AU2019100907A4 - Microzone antimicrobial performance with inactivation - Google Patents

Abstract

MICROZONE ANTIMICROBIAL PERFORMANCE WITH INACTIVATION The present invention is directed to filamentous material comprising an antimicrobial agent element which exhibits useful antimicrobial performance during the time of utilization in a consumer product while having a second antimicrobial antagonist or inactivating element designed to mitigate lasting deleterious impact(s) of the antimicrobial agent on the environment. The filamentous material is comprised of a two-part system wherein a first part is the presence of an agent or chemical functionality that imparts antimicrobial performance and a second part which is one or more agents or chemical functionalities that act upon the antimicrobial performance and render that performance ineffective or inactive. Having the first antimicrobial performance part and the second antimicrobial performance inactivating part in interactive proximity, at least some excess, unused or residual antimicrobial agent is deactivated and prevented from negatively effecting the environment and related decomposition pathways. 70 - - - i bN R h

Description

MICROZONE ANTIMICROBIAL PERFORMANCE WITH INACTIVATION

BACKGROUND OF THE INVENTION [0001] The present invention is directed to a construct comprising components imparting favorable immediate and long-term performance attributes in disposable polymeric constructs and more particularly to filamentous material comprising an antimicrobial component which exhibits useful antimicrobial performance during the time of utilization in a consumer product, while having a co-located antimicrobial antagonist or inactivating component designed to mitigate lasting deleterious impact(s) of the antimicrobial agent upon the environment. The filamentous material is comprised of a two-part system wherein a first part is the presence of an agent or chemical functionality that imparts antimicrobial performance and a second part which is one or more agents or chemical functionalities that act upon the antimicrobial performance and render that performance ineffective or inactive. Having the first antimicrobial performance part and the second antimicrobial performance inactivating part in interactive proximity, at least some excess, unused or residual antimicrobial agent is deactivated and prevented from negatively effecting the environment and related decomposition pathways found therein. Representative means and methods for fabricating such filamentous materials with an aforementioned two-part system are provided herein.

[0002] Antimicrobial agent which is not consumed in the deactivation steps of viable organisms is free to interact with the environment.

[0003] Deleterious environment impact through disruption of such natural mechanisms as decomposition of wastes, nitrogen fixation, ground alkylation, and disease-bome organism competition provided through normal ground flora. Further induces reduced vitality of higher organism dependent upon presence in number of viable soil-based lower organisms and the resulting loss of beneficial contribution thereof.

[0004] Proliferation of antimicrobial agents for improved immediate wellbeing is evident in consumer products. Negatively impacts both environment health as well as potentially extending the life of disposed consumer articles in landfills; a product life which is already protracted due to use of slow to breakdown plastics.

23282200 (IRN: P0012175AU)

2019100907 15 Aug 2019 [0005] Present invention addresses unmet need of a means for obtaining short term antimicrobial performance while reducing long term negative side-effects of that antimicrobial performance.

SUMMARY OF THE INVENTION [0006] It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.

[0007] Accordingly, the invention provides a finite-lifespan antimicrobial filamentous material comprised of a two-part system wherein a first part is the presence of an agent or chemical functionality that imparts antimicrobial performance and a second part which is one or more agents or chemical functionalities that act upon the antimicrobial performance and render that performance ineffective or otherwise inactive. Having the first antimicrobial performance part and the second antimicrobial performance inactivating part in interactive proximity, at least some excess, unused or residual antimicrobial agent is deactivated and prevented from negatively effecting the environment.

[0008] Favorable antimicrobial performance includes the reduction of noisome odors, reduction in deleterious effects upon the skin from prolonged wetness exposure, antifungal performance in socks and shoe liners, reduction/inhibition of molds in housing construction materials.

[0009] Antimicrobial parts include agents with microbial-static (prevent organism proliferation) and/or microbial-cidal (induce organism cell death) such as: metal ion chemistries including microparticles and oxide forming additives, peroxides, iodophors, phenols, and active halide compounds.

[0010] Antimicrobial inactivator part includes agents with chemical intervention behaviors in presence of antimicrobial agents including sequestrants and disruptors. Sequestrants interact with antimicrobial agents and act to isolate the agent from interacting with the environment, such as by fixed phase, precipitation and flocculation. An example of sequestrants includes chelators such as EDTA, cage forming clathrates and chemical adsorbents such a clays and activated carbon. Disruptors act upon the antimicrobial agents to change the chemistry of the agents so that the agent is no longer functional for its original or intended antimicrobial purpose. The disruptor may induce chemical reactions upon the antimicrobial agent by mechanisms such as ethoxylation, hydrolysis,

23282200 (IRN: P0012175AU)

2019100907 15 Aug 2019 halide ion replacement, phosphorylation, adenylation, and acetylation, reduction (such as by ascorbic acid), enzymatic modification, cleavage, polar linking with detergents and/or catalysis.

