US20210145097A1

US20210145097A1 - Antimicrobial silver fiber products and methods of manufacturing the same

Info

Publication number: US20210145097A1
Application number: US17/047,644
Authority: US
Inventors: Megan Rita Eddings
Original assignee: Accel Lifestyle LLC
Current assignee: Accel Lifestyle LLC
Priority date: 2018-04-20
Filing date: 2018-04-20
Publication date: 2021-05-20
Also published as: WO2019203854A1

Abstract

The present disclosure relates to antimicrobial garments and antimicrobial fabric products that include an antimicrobial fabric, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, and methods of manufacturing the same. One benefit of the antimicrobial garments and antimicrobial fabric products disclosed herein can be the reduction or elimination of odor or infection causing microbes, including a bacteria, a fungi, and a virus, even after multiple washes.

Description

TECHNICAL FIELD

The present disclosure relates to antimicrobial garments and antimicrobial fabric products that include an antimicrobial fabric, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, and methods of manufacturing the same.

BACKGROUND

Almost everyone who wears clothes and sweats has noticed that over time those clothes start to smell bad. Worse, washing the smelly clothes with perfumes and fragrances only masks these pungent odors for a short time. What many consumers do not realize is that these offensive odors are due to the growth of bacteria, yeasts, fungi and other microbes in the fabric of the clothing itself. The conventional washing of a garment, such as a workout shirt, is usually ineffective in killing off or impeding the growth of such odor causing microbes. Over time, people notice that their favorite workout clothes smell worse and worse. To combat this embarrassing trend, many people wash their smelly clothes more often, which results in the clothing deteriorating faster due to the increased exposure of the clothing to chemicals and abrasion during the washing process. The result is that many consumers get caught in a frustrating, costly, and embarrassing loop of buying clothing, noticing that the clothing starts to smell bad, ineffectively washing their clothing to death, and then buying more clothing. There is a need to break this cycle.
There remains a need for garments and cloth products that kill and/or limit the growth of microbes, including bacteria, over long periods of time and after many cycles of wash and wear. There remains a need for garments and fabric products that prevent, eliminate, or reduce bad odors even after many cycles of wash and wear. There remains a need for garments and fabric products that incorporate silver metal in a form that retains its antimicrobial properties even after many cycles of wash and wear.

SUMMARY

The present disclosure relates to an antimicrobial garment including an antimicrobial fabric, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber. In an embodiment of the antimicrobial garment, from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 30 micrometers. In an embodiment of the antimicrobial garment, the synthetic silver fiber includes from about 0.01 to about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber. In an embodiment of the antimicrobial garment, the antimicrobial fabric has from about 10 mg/kg to about 100 mg/kg of the elemental silver particles per the antimicrobial fabric. In an embodiment of the antimicrobial garment, the synthetic silver fiber has a thickness characterized by from about 30 g per 9000 meters of fiber to about 900 g per 9000 meters of fiber. In an embodiment of the antimicrobial garment, the synthetic silver fiber has a thickness characterized by from about 10 km/kg to about 60 km/kg. In an embodiment of the antimicrobial garment, the antimicrobial garment contains from about 10% to 100% weight of the antimicrobial fabric based on a total weight of the antimicrobial garment. In an embodiment of the antimicrobial garment, the antimicrobial garment has a fabric weight of from about 50 g/m²to about 350 g/m². In an embodiment of the antimicrobial garment, the antimicrobial garment contains from about 10 to about 20 weight percent of the antimicrobial fiber based on a total weight of the antimicrobial garment. In an embodiment of the antimicrobial garment, the synthetic fiber includes at least one of a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer, an acrylic polymer, or a combination, co-polymer, or blend thereof. In an embodiment of the antimicrobial garment, the at least one basic fiber includes a natural fiber, wherein the natural fiber includes a cotton, a wool, a silk, a hemp, a rayon, a bamboo, a banana, a modal, a lyocell, or combination, a blend or weave thereof. In an embodiment of the antimicrobial garment, the at least one basic fiber includes an unnatural fiber, wherein the unnatural fiber includes a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer, an acrylic polymer, or a combination, co-polymer, or blend thereof. In an embodiment, the antimicrobial garment is selected from the group consisting of a shirt, a yoga pant, a tight, a legging, a short, an arm warmer, an ankle brace, a hat, a gi, a leg warmer, a hosiery, a leotard, a unitard, a tutu, a jersey, a sock, a fatigue, a uniform, a costume, a jockstrap, a sweat pant, a sweat shirt, a bra, a swimsuit, a belt, a coat, a headband, a dress, a skirt, a short, an undergarment, a jacket, a trouser, a suit, a robe, a saris, a scrub, a neckwear, and a top. In an embodiment of the antimicrobial garment, the antimicrobial garment further includes an optical brightener and at least one of a dye or a pigment. In an embodiment of the antimicrobial garment, the antimicrobial garment reduces growth of gram positive bacteria by from about 95% to 100% relative to a garment without the antimicrobial fabric.
A method of manufacturing an antimicrobial garment is disclosed herein. In an embodiment, the method includes weaving or knitting or providing the at least one synthetic silver fiber and at least one silver-free fiber together to form an antimicrobial fabric, and cutting or sewing the antimicrobial fabric to form the antimicrobial garment, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1% weight of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.
An antimicrobial fabric product is disclosed herein. In an embodiment, antimicrobial fabric product includes an antimicrobial fabric, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1% weight of silver particles bound to the basic fiber based on a total weight of the silver-free fiber. In an antimicrobial fabric product, from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 30 micrometers. In embodiment of the antimicrobial fabric product, the synthetic silver fiber includes from about 0.01 to about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber. In embodiment of the antimicrobial fabric product, a fabric in the antimicrobial fabric product has from about 10 mg/kg to about 100 mg/kg of elemental silver particles per a total weight of the fabric in the antimicrobial fabric product. In embodiment of the antimicrobial fabric product, the synthetic silver fiber has a thickness characterized by from about 30 g per 9000 meters of fiber to about 900 g per 9000 meters of fiber. In embodiment of the antimicrobial fabric product, the synthetic silver fiber has a thickness characterized by from about 10 km/kg to about 60 km/kg. In embodiment of the antimicrobial fabric product, a fabric in the antimicrobial fabric product contains from about 90% to 100% weight of the antimicrobial fabric based on a total weight of the fabric in the antimicrobial fabric product. In embodiment of the antimicrobial fabric product, the fabric in the antimicrobial fabric product has a fabric weight of from about 50 g/m²to about 350 g/m². In embodiment of the antimicrobial fabric product, the fabric in the antimicrobial fabric product further comprises an optical brightener and at least one of a dye or a pigment. In embodiment, the antimicrobial fabric product is a garment, a diaper, a piece of cloth furniture, a bag, a bed lining, a towel, a pillow case, a bandage, an article of feminine hygiene, a cleaning cloth, a foot wear, an insole, or an accessory.
A method of manufacturing an antimicrobial fabric product is disclosed. In an embodiment, the method includes weaving or knitting the at least one synthetic silver fiber and at least one silver-free fiber together to form an antimicrobial fabric, and cutting or sewing the antimicrobial fabric to form the antimicrobial fabric, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1% weight of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of the embodiments, will be better understood when read in conjunction with the attached drawings. For the purpose of illustration and evidence, there are shown in the drawings some embodiments, which may be preferable. It should be understood that the embodiments depicted are not limited to the precise details shown.

