U.S. patent application number 11/897560 was filed with the patent office on 2008-10-30 for yarns and fabrics having a wash-durable non-electrically conductive topically applied metal-based finish.
Invention is credited to Leland G. Close, Robert J. Goulet, David E. Green, Shulong Li, Dirk L. Van Hyning.
Application Number | 20080268732 11/897560 |
Document ID | / |
Family ID | 24345505 |
Filed Date | 2008-10-30 |
United States Patent
Application |
20080268732 |
Kind Code |
A1 |
Green; David E. ; et
al. |
October 30, 2008 |
Yarns and fabrics having a wash-durable non-electrically conductive
topically applied metal-based finish
Abstract
Durable non-electrically conductive metal treatments (such as
coatings or finishes) for yarns and textile fabrics are provided.
Such treatments preferably comprise silver and/or silver ions;
however, other metals, such as zinc, iron, copper, nickel, cobalt,
aluminum, gold, manganese, magnesium, and the like, may also be
present or alternatively utilized. Such a treatment provides, as
one example, an antimicrobial fiber and/or textile fabric which
remains on the surface and does not permit electrical conductivity
over the surface. The treatment is extremely durable on such
substrates; after a substantial number of standard launderings and
dryings, the treatment does not wear away in any appreciable amount
and thus the substrate retains its antimicrobial activity (or other
property).
Inventors: |
Green; David E.;
(Simpsonville, SC) ; Van Hyning; Dirk L.;
(Spartanburg, SC) ; Close; Leland G.;
(Spartanburg, SC) ; Li; Shulong; (Spartanburg,
SC) ; Goulet; Robert J.; (Spartanburg, SC) |
Correspondence
Address: |
Legal Department (M-495)
P.O. Box 1926
Spartanburg
SC
29304
US
|
Family ID: |
24345505 |
Appl. No.: |
11/897560 |
Filed: |
August 31, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09586381 |
Jun 2, 2000 |
7291570 |
|
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11897560 |
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Current U.S.
Class: |
442/117 |
Current CPC
Class: |
D06M 11/42 20130101;
Y10T 442/2475 20150401; Y10T 428/277 20150115; D06M 11/44 20130101;
D06M 16/00 20130101; Y10T 428/27 20150115; A01N 2300/00 20130101;
D06M 11/83 20130101; Y10T 442/2525 20150401; Y10T 428/273 20150115;
A01N 25/34 20130101; A01N 59/16 20130101; Y10T 29/49982 20150115;
A01N 59/16 20130101 |
Class at
Publication: |
442/117 |
International
Class: |
B32B 27/00 20060101
B32B027/00 |
Claims
1. A printed fabric having a first surface and a second surface,
wherein said fabric has a non-continuous finish printed on at least
a portion of said first surface, wherein said finish comprises: (a)
0.1 to 40 weight percent of a metal compound selected from the
group consisting of silver particle-containing compounds, silver
ion-containing compounds, silver ion-generating compounds, and any
combinations thereof, and (b) a binder agent; and wherein said
printed fabric is electrically non-conductive.
2. The printed fabric of claim 1, wherein said metal compound is a
silver ion-containing compound.
3. The printed fabric of claim 2, wherein said silver
ion-containing compound is silver zirconium phosphate.
4. The printed fabric of claim 1, wherein said binder agent is
anionic or nonionic, and wherein said binder agent, after
processing and application to said fabric: (a) is not readily
soluble in water, (b) is not susceptible to attack by standard
laundering additives selected from the group consisting of
detergents, solvents, bleaches, and mixtures thereof, and (c) is
not susceptible to degradation due to exposure to high temperatures
associated with standard laundry drying temperatures.
5. The printed fabric of claim 1, wherein said binder agent is
selected from the group consisting of cross-linked
imidazolidinones, acrylic binders, melamine resins, polyvinyl
chloride-containing polymers, ethoxylated polyesters, and blends
thereof.
6. The printed fabric of claim 1, wherein said fabric is comprised
of fibers selected from the group consisting of cotton fibers, wool
fibers, ramie fibers, hemp fibers, linen fibers, polyolefin fibers,
polyester fibers, polyamide fibers, polyaramid fibers, acetate
fibers, rayon fibers, acrylic fibers, and blends thereof.
7. The printed fabric of claim 1, wherein said finish is printed on
said fabric via screenprinting techniques.
8. The printed fabric of claim 1, wherein at least a portion of
said second surface of said fabric is printed with said
non-continuous finish.
9. The printed fabric of claim 1, wherein said fabric exhibits
antimicrobial properties.
10. A printed fabric, wherein said fabric is comprised of 100%
polyester fiber, wherein said fabric is characterized by having a
non-continuous finish printed on at least one surface of said
fabric, wherein said finish comprises: (a) 0.1 to 40 weight percent
of a silver particle-containing compound, and (b) a binder agent
selected from the group consisting of polyvinyl chloride-containing
polymers, acrylic binders, and blends thereof; and wherein said
printed fabric is electrically non-conductive.
11. The printed fabric of claim 10, wherein said fabric exhibits
antimicrobial properties.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to
co-pending application Ser. No. 09/586,381 filed Jun. 2, 2000. This
parent application is herein entirely incorporated by
reference.
FIELD OF THE INVENTION
[0002] This invention relates to improvements in durable
non-conductive metal-based treatments (such as coatings or
finishes) for yarns and textile fabrics. Such treatments preferably
comprise silver and/or silver ions; however, other metals, such as
zinc, iron, copper, nickel, cobalt, aluminum, gold, manganese,
magnesium, and the like, may also be present or alternatively
utilized. Such a treatment provides, as one example, an
antimicrobial fiber and/or textile fabric which remains on the
surface and does not permit electrical conductivity over the
surface. The treatment is extremely durable on such substrates;
after a substantial number of standard launderings and dryings, the
treatment does not wear away in any appreciable amount and thus the
substrate retains its antimicrobial activity (or other property).
The method of adherence to the target yarn and/or fabric may be
performed any number of ways, most preferably through the
utilization of a binder system or through a transfer method from a
donor fabric to a target textile fabric in the presence of moisture
and upon exposure to heat. The particular methods of adherence, as
well as the treated textile fabrics and individual fibers are also
encompassed within this invention.
BACKGROUND OF THE INVENTION
[0003] There has been a great deal of attention in recent years
given to the hazards of bacterial contamination from potential
everyday exposure. Noteworthy examples of such concern include the
fatal consequences of food poisoning due to certain strains of
Eschericia coli being found within undercooked beef in fast food
restaurants; Salmonella contamination causing sicknesses from
undercooked and unwashed poultry food products; and illnesses and
skin infections attributed to Staphylococcus aureus, Klebsiella
pneumoniae, yeast, and other unicellular organisms.
[0004] With such an increased consumer interest in this area,
manufacturers have begun introducing antimicrobial agents within
various household products and articles. For instance, certain
brands of polypropylene cutting boards, liquid soaps, etc., all
contain antimicrobial compounds. The most popular antimicrobial for
such articles is triclosan. Although the incorporation of such a
compound within liquid or polymeric media has been relatively
simple, other substrates, including the surfaces of textiles and
fibers, have proven less accessible. There is a long-felt need to
provide effective, durable, and long-lasting antimicrobial
characteristics for textile surfaces, in particular on apparel
fabrics, and on film surfaces. Such proposed applications have been
extremely difficult to accomplish with triclosan, particularly when
wash durability is a necessity (triclosan easily washes off any
such surfaces).