[0011] Filamentous material may be a woven, nonwoven, film or other disposable polymer construct.

[0012] Polymers include thermoplastic, thermosets, topically treated natural fiber.

[0013] Formation of an antimicrobial “microzone”, a reactive area or volume (singular or plural) defined between the source of the antimicrobial agent and the location of antimicrobial agent inactivation. Preferential migration of the antimicrobial agent from the source or chemical reservoir to the antimicrobial agent inactivation location may create a focusing effect of the antimicrobial agent within the microzone thus enhancing the antimicrobial agent activity against microbial organisms located therein.

[0014] Microzone formed by a spatial dislocation or separation of the antimicrobial agent part and the antimicrobial agent inactivator part. Preferentially, the parts are in a final proximal orientation. Final refers to the mode or mechanism by which first and second part are incorporated into an enduse article at time of disposal, such as a soiled hygiene or medical products.

[0015] Intrastructure microzones may be created wherein a singular laminate or composite material is formed having a first outer antimicrobial agent layer and second and opposing outer antimicrobial inactivation layer, between the first and second outer layers there may be one or more spatial separating means. Spatial separating means include such materials as create a fluidic communication between the first and second outer layer, such as wovens, nonwovens, apertured or fibrillated films, cast structures, cellulosic materials, and the like. Fluid communication includes transfer of materials via contact with a liquid, such as by hydration from the environment or other effluent, liquid vapors and carrier gases.

[0016] Useful embodiments of products including intrastructure microzone construction include such things as: “SMS” or spunbond-meltblown-spunbond nonwoven fabrics wherein a first spunbond layer comprises an antimicrobial agent, a second spunbond layer comprises an antimicrobial inactivation agent, and a meltblown material creates a spatial separation between the first and second spunbond layers. Such an embodiment can include variations in the number,

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2019100907 15 Aug 2019 composition, construction and basis weight of layers of spunbond and/or meltblown as well as inclusion of one or more components comprising manmade or natural finite length fibers such as absorbents including cellulosics and superabsorbent beads, particles or fibers.

[0017] Interstructure microzones may be created with a first material comprising one or more antibicrobial agents is placed into fluidic communication with a second material comprising one or more antimicrobial agent inactivators. Interstructure microzones may be created through inherent separation of the two layers due to construct design of the end use article and/or through interceding a third layer which physically separates the antimicrobial agent layer and the antimicrobial agent inactivator layer.

[0018] Interstructure microzones may also be created by at least partially encapsulating or surrounding a composite or end-use article comprising an antimicrobial agent layer with a wrap, bag, package or envelop that comprises the antimicrobial inactivation agent layer.

[0019] Useful embodiments of products including interstructure microzone construction include such things as: feminine pads comprising one or more antimicrobial agents with antimicrobial inactivation disposable envelopes; antimicrobial component adult incontinence diapers with antimicrobial inactivation individual or bulk disposal bags; and, antimicrobial bandaging with antimicrobial inactivation wraps.

[0020] It is envisioned that useful embodiments of interstructure microzone construction can include such means as the antimicrobial agent layer and antimicrobial inactivation layer are physically separated by spacing in the same article. For example, a baby diaper may be comprised of a topsheet having an antimicrobial agent included therein and a backsheet having an antimicrobial inactivation agent included therein. Upon soiling of such a diaper construct, the diaper is inter-wrapped within itself such that soiled antimicrobial topsheet is then in fluidic communication with the antimicrobial inactivation backsheet. It is further envisioned that fluidic communication may be formed in situ within the diaper such as through degradation or liquid transfer across a diaper’s absorbent core material such that over time the antimicrobial agent and the antimicrobial inactivation agent are exposed to and allowed to react or interact with one another.

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2019100907 15 Aug 2019 [0021] It is envisioned that useful embodiments of interstructure microzone construction can include such means as the antimicrobial agent layer and antimicrobial inactivation layer are bundled into an initially non-interactive article. Upon use of a first product comprising the antimicrobial agent, a second product is then used to replace the used, soiled or depleted first product, the antimicrobial inactivation layer of the second article is then used to dispose of the first antimicrobial agent layer. Such embodiment can include for example a feminine hygiene pad comprising an antimicrobial agent packaged in an antimicrobial inactivation envelope, wherein the antimicrobial inactivation envelope does not prematurely act upon the antimicrobial agent. When a first hygiene pad becomes soiled, a second hygiene pad enclosed within an inverted envelope is used to replace the first hygiene pad, and the envelope reversed and used to dispose of the first hygiene pad.

[0022] Hybrid microzones can be created wherein a laminate or composite material is formed having a first outer antimicrobial part or layer and second and opposing outer antimicrobial inactivation part or layer, between the first and second outer layers there may be one or more barrier or separating means. Barrier or separating means include such materials that essentially block fluidic communication between the first and second outer layer, such as treated wovens, nonwovens, cast or blown films, molded structures, glass materials, and the like. Hybrid microzones become functional in the scope of the present invention when the described laminate is then used in such a way as one or more sheets of the opposing face laminate with barrier layers are placed in spatial approximation to one or more sheets of the same material such that an antimicrobial outer layer of a first sheet is opposed by an antimicrobial inactivation layer of a second sheet.