FIG. 1 is a picture of a swatch of an embodiment of an antimicrobial fabric.

FIG. 2 is a picture of three bolts of embodiments of an antimicrobial fabric dyed, from top to bottom, white, gray, and black, respectively.

FIG. 3 is a picture of an embodiment of an antimicrobial garment containing an antimicrobial fabric. The fabric has been dyed black, and cut and sewn to form a top.

FIG. 4 is a picture of an embodiment of an antimicrobial garment containing an antimicrobial fabric. The fabric has been dyed white, and cut and sewn to form a shirt.

DETAILED DESCRIPTION

The present disclosure relates to antimicrobial garments and antimicrobial fabric products containing an antimicrobial fabric. The antimicrobial properties of the antimicrobial fabric are based on the presence of elemental silver particles bound to a synthetic fiber. Some manufacturers have tried to incorporate antibacterial or antimicrobial chemicals, such as small organic molecules, into clothes. However, many such antimicrobial organic molecules are only useful during shipping, storage, and a few wear cycles because the chemicals quickly wash out. Other manufacturers have tried to incorporate antimicrobial metals, such as silver, copper, or zinc into clothes. For example, some manufacturing methods deposit silver particles onto the already woven cloth of a garment to imbue the garment with antimicrobial properties. However, the benefits of these garments have typically been short lived due to the silver metal flaking off, easily washing out, or the silver metal being too quickly depleted.
In an embodiment, it has been discovered that the antimicrobial properties of silver particles can be made to last longer, through multiple wash and wear cycles, by controlling the composition, concentration, and/or particle size distribution of the silver particles by binding or attaching the silver metal particles to a synthetic fiber to form a synthetic silver fiber. In an embodiment, conventional fabric sewing techniques can weave or combine synthetic silver fibers and silver-free fibers to further control the concentration and effectiveness of the elemental silver particles in the antimicrobial fabric, antimicrobial garment, and/or antimicrobial fabric product. It has been surprisingly discovered that less than 20% by weight of the synthetic silver fiber in an antimicrobial fabric can kill or reduce the growth of gram positive bacteria by over 98%, even after two washings. It has been surprisingly discovered that antimicrobial garments containing the antimicrobial fabric can remain free of offensive odors even after 50 workouts and wash cycles using a conventional washing machine and detergents.
Unless otherwise noted, all measurements are in standard metric units.
Unless otherwise noted, all instances of the words “a,” “an,” or “the” can refer to one or more than one of the word that they modify.
Unless otherwise noted, the term “fiber” refers to a type of fiber rather than a single strand of fiber. For example, the phrase “one natural fiber” would be understood to mean one type of natural fiber, such as cotton or wool. Similarly, a phrase such as “at least one synthetic silver fiber” would be understood to mean one or more than one types of synthetic silver fibers, where one type of synthetic silver fiber can differ in characteristics from another type of synthetic silver fiber.
Unless otherwise noted, the phrase “at least one” means one or more than one of an object. Unless otherwise noted, the phrase “at least one of” means one or more than one of the lists options in any combination. For example, the phrase “at least one of a polyester and a nylon” or “at least one of a polyester or a nylon” would mean a polyester, a nylon, and/or both.
Unless otherwise noted, the phrases “antimicrobial fiber” and “synthetic silver fiber” are used interchangeably.
Unless otherwise noted, all ranges, except for results, include all intermediate integer numbers as well as the endpoints. For example, the range of from 5 to 10 micrometers would be understood to include 5, 6, 7, 8, 9, and 10 micrometers.
Unless otherwise noted, the phrase “silver-free fiber” can, optionally, be referred to as a “basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the basic fiber.
Unless otherwise noted, the term “antimicrobial” can, optionally, be referred to as “antibacterial.”
Unless otherwise noted, the term “about” refers to ±5% of the non-percentage number that is described. For example, about 100 mm, would include from to 95 to 115 mm. Unless otherwise noted, the term “about” refers to ±5% of a percentage number. For example, about 20% would include from 15 to 25%. When the term “about” is discussed in terms of a range, then the term refers to the appropriate amount less than the lower limit and more than the upper limit. For example, from about 100 mm to about 200 mm would include from 95 to 210 mm.
Unless otherwise noted, the term “particle size” refers a measurement of the longest dimension of the particle.
Unless otherwise noted, the terms “weight percent” and “% weight” are used interchangeably.