[0005] Furthermore, although triclosan has proven effective as an
antimicrobial compound, the presence of chlorines and chlorides
within such a compound causes skin irritation which makes the
utilization of such with fibers, films, and textile fabrics for
apparel uses highly undesirable. Furthermore, there are
commercially available textile products comprising acrylic and/or
acetate fibers co-extruded with triclosan (for example Celanese
markets such acetate fabrics under the name Microsafe.RTM. and
Acordis markets such acrylic fibers under the tradename
Amicor.RTM.). However, such an application is limited to those
types of fibers; it does not work specifically for and within
polyester, polyamide, cotton, spandex, etc., fabrics. Furthermore,
this co-extrusion procedure is very expensive.
[0006] Silver-containing inorganic microbiocides have recently been
developed and utilized as antimicrobial agents on and within a
plethora of different substrates and surfaces. In particular, such
microbiocides have been adapted for incorporation within melt spun
synthetic fibers, as taught within Japanese unexamined Patent
Application No. H11-124729, in order to provide certain fabrics
which selectively and inherently exhibit antimicrobial
characteristics. Furthermore, attempts have been made to apply such
specific microbiocides on the surfaces of fabrics and yarns with
little success from a durability standpoint. A topical treatment
with such compounds has never been successfully applied as a
durable finish or coating on a fabric or yarn substrate. Although
such silver-based agents provide excellent, durable, antimicrobial
properties, to date such is the sole manner available within the
prior art of providing a long-lasting, wash-resistant, silver-based
antimicrobial textile. However, such melt spun fibers are expensive
to make due to the large amount of silver-based compound required
to provide sufficient antimicrobial activity in relation to the
migratory characteristics of such a compound within the fiber
itself to its surface. A topical coating is also desirable for
textile and film applications, particularly after finishing of the
target fabric or film. Such a topical procedure permits treatment
of a fabric's individual fibers prior to or after weaving,
knitting, and the like, in order to provide greater versatility to
the target yarn without altering its physical characteristics. Such
a coating, however, must prove to be wash durable, particularly for
apparel fabrics, in order to be functionally acceptable.
[0007] Furthermore, in order to avoid certain problems, it is
highly desirable for such a metallized treatment to be electrically
non-conductive on the target fabric, yarn, and/or film surface.
With the presence of metals and metal ions, such a wash durable,
non-electrically conductive coating has not been available in the
past. Such an improvement would thus provide an important
advancement within the textile, yarn, and film art. Although
antimicrobial activity is one desired characteristic of the
inventive metal-treated fabric, yarn, or film, this is not a
required property of the inventive article. Odor-reduction, heat
retention, distinct colorations, reduced discolorations, improved
yarn and/or fabric strength, resistance to sharp edges, etc., are
all either individual or aggregate properties which may be accorded
the user of such an inventive treated yarn, fabric, or film.
DESCRIPTION OF THE INVENTION
[0008] It is thus an object of the invention to provide a simple
manner of effectively treating a yarn, textile, or film with a
wash-durable antimicrobial metal or metal-ion containing treatment.
A further object of the invention is to provide a treatment for
textiles or films which is wash-durable and continuously reduces
and/or removes malodors from the target surface through the
utilization of metals or metal-ions. Another object of the
invention is to provide an aesthetically pleasing metal- or
metal-ion-treated textile or film which is non-electrically
conductive, wash durable, non-yellowing, non-irritating to skin,
and which provides either or both antimicrobial or odor-reducing
properties.
[0009] Accordingly, this invention encompasses a treated substrate
comprising a non-electrically conductive treatment comprising
metal-containing compounds selected from the group consisting of
metal particle-containing compounds, metal ion-containing
compounds, and any combinations thereof, and a substrate selected
from the group consisting of a yarn, a fabric comprised of
individual yarns, and a film; wherein said compound or compounds is
present on at least a portion of the surface of said substrate; and
wherein at least about 30%, of the originally adhered
metal-containing treatment remains on said treated portion of said
substrate surface after at least 10 washes, said washes being
performed in accordance with the wash procedure as part of AATCC
Test Method 130-1981. Still more preferably at least 50% of the
metal-containing compounds remain after 10 washes, more preferably
60% after 10 washes, and most preferably at least 75% after the
same number of washes. Furthermore, it is also highly preferred
that at least 30% of the finish is retained after 15 washes, 20
washes, and most preferably about 30 washes.
[0010] Also, and alternatively, this invention encompasses a
treated substrate comprising a non-electrically conductive
treatment comprising metal-containing compounds selected from the
group consisting of metal particle-containing compounds, metal
ion-containing compounds, and any combinations thereof, and a
substrate selected from the group consisting of a yarn, a fabric
comprised of individual yarns, and a film; wherein said compound or
compounds is adhered to at least a portion of the surface of said
substrate; and wherein said treated substrate exhibits a log kill
rate for Staphylococcus aureus of at least 1.5, preferably above
2.0, more preferably above 3.0, and a log kill rate for Klebsiella
pneumoniae of at least 1.5, preferably above 2.0, and more
preferably above 3.0, both as tested in accordance with AATCC Test
Method 100-1993 for 24 hour exposure, after at least 10 washes,
said washes performed in accordance with the wash procedure as part
of AATCC Test Method 130-1981. Such an invention also encompasses
the different methods of producing such a treated substrate. The
wash durability test noted above is standard and, as will be well
appreciated by one of ordinary skill in this art, is not intended
to be a required or limitation within this invention. Such a test
method merely provides a standard which, upon 10 washes in
accordance with such, the inventive treated substrate will not lose
an appreciable amount of its electrically non-conductive metal
finish.
[0011] The amount retained may be measured in any standard manner,
such as, for example, inductively coupled plasma (ICP), X-ray
fluorescence (XRF), or atomic absorption (AA) spectroscopic
analysis. Or, again, in the alternative, the durability of certain
finishes may be determined (i.e., the retention of finish on the
surface) in relation to antimicrobial performance. Thus, with an
antimicrobially effective finish, the exhibition of log kill rates
for Klebsiella pneumoniae or Staphylococcus aureus after 24 hours
exposure in accordance with AATCC Test Method 100-1993 of at least
1.5, and higher, as noted above, for both after 10 washes in
accordance with AATCC Test Method 130-1981. Preferably, these log
kill rates are above 3.2, more preferably 3.5, and most preferably
at least 4.0. Again, such log kill rates after the minimum number
of washes symbolizes the desired durability level noted above.
[0012] Nowhere within the prior art has such a specific treated
substrate or method of making thereof been disclosed, utilized, or
fairly suggested. The closest art is a product marketed under the
tradename X-STATIC.RTM. which is a fabric article electrolessly
plated with a silver coating. Such a fabric is highly electrically
conductive and is utilized for static charge dissipation. Also, the
coating alternatively exists as a removable silver powder finish on
a variety of surfaces. The aforementioned Japanese patent
publication to Kuraray is limited to fibers within which a
silver-based compound has been incorporated through melt spun fiber
techniques. Nowhere has such a wash-durable topical treatment as
now claimed been mentioned or alluded to.