[0023] Materials comprising hybrid microzone functionality may further include a secondary spatial separating layer or structure affixed to the outer surface of the antimicrobial agent layer and/or antimicrobial inactivation layer so as to reliably create the microzone upon inversion, stacking or wrapping of said first sheet and second sheets. It is envisioned that a potential mechanism of creating a hybrid microzone is by wrapping a single sheet of material having a secondary spatial separating layer about itself such that an antimicrobial outer layer of a first wrap is opposed by an antimicrobial inactivation layer of a second wrap.

[0024] A further element of the invention includes the use of soluble or disruptable compositions in the spatial separating layers and/or barrier layer(s). The soluble or disruptable composition is

23282200 (IRN: P0012175AU)

2019100907 15 Aug 2019 chosen to be of suitable chemistry such that upon shifts in environmental conditions found in a landfill, is sea water or other disposal mechanism, that the spatial separating and/or barrier layer(s) is rendered ineffective. By rendering the spatial separating and/or barrier layer(s) ineffective, the antimicrobial agent layer and the antimicrobial inactivation layer may then come into closer spatial approximation with a corresponding increase in inactivation performance.

[0025] It is also envisioned that the antimicrobial inactivation agent is the migratory species and the antimicrobial agent is stationary. Once the antimicrobial inactivation agent is exposed to suitable disposal environmental conditions, the inactivation agent may then be released to interact with one or more proximal antimicrobial agents thereby.

[0026] It is also envisioned that the spatial layer may be comprised of materials that impart a high degree of bulk or thickness with relative low density. Nonwoven fabrics having unbonded regions can be particularly useful as such a component.

[0027] Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS [0028] The invention will be more easily understood by a detailed explanation of the invention including drawings. Accordingly, drawings, which are particularly suited for explaining the inventions, are attached herewith; however, it should be understood that such drawings are for descriptive purposes only and as thus are not necessarily to scale beyond the measurements provided. The drawings are briefly described as follows:

[0029] FIGURE 1 is a representative method of producing filamentous material in accordance with the present invention.

[0030] FIGURE 2 is a representative filamentous material in accordance with the present invention utilizing a contiguous thermal bond pattern comprising thermal point bonds induced by a plurality of individual contact elements on a contact surface whereby the distance between any two individual contact elements is less than 0.5mm.

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2019100907 15 Aug 2019 [0031] FIGURE 3 is a representative filamentous material in accordance with the present invention depicting more closely repeating surface areas having reduced bonding therein.

[0032] FIGURE 4 is a representative filamentous material in accordance with the present invention depicting a contiguous bonding pattern is defined as a pattern of thermal bonds wherein the pattern is comprised of a first and a second repeating unit surface area.

[0033] FIGURE 5 is an enlarged portion of the filamentous material illustrated in FIGURE 4.

[0034] FIGURE 6 is another enlarged portion of the filamentous material illustrated in FIGURE 4.

[0035] FIGURE 7 is a representative intrastructure microzonefilamentous material in accordance with the present invention depicting a first antimicrobial layer, a spatial layer, and an antimicrobial inactivity component layer.

[0036] FIGURE 8 is a representative intrastructure microzone filamentous material in accordance with the present invention depicting a first antimicrobial layer, a spatial layer, and an antimicrobial inactivity component layer, wherein optional secondary spatial layers are depicted.

[0037] FIGURE 9 is a representative hybrid microzone further including a fluidic communication barrier layer.

[0038] FIGURE 10 is a representative hybrid microzone further including a fluidic communication barrier layer depicting partial and complete solubilization/dissolution mechanisms for infrastructure microzone creation.

[0039] FIGURE 11 is a representative interstructure microzone construct.

[0040] FIGURE 12 is a representative interstructure microzone construct with optional secondary spatial layers depicted.

[0041] FIGURE 13 is a representative interstructure microzone embodiment comprising separate antimicrobial functional article subsequently inserted into an antimicrobial inactivating envelope for disposal in accordance with the present invention.

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2019100907 15 Aug 2019

LIST OF REFERENCE NUMERALS

Antimicrobial component layer 10, spatial layer 20, antimicrobial inactivating component layer 30, Unbonded region 50, bonding region 60, low bond surface area 70, high bond surface area 80.

DETAILED DESCRIPTION OF THE INVENTION [0042] While the present invention is susceptible of embodiment in various forms, there is shown in the drawings and will hereinafter be described a presently preferred embodiment of the invention, with the understanding that the present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated.

[0043] Relevant Background Art for Antimicrobial agents and impact on environment [0044] Prior art references incorporated by reference in their respective entireties:

[0045] “Role of Copper Oxides in Contact Killing of Bacteria”, Hans et al, Langmuir, 2013,29 (52), pp 16160-16166.