Antimicrobial Garment

The present disclosure relates to an antimicrobial garment. In an embodiment, the antimicrobial garment includes an antimicrobial fabric, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.
In an embodiment, the antimicrobial fabric includes at least one synthetic silver fiber. In an embodiment, the at least one synthetic silver fiber can include a synthetic fiber having elemental silver particles bound to the synthetic fiber. In an embodiment, the elemental silver particles contain from about 80% weight to 100% weight silver metal based on a total weight of the elemental silver particles. In an embodiment, the elemental silver particles contain from about 85% weight to 100% weight, including from about 90% weight to 100% weight, including from about 95% weight to 100% weight, silver metal based on a total weight of the elemental silver particles. In an embodiment, the elemental silver particles contain from about 20% weight to 0% weight, including from about 10% weight to 0% weight, including from 5% weight to 0% weight, silver oxide or a silver alloy. One benefit of an antimicrobial garment containing a weight percent of from about 80% weight to 100% weight silver metal and/or less than 20% weight to 0% weight of silver oxide or silver alloy can be that silver metal has broad spectrum antimicrobial properties against odor causing agents and infection causing agents that include a bacteria, a fungi, and/or a virus. Without wishing to be bound by theory, it is believed that the higher the silver metal content of the elemental silver particles, the more effective the antimicrobial properties of the elemental silver particles will be due, in part, to surface interactions and charge effects associated with silver in its pure metal form.
In an embodiment, the size of the elemental silver particles is not generally limited, so long as the elemental silver particles retain their antimicrobial properties. In an embodiment, the size of the silver particles ranges from about 1 micrometer to about 50 micrometers, including from about 1 micrometer to about 30 micrometers, including from about 1 micrometer to about 10 micrometers, including from about 1 micrometer to about 5 micrometers. In an embodiment, the size distribution of the elemental silver particles ranges from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 30 micrometers. In an embodiment, the size distribution of the elemental silver particles ranges from about 90% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 20 micrometers. In an embodiment, the size distribution of the elemental silver particles ranges from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 10 micrometers, including from about 1 micrometer to about 5 micrometers.
One challenging facing the use of silver particles for their antimicrobial effects can be that silver particles below 1 micrometer are easily depleted. Without wishing to be bound by theory, one reason for this may be that silver particles of less than 1 micrometer lose their ability to produce silver ions too quickly. Another challenge facing the use of silver particles is that large sizes tend to result in flakes and clumps that are not evenly distributed along fibers. These larger sizes can be much more easily removed by wear, abrasion and/or washing. One benefit of the elemental silver particles of the present disclosure is that the elemental silver particles have a size distribution of from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 10 micrometers, which can provide longer retention of elemental silver particles and their antimicrobial properties.
In an embodiment, the at least one synthetic silver fiber can be a synthetic fiber having elemental silver particles bound, attached, adhered, and/or retained onto the surface of the synthetic fiber. In an embodiment, the at least one synthetic silver fiber can be a synthetic fiber having elemental silver particles bound, entangled, partially absorbed, or otherwise retained by synthetic fibers. The elemental silver particles bound to the synthetic fiber can be viewed and quantified by scanning electron microscopy (SEM) at from about 300 times to about 2,400 times magnification. One test for determining whether elemental silver particles are sufficiently retained by the synthetic fiber to constitute elemental silver particles “bound” to the synthetic fiber can be to quantify the number of elemental silver particles before and after 10 washes in a conventional washing machine. For example, a swatch of antimicrobial fabric can be examined by SEM in 5 spots to quantify the amount of elemental silver particles which appear on a length of synthetic thread. Then, the antimicrobial fabric can be washed in warm water with a delicate cycle in a conventional top-load washing machine with a conventional detergent, such as TIDE®, 10 times. After the 10 washes, the swatch of antimicrobial fabric can be examined by SEM using the same magnification in 5 spots, which may or may not be the exact same spots as before, to quantify the amount of elemental silver particles which appear on the same length of synthetic thread. If the quantity of elemental silver particles measured after 10 washes ranges from about 50% or more, including 60% to 100%, including 70% to 100%, including 80% to 100% or more, relative to the quantity of elemental silver particles before the washing steps, then the elemental silver particles are “bound” to the synthetic fiber.
In an embodiment of the synthetic silver fiber, the synthetic silver fiber includes from about 0.01 weight percent to about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber. In an embodiment of the synthetic silver fiber, the synthetic silver fiber includes from about 0.1 weight percent to about 2.0 weight percent, including from about 0.2 weight percent to about 1.0 weight percent, of elemental silver particles based on a total weight of the synthetic silver fiber. One benefit of having an amount of elemental silver particles having a weight percent of less than about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber can be a reducing or eliminating problems of silver particles flaking off of the fiber. One benefit of having an amount of elemental silver particles having a weight percent of less than about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber can be a reducing or eliminating problems of silver particles clumping together to form overly large particles that are poorly distributed along the synthetic silver fiber. One benefit of having an amount of elemental silver particles having a weight percent of more than about 0.01 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber can be retaining the antimicrobial properties of the elemental silver particles when the synthetic silver fiber is woven into an antimicrobial fabric.
In an embodiment of the antimicrobial fabric, the antimicrobial fabric contains from about 10 mg/kg to about 100 mg/kg, including from about 20 mg/kg to about 80 mg/kg, of the elemental silver particles per the antimicrobial fabric. One benefit of antimicrobial fabric having more than 10 mg/kg of the elemental silver particles per the antimicrobial fabric can be that the antimicrobial properties of the fabric are retained. One benefit of antimicrobial fabric having less than 100 mg/kg of the elemental silver particles per the antimicrobial fabric can reduce or avoid the feeling of synthetic fibers on skin, which can be desirable for many applications of the antimicrobial fabric, such as an antimicrobial garment.
In an embodiment, an antimicrobial garment contains from about 10 weight percent to about 20 weight percent, including from about 12 weight percent to about 18 weight percent, of the antimicrobial fiber based on a total weight of the antimicrobial garment. One benefit of an antimicrobial garment having more than 10 weight percent of the antimicrobial fiber based on a total weight of the antimicrobial garment can be the retention of antimicrobial properties. One benefit of an antimicrobial garment having less than about 20 weight percent of the antimicrobial fiber based on a total weight of the antimicrobial garment can be the retention of the appearance and feel of the material of the at least one silver-free fiber. For example, a garment having about 20 weight percent of the antimicrobial fiber or synthetic silver fiber and about 80 weight percent cotton as the at least one silver-free fiber can retain the appearance and feel of a cotton garment.
In an embodiment, the synthetic silver fiber has a thickness characterized by from about 30 g per 9000 meters of fiber to about 900 g per 9000 meters of fiber (from about 30 denier to about 900 denier). In an embodiment, the synthetic silver fiber has a thickness characterized by from about 50 g per 9000 meters of fiber to about 800 g per 9000 meters of fiber, including from about 80 g per 9000 meters of fiber to about 700 g per 9000 meters of fiber. In an embodiment, the synthetic silver fiber has a thickness characterized by from about 10 km/kg to about 60 km/kg, including from about 20 km/kg to about 50 km/kg. The thickness of the synthetic silver fiber is generally not limited, so long as the thickness can allow for the weight of the elemental silver particles per thread to be woven into an antimicrobial fabric that contains from about 10 mg/kg to about 100 mg/kg of the elemental silver particles per the antimicrobial fabric, as discussed in the previous paragraph.