[0013] Any yarn, fabric, or film may be utilized as the substrate
within this application. Thus, natural (cotton, wool, and the like)
or synthetic fibers (polyesters, polyamides, polyolefins, and the
like) may constitute the target substrate, either by itself or in
any combinations or mixtures of synthetics, naturals, or blends or
both types. As for the synthetic types, for instance, and without
intending any limitations therein, polyolefins, such as
polyethylene, polypropylene, and polybutylene, halogenated
polymers, such as polyvinyl chloride, polyesters, such as
polyethylene terephthalate, polyester/polyethers, polyamides, such
as nylon 6 and nylon 6,6, polyurethanes, as well as homopolymers,
copolymers, or terpolymers in any combination of such monomers, and
the like, may be utilized within this invention. Nylon-6,
nylon-6,6, polypropylene, and polyethylene terephthalate (a
polyester) are particularly preferred. Additionally, the target
fabric may be coated with any number of different films, including
those listed in greater detail below. Furthermore, the substrate
may be dyed or colored to provide other aesthetic features for the
end user with any type of colorant, such as, for example,
poly(oxyalkylenated) colorants, as well as pigments, dyes, tints,
and the like. Other additives may also be present on and/or within
the target fabric or yarn, including antistatic agents, brightening
compounds, nucleating agents, antioxidants, UV stabilizers,
fillers, permanent press finishes, softeners, lubricants, curing
accelerators, and the like.
[0014] Particularly desired as optional and supplemental finishes
to the inventive fabrics are soil release agents which improve the
wettability and washability of the fabric. Preferred soil release
agents include those which provide hydrophilicity to the surface of
polyester. With such a modified surface, again, the fabric imparts
improved comfort to a wearer by wicking moisture. The preferred
soil release agents contemplated within this invention may be found
in U.S. Pat. Nos. 3,377,249; 3,540,835; 3,563,795; 3,574,620;
3,598,641; 3,620,826; 3,632,420; 3,649,165; 3,650,801; 3,652,212;
3,660,010; 3,676,052; 3,690,942; 3,897,206; 3,981,807; 3,625,754;
4,014,857; 4,073,993; 4,090,844; 4,131,550; 4,164,392; 4,168,954;
4,207,071; 4,290,765; 4,068,035; 4,427,557; and 4,937,277. These
patents are accordingly incorporated herein by reference.
Additionally, other potential additives and/or finishes may include
water repellent fluorocarbons and their derivatives, silicones,
waxes, and other similar water-proofing materials.
[0015] The particular treatment must comprise at least one type of
metal-incorporating compound (namely metal particles), metal-ion
containing particles, or mixtures thereof. The term metal is
intended to include any such historically understood member of the
periodic chart (including transition metals, such as, without
limitation, silver, zinc, copper, nickel, iron, magnesium,
manganese, vanadium, gold, cobalt, platinum, and the like, as well
as other types including, without limitation, aluminum, tin,
calcium, magnesium, antimony, bismuth, and the like). More
preferably, the metals utilized within this invention are generally
those known as the transition metals. Of the transition metals, the
more preferred metals are silver, zinc, gold, copper, nickel,
manganese, and iron. Most preferred are silver and zinc. Such
metals provide the best overall desired characteristics, such as,
preferably, antimicrobial and/or odor reducing characteristics,
certain colorations, good lightfastness, and, most importantly,
wash durability on the target substrate.
[0016] The term metal particle is intended to encompass any
compound within which the metal is present in its pure non-ionic
state (thus silver particles are present, as one example). The term
metal-ion containing encompasses compounds within which the ionic
species of metals are present (such as metal oxides, including, as
mere examples, zinc oxide for Zn.sup.2+, silver oxide for Ag.sup.+,
and iron oxide for Fe.sup.2+ or Fe.sup.3+, or, as alternatives,
ion-exchange resins, zeolites, or, possibly substituted glass
compounds, which release the particular metal ion bonded thereto
upon the presence of other anionic species). The preferred metal
particle compound is produced through a reduction procedure and may
be any of silver, nickel, copper, zinc, and iron. With a reducing
agent, the salts utilized for this purpose are thus preferably
silver (I) nitrate, nickel (II) perchlorate, copper (II) acetate,
and iron (II) sulfate. The preferred metal-ion containing compound
for this invention is an antimicrobial silver zirconium phosphate
available from Milliken & Company, under the tradename
ALPHASAN.RTM., although any silver-containing antimicrobial
compound, including, for instance, and as merely some examples, a
silver-substituted zeolite available from Sinanen under the
tradename ZEOMIC.RTM. AJ, or a silver-substituted glass available
from Ishizuka Glass under the tradename IONPURE.RTM., may be
utilized either in addition to or as a substitute for the preferred
species. Also preferred as such a compound is zinc oxide, zinc
ricinoleate, zinc chloride, and zinc sulfate. Other metals, as
noted above, may also be utilized; however, from a performance
standpoint, silver and zinc, are most preferred.
[0017] Generally, such a metal compound is added in an amount of
from about 0.01 to 40% by total weight of the particular treatment
composition; more preferably from about 0.05 to about 30%; and most
preferably from about 0.1 to about 30%, all dependent upon the
selected method of application. The metal compound is then added to
the target substrate in a) amounts of between 0.01 and 1.0 ounces
per square yard, or, alternatively, b) from about 0.01 to about 5%
on weight of fabric ("owf"), depending on the selected application
and method for measuring. Such proportions provide the best
antimicrobial and/or odor-reducing performance in relation to wash
durability, electrical non-conductivity, and overall cost.
Preferably this metal compound add-on weight is a) about 0.1, or b)
about 1.0% owf. The treatment itself, including any necessary
binders, adherents, thickeners, and the like, is added to the
substrate in an amount of a) about 0.01 to about 4.0 ounces per
square yard, or b) from about 0.01 to about 10% owf.
[0018] Furthermore, the inventive substrates necessarily do not
exhibit any appreciable electrical conductivity (due to the low
amounts of metal present and thus the nonexistence of any
percolation over or through the target substrate) as measured by
attaching a two-inch by two-inch fabric specimen to two electrodes
and applying a voltage gradient of about 100 volts per inch through
the fabric (i.e., in accordance with AATCC Test Method 76-1978).
The measured resistance in ohms per square inch should exceed about
10,000, preferably 1,000,000, and most preferably 1.times.10.sup.9
in order to provide a substantially non-electrically conductive
fabric.
[0019] The selected substrate may be any of an individual yarn, a
fabric comprising individual fibers or yarns (though not
necessarily previously coated yarns), or a film (either standing
alone or as laminated to a fabric, as examples). The individual
fibers or yarns may be of any typical source for utilization within
fabrics, including natural fibers (cotton, wool, ramie, hemp,
linen, and the like), synthetic fibers (polyolefins, polyesters,
polyamides, polyaramids, acetates, rayon, acrylics, and the like),
and inorganic fibers (fiberglass, boron fibers, and the like). The
target yarn may be of any denier, may be of multi- or
mono-filament, may be false-twisted or twisted, or may incorporate
multiple denier fibers or filaments into one single yarn through
twisting, melting, and the like. The target fabrics may be produced
of the same types of yarns discussed above, including any blends
thereof. Such fabrics may be of any standard construction,
including knit, woven, or non-woven forms. The films may be
produced from any thermoplastic or thermoset polymer, including,
but not limited to, polyolefins (polypropylene, polyethylene,
polybutylene), polyvinyl chloride, polyvinylidene chloride,
polyvinyl acetate, and the like, polyesters (polyethylene
terephthalate, isophthalates, and the like) polyethers, acetates,
acrylics, and polyamides, as well as any copolymer films of any of
the above. Such films may be extruded, blown, rolled, and the like,
and may be produced in situ on the surface of a target fabric or
produced separately and subsequently adhered or laminated on a
target surface. Also, such films may be produced, treated, and
utilized separately from any other substrates.