[0046] “Copper oxide impregnated wound dressing: biocidal and safety studies”, Borkow et al, Wounds. 2010 Dec;22(12):301-10.

[0047] “The Impact of anti-odor clothing on the environment”, ACS News Service Weekly PressPac: March 30, 2016.

[0048] “Potential Environmental Impacts and Antimicrobial Efficacy of Silver- and NanosilverContaining Textiles”, Reed, et al., Environ. Sci Technol., 2016, 50(7), pp 4018-4026.

[0049] “Microbial Degradation of Plastic Waste: A Review”, Raziyafathamia, et al., Journal of Pharmaceutical, Chemical and Biological Sciences, 2016, 4(2), pp 231-242.

[0050] “Chelating Agents of a New Generation as an Alternative to Conventional Chelators for Heavy Metal Ions Removal from Different Waste Streams”, Kolodynska, 2011, Expanding Issues in Desalination, Prof. Robert Y. Ning (Ed.), ISBN: 978-953-307-624-9, InTech.

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2019100907 15 Aug 2019 [0051] “Moisture Control Guidance for Building Design, Construction, and Maintenance”, EP A 402-F-13053, December 2013.

[0052] “Chemistry and Problems of Industrial Water, Sanitation: Cleaning and Disinfection in the Food Industry”, Stanga, 2010, Wiley VCH, ISBN 978-3-527-32685-3; pp 1-76.

[0053] “Biodegradation of polyethylene and polypropylene”, Arutchelvi et al., Indian Journal of Biotechnology, Vol 7., January 2008, pp 9-22.

[0054] “The Fate and Removal of Triclosan during Wastewater Treatment”, Thompson et al., Water Environ. Res., Vol 77, 63 2005, pp 63-67.

[0055] Presentation: “Scientific and Regulatory Excellence” Antimicrobial Material Preservatives & Sustainability Considerations Erin Tesch Technology Sciences Group Inc. (TSG) 115018th Street, NW Suite 1000 Washington, DC 20037 etesch@tsgusa.com 9/8/2016.

[0056] Background Art for Production of Materials [0057] Early prior art first address the means and methods of forming a basic spunmelt (as exemplified by spunbond and meltblown nonwoven technologies), such as provided in U.S. Patent No.’s , 3,849,241 to Butin, et al., 3,855,046 to Hansen, 4,041,203 to Brock, et al. and 7,611,594 to Sommer et al. Various methods of fabricating laminate materials into nonwoven fabrics include disclosure in the prior art of layered meltspun components mechanically engaged by application of hydraulic energy to influence filament displacement beginning with U.S. Patent No. 3,485,706 to Evans. U.S. Patent No’s 4,879170, 4,931,355, 4,950,531 and 4,939,016 to Radwanski, et al., disclose lay-down of multiple meltspun nonwoven fabrics materials or coforms with hydraulic energy used as a means of durably engaging said meltspun layers. U.S. Patent No. 5,023,130 to Simpson, et al. presents a high pressure means to attain total impact energies of 0.7MJ-N/Kg to form an integrated web. Similarly, Japanese Patent Application offer a means of fracturing filaments at self-fused zones wherein total impact energies of 1.4MJ-N/Kg or greater are used. An alternate means of filament control is disclosed in U.S. Patent No. 6,321,425 to Putnam, et al. wherein foraminous surfaces are used to support and direct filament movement under the influence of hydraulic energy. U.S. Patent No. 4,329,763 to Alexander et al., is directed to a softening process for thermal point bonded fabrics wherein a 25% reduction in bending modulus

23282200 (IRN: P0012175AU) ίο

2019100907 15 Aug 2019 occurs. U.S. Patent No. 5,023,130 to Simpson et al., teaches a method by which unbonded continuous filaments are hydroentangled through application of high energy water jets. U.S. Patent No.’s 7,858,544 and 8,093,163 to Turi, et al. offer an approach wherein to attain suitable filament movement and integration it is necessary to have either a low thermal point bond of less than 10% of the material surface area or an anisoptropic bond pattern allowing for sufficient free filament length and engagement thereof. Each of the aforementioned prior art patents are incorporated by reference in their respective entireties.

[0058] Any component layer may be comprised of such fibrous materials as are suitable for the fabrication of nonwoven fabrics, including finite length fibers, continuous filaments, fibrillated films and the combinations thereof. The fibrous materials may include polymeric materials, natural fibers and the combination thereof. Suitable polymeric materials include thermal melt and thermoset polymers, with thermal melt plastics being particularly preferred. Thermal melt plastics include polyolefins, and more preferably polypropylene or polyethylene. Other polymers suitable for use include polyesters, such as polyethylene terephthalate; polyamides; polyacrylates; polystyrenes; thermoplastic elastomers, block polymers, polymer alloys; and blends of these and other known fiber forming thermoplastic materials.