In an embodiment, an antimicrobial garment has a fabric weight of from about 50 g/m²to about 350 g/m², including from about 126 g/m²to about 339 g/m², including from about 140 g/m²to about 240 g/m². The fabric weight of the antimicrobial garment is not generally limited so long as the feel and texture of the garment is acceptable or pleasing to the wearer. For example, a fabric weight of about 140 g/m²to about 240 g/m²has been found by many wearers to be desirable for shirts.
In embodiment, an antimicrobial garment can include areas, layers, and/or patterns of antimicrobial fabric and non-antimicrobial fabric. For example, a shirt can patterned such that antimicrobial fabric is located in a high-sweat area, such as the arm pit area of a shirt, and a less expensive non-antimicrobial fabric can be used for the rest of the shirt. In an embodiment, the antimicrobial garment contains from about 10% weight to 100% weight, including about 30% weight to about 100% weight, including from about 50% weight to about 100% weight, of the antimicrobial fabric based on a total weight of the antimicrobial garment.
In an embodiment, the synthetic fiber is not generally limited and can include at least one of a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer (including spandex, LYCRA®, and elastane), an acrylic polymer, or a combination, co-polymer, or blend thereof. In an embodiment, the synthetic fiber is a polyester, such as polyethylene terephthalate, and can include polyesters made from terephthalic acid or dimethyl ester dimethyl terephthalate and monoethylene glycol.
In an embodiment, the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber. In an embodiment, the at least one silver-free fiber includes a basic fiber having less than 1.0 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber. It is understood that a few silver particles may rub off onto the silver-free fiber from another source, but a “silver-free fiber” refers to a fiber that has not been treated by any industrial or manufacturing chemical or physical process that would deposit, bind, and/or adhere a silver particle to the basic fiber.
One benefit of an antimicrobial fabric made from at least one synthetic silver fiber and at least one silver-free fiber can be that the amount and/or concentration of elemental silver particles can be varied by changing the amount of synthetic silver fiber in the garment using conventional weaving techniques known in the art. In contrast, trying to controllably vary the concentration of elemental silver particles on the synthetic fiber can greatly increase the expense of the production of the fiber and can adversely affect the quality and consistency of the elemental silver particles bound to the synthetic fiber. For example, it has been found that trying to increase the size and concentration of silver particles beyond certain values results in the flocculation of silver particles into clumps that are poorly distributed and easily flaked off during wear and washing of the fabric. Many manufactures have tried to weave a garment, and then used a chemical or physical process to deposit various types of silver particles onto the garment. However, these methods tend to suffer from poor particle size control; uneven particle distribution; reduced purity of silver particles by the formation of silver oxides and/or alloys; and/or poor adhesion of the silver particles to the fibers of the fabric. As such, the antimicrobial properties of these bulk chemical processes tend to have reduced or no antimicrobial properties after a few wear and wash cycles.
In an embodiment, the silver-free fiber includes at least one basic fiber. The material of the basic fiber is not generally limited so long as the fiber is acceptable for application in a garment. In an embodiment, the at least one basic fiber includes a natural fiber, wherein the natural fiber includes a cotton, a wool, a silk, a hemp, a rayon, a bamboo, a banana, a modal, a lyocell, or combination, a blend, or a weave thereof. In an embodiment, the basic fiber includes cotton. In an embodiment, the at least one basic fiber includes an unnatural fiber, wherein the unnatural fiber includes a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer, an acrylic polymer, or a weave, combination, co-polymer, or blend thereof. In an embodiment, the at least one basic fiber includes one natural fiber. In an embodiment, the at least one basic fiber includes one unnatural fiber. In an embodiment, the antimicrobial fabric includes at least one basic fiber, which includes a weave or blend of a natural fiber and an unnatural fiber.
In an embodiment, the antimicrobial garment is not generally limited regarding the type of garment or the cut or style of a garment. In an embodiment, the antimicrobial garment can be any garment worn by a human or mammal. In an embodiment, the antimicrobial garment is a garment that typically makes direct contact with skin or water. In an embodiment, the antimicrobial garment includes a top, a bottom or pant, a dress, a skirt, a head wear, a footwear, and/or an undergarment. In an embodiment, the antimicrobial garment is selected from group consisting of a shirt, a yoga pant, a tight, a legging, a short, an arm warmer, an ankle brace, a hat, a gi, a leg warmer, a hosiery, a leotard, a unitard, a tutu, a jersey, a sock, a fatigue, a uniform, a costume, a jockstrap, a sweat pant, a sweat shirt, a bra, a swimsuit, a belt, a coat, a headband, a dress, a skirt, a short, an undergarment, a jacket, a trouser, a suit, a robe, a saris, a scrub, a neckwear, and a top.
In an embodiment, the antimicrobial garment further includes an optical brightener and at least one of a dye or a pigment. In an embodiment, optical brightener can include a triazine-stilbene, a coumarin, an imidazoline, a diazole, a triazole, a benzoxazoline, and a biphenyl-stilbene. One benefit to including a dye or a pigment can be that many consumers prefer garments that are aesthetically pleasing or convey a social role, such as a police uniform. One benefit of including an optical brightener can be that the optical brightener provides brighter colors and more light in the visible spectrum. Also, it has been discovered that antimicrobial garments treated with dyes or pigments alone tended to be ineffective or inconsistent in their coloring. Without wishing to be bound by theory, it is believed that the presence of synthetic silver fibers and/or elemental silver particles in the antimicrobial garments adversely effected the ability of the dyes and pigments to perform adequately. This poor performance may be caused by a change in wettability of the garment due to the presence of silver particles during the dying or pigmentation process. One benefit of adding an optical brightener to the antimicrobial fabric or using optically bright materials, such as optically bright polyester or optically bright nylon as a source of synthetic fibers, can be that the presence of the optical brightener allows for the dying or pigmentation process to provide accurate and consistent coloring. A sample of antimicrobial fabric dyed dark gray is shown in FIG. 1. Three examples of antimicrobial cloth dyed different colors are shown in FIG. 2. Examples of embodiments of antimicrobial garments successfully dyed black and white, respectively, are shown in FIGS. 3 and 4.
In an embodiment, the antimicrobial garment reduces growth of gram positive bacteria by from about 95% to 100% relative to a garment without the antimicrobial fabric. In an embodiment, the antimicrobial garment reduces or slows growth of gram positive bacteria, including S. aureus ATCC 6538, by from about 80% to about 100%, including from about 85% to 99%, including from 90% to 100%, including from about 95% to 100%, relative to a garment without the at least one antimicrobial fiber or synthetic silver fiber. In an embodiment, the antimicrobial garment reduces or slows the growth of gram negative bacteria, including Klebsiella pneumoniae ATCC 4352, by from about 100% to about 5% relative to a garment without the at least one antimicrobial fiber or synthetic silver fiber, including from 80% to 5%, including from 60% to 5%, including from 20% to 5%. In an embodiment, the antimicrobial garment reduces, eliminates, or impedes the growth of a bacteria, a fungi, and/or a virus.
A method of manufacturing an antimicrobial garment is disclosed. In an embodiment, the method includes weaving or knitting the at least one synthetic silver fiber and at least one silver-free fiber together to form an antimicrobial fabric, and cutting or sewing the antimicrobial fabric to form the antimicrobial garment, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.
In an embodiment, if the at least one synthetic silver fiber and at least one silver-free fiber are provided, then the method of weaving, knitting, cutting, and/or sewing are not limited. Generally any method of weaving, knitting, cutting, and/or sewing known to those skilled in these arts is suitable for manufacturing the antimicrobial garments described herein. In an embodiment, the method includes providing an antimicrobial fabric, and cutting or sewing the antimicrobial fabric to form the antimicrobial garment, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.

