WO2023086213A1

WO2023086213A1 - Wet wipes with zinc loading

Info

Publication number: WO2023086213A1
Application number: PCT/US2022/048017
Authority: WO
Inventors: Gregory KIGGINS
Original assignee: Ascend Performance Materials Operations Llc
Priority date: 2021-11-13
Filing date: 2022-10-27
Publication date: 2023-05-19

Abstract

This disclosure relates to a wet wipe fabric sheet comprising fibers comprising a polymer and zinc; and a lotion composition comprising less than 0.5 wt% preservative, such as phenoxyethanol, wherein the fibers retain greater than 200 wt% liquid, and the fibers inhibit mold formation. The disclosure also relates to a method of inhibiting or preventing mold and/or odor in a wet wipe fabric sheet, without the use of synthetic preservatives.

Description

WET WIPES WITH ZINC LOADING

PRIORITY CLAIM

[0001] The This application claims priority to U.S. Provisional Application No. 63/279,081, filed on November 13, 2021, which is incorporated herein by reference.

FIELD

[0002] The present disclosure relates to a wet wipe made of fibers comprising a polymer and zinc that inhibit mold formation.

BACKGROUND

[0003] Wet wipes are typically constructed from porous or absorbent sheets impregnated with a lotion, and have a variety of uses. Two main categories of use include (1) those for general household cleaning tasks, such as the cleaning of hard surfaces like floors or kitchen surfaces, and (2) those made for personal cleansing, such as the removal of make-up, the cleaning of infants, or the cleaning of the hands/skin after meals or while traveling. Wipes have also found use with feminine health and adult incontinence products.

[0004] A major portion of the wipes intended for the cleansing of human skin are wet wipes that are designed for use with infants and young children. They are particularly used by parents during the changing of babies to clear away any excess fecal or urine residues before applying a fresh diaper. Wet wipes should be effective at cleaning, and inhibit mold formation and prevent odor, while at the same time being gentle and mild on the skin.

[0005] Preservative systems are typically added to wet wipes to inhibit mold formation and prevent odor. However, large amounts of preservative systems can introduce harsh chemicals into the lotion of the wet wipe, which creates irritability on the skin.

[0006] There is therefore a need for a wet wipe that inhibits or prevents mold formation and odor while containing low amounts of preservatives, so as to maintain a wet wipe that is gentle and mild on the skin. This invention answers that need.

SUMMARY

[0007] In some cases, the present disclosure relates to a wet wipe fabric sheet comprising fibers comprising a polymer (e.g. PA66) and zinc; and a lotion composition comprising less than 0.5 wt% preservative (e.g. phenoxyethanol); wherein the fibers retain greater than 200 wt% liquid; and the fibers inhibit mold formation.

[0008] In some cases, the present disclosure relates to a preservative-free wet wipe fabric sheet comprising fibers comprises a polyamide polymer matrix embedded with ionic zinc (Zn²⁺); and a lotion composition free of any synthetic preservative (e.g. phenoxyethanol); wherein the fibers retain greater than 200 wt% liquid; and the fibers inhibit mold formation.

[0009] In some cases, the present disclosure relates to a method of inhibiting or preventing mold and/or odor in a wet wipe fabric sheet, without the use of synthetic preservatives (e.g. phenoxyethanol), comprising the steps of (a) introducing fibers comprising a polymer (e.g. PA66) and zinc into a wet wipe fabric sheet, and (b) adding a lotion composition to the wet wipe fabric sheet; wherein the fibers inhibit or prevent mold and/or odor in the wet wipe fabric sheet without the need for synthetic preservatives.

DETAILED DESCRIPTION

Introduction

[0010] As noted above, conventional wet wipes are often employed for cleansing the skin of infants and young children. These wet wipes, however, require significant amounts of harsh preservatives (e.g. phenoxyethanol), so as to inhibit mold formation and prevent odor. Unfortunately, these preservatives have the detrimental effect of irritating the skin, especially in the case of young children.