[0059] Representative methods of producing a filamentous material in accordance with present invention are depicted in FIGURES 1 through 13. It should be noted that consolidation, pretreatment by chemical or mechanical modification, and application of hydraulic energy may be affected at various stages of lay-down of a component layer and optionally one or more spatial filamentous components.

[0060] A representative means for production of a component surface layer of continuous filaments includes those produced by spunbond nonwoven technology, though other woven, knitted or continuous spinning technologies are equally suitable as exemplified by exemplified in U.S. Patent No.’s , 3,849,241 to Butin, et al., 3,855,046 to Hansen, 4,041,203 to Brock, et al. and 7,611,594 to Sommer et al., incorporated in their respective entireties. The spunbond continuous filaments used in the present invention have a basis weight of preferably at least about 1 gsm. One or more component layers in a multiple layer spunbond may include antimicrobial agents, and when in the form of either an intrastructure microzone or hybrid microzone construct, including an intermediate spatial layer and at least one component layer comprising an antimicrobial inactivating agent.

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2019100907 15 Aug 2019 [0061] A representative process for the formation of spunbond involves supplying a molten thermal melt polymer, with or without active agents, which is then extruded under pressure through a plate known as a spinneret or die head. The die head includes a spaced array of die orifices having diameters of generally about 0.1 to about 1.0 millimeters (mm). The resulting continuous filaments are quenched and drawn by any of a number of methods, such as slot draw systems, attenuator guns, or Godet rolls. The continuous filaments are collected as a loose web upon a moving collection surface, such as a wire mesh conveyor belt. When more than one spinneret is used in line for the purpose of forming a multi-layered fabric, the subsequent webs of filaments are collected upon the uppermost surface of the previously formed layer or web either continuously or in separately initiated batch processes.

[0062] The individual or combined layers or webs may be optionally consolidated at any step in the overall process, whether in an intermediate form or in a final, pre-conversion roll for, such as by means involving; 1.) heat and pressure, such as by thermal point bonding, 2.) application of hydraulic energy, such as by direct pressurized streams or sprays of water, 3.) chemical bonding, such as by glues or adhesives, 4) through air bonding, such as passage of elevated of elevated temperature air through the material, and 5.) combinations thereof. When a thermal point bond consolidation method is used, the web or layers of webs come into contact with a thermally conductive rolls, which may be either smooth or with an embossed pattern of individual contact elements to impart and achieve the desired degree of bonding, usually on the order of 1 to 40 percent of the overall surface area being so bonded. These thermal point bonds may remain present in the final material, partially removed due to the optional application of a first degree of applied hydraulic energy, or essentially removed due to the application of a second degree of applied hydraulic energy. Further, the pattern or profile of the embossed roll may include a cross directional bias to the elements which impart the partial or complete consolidation of the fibrous components.

[0063] The formation of thermal point bonds by application of pressure and/or heat through direct contact of the outer or surface component layer of continuous filaments, the intermediate filamentous component, or combinations thereof with one or more patterned rolls or rollers can exhibit particularly useful attributes in terms of both mode of integration and material formation, as well as resulting performance attributes, such as tactile and ductile softness, in the finished article. U.S. Patent numbers 6,537,644 and 6,610,390 to Kauschke, et al., hereby incorporated by reference in their respective entireties, in conjunction with the previously referenced U.S.

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2019100907 15 Aug 2019

Patent No.’s 7,858,544 and 8,093,163 to Turi, et al., direct their focus to fibrous materials exhibiting a defined nature of a bonding pattern to achieve a desired result (reference Figures 4, 5 and 6). Specifically, the referenced patents disclose nonwovens having a non-symmetrical pattern of fusion bonds (that is, an anisotropic or asymmetrical pattern). As disclosed in these documents, bonds in an asymmetrical pattern may have a common orientation and common dimensions, yet define a total bond area along one direction (e.g., the “machine direction” or MD) greater than along another direction (e.g., the “cross direction” or CD) which is oriented orthogonally to the first direction, such that the points form a uniform pattern of bond density in one direction different from the uniform pattern of bond density in the other direction. Alternatively, as also disclosed in these documents, the bonds themselves may have varying orientations or varying dimensions, thereby to form a pattern of bond density which differs along the MD and CD directions. The bonds may be simple fusion bonds or closed figures elongated in one direction. The bonds may be closed figures elongated in one direction and selected from the group consisting of closed figures (a) oriented in parallel along the one direction axis, (b) oriented transverse to adjacent closed figures along the one direction axis, and (c) oriented sets with proximate closed figures so as to form therebetween a closed configuration elongated along the one direction axis.