Antimicrobial Fabric Product

The present disclosure relates to an antimicrobial fabric product. In an embodiment, the antimicrobial fabric product includes an antimicrobial fabric, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.
In an embodiment, the antimicrobial fabric includes at least one synthetic silver fiber. In an embodiment, the at least one synthetic silver fiber can include a synthetic fiber having elemental silver particles bound to the synthetic fiber. In an embodiment, the elemental silver particles contain from about 80% to 100% weight silver metal based on a total weight of the elemental silver particles. In an embodiment, the elemental silver particles contain from about 85% to 100% weight, including from about 90% to 100% weight, including from about 95% to 100% weight, silver metal based on a total weight of the elemental silver particles. In an embodiment, the elemental silver particles contain from about 20% to 0% weight, including from about 10% to 0%, including from 5% to 0% weight, silver oxide or a silver alloy. One benefit of an antimicrobial fabric product containing a weight percent of from about 80% to 100% weight silver metal and/or less than 20% to 0% weight of silver oxide or silver alloy can be that silver metal has broad spectrum antimicrobial properties against odor causing agents and infection causing agents that include a bacteria, a fungi, and a virus. Without wishing to be bound by theory, it is believed that the higher the silver metal content of the elemental silver particles, the more effective the antimicrobial properties of the elemental silver particles will be due, in part, to surface interactions and charge effects associated with silver in its pure metal form.
In an embodiment, the size of the elemental silver particles is not generally limited, so long as the elemental silver particles retain their antimicrobial properties. In an embodiment, the size of the silver particles ranges from about 1 micrometer to about 50 micrometers, including from about 1 micrometer to about 30 micrometers, including from about 1 micrometer to about 10 micrometers, including from about 1 micrometer to about 5 micrometers. In an embodiment, the size distribution of the elemental silver particles ranges from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 30 micrometers. In an embodiment, the size distribution of the elemental silver particles ranges from about 90% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 20 micrometers. In an embodiment, the size distribution of the elemental silver particles ranges from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 10 micrometers, including from about 1 micrometer to about 5 micrometers.
One challenge facing the use of silver particles for their antimicrobial effects can be that silver particles below 1 micrometer are easily depleted. Without wishing to be bound by theory, one reason for this may be that silver particles of less than 1 micrometer lose their ability to produce silver ions too quickly. Another challenge facing the use of silver particles is that large sizes tend to result in flakes and clumps that are not evenly distributed along fibers. These larger sizes can be much more easily removed by wear, abrasion and/or washing. One benefit of the elemental silver particles of the present disclosure is that the elemental silver particles have a size distribution of from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 10 micrometers, which can provide longer retention of elemental silver particles and their antimicrobial properties.
In an embodiment, the at least one synthetic silver fiber can be a synthetic fiber having elemental silver particles bound, attached, adhered, and/or retained onto the surface of the synthetic fiber. In an embodiment, the at least one synthetic silver fiber can be a synthetic fiber having elemental silver particles bound, entangled, partially absorbed, or otherwise retained by the synthetic fibers. The elemental silver particles bound to the synthetic fiber can be viewed and quantified by scanning electron microscopy (SEM) at from about 300 times to about 2,400 times magnification. One test for determining whether elemental silver particles are sufficiently retained by the synthetic fiber to constitute elemental silver particles “bound” to the synthetic fiber can be to quantify the number of elemental silver particles before and after 10 washes in a conventional washing machine. For example, a sample or swatch of antimicrobial fabric can be examined by SEM in 5 spots to quantify the amount of elemental silver particles which appear on a length of synthetic thread. Then, the antimicrobial fabric can be washed in warm water of 30° C.±5° C. with a delicate cycle in a conventional top-load washing machine with a conventional detergent, such as TIDE®, 10 times. After the 10 washes, the swatch of antimicrobial fabric can be examined by SEM using the same magnification in 5 spots, which may or may not be the exact same spots as before, to quantify the amount of elemental silver particles which appear on the same length of synthetic thread. If the quantity of elemental silver particles measured after 10 washes ranges from about 50% or more, including 60% to 100%, including 70% to 100%, including 80% to 100% or more, relative to the quantity of elemental silver particles before the washing steps, then the elemental silver particles are “bound” to the synthetic fiber.
In an embodiment of the synthetic silver fiber, the synthetic silver fiber includes from about 0.01 weight percent to about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber. In an embodiment of the synthetic silver fiber, the synthetic silver fiber includes from about 0.1 weight percent to about 2.0 weight percent, including from about 0.2 weight percent to about 1.0 weight percent, of elemental silver particles based on a total weight of the synthetic silver fiber. One benefit of having an amount of elemental silver particles having a weight percent of less than about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber can be reducing or eliminating problems of silver particles flaking off of the fiber, which can result in growing areas of poor antimicrobial properties. One benefit of having an amount of elemental silver particles having a weight percent of less than about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber can be reducing or eliminating problems of silver particles clumping together to form overly large particles that are poorly distributed along the synthetic silver fiber, which can result in areas of poor antimicrobial properties. One benefit of having an amount of elemental silver particles having a weight percent of more than about 0.01 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber can be retaining the antimicrobial properties of the elemental silver particles when the synthetic silver fiber is woven into an antimicrobial fabric.
In an embodiment of the antimicrobial fabric, the antimicrobial fabric contains from about 10 mg/kg to about 100 mg/kg, including from about 20 mg/kg to about 80 mg/kg, of the elemental silver particles per the antimicrobial fabric. One benefit of antimicrobial fabric having more than 10 mg/kg of the elemental silver particles per the antimicrobial fabric can be that the antimicrobial properties of the fabric are retained. One benefit of antimicrobial fabric having less than 100 mg/kg of the elemental silver particles per the antimicrobial fabric can reduce or avoid the feeling of synthetic fibers on skin, which can be desirable for many applications of the antimicrobial fabric, such as an antimicrobial garment.
In an embodiment, an antimicrobial fabric product contains an antimicrobial fabric that includes from about 10 weight percent to about 20 weight percent, including from about 12 weight percent to about 18 weight percent, of the antimicrobial fiber based on a total weight of the antimicrobial fabric. One benefit of an antimicrobial fabric product having more than 10 weight percent of the antimicrobial fiber based on a total weight of the antimicrobial fabric can be the retention of antimicrobial properties. One benefit of an antimicrobial fabric product having less than about 20 weight percent of the antimicrobial fiber based on a total weight of the antimicrobial fabric can be the retention of the properties of the material of the at least one silver-free fiber. For example, a fabric product, such as a gym bag made entirely of antimicrobial fabric, having about 20 weight percent of the antimicrobial fiber or synthetic silver fiber and about 80 weight percent cotton as the at least one silver-free fiber can retain the properties of a cotton gym bag. Similarly, a fabric product, such as a gym bag made entirely of antimicrobial fabric, having about 20 weight percent of the antimicrobial fiber or synthetic silver fiber and about 80 weight percent nylon as the at least one silver-free fiber can retain the properties, such as strength, of a nylon gym bag.
In an embodiment, the synthetic silver fiber has a thickness characterized by from about 30 g per 9000 meters of fiber to about 900 g per 9000 meters of fiber (from about 30 denier to about 900 denier). In an embodiment, the synthetic silver fiber has a thickness characterized by from about 50 g per 9000 meters of fiber to about 800 g per 9000 meters of fiber, including from about 80 g per 9000 meters of fiber to about 700 g per 9000 meters of fiber. In an embodiment, the synthetic silver fiber has a thickness characterized by from about 10 km/kg to about 60 km/kg, including from about 20 km/kg to about 50 km/kg. The thickness of the synthetic silver fiber is generally not limited, so long as the thickness can allow for the weight of the elemental silver particles per thread to be woven into an antimicrobial fabric that contains from about 10 mg/kg to about 100 mg/kg of the elemental silver particles per the antimicrobial fabric, as discussed in the previous paragraph.