[0011] It has now been found that the employment of the antiodor, antifungal, antimicrobial, and/or antiviral (“AM/ AV”) compounds in materials used for personal-cleaning compositions has been shown to demonstrate efficacy against odor, microbials, bacteria, viruses, fungi, or parasites, while beneficially reducing or eliminating the need for harsh, skin-irritating preservatives. The addition of the AM/ AV compounds to wet wipes are particularly advantageous when utilized in conjunction with fabrics made of hygroscopic polymers, e.g., polyamides (collectively AM/ AV (polymer) compositions). The inventors have unexpectedly found that the disclosed polyamides, when combined with the AM/ AV compounds, provide both the a synergistic combination of benefits, e.g., the ability to retain moisture content and the ability to inhibit mold. Because the fibers contribute AM/ AV properties such as mold inhibition, wet wipes formed therefrom are able to be formulated with little or no synthetic preservatives. Stated another way, the mold inhibition characteristics traditionally achieved with synthetic preservatives can now advantageously be achieved with the AM/ AV fibers.

[0012] In addition, the disclosed AM/ AV polymer compositions form AM/ AV materials that have also been found to be unexpectedly compliant, soft feeling (low denier/small diameter), and nonirritating to the skin. This is particularly beneficial when the wet wipes are used on infants, whose skin is even more sensitive or rash-prone. It was found that the disclosed AM/ AV compounds, e.g., zinc compounds, are particularly advantageous for this reason (vs. silver or other less skin-friendly compounds). The AM/ AV polymer compositions, which include both the AM/ AV compounds and the polymer components are discussed in detail below.

Wet Wipes

[0013] The present disclosure relates to a wet wipe fabric sheet (wet wipe) comprising an AM/ AV material of fibers that are made from or that comprise an AM/ AV polymer composition the AM/ AV polymer composition comprises a polymer and an AM/ AV compound, e.g., zinc, and these are described in more detail herein. The wet wipe further comprises a lotion composition, and the lotion composition beneficially comprises little or no preservative, e.g., less than 0.5 wt% preservative. As a result of their compositional make-up, the fibers inhibit mold formation and also optionally retain greater than 200 wt% liquid.

[0014] The AM/ AV material may be a fiber or collection of fibers (thus forming a fabric). The AM/ AV materials have the beneficial performance properties discussed herein. The wet wipe AM/ AV materials of the present disclosure may be utilized in a variety of industries, including household cleaning, personal cleansing, feminine hygiene, adult incontinence, public safety, healthcare, and pet industries. The AM/ AV material, and the wet wipes generally, in some cases, may comprises a single layer/sheet of fibers. In other cases the wet wipes comprise multiple layers. The composition of the fibers, fabrics, and layers is discussed in more detail herein. And the methods of producing the fibers, fabrics, layers, and materials, e.g., spunbonding, spun lace, melt blowing, electrospinning, inter alia, are discussed in more detail herein. Other production processes are contemplated, including textile spinning and weaving. [0015] The lotion composition may contain water, one or more surfactants, moisturizer, preservatives, fragrants, emollients, colorants, opacifying agents, film-formers, soothing agents, skin protectants, medically active ingredients, healing actives, and other components known to those of skill in the art. [0016] Advantageously, the lotion composition (and the wet wipes as a whole) comprises little or no preservative. In some embodiments, the wet wipes comprise less than 10 wt% preservative, e.g., less than 8 wt%, less than 5 wt%, less than 3 wt%, less than 2 wt%, less than 1 wt%, less than 0.5 wt%, less than 0.3 wt%, less than 0.1 wt% or less than 0.05 wt%. In term of ranges, the wt wipes may comprise from 1 ppb to 10 wt% preservative, e.g., from 1 ppb to 5 wt%, from 100 ppb to 1 wt%, from 1 ppm to 5 wt%, from 10 ppm to 3 wt%, from 50 ppm to 1 wt%, or from 100 ppm to 0.5 wt%. In some cases, the wet wipes may comprise some preservative, albeit a reduced amount, e.g., greater than 1 ppb, greater than 10 ppb, greater than 100 ppb, greater than 1 ppm, greater than 10 ppm, greater than 100 ppm, greater than 0.1 wt%, greater than 1 wt%, or greater than 3 wt%. These percentages are based on the total weight of the lotion composition.