[0020] The yarns are preferably incorporated within specific
fabrics, although any other well known utilization of such yarns
may be undertaken with the inventive articles (such as tufting for
carpets). The inventive fabrics may also be utilized in any
suitable application, including, without limitation, apparel,
upholstery, bedding, wiping cloths, towels, gloves, rugs, floor
mats, drapery, napery, bar runners, textile bags, awnings, vehicle
covers, boat covers, tents, and the like. The inventive films may
be present on fabrics, or utilized for packaging, as coatings for
other types of substrates, and the like.
[0021] Yarn and fabric substrates are preferably treated with a
metal particle or metal-ion containing finish. Films are preferably
treated with metal-ion containing formulations on the surface of
film-coated fabrics.
Metal Particle Treatments
[0022] The preferred metal particle composition will generally
comprise four components: water, a metal salt, a reducing agent,
and a polymeric binder. As noted above, the metal is produced
through the reduction of the metal ion upon dissolution of the
metal salt in solution. This specific process actually blends two
different technologies, specifically the formation of colloidal
particles by chemical reduction and steric stabilization of such
particles by surfactant or polymer and the modification of a fiber
(or textile) surface through the utilization of a polymeric binder.
In the instance, the steric stabilizer and the fiber (or textile)
binder are the same polymeric compound.
[0023] Such a metal particle dispersion is generally produced as
follows: A solution of the polymeric binder and water is produced
having a polymer concentration between 0.1% and 20% (w/w). The
solution is then divided between two containers, one containing a
dissolved metal salt (i.e. a metal salt MA dissociates completely
to M.sup.+ and A.sup.-) and in the other, a dissolved reducing
agent. When the two solutions are thoroughly mixed, they are then
combined very quickly. When combined, the reducing agent transfers
an electron to the metal cation and reduces it to its neutral form
(M.sub.n.sup.++e.sup.-.fwdarw.M.sub.n.sup.0). The metal atoms
quickly agglomerate to form larger (1-1000 nm) particles. The
steric stabilizer acts by adsorbing to the surface of the growing
particles and thereby prevents catastrophic flocculation of the
particles into macroscopic (.about.mm in diameter) aggregates by
limiting the distance of closest approach.
[0024] It is important to note that the selection of the particular
polymeric binder is crucial to the success in attaining the desired
durability and effectiveness of the specific coating as this binder
component must meet a number of important criteria. First, since
high salt concentrations are necessary to generate large numbers of
metal particles, and such salts generally cause many polymeric
binder dispersions to flocculate out of solution, the particular
binder must not react in such a manner in order to effectively
stabilize the particles that are produced (as noted above).
Secondly, the binder must not act like typical textile binders
(which do not stabilize the particles and thus allow the nucleated
particles to flocculate rapidly into macroscopic assemblies) which
would render the resultant solution unusable in this application.
Thirdly, it is important that the polymeric stabilizer, once
processed, be able to withstand home washing under a wide range of
conditions and maintain the silver concentration on the textile.
Thus, it must not be readily soluble in water, must not be
susceptible to attack by standard and/or industrial detergents,
solvents, and/or bleaches, and must not melt upon exposure to
drying temperatures. The utilization of such a specific binder to
provide a metal coating to fibers and/or fabrics is thus
drastically different from other previous practices in this area
and permits a topical application of such a coating either before
or after the particular substrate has been finished. In order to
provide the requisite wash durability, this binder must pass these
stringent criteria. No teaching or fair suggestion exists within
the prior art of such requirements.
[0025] As noted previously, the preferred metal salts for this
procedure are silver (I) nitrate, nickel (II) perchlorate, copper
(II) acetate, and iron (II) sulfate. The concentrations of these
salts within the immersion bath can be increased to .about.2%
before the kinetics of reduction and aggregation overwhelm the
kinetics of polymer adsorption and mixing and cause significant
aggregation/clumping of the metal. The preferred metal salt is
silver (1) nitrate and is present in a concentration of from about
0.01% to about 10%, more preferably from about 0.1% to about 5.0%,
and most preferably about 1.0% within the immersion bath.
[0026] The preferred reducing agents are sodium borohydride
(NaBH.sub.4), sodium hydrosulfite, and trisodium citrate
(Na.sub.3C.sub.6H.sub.5O.sub.7), although any standard reducing
agent associated with the above-listed metal salts may be utilized.
The former is a stronger reducing agent that reacts with the metal
completely within seconds of mixing. An undesirable byproduct of
this reaction is hydrogen gas that causes significant foaming when
mixed. The latter two do not have this effect, but are milder
reducing agents and require heating to near boiling to cause the
reaction to proceed.
[0027] The polymeric binder may be selected from certain resins and
thermoplastics, such as melamine resins and polyvinyl
chloride-containing polymers. Of particular interest, and thus the
preferred polymeric binders for this process are
melamine-formaldehyde resins (such as a resin available from BF
Goodrich under the tradename Aerotex.RTM.), polyvinyl
chloride/vinyl copolymers (such as a copolymer also available from
BF Goodrich under the tradename Vycar.RTM. 460.times.49), and
PVC/acrylic resins available from BF Goodrich. It has been found
that upon exposure to an ammonium sulfate catalyst and curing at
350.degree. C. for 2 minutes, the melamine provides durable finish
on either a fiber or a fabric of at least 30 washes. The copolymer
requires no catalyst and performs similarly to the melamine in wash
durability when cured for the same time and at the same
temperature. (Table 1 lists the ICP reading for silver as a
function of home washes using Aerotex.RTM. M3 and BFG Vycar.RTM. in
a pad.)
[0028] The solution described above can be applied to fabric or
yarn in a number of ways. Included in this list, which is by no
means exhaustive, are pad coating, screen coating, spraying, and
kiss-coating (particularly for yarn applications). The preferred
coating and method are discussed in greater depth below.
Metal-Ion Containing Coatings
[0029] The preferred procedures utilizing metal-ion containing
compounds include any of the following, depending on the desired
characteristics of the final product. One alternative utilizes the
silver-ion compound noted above, such as either ALPHASAN.RTM.,
ZEOMIC.RTM., or IONPURE.RTM. as preferred compounds (although any
similar types of compounds which provide silver ions may also be
utilized), exhausted on the target fabric or film surface and then
overcoated with a binder resin. Alternatively, the metal-ion
containing compound may be admixed with a binder within a dye bath,
into which the target fabric or fiber is then immersed at elevated
temperatures (i.e., above about 50.degree. C.).
[0030] Such a procedure was developed through an initial attempt at
understanding the ability of such metal-ion containing compounds to
attach to a fabric surface. Thus, a sample of ALPHASAN.RTM. was
first exhausted from a dye bath on to a target polyester fabric
surface. The treated fabric exhibited excellent log kill rate
characteristics; however, upon washing in a standard laundry method
(AATCC Test Method 130-1981, for instance), the antimicrobial
activity was drastically reduced. Such promising initial results
led to the inventive wash-durable antimicrobial treatment wherein
the desired metal-ion containing compound would be admixed or
overcoated with a binder resin on the target fabric surface.
[0031] The binder resin should exhibit little or no water
solubility (substantially water-insoluble), and must readily adhere
to either the fabric surface or to the metal-ion containing
compound itself. Such a binder resin can thus be selected from the
group consisting of nonionic permanent press binders (i.e.,
cross-linked adhesion promotion compounds, including, without
limitation, cross-linked imidazolidinones, available from Sequa
under the tradename Permafresh.RTM.) or slightly anionic binders
(including, without limitation, acrylics, such as Rhoplex.RTM.