[0064] While practice of an asymmetrical bonding pattern can be used to beneficially impact the production and performance of spunmelt nonwoven fabric, the inventors have found that similar or enhanced properties can be also obtained through a contiguous bonding pattern methodology. A contiguous bonding pattern is defined as a pattern of thermal bonds wherein the pattern is comprised of a first and a second repeating unit surface area. The first and second repeating surface areas are proximal to one another such that pattern of repeating surface areas extending in both the machine direction of production (length) and the cross direction of production (width). The first repeating unit surface area includes a thermal bond area of 1.) of at least 30% of the total area making up the first repeating unit surface area or 2.) a single bonding area or region extending completely though the machine direction, cross direction or combined machine and cross direction of the first repeating unit surface area. The second repeating unit surface area comprises a thermal bond area of less than 10% of the total area making up the second repeating unit surface area.

[0065] In the instance whereby the first repeating unit surface area is comprised of a thermal bond area of at least 30% of the total surface area of the first repeating unit surface area, the thermal

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2019100907 15 Aug 2019 point bond may be induced by a plurality of individual contact elements on a contact surface whereby the distance between any two individual contact elements is less than 0.5mm, as represented by Figures 4 through 6. As exemplified in Figure 4, multiple thermal point bonds are induced in a first repeating unit high bond surface area 80 to create a higher degree of bonding than are created in the adjacent second repeating unit low bond surface area 70. It should be noted that the repeating unit surface area for 70 and 80 are defined as being rectilinear boundaries having the same total area as shown in detail in Figures 5 and 6. Further, it should be noted that a given low bond surface area 70 will be circumscribed by a total of four (4) identical low bond surface areas 70 , wherein each low bond surface area 70 comes into proximity with the vertex of an high bond surface area 80, (Figures 5 and 6) and four (4) identical high bond surface area 80 units, wherein each high bond surface area 80 unit comes into contact with the side of an low bond surface area 70 unit. Conversely, it should be noted that a given high bond surface area 80 will be circumscribed by a total of four (4) identical high bond surface area 80 units, wherein each high bond surface area 80 comes into contact with the adjacent vertex of a high bond surface areas 80, and four (4) identical low bond surface areas 70, wherein each low bond surface area 70 comes into contact with the side of an high bond surface area 80 unit.

[0066] To further form the filamentous material of the present invention, the aforementioned outer or surface component layers of continuous filaments receives at least one intermediate filamentous component, wherein the addition and integration of the intermediate filamentous component results in a composite material exhibiting a useful function of tactile and ductile softness while retaining finite control of fluids. Such finite fluid control includes management of both liquids and gases in the same composite while providing favorable consumer perceived “fabric” or “flannel” like characteristics as well as retaining attributes such as strength and elongation to allow for subsequent converting processes. A particularly preferred mode of attaining a filamentous material having fabric or flannel like characteristics is whereby production includes an initial application of thermal bonding step through use of a symmetric or asymmetric pattern of point bonds, followed by application of hydraulic energy and then by application of thermal bonding step though use of point bonds. Optionally, the secondary application of a thermal point bonding step uses a contiguous pattern.

[0067] Representative means and methods for fabricating such intermediate filamentous components includes those produced by the meltblown nonwoven technology, though other technologies which produce fibrous elements of less than 10 micrometers in diameter are

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2019100907 15 Aug 2019 technologies referred to as flash-spinning and nano fiber, as well as, the aforementioned spunbond technology with fibrous elements are greater than 10 micrometers.

[0068] A representative meltblown process is similar in nature to the aforementioned spunbond process, which in place of essentially continuous filaments, this process involves the formation of discontinuous filamentary material. Again, a molten thermal melt polymer is extruded under pressure through orifices in a spinneret or die. High velocity air impinges upon and entrains the filaments as they exit the die. The energy of this step is such that the formed filaments are greatly reduced in diameter and are fractured so that micro fibers of finite length are produced. This differs from the spunbond process whereby the continuity of the filaments is preserved. The process to form either a single layer or a multiple-layer fabric is continuous, that is, the process steps are uninterrupted from extrusion of the filaments to form the first layer until the bonded web is wound into a roll. Methods for producing these types of fabrics are described in U.S. Pat. No. 4,041,203. The cross-sectional profile of individual elements within the exterior surface layer or the intermediate filamentous components is not a critical limitation to the practice of the present invention.

[0069] The individual elements within the exterior or outer surface component layers or the intermediate filamentous components may further be of homogenous or heterogeneous composition, include performance or aesthetic modifying melt additives, and be comprised of monocomponent, bicomponent, and/or multicomponent filament or fiber construction of any suitable cross-sectional profile. Further, it is anticipated and within the purview of the present invention that one or more continuous filament exterior or outer surface component layers may be layered with one or more intermediate filamentous components such that in the manufacturing or lay-down process: 1.) the components of each type alternate in order of lay-down; 2.) two or more layers of a component type are sequentially ordered for lay-down; 3.) an equal number of component type are used; 4.) and odd number of component types are used; 5.) the amount of component types are introduced in equal mass, composition or diameter; 6.) the amount of component types are introduced in different, varying, or incremental adjustment of introduced mass, composition, or diameter; and, 7.) combinations thereof. As mentioned previously, one or more consolidation step may be used between one or more lay-down steps in the manufacturing process. Chemical based performance and/or aesthetic modifying melt additives includes those chemistries which result in modified properties of the filaments or fibers, such as to render the fibrous element

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2019100907 15 Aug 2019 hydrophobic, hydrophilic, enhance absorbency, render anti-static or flame retardant, modify crystallinity or strength, alter melt-flow rheology, and the like.