[0017] The preservatives that are present in low amounts or not present at all may vary widely, and many suitable preservatives are known. On example of a preservative is phenoxyethanol. In some embodiments, the phenoxyethanol can be avoided altogether. Thus, embodiments of this invention relate to wet wipe fabric sheets that do not contain any phenoxyethanol. Without being bound by theory, it is believed that phenoxyethanol (and many preservatives generally) is particularly abrasive and caustic when used in formulations like wet wipes, which are designed to be mild and gentle on the skin. The limited amounts of phenoxyethanol provide a wet wipe having significantly improved skin-friendly chemistry, while still imparting the anti-mold/mildew/microbial benefits (via the AM/ AV compound). This is achieved through the beneficial and synergistic relationship from the polyamide fibers and zinc, discussed below.

[0018] In some cases, the wet wipe may contain a small amount of (natural) preservatives, see limits above. Natural (or non- synthetic) preservatives, including organic acids, such as citric acid, are contemplated being used in the lotion composition. Suitable organic acids include citric acid, anisic acid, malic acid, lactic acid, dehydroacetic acid, gluconic acid, salicylic acid, benzoic acid, sorbic acid, levulinic acid, and mixtures thereof. Even the natural or non-synthetic preservatives can be used in small amounts, such as less than 1.0 wt%, less than 0.75 wt%, less than 0.5 wt%, less than 0.25 wt% and less than 0.1 wt%. In terms of ranges, the natural or nonsynthetic preservatives range from 0.1 wt% to 1.0 wt%, 0.25 wt% to 0.75 wt%, 0.1 wt% to 0.5 wt%, or 0.5 wt% to 1.0 wt%. [0019] The surfactant may be an individual surfactant or a mixture of surfactants. For instance, the surfactant may be a polymeric surfactant or a non-polymeric one. The surfactant or combinations of surfactants may be mild, meaning that the surfactants provide sufficient cleaning or detersive benefits but do not overly dry or otherwise harm or damage the skin. The surfactant, when present in the lotion, is typically present in an amount ranging from about 0.05% to about 1%, alternatively from about 0.075% to about 0.5%, alternatively from about 0.1% to about 0.2%, and alternatively from about 0.15% to about 0.2% by weight of the lotion. [0020] In some cases, the AM/ AV materials or the layers thereof are not harmful or are less harmful to the wearer/user. As one metric for example, the AM/ AV materials or the layers thereof may be tested to assess in vitro cytotoxicity of the materials (e.g., according to ISO 10993-5:2009) and/or to assess the potential of the materials to produce skin irritation (e.g., according to ISO 10993-10:2010). The AM/ AV materials or the layers thereof adequately passes such testing.

[0021] Further, the use of the AM/ AV compositions has been shown to increase overall hydrophilicity and/or hygroscopy of the AM/ AV materials. For example, it is theorized that a polymer of increased hydrophilicity and/or hygroscopy both may better attract liquid and/or capture media that carry microbials and/or viruses, e.g., waste, and may also absorb more moisture, e.g., from the air, and that the increased moisture content allows the polymer composition and the AM/ AV compound to more readily destroy, limit, reduce, or inhibit infection and/or pathogenesis of a microbe or virus. For example, the moisture may dissolve an backsheet layer, e.g., capsid, of a virus, exposing the genetic material, e.g., DNA or RNA, of the virus.