TR3082 from Rohm & Haas). Other nonionics and slightly anionics
may be utilized as long as they provide the desired adhesion
characteristics. Such potential compounds include melamine
formaldehyde, melamine urea, ethoxylated polyesters, such as Lubril
QCX.TM. available from Rhodia, and the like. The initial exhaustion
of ALPHASAN.RTM. is thus preferably followed by a thin coating of
binder resin to provide the desired wash durability characteristics
for the metal-based particle treatment. The antimicrobial
characteristics of the treated fabric remained very effective for
the fabric even after as many as ten standard laundering
procedures.
[0032] Also possible, though less effective as compared to the
aforementioned binder resin overcoat, but still an acceptable
method of providing a wash-durable antimicrobial metal-treated
fabric surface, is the application of a metal-ion containing
compound/binder resin from a dye bath mixture. The exhaustion of
such a combination is less efficacious from an antimicrobial
activity standpoint than the overcoat procedure, but, again, still
provides a wash-durable treatment with acceptable antimicrobial
benefits. In actuality, this mixture of compound/resin may be
applied through spraying, dipping, padding, and the like.
[0033] Another preferred alternative concerns the treating of
individual fibers. Such an alternative has proven very effective,
most particularly in a package dyeing method. In such a procedure,
a dye bath comprising the desired metal-ion containing compounds
and binder agents is pumped through a tightly wound spool of yarn
(or fiber). This is generally a rather difficult process to perform
effectively since the particle sizes of the constituent dye bath
solids might interfere with the requisite pump pressure to force
the dye bath liquor through the entire "package" of yarn.
Furthermore, such a dyeing method must produce a uniform treatment
of all the portions of the target yarn throughout the "package";
particle size and thoroughness of mixing are thus of vital
importance to impart of even treatment over the entire yarn.
[0034] Surprisingly, this procedure works very well for imparting a
wash-durable metal treatment on the yarn surface. Upon treatment of
target yarns, such yarns can then be woven, knit, or incorporated
within a non-woven fabric structure to form a textile. The textile
exhibits similar colorations, log kill rates, and the like, at
discrete locations of the textile. Without intending to be bound to
any specific theory, it is believed that the binding agent appears
to affix itself over the metal-ion containing compounds adhered to
the yarn surface, or that the binding agent adheres to the yarn
surface, to which the metal-ion containing compound then affixes
itself (and to which binding agent may also affix). As such, and
again, very surprisingly, the desired metal-ion containing
compounds were small enough to be forced through the yarn "package"
in order to treat the entire target yarn. In such an alternative
method, the high pressure procedure necessary for providing the
antimicrobial solid application on the surface of the target yarns
must be sufficient to permit penetration of the solid compounds
into the actual yarn structure. A high temperature may be desired
to permit "opening" of the fiber structure to facilitate such
solids introduction within a solid yarn. In general, the high
pressure conditions must be from about 0.1 and 100 pounds per
square inch with an exposure time of from about 5 seconds to about
5 hours at a temperature in the range from about 25.degree. to
about 325.degree. C. Such conditions are most readily provided
within a jet dye, closed vessel system, and appears to work most
readily for package dyed yarns. The type of fiber is consequential
only to the extent that certain temperatures permit easier
penetration within certain fibers. Thus, natural fibers (such as
cotton) require relatively low temperatures to "open" of the
cellulosic structure; nylon requires a much higher temperature (to
exceed its glass transition temperature, typically) to provide the
most effective antimicrobial characteristics. For the most part,
the high pressure actually appears to force the solid particles
into the yarns; surprisingly, such solid-solid interaction works to
retain a substantial amount of the solid antimicrobial, even after
washing. Preferably, however, a binder agent is added to aid in
solid particle retention since such solid particles will most
likely exhibit a desire to become detached from the yarn over
time.
[0035] Another alternative utilizes a metal oxide treatment on a
fabric or film surface, such as, preferably, zinc oxide, coated
with a hydrophobic binding agent mixed with a synergistic amount of
a polymeric hydrophilic material, applied to a fabric or film
surface, primarily to provide a wash-durable odor-reducing finish
on the target fabric. Generally, the presence of such a
wash-durable hydrophobic binding agent is possible only on a
hydrophobic fabric surface. However, hydrophobic fabric does not
wick moisture and thus is very uncomfortable to wear (if utilized
as apparel fabric) as compared to a hydrophilic moisture-wicking
fabric. Also, such a hydrophobic binding agent overcoat for the
metal oxide odor-reducing material would detrimentally mask the
metal oxide surface and retard the odor neutralizing action of the
effective compound, particularly when present on and/or in a wet
fabric. However, in order to provide a wash-durable metal oxide
odor-reducing finish to a textile or fabric, seemingly there is a
need to provide a complete hydrophobic binding agent over the metal
oxide. When such a "required" excess of hydrophobic agent binder is
present, again, the metal oxide (i.e., zinc oxide) would most
likely be encapsulated and thus will not contact the targeted
odor-producing compounds. A reduction in such hydrophobic binding
agent results in a lack of sufficient adhesion between the metal
oxide particles and the target fabric to provide a wash-durable and
wear-durable finish. It was found, surprisingly, that the necessary
comfort (due to wicking of moisture) and simultaneous retention of
sufficient adhesion are provided through the addition of a
hydrophilic agent to the zinc oxide/binding agent formulation. With
such an addition, a durable, moisture-wicking, and odor-reducing
textile finish/coating is provided.
[0036] Of great and surprising interest is the apparent synergistic
interaction between the zinc oxide, binding agent and hydrophilic
agent. The hydrophilic agent not only provides moisture-wicking
comfort to the target fabric, but also facilitates the interaction
of odor compounds in human perspiration with the preferred zinc
oxide to allow efficient odor neutralization. In general the weight
ratio of zinc oxide to resin binder is in the range of 100:1 to
1:100 to be effective. The ratio between 1:2 and 2:1 is preferred.
One suitable wetting agent for this application may possess both
hydrophilic and hydrophobic moieties within its structure. In such
an instance, the specific hydrophilic moiety must be present in an
amount sufficient to permit any moisture spread on the treated
fabric surface. The finish also requires sufficient amounts of a
hydrophobic moiety within its structure to make it water soluble.
As a result, the finish will not be easily washed off in repeated
washing cycles. Examples of such preferred wetting agents are
sulfonated polyesters, ethylene oxide-propylene oxide copolymers,
and ethoxylated polyesters. The preferred metal oxide is zinc oxide
with fine particle size and high surface area. Fine particle size
allows uniform distribution in an application medium and renders
the treatment substantially transparent. Large particle zinc oxide
tends to give a white background shade to a textile and therefore
affects the appearance of the product. Particle sizes for this
application should be preferably below 3 micrometers, most
preferably, less than 1 micrometer. Zinc oxide high specific
surface area is also preferred for this application. Preferred
specific surface area of zinc oxide for this application is 10
m.sup.2/g or more. The preferred embodiments of these alternatives
fabric treatments are discussed in greater detail below.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] Examples of particularly preferred compounds within the
scope of the present invention are set forth below. None of the
following inventive fabrics exhibited any electrical
conductivity.
A) Silver-Particle Yarn and Fabric Treatments
[0038] The dispersions used in the durability and log kill study
for the resultant articles with silver-particle treatments
contained the following concentrations (all % are per weight of
solution): 1% AgNO.sub.3, 0.5% NaBH.sub.4, 5% binder resin, 3%
hydroxyethylcellulose thickener, and 90.5% water. The print pattern
used was a 12 dpi dot pattern with each dot having .about.0.5 mm
diameter circular shape.