[0070] The filamentous material in accordance with the present invention, including selective application to continuous filament exterior surface layer elements, to intermediate filamentous components, or precursor combinations thereof, are subjected to waterjet treatment. The waterjet treatment allows for hydraulic energy to be imparted as a force on the elements in the filamentous material being produced. This hydraulic energy acts to displace or motivate elements within the filamentous material to inter-engage and form a composite performance, with such processes being known in the art as being “hydroentangled” or “hydroengorged”. Application of hydraulic energy may occur upon either expansive plane or surface of the filamentous material being produced and may occur in one or more sequential or alternating steps. The waterjets are preferably present in an amount of 1-10 heads or manifolds per fabric side and the water is provided at a pressure predetermined by the quality of the resultant fabric desired. Preferably the pressure of the water in the jets is in a range of about 50-about 400 bar per head, with the range of 100 to 300 bar being preferred. Unique to the produced filamentous material of the present invention, a high degree of integration is obtained wherein the fiber volume, as defined by the basis weight divided by bulk, in the range of 0.05 milligrams/cubic centimeter to 0.40 milligrams/cubic centimeter and exhibits an air permeability of 250 1/sqm/sec or greater per gram/square meter material construct total or final weight. Through a combination of manufacturing controls and specific management of the filamentary and fibrous composition, production and lay-down, we have identified means by which to allow effective application of hydraulic energy to filamentous material having a low volume of filamentary and fibrous targets by which to impinge said hydraulic energy and induce movement by relative force vectors imparted thereby.

[0071] Following waterjet treatment, and preferably before drying of the resultant filamentous material, the filamentous material can be treated with one or more chemical agents to further affect, e.g., enhance or modify, web secondary properties such as flame retardancy, anti-static nature, and the like. The chemical agents may be topically applied over the entire surface of the filamentous material or within preselected zones. These zones may be provided with the same surfactant or additive or a different surfactant or additive in order to provide zones with different or the same properties. An example of topical treatment suitable for use is described in U.S. Pat. Nos. 5,709,747 and 5,885,656, incorporated herein by reference in their respective entireties.

23282200 (IRN: P0012175AU)

2019100907 15 Aug 2019 [0072] A variation upon the topical treatment of the filamentous material is that performance modifying chemistries, including antimicrobial agents/antimicrobial inactivating agents, can be applied as an array or in discrete strips across the width of the filamentous material in order to create zoned treatments to which different performance, functional and/or aesthetic properties can be provided.

[0073] The invention allows for the production of a filamentous material in one continuous process including various features to provide new or enhanced properties within the filamentous material, in particular with respect to absorbency and softness. However, the invention also allows for the production of the nonwoven filamentous material in different individual process stages, e.g., as a two or more step process wherein one is the manufacture of the exterior surface layer of continuous filaments, one is the application or manufacture of intermediate filamentous components and one involving hydraulic processing of the composite. This versatility allows for cost savings since a continuous line does not have to be provided in one place or utilized at one continuous time. For example, a composite including an exterior surface layer and an intermediate filamentous component can be produced and then wound for temporary storage before being subjected to water jet treatment. Further, the layers may be subjected to waterjet treatment to provide for a filamentous material of the invention which is usable as such or may be placed in storage and subsequently treated based upon a desired end use for the filamentous material. This versatility provides for cost efficiency in terms of plant space required for the provision of equipment, versatility in the use of different equipment with respect to timing and products and the ability to provide filamentous material with varying properties based on the application to which the material will be put.

[0074] The filamentous material of the present invention exhibits retention of form and function when subjected to external forces, such as those imparted by stretching, loading, straining, wetting, or abrasion, whether such forces are of a singular, periodic, cyclical, or variable nature. This durability aspect of the filamentous material is useful in the making of numerous end-use consumer products, including but not limited to hygiene products, personal and surface wipes as well as medical products. Of particular importance, the durable aesthetic and physical performance relative to basis weight embodied by the inventive filamentous material offers desirable integration as one or more components of a diaper wherein use in affixation of the diaper to the wearer and/or skin contact and skin health properties when subjected to liquid insult suggestive of use in diaper constructs, are beneficial in view of the simultaneous presence of strength, elongation and low23282200 (IRN: P0012175AU)

2019100907 15 Aug 2019 linting performance that influence the materials convertibility by high-speed automated platforms and end use application.