[0022] In addition, in some cases, the disclosed AM/ AV materials may contain little or no reinforcement material, e.g., glass- and/or carbon fibers, (carbon) nanotubes, particulate fillers, such as mineral fillers based on natural and/or synthetic layer silicates, talc, mica, silicate, quartz, titanium dioxide, wollastonite, kaolin, amorphous silicic acids, magnesium carbonate, magnesium hydroxide, chalk, lime, feldspar, barium sulphate, solid or hollow glass balls or ground glass, permanently magnetic or magnetizable metal compounds and/or alloys and/or combinations thereof, and also combinations thereof. In some cases, the disclosed AM/ AV materials comprise less than 50 wt% of these materials, e.g., less than 25 wt%, less than 10 wt%, less than 5 wt%, less than 1 wt%, less than 5000 wppm, or less than 1000 wppm. In some case, because the AM/ AV materials comprise little or no reinforcement material, they have also been found to be unexpectedly compliant and soft feeling (having low denier/small diameter), as noted above.

[0023] The disclosed AM/ AV materials, e.g., fabric sheets, may provide comfort to the user, for example due to the softness or formability of the layer, e.g., due to the characteristics of the fabric sheet such as fiber diameter or denier, which may provide the softness. The fabrics may be constructed of AM/ AV fibers and/or fabrics, and as such, may impart AM/ AV capabilities thereto. As a result, the fabric sheet may prevent transmission of pathogens from contact that otherwise would allow the pathogen to spread or to pass through the material to the wearer. [0024] The fabric sheet may be composed of fibers or a fabric. In some cases, the fibers are polymer fibers, e.g., polyamide fibers, such as polyamide microfibers or polyamide nanofibers. The structure of the fibers is not particularly limited. In some embodiments, the fiber is a nonwoven fiber. In some embodiments, the fabric is a woven fabric. For example, the fabric may be composed of spunlaced fibers, spunbond fibers, meltblown fibers, staple fibers, flashspun fibers, carded fibers, or airlaid fibers, although other formation methods are contemplated.

[0025] Generally speaking, the differences in production method have been found to be important. For example, because of the nature of the respective processing, the characteristics of the various fabrics have been found to be unexpectedly beneficial. In some cases, spunlace (hydroentangled) fabrics are beneficial because they advantageously provide softness, which beneficially improves performance in next-to-skin applications. As another example, the polyamide polymer composition may provide hydrophilic and/or hygroscopic features, which are beneficial for the reasons discussed herein. Also, the integrity of spunbond fabrics, especially those fabrics that have been calendered may contribute to the overall strength, wear, and durability of the resultant materials.

[0026] The composition of the wet wipe fabric sheet, e.g., the composition of the fabric and/or the fibers thereof, may vary widely. In some embodiments, the fabric sheet and/or the fibers thereof are made from and/or comprises the polyamide composition that is discussed in detail below. The polyamide composition comprises a polymer and an AM/ AV compound, and in some cases, the AM/ AV compound provided for the AM/ AV benefits. In some cases, the fabric is a polymer, e.g., polyamide, fabric made from the polymer compositions described herein. [0027] In some embodiments, the fabric sheet comprises a plurality of fibers having an average fiber diameter less than 50 microns, e.g., less than 45 microns, less than 40 microns, less than 35 microns, less than 30 microns, less than 25 microns, less than 20 microns, less than 15 microns, less than 10 microns, or less than 5 microns. In terms of lower limits, the plurality of fibers may have an average fiber diameter greater than 1 micron, e.g., greater than 1.5 microns, greater than 2 microns, greater than 2.5 microns, greater than 5 microns, or greater than 10 microns. In terms of ranges, the plurality of fibers may have an average fiber diameter from 1 micron to 50 microns, e.g., from 1 micron to 45 microns, from 1 micron to 40 microns, from 1 micron to 35 microns, from 1 micron to 30 microns, from 1 micron to 20 microns, from 1 micron to 15 microns, from 1 micron to 10 microns, from 1 micron to 5 microns, from 1.5 microns to 25 microns, from 1.5 microns to 20 microns, from 1.5 microns to 15 microns, from 1.5 microns to 10 microns, from 1.5 microns to 5 microns, from 2 microns to 25 microns, from 2 microns to 20 microns, from 2 microns to 15 microns, from 2 microns to 10 microns, from 2 microns to 5 microns, from 2.5 microns to 25 microns, from 2.5 microns to 20 microns, from 2.5 microns to 15 microns, from 2.5 microns to 10 microns, from 2.5 microns to 5 microns, from 5 microns to 45 microns, from 5 microns to 40 microns, from 5 microns to 35 microns, from 5 microns to 30 microns, from 10 microns to 45 microns, from 10 microns to 40 microns, from 10 microns to 35 microns, from 10 microns to 30 microns. In some cases, fibers of this size may be referred to as microfibers.