In an embodiment, a fabric in the antimicrobial fabric product has a fabric weight of from about 50 g/m²to about 350 g/m², including from about 130 g/m²to about 339 g/m², including from about 140 g/m²to about 240 g/m². The fabric weight of a fabric in the antimicrobial fabric product is not generally limited so long as the properties of the fabric are acceptable for the application of the fabric product. For example, a fabric weight of about 140 g/m²to about 240 g/m²has been found by many wearers to be desirable for shirts.
In embodiment, an antimicrobial fabric product can include areas, layers, and/or patterns of antimicrobial fabric and non-antimicrobial fabric or basic fabric. For example, a shirt can patterned such that an antimicrobial fabric is located in a high-sweat area, such as the arm pit area of a shirt, and a less expensive non-antimicrobial fabric can be used for the rest of the shirt. In an embodiment, the fabric in the antimicrobial fabric product contains from about 10% to 100% weight, including about 30% to about 100% weight, including from about 50% to about 100% weight, of antimicrobial fabric based on a total weight of the fabric in antimicrobial fabric product.
In an embodiment, the synthetic fiber is not generally limited and can include at least one of a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer (including spandex, LYCRA®, and elastane), an acrylic polymer, or a combination, co-polymer, or blend thereof. In an embodiment, the synthetic fiber is a polyester, such as polyethylene terephthalate, and can include polyesters made from terephthalic acid or dimethyl ester dimethyl terephthalate and monoethylene glycol.
In an embodiment, the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber. In an embodiment, the at least one silver-free fiber includes a basic fiber having less than 1.0 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber. It is understood that a few silver particles may rub off onto the silver-free fiber from another source, but a “silver-free fiber” refers to a fiber that has not been treated by any industrial or manufacturing chemical or physical process that would deposit, bind, and/or adhere a silver particle to the basic fiber.
One benefit of an antimicrobial fabric made from at least one synthetic silver fiber and at least one silver-free fiber can be that the amount and/or concentration of elemental silver particles can be varied by changing the amount of synthetic silver fiber woven into the fabric product using conventional weaving techniques known in the art. In contrast, trying to controllably vary the concentration of elemental silver particles on the synthetic fiber can greatly increase the expense of the production of the fiber and can adversely affect the quality and consistency of the elemental silver particles bound to the synthetic fiber. For example, it has been found that trying to increase the size and concentration of silver particles beyond certain values results in the flocculation of silver particles into clumps that are poorly distributed and easily flaked off during wear and washing of the fabric. Many manufactures have tried to weave a fabric product, and then used a chemical or physical process to deposit various types of silver particles onto the fabric product. However, these methods tend to suffer from poor particle size control; uneven particle distribution; reduced purity of silver particles by the formation of silver oxides and/or alloys; and/or poor adhesion of the silver particles to the fibers of the fabric. As such, the antimicrobial properties of these bulk chemical processes tend to have reduced or no antimicrobial properties after a few wear and wash cycles.
In an embodiment, the silver-free fiber includes at least one basic fiber. The material of the basic fiber is not generally limited so long as the fiber is acceptable for application in a fabric product. In an embodiment, the at least one basic fiber includes a natural fiber, wherein the natural fiber includes a cotton, a wool, a silk, a hemp, a rayon, a bamboo, a banana, a modal, a lyocell, or combination, a blend or weave thereof. In an embodiment, the basic fiber includes cotton. In an embodiment, the at least one basic fiber includes an unnatural fiber, wherein the unnatural fiber includes a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer, an acrylic polymer, or a combination, co-polymer, weave, or blend thereof. In an embodiment, the at least one basic fiber includes one natural fiber. In an embodiment, the at least one basic fiber includes one unnatural fiber. In an embodiment, the antimicrobial fabric includes at least one basic fiber, which includes a weave or blend of a natural fiber and an unnatural fiber.
In an embodiment, the antimicrobial fabric product is not generally limited regarding the type of fabric product or the cut or style of the fabric product. In an embodiment, the antimicrobial fabric product is a garment, a diaper, a piece of cloth furniture, a bag, a bed lining, a towel, a pillow case, a bandage, an article of feminine hygiene, a cleaning cloth, a foot wear, an insole, or an accessory, so long as the product contains a portion of fiber.
In an embodiment, the antimicrobial fabric product further includes an optical brightener and at least one of a dye or a pigment. In an embodiment, an optical brightener can include a triazine-stilbene, a coumarin, an imidazoline, a diazole, a triazole, a benzoxazoline, and a biphenyl-stilbene. One benefit to including a dye or a pigment can be that many consumers prefer fabric products that are aesthetically pleasing or convey a social role, such as a police uniform or a designer bag. One benefit of including an optical brightener can be that the optical brightener provides brighter colors and more light in the visible spectrum. Also, it has been discovered that antimicrobial fabric products treated with dyes or pigments alone tended to be ineffective or inconsistent in their coloring. Without wishing to be bound by theory, it is believed that the presence of synthetic silver fibers and/or elemental silver particles in the antimicrobial fabric products adversely effected the ability of the dyes or pigments to perform adequately. This poor performance may be caused by a change in wettability of the fabric product due to the presence of silver particles during the dying or pigmentation process. One benefit of adding an optical brightener to the antimicrobial fabric or using optically bright materials, such as optically bright polyester or optically bright nylon as a source of synthetic fibers, can be that the presence of the optical brightener allows for the dying or pigmentation process to provide accurate and consistent coloring. A sample of antimicrobial fabric dyed dark gray is shown in FIG. 1. Three examples of antimicrobial fabric dyed different colors are shown in FIG. 2. Examples of embodiments of antimicrobial fabric products successfully dyed black and white, respectively, are shown in FIGS. 3 and 4.
In an embodiment, the fabric in the antimicrobial fabric product reduces growth of gram positive bacteria by from about 95% to 100% relative to the fabric in the fabric product without the at least one antimicrobial fabric. In an embodiment, the fabric in the antimicrobial fabric product reduces growth of gram positive bacteria, S. aureus ATCC 6538, by from about 80% to about 100%, including from about 85% to 99%, including from 90% to 100%, including from about 95% to 100%, relative to the fabric in the fabric product without the at least one antimicrobial fiber or synthetic silver fiber. In an embodiment, the fabric in the antimicrobial fabric product reduces or slows the growth of gram negative bacteria, including Klebsiella pneumoniae ATCC 4352, by from about 90% to about 5% relative to the fabric in the fabric product without the at least one antimicrobial fiber or synthetic silver fiber, including from 80% to 5%, including from 60% to 5%, including from 20% to 5%. In an embodiment, the antimicrobial fabric product reduces, eliminates, or slows the growth of a bacteria, a fungi, and/or a virus.
A method of manufacturing an antimicrobial fabric product is disclosed. In an embodiment, the method includes weaving or knitting the at least one synthetic silver fiber and at least one silver-free fiber together to form an antimicrobial fabric, and/or cutting or sewing the antimicrobial fabric to form the antimicrobial fabric product, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.
In an embodiment, if the at least one synthetic silver fiber and at least one silver-free fiber are provided, then the method of weaving, knitting, cutting, and/or sewing are not limited. Generally any method of weaving, knitting, cutting, and/or sewing known to those skilled in these arts is suitable for manufacturing the antimicrobial fabric products described herein. In an embodiment, the method includes providing an antimicrobial fabric, and cutting or sewing the antimicrobial fabric to form the antimicrobial fabric product, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber, wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and wherein the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.
In an embodiment of the method, the method can include a step of providing an antimicrobial fabric. The term “providing” is not generally limited, and can include receiving the antimicrobial fabric from another source, including purchasing an antimicrobial fabric.
The named inventor has arranged to commercially purchase a synthetic silver fiber, namely, FORTIFY® AMX, from Fiber and Yarn Products, Inc., in Hickory, N.C., USA. This product is available after extensive consultation with the Fiber and Yarn Products. It is believed that this product has not been previously patented, published, or made publically available as a garment or an antimicrobial fabric product.