[0075] Apparatus useful in preparing the filamentous material of the invention is conventional in nature and known to one skilled in the art. Such apparatus includes extruders, conveyor lines, water jets, rewinders or unwinders, topical applicators, calenders or compactors, and the like.

[0076] Barrier layers may include cast or blown films laminated into the structures. The film may be composed of materials inert to the antimicrobial or antimicrobial inactivating agent, but upon exposure to conditions found in landfills, disposal sites, and sea disposal, are induced to become porous or are otherwise removed from separating the two active layers and thus allowing the antibacterial inactivating layer to interact with the antibacterial agent(s) present.

[0077] Antibacterial agents of particular interest to segregate or disrupt include: oxides of transition metals such as titanium, iron, copper, zinc and silver, derivatives of diatomic nonmetals such as modified phenols. Specific agents include those chemistries and their derivatives known or suspected to have a deleterious effect on the environment or are otherwise harmful to normal flora and fauna, including humans: cloflucarban, fluorosalan, hexachlorophene, hexylresorcinol, Iodophors, methylbenzethonium chloride, phenols, secondary amyltricresols, sodium oxychlorosene, tribromsalan, triclocarban, triclosan, triple dye, bezalkonium cetyl phosphate, cetylpridinium chloride, chlorhexidine gluconate, polyhexamethylenebiguanide, salicylic acid, derivatized tree oils.

23282200 (IRN: P0012175AU)

2019100907 15 Aug 2019

EXAMPLE 1Materials were formed in accordance with the present invention and tested per the following protocols or standards:

Test	Test method
Basis weight [gsm|	Avgol
MD tensile [N/5 cm]	WSP 110.4(05) B
CD tensile [N/5 cm]	WSP 110.4(05) B
MD Elongation [%|	WSP 110.4(05) B
CD Elongation [%|	WSP 110.4(05) B
MD HOM [gf|	WSP 90.3(05)
CD HOM [gf|	WSP 90.3(05)
Strike through [sec]	WSP 70.3(05
Rewet [gr|	WSP 80.10(05)
Run-off [%]	WSP 80.9
Air permeability [1/sqm/sec]	WSP 70.1 (05)
Fabric thickness [mm|	ASTM D645
MD linting E-side [gr|	WSP 400.0
MD linting S-side [gr|	WSP 400.0

[0078] From the foregoing, it will be observed that numerous modifications and variations can be affected without departing from the true spirit and scope of the novel concept of the present invention. It is to be understood that no limitation with respect to the specific embodiments illustrated herein is intended or should be inferred. The disclosure is intended to cover, by the appended claims, all such modifications as fall within the scope of the claims.

Claims (2)

1. A finite-lifespan antimicrobial filamentous material comprised of a two-part system wherein a first part is comprised of one or more agent or chemical functionalities that impart antimicrobial performance and a second part which is comprised of one or more agents or chemical functionalities that act upon the antimicrobial performance and render that performance ineffective or otherwise inactive, wherein the first antimicrobial performance part and the second antimicrobial performance inactivating part are placed into interactive proximity, at least some excess, unused or residual antimicrobial agent is deactivated and prevented from interacting with the environment.

Avgol Ltd.

Patent Attorneys for the Applicant/Nominated Person

SPRUSON & FERGUSON

23282200 (IRN: P0012175AU)

2019100907 15 Aug 2019

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FIG. 1

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FIG. 2

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2019100907 15 Aug 2019

FIG. 4

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2019100907 15 Aug 2019

FIG. 5

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FIG. 6

2019100907 15 Aug 2019

7/13

FIG. 7

Spatial Layer

Antimicrobial

Layer

Antimicrobial

Inactivation

Layer

8/13

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FIG. 8

Spatial Layer

Antimicrobial

Layer

Antimicrobial

Inactivation

Layer

Optional Secondary

Spatial Layer

9/13

FIG. 9

2019100907 15 Aug 2019

Barrier Layer

Antimicrobial

Layer

Antimicrobial

Inactivation

Layer

Optional Secondary

Spatial Layer

10/13

2019100907 15 Aug 2019

FIG. 10

Antimicrobial

Layer Disruption of barrier:

Fluidic communication through formed pores

Unilateral or bilateral fluidic communication through an intermediate such a cellulosics or superabsorbents

Dissolution or disruption resulting in direct point of contact between layers

Dissolution or disruption resulting in direct face to face contact between layers

Barrier Layer

Antimicrobial

Inactivation

Layer

Optional Secondary

Spatial Layer

11/13

FIG. 11

2019100907 15 Aug 2019

Soiled

Antimicrobial

Layers

Wrap 2

Barrier Layer

Antimicrobial

Inactivation

Layer

12/13

2019100907 15 Aug 2019

FIG. 12

Soiled

Antimicrobial

Layers

Optional Secondary

Separation

Barrier Layer

Antimicrobial

Inactivation

Layer

13/13

FIG. 13

2019100907 15 Aug 2019

Soiled

Antimicrobial

Inactivation

Layer