[0028] In some embodiments, the fabric sheet comprises a plurality of fibers having an average fiber diameter less than 1 micron, e.g., less than 0.9 microns, less than 0.8 microns, less than 0.7 microns, less than 0.6 microns, less than 0.5 microns, less than 0.4 microns, less than 0.3 microns, less than 0.2 microns, less than 0.1 microns, less than 0.05 microns, less than 0.04 microns, or less than 0.03 microns. In terms of lower limits, the average fiber diameter of the plurality of fibers may be greater than 1 nanometer, e.g., greater than 10 nanometers, greater than 25 nanometers, or greater than 50 nanometers. In terms of ranges, the average fiber diameter of the plurality of fibers may be from 1 nanometer to 1 micron, e.g., from 1 nanometer to 0.9 microns, from 1 nanometer to 0.8 microns, from 1 nanometer to 0.7 microns, from 1 nanometer to 0.6 microns, from 1 nanometer to 0.5 microns, from 1 nanometer to 0.4 microns, from 1 nanometer to 0.3 microns, from 1 nanometer to 0.2 microns, from 1 nanometer to 0.1 microns, from 1 nanometer to 0.05 microns, from 1 nanometer to 0.04 microns, from 1 nanometer to 0.3 microns, from 10 nanometers to 1 micron, from 10 nanometers to 0.9 microns, from 10 nanometers to 0.8 microns, from 10 nanometers to 0.7 microns, from 10 nanometers to 0.6 microns, from 10 nanometers to 0.5 microns, from 10 nanometers to 0.4 microns, from 10 nanometers to 0.3 microns, from 10 nanometers to 0.2 microns, from 10 nanometers to 0.1 microns, from 10 nanometers to 0.05 microns, from 10 nanometers to 0.04 microns, from 10 nanometers to 0.03 microns, from 25 nanometers to 1 micron, from 25 nanometers to 0.9 microns, from 25 nanometers to 0.8 microns, from 25 nanometers to 0.7 microns, from 25 nanometers to 0.6 microns, from 25 nanometers to 0.5 microns, from 25 nanometers to 0.4 microns, from 25 nanometers to 0.3 microns, from 25 nanometers to 0.2 microns, from 25 nanometers to 0.1 microns, from 25 nanometers to 0.05 microns, from 25 nanometers to 0.04 microns, from 25 nanometers to 0.03 microns, from 50 nanometers to 1 micron, from 50 nanometers to 0.9 microns, from 50 nanometers to 0.8 microns, from 50 nanometers to 0.7 microns, from 50 nanometers to 0.6 microns, from 50 nanometers to 0.5 microns, from 50 nanometers to 0.4 microns, from 50 nanometers to 0.3 microns, from 50 nanometers to 0.2 microns, from 50 nanometers to 0.1 microns, from 50 nanometers to 0.05 microns, from 50 nanometers to 0.04 microns, or from 50 nanometers to 0.03 microns. In some cases, fibers of this size may be referred to as nanofibers.

[0029] In some cases, the fabric sheet has a thickness ranging from 25 microns to 500 microns, e.g., from 25 microns to 400 microns, from 35 microns to 300 microns, or from 50 microns to 275 microns. In terms of upper limits, the fabric sheet may have a thickness less than 500 microns, e.g., less than 400 microns, less than 300 microns, or less than 275 microns. In terms of lower limits, the topsheet layer may have a thickness greater than 25 microns, e.g., greater than 35 microns, greater than 50 microns, or greater than 60 microns.