Exemplary Embodiments

Embodiment 1. An antimicrobial garment comprising:
an antimicrobial fabric, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber,
wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and
wherein the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.
Embodiment 2. The antimicrobial garment of embodiment 1, wherein from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 30 micrometers.
Embodiment 3. The antimicrobial garment of any one of embodiments 1-2, wherein the synthetic silver fiber includes from about 0.01 to about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber, or
wherein the antimicrobial fabric has from about 10 mg/kg to about 100 mg/kg of the elemental silver particles per the antimicrobial fabric.
Embodiment 4. The antimicrobial garment of any one of embodiments 1-3, wherein the synthetic silver fiber has a thickness characterized by from about 30 g per 9000 meters of fiber to about 900 g per 9000 meters of fiber or from about 10 km/kg to about 60 km/kg,
wherein the antimicrobial garment contains from about 10% to 100% weight of the antimicrobial fabric based on a total weight of the antimicrobial garment,
wherein the antimicrobial garment has a fabric weight of from about 50 g/m²to about 350 g/m², and
wherein the antimicrobial garment contains from about 10 to about 20 weight percent of the synthetic silver fiber based on a total weight of the antimicrobial garment.
Embodiment 5. The antimicrobial garment of any one of embodiments 1-4, wherein the synthetic fiber includes at least one of a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer, an acrylic polymer, or a combination, co-polymer, or blend thereof and
wherein the at least one basic fiber includes
a natural fiber, wherein the natural fiber includes a cotton, a wool, a silk, a hemp, a rayon, a bamboo, a banana, a modal, a lyocell, or combination, a blend or weave thereof, or
an unnatural fiber, wherein the unnatural fiber includes a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer, an acrylic polymer, or a combination, co-polymer, or blend thereof.
Embodiment 6. The antimicrobial garment of any one of embodiments 1-5, wherein the antimicrobial garment is selected from group consisting of a shirt, a yoga pant, a tight, a legging, a short, an arm warmer, an ankle brace, a hat, a gi, a leg warmer, a hosiery, a leotard, a unitard, a tutu, a jersey, a sock, a fatigue, a uniform, a costume, a jockstrap, a sweat pant, a sweat shirt, a bra, a swimsuit, a belt, a coat, a headband, a dress, a skirt, a short, an undergarment, a jacket, a trouser, a suit, a robe, a saris, a scrub, a neckwear, and a top.
Embodiment 7. The antimicrobial garment of any one of embodiments 1-6, the antimicrobial garment further comprising an optical brightener and at least one of a dye or a pigment.
Embodiment 8. The antimicrobial garment of any one of embodiments 1-7, wherein the antimicrobial garment reduces growth of gram positive bacteria by from about 95% to 100% relative to a garment without the antimicrobial fabric.
Embodiment 9. A method of manufacturing an antimicrobial garment comprising:
weaving or knitting the at least one synthetic silver fiber and at least one silver-free fiber together to form an antimicrobial fabric, and
cutting or sewing the antimicrobial fabric to form the antimicrobial garment of any one of embodiments 1-8,
wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and
wherein the at least one silver-free fiber includes a basic fiber having less than 0.1% weight of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.
Embodiment 10. An antimicrobial fabric product comprising:
an antimicrobial fabric, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber,
wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and
wherein the at least one silver-free fiber includes a basic fiber having less than 0.1% weight of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.
Embodiment 11. The antimicrobial fabric product of embodiment 10, wherein from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 30 micrometers.
Embodiment 12. The antimicrobial fabric product of any one of embodiments 10-11, wherein the synthetic silver fiber includes from about 0.01 to about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber, or
wherein a fabric in the antimicrobial fabric product has from about 10 mg/kg to about 100 mg/kg of elemental silver particles per a total weight of the fabric in the antimicrobial fabric product.
Embodiment 13. The antimicrobial fabric product of any one of embodiments 10-12,
wherein the synthetic silver fiber has a thickness characterized by from about 30 g per 9000 meters of fiber to about 900 g per 9000 meters of fiber or from about 10 km/kg to about 60 km/kg,
wherein a fabric in the antimicrobial fabric product contains from about 90% to 100% weight of the antimicrobial fabric based on a total weight of the fabric in the antimicrobial fabric product, and
wherein the fabric in the antimicrobial fabric product has a fabric weight of from about 50 g/m²to about 350 g/m².
Embodiment 14. The antimicrobial fabric product of any one of embodiments 10-13, wherein the fabric in the antimicrobial fabric product further comprises an optical brightener and at least one of a dye or a pigment.
Embodiment 15. The antimicrobial fabric product of any one of embodiments 10-14, wherein the antimicrobial fabric product is a garment, a diaper, a piece of cloth furniture, a bag, a bed lining, a towel, a pillow case, a bandage, an article of feminine hygiene, a cleaning cloth, a foot wear, an insole, or an accessory.
Embodiment 15. The antimicrobial fabric product of any one of embodiments 10-15, wherein the fabric in the antimicrobial fabric product reduces growth of gram positive bacteria by from about 95% to 100% relative to a fabric product without the antimicrobial fabric.

EXAMPLES

Example 1

Provide a synthetic silver fiber, namely, FORTIFY® AMX from Fiber and Yarn Products, Inc., in Hickory, N.C., USA. Place an order with the following parameters:
1. Threads sent to Knitter:
50.8 kms of yarn per kg (30/1 CC) US Pima Cotton
50.8 kms of yarn per kg (30/1 CC) Optically Bright Polyester
50.8 kms of yarn per kg (30/1 CC) FORTIFY® AMX
2. Single Knit Jersey Fabric (sewn by knitter) per requirement from Accel Lifestyle:
US Pima Cotton—50%
Polyester—50% (Includes 16.67% FORTIFY® AMX)
1.49 g/m²(4.4 oz.sq.yd.) 254 g/m²(7.5 oz./yd)@152.4 cm to 157.5 cm (60/62″) fabric
Fabric is dyed by the knitters (to a selected color)
3. Fabric is then sent to a cut and sew manufacturer:
Using patterns developed by Accel Lifestyle, shirts are sewn using the fabric listed above.
4. After shirt is sewn:
Tags, logos, and quotes (using discharge ink) are applied per instruction from Accel Lifestyle
The garments shown in FIGS. 3 and 4 were made in a manner consistent with this process.