[0039] Three sets of samples were tested at three different numbers
of washes. The three sets were: a) untreated 100% polyester
multifilament fabric, b) the same type of fabric treated with just
the desired binder resin, and c) the same type of fabric treated
with the above-described silver-particle dispersion. Each sample
was tested for 0, 15 and 30 washes. To minimize the potential
biocidal activity of the detergent, the 15 and 30 wash samples were
run through two additional rinse cycles before analysis. In the
pertinent Tables which follow, the log kill results were performed
with a) an initial Staphylococcus aureus concentration of
3.8.times.10.sup.6 CFU/mL and b) a Klebsiella pneumoniae inoculum
initial concentration of about 18,000,000 CFU/mL.
[0040] The following three treatments were performed and shown to
create a highly washfast metal particle finish:
1) Pad Coating
[0041] The fabric article (100% polyester fabric) was dipped into a
silver particle/polymeric dispersion comprising about 1 part of
silver colloid solution and about 5 parts of a binder resin.
Particular resins tested were Aerotex.RTM. M3, Vycar.RTM.
460.times.49, and a PVC/Acrylic resin (all resins available from BF
Goodrich). The immersed fabric was then removed and run through a
pad roll. The fabric was then heated to 350.degree. C. for 2
minutes. The resulting fabric was then first analyzed for particle
count remaining on the fabric surface after treatment by ICP
spectroscopy, both initially and after a number of washes utilizing
the standard laundering procedure of AATCC Test Method 130-1981.
The results are presented in tabular form below:
TABLE-US-00001 TABLE 1 Particle Count on Fabrics Pad Coated with
Silver Particle Dispersions # of ICP for Silver (ppm) ICP for
Silver (ppm) Washes PVC/Acrylic Binder With Aerotex .RTM. M3 Binder
1 5210 7074 10 3993 6250 20 3555 6149 30 2841 4965
[0042] Thus, the retention of the metal finish was excellent for
both binders (77% after 10 washes, 68% after 20, 55% after 30 for
the PVC/Acrylic binder; 88% after 10 washes, 87% after 20, and 70%
after 30). It should be noted that these measurements are subject
to the variability within the measuring instrument as well;
although they are considered relatively and should not deviate in
any significant amount from the tabulated results, variations in
results may occur. Furthermore, the treated fabrics were also
tested for electrical conductivity through the method noted above
(AATCC Test Method 76-1978); the noise of the measuring instrument
exceeded any signal of the resistance measuring instrument, thus,
the resistance is so high for the fabric that no appreciable
conductivity was exhibited by all of the tested samples.
2) Yarn Application
[0043] In this method, the metal particle dispersion was applied
utilizing a kiss-coater, which consists of a roll which constantly
rotates in a bath of the metal dispersion. The roll transferred the
solution to the top side of the roller, where an end of yarn passed
against the roller and into an oven where it was cured at
350.degree. C. for 2 minutes then taken up onto a bobbin for
further processing. The metal particle coated yarn was measured to
be electrically non-conductive (by the spaced electrode method
noted above) and typically included from about 20 to 30% by weight
of the metal-particle dispersion. The silver-coated yarn was then
knit or woven into a fabric with non-treated yarns at a ratio of 1
treated yarn to every 15 untreated yarns. The treated yarns were
visible on only one side of the treated fabric and the resultant
fabric exhibited excellent sustained antimicrobial performance.
Table 3 shows ICP results for silver as a function of washes for a
"sock" knit from 70 denier treated yarn and 500 denier untreated
yarn.
TABLE-US-00002 TABLE 2 Durability of Silver-Particle Coated Yarns
Woven into Fabrics # of Home ICP for Silver (ppm) Washes With
Aerotex .RTM. M3 Binder 0 3798 10 3709 20 3297 30 3286
3) Screen Printing
[0044] In a screen printing application, the dispersion described
above was thickened and pressed through a printing screen onto one
side of a fabric in a finishing step. The preferred thickening
agent for this embodiment is Aqualon.RTM. Natrosol 99-250 HHR (in a
concentration range of 1-10% by weight of solution) with the
preferred concentration being 3% (which provides a desired
intrinsic viscosity of from about 100,000 to about 400,000,
preferably 200,000, centipoise at standard temperature and
pressure). The viscosity of the metal particle/polymer dispersion
may also be adjusted with the utilization of sufficient amounts of
hydroxyethylcellulose; however, mixtures of HEC and the
Aqualon.RTM. thickeners may prove sufficient to provide a
resultant, preferred viscosity of 200,000 cps. Although preferred
thickeners for screen printing have been found, one of ordinary
skill in this art would appreciate that any number of acceptable
thickeners may be utilized, either alone, or in combination, to
provide the desired and/or necessity viscosity level in order to
perform such a screen printing procedure. The thickened
metal-particle containing dispersion was applied to the target
fabric by squeezing it through a patterned rotary screen. The
"coated" fabric was then cured at 350.degree. F. for at least 2
minutes to produce a coating that was washfast through at least 30
washes. Table 4 provides this durability data:
TABLE-US-00003 TABLE 3 Durability of Screen Printing on Fabric with
Silver-Particle Dispersions # of Home ICP for Silver (ppm) Washes
With PVC/Acrylic Binder 0 312 10 266 20 135 30 109
[0045] The treated fabric was then analyzed for its ability to
provide antimicrobial effectiveness against Staphylococcus aureus
and Klebsiella pneumoniae. The results were as follows:
TABLE-US-00004 TABLE 4 Staphylococcus aureus Effectiveness # Washes
Control Binder Fabric from TABLE 3 0 0.35 0.83 5.56 15 1.00 1.06
4.08 30 0.07 1.20 5.54
TABLE-US-00005 TABLE 5 Klebsiella pneumoniae Effectiveness # Washes
Control Binder Fabric from TABLE 3 0 1.93 2.28 3.94 15 2.73 2.79
5.33 30 2.04 2.66 5.33
[0046] The durable treatment not only retained its integrity over
the target fabric surface, but also continued to provide an
effective antimicrobial treatment as well.
B) Silver Ion Exchange, Silver Zeolite, and Zinc Oxide Fabric
Treatments
[0047] As noted above, treatments of specific metal-ion containing
compounds have proven to be wash-durable on certain yarn and fabric
surfaces as well. These include the following, preferably with
either the ALPHASAN.RTM. silver-based compounds or with zinc oxide.
The following preferred embodiments exhibited resistivity
measurements well in excess of 1.times.10.sup.9 ohms per square
inch of fabric in accordance with AATCC Test Method 76-1978.
1) Exhaustion of Compound Followed with Binder Resin Overcoat a)
Acrylic Binder Resin--A dispersion of ALPHASAN.RTM. (silver-based
ion exchange compound available from Milliken & Company) was
first produced through the mixing of about 30% by weight of the
silver-based compound, about 23.0% by weight of a mixture of
anionic surfactants, Tamol.RTM. SN, available from Rohm & Haas,
and Synfac.RTM.) 8337, available from Milliken & Company, and
the remainder water. This dispersion was then applied through
exhaustion within a dye bath to four fabric samples (all of 100%
polyester construction; with 51 picks by 52 ends; 300 denier
multifilament yarn). Two were dyed at a temperature of about
280.degree. F.; the others at a temperature of about 265.degree. F.