[0030] It has been found that the fabric sheet may advantageously be composed of a relatively hydrophilic and/or hygroscopic material. A polymer of increased hydrophilicity and/or hygroscopy may better attract and hold moisture to which to the AM/ AV material is exposed. As discussed below, improved, e.g., increased, hydrophilicity and/or hygroscopy may be accomplished by utilizing the polymer compositions described herein. Thus, it is particularly beneficial to form the fabric sheet, e.g., the fibers, from a disclosed polymer composition.

Package of wet wipes [0031] An article of commerce may comprise a package, or packaging, and a plurality of the wet wipes fabric sheets. The packaging may be in the form of a container. Containers may include, but are not limited to, tubs, flow wrap pouches, individual sachets, chained sachets comprising a tear line between each sachet, and other forms known in the art as suitable for storing nonwoven articles. Additionally, the container may also be manufactured to facilitate removal of individual wet wipes.

[0032] The container may be made of any suitable material or materials and may be manufactured in any suitable manner. For example, the container may be made of polystyrene, polypropylene, PET, POET, polyethylene, polyester, polyvinyl alcohol, or the like. The container may also be made of a mixture of the above materials. The container may be made of a metal foil. The container may be manufactured by, for example, a vacuum molding process or an injection molding process, or any suitable process.

[0033] In some cases, the disclosure relates to a method of inhibiting or preventing mold and/or odor in a wet wipe fabric sheet, optionally without the use of synthetic preservatives, comprising the step of introducing fibers comprising a polymer and zinc into a wet wipe fabric sheet. The method further comprises the step of adding a lotion composition to the wet wipe fabric sheet. The fibers inhibit or prevent mold and/or odor in the wet wipe fabric sheet without the need for synthetic preservatives.

[0034] In some embodiments, the disclosure relates to a method comprising the step of forming a wet wipe fabric sheet comprising fibers comprising the AM/ AV composition disclosed herein. The forming may be performed by employing the fabric forming methods disclosed herein and using the AM/ AV composition. The method further comprises the step of adding a lotion composition to the wet wipe fabric sheet. The lotion can be added at any point.

Physical Characteristics

[0035] As noted, each layer of the AM/ AV material may benefit from increased hydrophilicity and/or hygroscopy. Each of the layers may benefit from increased hydrophilicity and/or hygroscopy, examples include the topsheet layer. In some embodiments, the topsheet layer and/or the pad layer demonstrates relatively high hydrophilicity and/or hygroscopy.

[0036] In some cases, the hydrophilicity and/or hygroscopy of a given layer of the AM/ AV material may be measured by saturation. In some cases, the hydrophilicity and/or hygroscopy of a given layer of the AM/ AV material may be measured by the amount of water it can absorb (as a percentage of total weight). In some embodiments, the layer is capable of absorbing greater than 1.5 wt.% water, based on the total weight of the polymer, e.g., greater than 2.0 wt.%, greater than 3.0%, greater than 5.0 wt.%, greater than 7.0 wt.%, greater than 10.0 wt.%. or greater than 25.0 wt.%. In terms of ranges, the hydrophilic and/or hygroscopic polymer may be capable of absorbing water in an amount ranging from 1.5 wt.% to 50.0 wt.%, e.g., from 1.5 wt.% to 14.0 wt.%, from 1.5 wt.% to 9.0 wt.%, from 2.0 wt.% to 8 wt.%, from 2.0 wt.% to 7 w%, from 2.5 wt.% to 7 wt.%, or from 1.5 wt.% to 25.0 wt.%.

[0037] In some cases, the hydrophilicity and/or the hygroscopy of a given layer of the AM/ AV material may be measured by the water contact angle of the layer. The water contact angle is the angle formed by the interface of a surface of the layer, e.g., of the topsheet layer. Preferably, the contact angle of the layer is measured while the layer is flat (e.g., substantially flat).

