial agent relative to the base polymer; and 
 the dispersion additive facilitates combination of the anti-microbial agent within the base polymer; 
   heating the mixture to a melt temperature;   extruding the heated mixture to form a synthetic fiber having the dispersion additive embedded therein; and   using the synthetic fiber to form a washable fabric exhibiting anti-microbial activity, wherein:
 the anti-microbial agent remains combined with the base polymer after laundering of the washable fabric; and 
 at least a portion of the embedded dispersion additive is dissolvable during laundering of the washable fabric to impart the synthetic fiber with striations that expose a quantity of the anti-microbial agent to pathogens. 
   
     
     
         47 . The method of  claim 46 , wherein the anti-microbial agent comprises silver and/or copper and/or zinc and/or gold in metallic form, salt form or ionic form. 
     
     
         48 . The method of  claim 46 , wherein the dispersion additive is a dispersion liquid selected from the group consisting of an anti-stat, an anionic anti-stat oil, a phosphate ester, a wax, and a vegetable oil.