The exhaustion level of the active ALPHASAN.RTM. compounds on the
target fabrics was about 1.0% owf. The fabrics were then coated
with an acrylic binder material, Rhoplex.RTM. TR3082, in an amount
of about 2.5% owf. The coated fabrics were then heat-set at
380.degree. F. The log kill rate for unwashed fabrics for S. aureus
was measured to be 4.9; for K. pneumoniae, 2.54. The results after
multiple washings are tabulated below:
TABLE-US-00006 TABLE 6 Log Kill Rates After Multiple Washings With
Acrylic Overcoat Log Kill Rate Log Kill Rate Number of Washes for
S. aureus for K. pneumoniae 1 4.59 2.28 5 4.15 2.20 10 3.13
1.97
[0048] It is important to note, and as is well appreciated and
understood by one of ordinary in the art, that variations in log
kill rate measurements are prevalent, though, reliable, due to
inherent difficulties in both biological testing and in the ability
to establish completely controlled bacterium counts on such
surfaces. These results thus show very favorable antimicrobial
performance and thus excellent wash durability on the fabric
surface.
b) Permanent Press Binder Resin--The same type of ALPHASAN.RTM.
dispersion and exhaustion procedure was followed as above. The
overcoat, however, was Permafresh.RTM., available from Sequa.
Again, about 2.5% owf of this overcoat resin was applied over the
ALPHASAN.RTM.-treated fabrics. Also added within the dye bath was a
butyl benzoate carrier in an amount of about 2.5% owf. The log kill
results for this sample were as follows:
TABLE-US-00007 TABLE 7 Log Kill Rates After Multiple Washings With
Permanent Press Overcoat Log Kill Rate Log Kill Rate Number of
Washes for S. aureus for K. pneumoniae 0 3.21 5.32 1 4.11 3.89 5
2.98 3.03 10 3.94 4.23
[0049] Excellent durability results were thus obtained with such a
system.
c) PD-92 Binder Resin--The same type of ALPHASAN.RTM. dispersion
and exhaustion procedure was followed as above. The overcoat,
however, was PD-92 available from Milliken & Company. Again,
about 2.5% owf of this overcoat resin was applied over the
ALPHASAN.RTM.-treated fabrics. Also added within the dye bath was a
butyl benzoate carrier in an amount of about 2.5% owf. The log kill
results for this sample were as follows:
TABLE-US-00008 TABLE 8 Log Kill Rates After Multiple Washings With
PD-92 Overcoat Log Kill Rate Log Kill Rate Number of Washes for S.
aureus for K. pneumoniae 0 3.30 3.36 1 3.15 2.72 5 3.18 2.26 10
3.03 1.78
[0050] Excellent durability results were thus obtained with such a
system as well.
d) Effect of Increased amount of ALPHASAN.RTM. on Wash
Durability--The same fabric treatments (with Permafresh.RTM. binder
resin) as above were performed with the amount of ALPHASAN.RTM.
increased to a 4% owf active addition to the target fabric surface
(about 13.3% owf of the dispersion). The same padding on of the
permanent press binder was followed as above. The log kill results
for K. pneumoniae are as follows:
TABLE-US-00009 TABLE 9 Log Kill Rates With High Add-On of
Silver-Based Compound Number of Washes Log Kill Rate for K.
pneumoniae 0 5.6 5 5.7 10 4.4
[0051] Again, excellent durability was obtained.
e) Effect of Increased amount of Permanent Press Binder Resin on
Wash Durability--The same fabric treatments (with Permafresh.RTM.
binder resin) as above were performed with the padded on amount of
binder resin increased to a 7.5% owf addition to the target fabric
surface. The log kill results for K. pneumoniae are as follows:
TABLE-US-00010 TABLE 10 Log Kill Rates With High Add-On of
Permanent Press Binder Resin Number of Washes Log Kill Rate for K.
pneumoniae 0 5.7 5 4.0 10 3.9
[0052] Again, excellent wash durability results were obtained.
2) Exhaustion of Compound with a Binder Resin
[0053] A dispersion of ALPHASAN.RTM. (silver-based ion exchange
compound available, from Milliken & Company) was first produced
through the mixing of about 30% by weight of the silver-based
compound, about 23.0% by weight of an anionic surfactant mixture of
Tamol.RTM. and Synfac.RTM. 8337 surfactant, and the remainder
water. This dispersion was then applied through exhaustion within a
dye bath which included an acrylic binder (Rhoplex.RTM. TR3082)
which was present within the dye bath in a concentration of about
2.5% owf. A 100% polyester fabric (same as above) was then placed
within the dye bath which was then heated to a temperature of about
280.degree. F. The exhaustion level of the active ALPHASAN.RTM.
compounds on the target fabrics was about 1.0% owf. The fabrics
were then heat-set at 380.degree. F. The log kill rate for unwashed
fabrics for S. aureus was measured to be 2.35; for K. pneumoniae,
5.38. The results after multiple washings are tabulated below:
TABLE-US-00011 TABLE 11 Log Kill Rates After Multiple Washings With
Acrylic Resin Log Kill Rate Log Kill Rate Number of Washes for S.
aureus for K. pneumoniae 1 1.50 2.37 5 1.17 2.37 10 1.36 2.98
[0054] These results show very favorable antimicrobial performance
and thus excellent wash durability on the fabric surface, though
less favorable than for the resin overcoated fabrics.
3 Exhaustion of Other Silver-Based Compounds
[0055] The same general exhaustion methods were followed as above
with the same padding on (denoted as P in the table below) and dye
bath application (D in the following table) of a permanent press
binder as above as well. The different silver-based compounds
applied were AmpZ200 (a TiO2/silver metal product available from
DuPont), and ZEOMIC.RTM. AJ80H. The add-on weights of these were
the same 1.0% owf treatment as for the ALPHASAN.RTM. noted above.
The durability results for these compounds were as follows for K.
pneumoniae log kill rates:
TABLE-US-00012 TABLE 12 Log Kill Rates With Other Silver-Based
Compounds Log Kill Rate Compound Number of Washes for K. pneumoniae
AmpZ200 (P) 0 2.76 AmpZ200 (P) 10 1.82 AmpZ200 (D) 0 2.06 AmpZ200
(D) 10 1.36 ZEOMIC .RTM. AJ80H (P) 0 5.31 ZEOMIC .RTM. AJ80H (P) 10
1.64 ZEOMIC .RTM. AJ80H (D) 0 4.31 ZEOMIC .RTM. AJ80H (D) 10
1.92
[0056] These are excellent durability results, although not as good
as for the ALPHASAN.RTM. treatments.
4) Package Dyeing Method
[0057] Again, as with all of the other inventive fabrics and yarns,
the measured resistivity of the following yarns and fabrics
exceeded 1.times.10.sup.9 ohms per square inch.
Example 1
[0058] Several spools of 150 denier polyester multifilament yarn
were placed within a sealed dye bath. The dye bath liquor contained
1.0% owf of active ALPHASAN.RTM., 0.5% by weight of nonionic
leveler 528 (butyl benzoate, available from Milliken &
Company), and the balance water. After sealing of the chamber, the
pump was activated at a pressure of 60 psi at a temperature of
about 280.degree. F. The pump remained activated for about 60
minutes. The resultant spools of yarn were then utilized in a
knitting operation to produce a sock. Three different discrete
areas of the sock were tested for log kill rates for K. pneumoniae
after different numbers of launderings. The colorations of the sock
remained virtually the same after such repeated launderings. The
log kill results are tabulated below:
TABLE-US-00013 TABLE 13 Log Kill Rates On The Knit Fabrics
(Binder-Free) Number of Washes Log Kill Rate for K. pneumoniae 0
4.43 5 4.13
[0059] The knit fabric thus retained a substantial amount of its
ALPHASAN.RTM. finish applied during the package dyeing process for
an extremely long duration.