[0038] In one embodiment, the fibers can retain greater than 100% liquid in the fabric sheet, e.g., greater than 200% liquid, greater than 250% liquid, greater than 300% liquid, greater than 350% liquid, greater than 400% liquid, greater than 500% liquid, greater than 600% liquid, greater than 700% liquid, greater than 800% liquid, greater than 900% liquid, or greater than 1000% liquid. The fibers, and the wet wipes, may retain more than their own weight of liquid. In terms of ranges, the fiber may retain a range from 100% to 1000% liquid, e.g., from 200% to 300% liquid, from 200% to 400% liquid, from 300% to 400% liquid, from 250% to 350% liquid, from 200% to 500% liquid, from 300% to 600% liquid, from 400% to 800% liquid, or from 500% to 1000% liquid.

[0039] The retention of liquid allows the wet wipe to have a longer shelf life, both after the wet wipe package has been opened and prior to the wet wipe package from being opened. For example, fibers having an ability to retain liquid, for instance 200% liquid or more, can demonstrate a shelf life of one year or more.

[0040] The AM/ AV materials of the present disclosure advantageously provide AM/ AV properties, e.g., pathogen-destroying properties. For example, the disclosed AM/ AV materials destroy pathogens via contact with the AM/ AV layer(s) before the pathogens have a chance to enter or contact the body. The AM/ AV properties are made possible, at least in part, by the composition of the fibers that make up the layers. At least one of the layers contains a polymer component along with an AM/ AV compound, e.g., zinc and/or copper, which in some cases, is embedded in the polymer structure (but may not be a component of a polymerized co-polymer). The presence of the AM/ AV compound in the polymers of the fibers provides for the pathogendestroying properties. As a result, the disclosed items prevent growth or transmission of pathogens from contact that otherwise would allow the pathogen to spread. Importantly, because the AM/ AV compound may be embedded in the polymer structure, the AM/ AV properties are durable, and are not easily worn or washed away. Thus, the AM/ AV materials disclosed herein achieve a synergistic combination of AM/ AV efficacy and biocompatibility, e.g. irritation and sensitization, performance. In contrast, conventional configurations that employ no AM/ AV compound (or that do not meet the disclosed physical characteristic limits, e.g., basis weight or fiber diameter) do not and cannot provide the aforementioned synergistic combination of performance features.

[0041] In some embodiments, a layer of the AM/ AV material demonstrates a water contact angle less than 90°, e.g., less than 85°, less than 80°, or less than 75°. In terms of lower limits, the water contact angle of a layer may be greater than 10°, e.g., greater than 20°, greater than 30°, or greater than 40°. In terms of ranges, the water contact angle of a layer may be from 10° to 90°, e.g., from 10° to 85°, from 10° to 80°, from 10° to 75°, from 20° to 90°, from 20° to 85°, from 20° to 80°, from 20° to 75°, from 30° to 90°, from 30° to 85°, from 30° to 80°, from 30° to 75°, from 40° to 90°, from 40° to 85°, from 40° to 80°, or from 40° to 75°.

[0042] As noted, the increased hydrophilicity and/or hygroscopy of AM/ AV material may be the result of a polymer composition from which the layer is formed. The polymer compositions described herein, for example, demonstrate increased hydrophilicity and/or hygroscopy and are therefore particularly suitable for the disclosed AM/ AV material.

[0043] In some embodiments, a polymer may be specially prepared to impart increased hydrophilicity and/or hygroscopy. For example, an increase in hygroscopy may be achieved in the selection and/or modification the polymer. In some embodiments, the polymer may be a common polymer, e.g., a common polyamide, which has been modified to increase hygroscopy. In these embodiments, a functional endgroup modification on the polymer may increase hygroscopy. For example, the polymer may be PA6,6, which has been modified to include a functional endgroup that increases hygroscopy. Performance Characteristics

[0044] The performance of the AM/ AV material described herein may be assessed using a variety of conventional metrics.

[0045] Antiodor performance may be measured by toilet odor reduction, as measured in accordance with ISO 17299-3 (2014). In some embodiments, the AM/ AV material demonstrates a toilet odor reduction greater than 50% e.g., greater than 60%, greater than 70%, greater than 80%, or greater than 90%. Toilet odor may be tested using specific test chemicals, e.g., ammonia, acetic acid, isovaleric acid, hydrogen sulfide, indole, and/or nonenal. At least one of the layers (or the fibers thereof) demonstrates the toilet odor reduction for one or more of these test chemicals. The disclosed wet wipes may demonstrate a toilet odor reduction greater than 50%, e.g., greater than 60%, greater than 70%, or greater than 80%, as measured in accordance with ISO 17299-3 (2014).