Example 2

Two knitted swatches of 50/50 Poly-Cotton Fortify® AMX (15%) were sent to Manufacturing Solutions Center (MSC) in North Carolina for testing. One swatch was washed twice using an AATCC Monograph M6 “Standardization of Home Laundry Test Conditions” which include a 1.8 kg (4 lbs.) load size in a Top Loading Machine Wash on Delicate Cycle with warm water 30° C.±5° C. and tumbled dry on the permanent press setting.
To test efficacy against gram positive bacteria, Staphylococcus aureus subsp. aureus Rosenbach (ATCC® 6538™) was used. To test efficacy against gram negative bacteria, Klebsiella pneumoniae subsp. pneumoniae (ATCC® 4352™) was used. Variables were as follows:
Growth media: Tryptic Soy Broth
Sample size # layers: 4
Sterilization: none
Neutralizer: 100 ml Letheen Broth w. Tween
Target inoculation. Level: (1.0-2.0)×105 CFU/ml
Inoculum carrier: 5% Nutrient broth
Inoculum size: 1.0 ml+/−0.1 ml
Wetting agent: 0.05% Triton X (available from Sigma Aldrich)
Contact time: 24 h

Temperature: 37+/−2° C.

Samples are prepared and enumerated using automatic equipment; Tempo, BioMerieux.
Cultures stored at 5°+/−2° C.
Calculate % reduction to formula 1) 100 (B−A)/B=R; section 11.2
Zero 24 hr Percent

Bacteria Contact Time Contact Time Reduction

S. aureus 1.90E+05 2.15E+03 98.87%

ATCC 6538 cfu/sample cfu/sample

Klebsiella 2.70E+05 2.49E+06 −820.37%

pneumoniae cfu/sample cfu/sample

ATCC 4352

The term “cfu” stands for colony forming unit. These results indicate that the antimicrobial fabric swatches tested killed off around 99% of the gram positive bacteria. It is understood that the growth of Klebsiella pneumoniae ATCC 4352 is typically 5000% over this time period, so an increase of −820.37% indicates that the growth of this gram negative bacteria was slowed by to about 20% of its normal growth rate.

Claims

What is claimed is:

1. An antimicrobial garment comprising:

an antimicrobial fabric, wherein the antimicrobial fabric includes at least one synthetic silver fiber and at least one silver-free fiber,

wherein the synthetic silver fiber includes a synthetic fiber having elemental silver particles bound to the synthetic fiber, and

wherein the at least one silver-free fiber includes a basic fiber having less than 0.1 weight percent of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.

2. The antimicrobial garment of claim 1, wherein from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 30 micrometers.

3. The antimicrobial garment of claim 1, wherein the synthetic silver fiber includes from about 0.01 to about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber, or

wherein the antimicrobial fabric has from about 10 mg/kg to about 100 mg/kg of the elemental silver particles per the antimicrobial fabric.

4. The antimicrobial garment of claim 1, wherein the synthetic silver fiber has a thickness characterized by from about 30 g per 9000 meters of fiber to about 900 g per 9000 meters of fiber or from about 10 km/kg to about 60 km/kg,

wherein the antimicrobial garment contains from about 10% to 100% weight of the antimicrobial fabric based on a total weight of the antimicrobial garment,

wherein the antimicrobial garment has a fabric weight of from about 50 g/m²to about 350 g/m², and

wherein the antimicrobial garment contains from about 10 to about 20 weight percent of the synthetic silver fiber based on a total weight of the antimicrobial garment.

5. The antimicrobial garment of claim 1, wherein the synthetic fiber includes at least one of a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer, an acrylic polymer, or a combination, co-polymer, or blend thereof; and

wherein the at least one basic fiber includes

a natural fiber, wherein the natural fiber includes a cotton, a wool, a silk, a hemp, a rayon, a bamboo, a banana, a modal, a lyocell, or combination, a blend or weave thereof, or

an unnatural fiber, wherein the unnatural fiber includes a polyester, a nylon, an aramid, a polypropylene, a polyethylene, a polyether-polyurea copolymer, an acrylic polymer, or a combination, co-polymer, or blend thereof.

6. The antimicrobial garment of claim 1, wherein the antimicrobial garment is selected from a group consisting of a shirt, a yoga pant, a tight, a legging, a short, an arm warmer, an ankle brace, a hat, a gi, a leg warmer, a hosiery, a leotard, a unitard, a tutu, a jersey, a sock, a fatigue, a uniform, a costume, a jockstrap, a sweat pant, a sweat shirt, a bra, a swimsuit, a belt, a coat, a headband, a dress, a skirt, a short, an undergarment, a jacket, a trouser, a suit, a robe, a saris, a scrub, a neckwear, and a top.

7. The antimicrobial garment of claim 1, the antimicrobial garment further comprising an optical brightener and at least one of a dye or a pigment.

8. The antimicrobial garment of claim 1, wherein the antimicrobial garment reduces growth of gram positive bacteria by from about 95% to 100% relative to a garment without the antimicrobial fabric.

9. A method of manufacturing an antimicrobial garment comprising:

weaving or knitting the at least one synthetic silver fiber and at least one silver-free fiber together to form an antimicrobial fabric, and

cutting or sewing the antimicrobial fabric to form the antimicrobial garment of claim 1,

wherein the at least one silver-free fiber includes a basic fiber having less than 0.1% weight of silver particles bound to the basic fiber based on a total weight of the silver-free fiber.

10. An antimicrobial fabric product comprising:

11. The antimicrobial fabric product of claim 10, wherein from about 80% to 100% of the elemental silver particles have a particle size of from about 1 micrometer to about 30 micrometers.

12. The antimicrobial fabric product of claim 10, wherein the synthetic silver fiber includes from about 0.01 to about 3.0 weight percent of elemental silver particles based on a total weight of the synthetic silver fiber, or

wherein a fabric in the antimicrobial fabric product has from about 10 mg/kg to about 100 mg/kg of elemental silver particles per a total weight of the fabric in the antimicrobial fabric product.

13. The antimicrobial fabric product of claim 10,

wherein the synthetic silver fiber has a thickness characterized by from about 30 g per 9000 meters of fiber to about 900 g per 9000 meters of fiber or from about 10 km/kg to about 60 km/kg,

wherein a fabric in the antimicrobial fabric product contains from about 90% to 100% weight of the antimicrobial fabric based on a total weight of the fabric in the antimicrobial fabric product, and

wherein the fabric in the antimicrobial fabric product has a fabric weight of from about 50 g/m²to about 350 g/m².

14. The antimicrobial fabric product of claim 10, wherein the fabric in the antimicrobial fabric product further comprises an optical brightener and at least one of a dye or a pigment.

15. The antimicrobial fabric product of claim 10, wherein the antimicrobial fabric product is a garment, a diaper, a piece of cloth furniture, a bag, a bed lining, a towel, a pillow case, a bandage, an article of feminine hygiene, a cleaning cloth, a foot wear, an insole, or an accessory.