Example 2
[0060] Several spools of 150 denier multifilament polyester yarn
were placed within a sealed dye bath. The dye bath liquor contained
1.0% owf of active ALPHASAN.RTM., 0.5% owf nonionic leveler 528,
2.0% owf of Rhoplex.RTM. TR3082 (an acrylic-based slightly anionic
binding agent), and the balance water. After sealing of the
chamber, the pump was activated at a pressure of 60 psi at a
temperature of about 280.degree. F. The pump remained activated for
about 60 minutes. The resultant spools of yarn were then utilized
in a knitting operation to produce a sock. Three different discrete
areas of the sock were tested for log kill rates for K. pneumoniae
after different numbers of launderings. The colorations of the sock
remained virtually the same after such repeated launderings. The
log kill results are tabulated below:
TABLE-US-00014 TABLE 14 Log Kill Rates On The Knit Fabrics (With
Acrylic Binder) Number of Washes Log Kill Rate for K. pneumoniae 0
4.43 5 4.20 10 4.03
[0061] The knit fabric thus retained a substantial amount of its
ALPHASAN.RTM. finish applied during the package dyeing process for
an extremely long duration.
Example 3
[0062] Several spools of 150 denier multifilament polyester yarn
were placed within a sealed dye bath. The dye bath liquor contained
1.0% owf of active ALPHASAN.RTM., 0.5% owf of nonionic leveler 528,
and the balance water. After sealing of the chamber, the pump was
activated at a pressure of 60 psi at a temperature of about
280.degree. F. The pump remained activated for about 60 minutes.
The resultant spools of yarn were then utilized in a knitting
operation to produce a sock. A permanent press binding agent (2.0%
owf of Permafresh.RTM., available from Sequa) was then padded on
the entire sock. After drying, three different discrete areas of
the sock were tested for log kill rates for K. pneumoniae after
different numbers of launderings. The colorations of the sock
remained virtually the same after such repeated launderings. The
log kill results are tabulated below:
TABLE-US-00015 TABLE 15 Log Kill Rates On The Knit Fabrics (With
Permanent Press Binder) Number of Washes Log Kill Rate for K.
pneumoniae 0 4.43 5 4.42 10 3.85
[0063] The knit fabric thus retained a substantial amount of its
ALPHASAN.RTM. finish applied during the package dyeing process for
an extremely long duration.
Metal Oxide Odor Reduction Fabric Treatments
[0064] A dispersion having the following components was mixed
thoroughly:
TABLE-US-00016 COMPOSITION Component Amount (in grams) Zinc oxide
powder (Aldrich, <1 micron) 2.0 grams Rhoplex .RTM. E-32NP
(acrylic resin binder) 8.0 grams Millitex .RTM. PD-92 (wetting
agent) 2.0 grams Ultratex .RTM. MES (fabric softener) 0.5 grams
water 90 grams
[0065] One swatch of dyed knit polyester fabric was impregnated
with the mixed solution and dried at 350.degree. F. for 3 min to
obtain a treated fabric. The treated fabric exhibited no noticeable
color or flexibility change. Several drops of a dilute aqueous
isovaleric acid solution (1 drop of acid in 50 grams of water), to
simulate unpleasant foot odor, was then applied to the unwashed
fabric. The solution quickly wicked into the fabric and the
unpleasant odor quickly disappeared. The treated fabric was then
laundered in accordance with the AATCC Test Method 130-1981 for 10
cycles; the same wicking and odor removal was exhibited by the zinc
oxide treated fabric. Thus, the zinc oxide treatment remained
intact on the fabric surface. Furthermore, the sample was tested
for electrical conductivity by measuring resistance over the entire
fabric. The fabric sample exhibited 1013 ohms/square inch of
fabric; thus, effectively no conductivity existed.
[0066] The sample was then washed in accordance with AATCC Test
Method 130-1981 and then analyzed for odor reduction and
antimicrobial activity in accordance with 24 hour inoculation
exposure of Klebsiella pneumoniae under AATCC Test Method 100-1983.
The results were as follows:
TABLE-US-00017 TABLE 16 # of Washes Log Kill Reduction Odor
Neutralization? 1 3.1 Yes 10 3.6 Yes 25 ~3.0 Yes
[0067] Furthermore, X-ray fluorescence was performed on the above
sample to indicate the amount of zinc retained on the fabric
surface as well through the peak size in relation to the signal
emitted by zinc on the substrate surface. The results were as
follows:
TABLE-US-00018 TABLE 17 Number of washes Zinc X-ray counts 0
162,644 2 113,133 10 87,471 20 49,801
[0068] Thus, excellent wash durability was exhibited even after
twenty washes since about 30% was retained from the initial zinc
count.
Lightfastness of Certain Samples
[0069] The samples tested in TABLE 6, above, as well as other
fabrics and comparative samples were analyzed for the lightfastness
of the color exhibited by the treated fabrics after topical
application of the desired metal-based finish. Such analysis
involved testing in accordance with The Engineering Society for
Advancing Mobility Land Sea Air and Space Textile Test method SAE
J-1885, "(R) Accelerated Exposure of Automotive Interior Trim
Components Using a Controlled Irradiance Water Cooled Xenon-Arc
Apparatus." Color lightfastness is generally calculated by the
following equation:
.DELTA.E*=((L'.sub.initial-L'.sub.exposed).sup.2+(a'.sub.initial-a'.sub.-
exposed).sup.2+(b'.sub.initial-b'.sub.exposed).sup.2).sup.1/2
wherein .DELTA.E* represents the difference in color between the
fabric upon initial latex coating and the fabric after the
above-noted degree of ultra violet exposure. L', a', and b' are the
color coordinates; wherein L' is a measure of the lightness and
darkness of the colored fabric; a' is a measure of the redness or
greenness of the colored fabric; and b is a measure of the
yellowness or blueness of the colored fabric. A low .DELTA.E* shows
excellent lighffastness for the tested fabric; a .DELTA.E* greater
than about 5.0 is unacceptable and shows a yellowing tendency for
the treated fabric. As noted above, the ALPHASAN.RTM.-treated
polyester sample from TABLE 6 was subjected to a Xenon Arc Lamp
Test at 225 kJ/m.sup.2 for both 20 and 40 hours to analyze the
yellowing characteristics of the treated fabric. At 20 hours, the
fabric exhibited a .DELTA.E* of about 1.95; at 40 hours, a
.DELTA.E* of about 3.38. Thus, the treated fabric exhibited
excellent lighffastness properties.
[0070] Further samples of 65%/35% polyester/cotton blend shirts
were also tested for such lighffastness results after receiving
ALPHASAN.RTM. treatments from dryer donor sheets comprising 0, 9%,
and 20% (made in accordance with the method discussed above) of the
silver-based ion exchange compound. The results were tabulated as
follows:
TABLE-US-00019 TABLE 18 Amount of ALPHASAN .RTM. .DELTA.E* at 20
hours .DELTA.E* at 20 hours 0 0.48 0.72 9 1.03 1.23 20 1.34
1.82
[0071] Clearly and surprisingly, the silver treated fabrics
exhibited acceptable lighffastness characteristics.
[0072] There are, of course, many alternative embodiments and
modifications of the present invention which are intended to be
included within the spirit and scope of the following claims.
* * * * *