[0046] In some cases, the AM/ AV performance relates to antifungal performance. The antifungal activity of the AM/ AV materials may be measured by the standard procedure defined by Mod. E3160. In one embodiment, the AM/ AV materials inhibits the growth (growth reduction) of Candida auris or Candida albicans in an amount greater than 10% fungal growth, e.g., greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90% or greater than 93%.

[0047] In some cases, the performance relates to comfort performance. The comfort of the AM/ AV materials may be measured by the standard procedure defined by cup crush testing, as defined be NWSP 402.0. Another measurement method is the use of the FTT Fabric Touch Tester from SDL Atlas.

[0048] Bacterial filtration efficiency (or “BFE”) measures how well the AM/ AV material traps or isolates bacteria when exposed to a bacteria-containing aerosol. BFE measures a percentage of bacteria that trapped or isolated by the AM/ AV material. ASTM International specifies testing with a droplet size of 3.0 microns containing Staph, aureus (average size 0.6-0.8 microns).

[0049] In some embodiments, the AM/ AV material demonstrates a BFE greater than 90%, e.g., greater than 92%, greater than 93%, greater than 94%, greater than 95%, greater than 97%, greater than 98%, greater than 99%, greater than 99.5%, greater than 99.9%, or greater than 99.99%. In terms upper limits, the AM/ AV material may demonstrate a BFE less than 100%, e.g., less than 99.999%, less than 99.995%, less than 99.99%, or less than 99.95%.

[0050] In some embodiments, the AM/ AV material demonstrates a BFE of about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 95.5%, about 96%, about 96.5%, about 97%, about 97.5%, about 98%, about 98.5%, about 99%, about 99.2%, about 99.3%, about 99.4%, about 99.5%, about 99.8%, about 99.9%, about 99.95%, or about 99.99%, or any percentage therebetween.

[0051] As has been noted, in some embodiments, the AM/ AV materials may demonstrate AM/ AV activity. In some cases, the AM/ AV activity may be the result of the polymer composition from which the AM/ AV materials or the layers/fabrics thereof or the fibers thereof are formed. For example, the AM/ AV activity may be the result of forming the AM/ AV materials from a polymer composition described herein.

[0052] In some embodiments, the AM/ AV materials exhibit permanent, e.g., near permanent, AM/ AV properties. Said another way, the AM/ AV properties of the polymer composition last for a prolonged period of time, e.g., longer than one or more day, longer than one or more week, longer than one or more month, or longer than one or more years.

[0053] The AM/ AV properties may include any antimicrobial effect. In some embodiments, for example, the antimicrobial properties of the AM/ AV material include limiting, reducing, or inhibiting infection of a microbe, e.g., a bacterium or bacteria. In some embodiments, the antimicrobial properties of the AM/ AV material include limiting, reducing, or inhibiting growth and/or killing a bacterium. In some cases, the AM/ AV material may limit, reduce, or inhibit both infection and growth of a bacterium.

[0054] The bacterium or bacteria affected by the antimicrobial properties of the AM/ AV material are not particularly limited. In some embodiments, for example, the bacterium is a Streptococcus bacterium (e.g., Streptococcus pneumonia, Streptococcus pyogenes), a Staphylococcus bacterium (e.g., Staphylococcus aureus, Methicillin-resistant Staphylococcus aureus (MRSA)), a Peptostreptococcus bacterium (e.g., Peptostreptococcus anaerobius, Peptostreptococcus asaccharolyticus), a coli bacterium (e.g., Escherichia coli), or a Mycobacterium bacterium, (e.g., Mycobacterium tuberculosis), a Mycoplasma bacterium (e.g., Mycoplasma adleri, Mycoplasma agalactiae, Mycoplasma agassizii, Mycoplasma amphoriforme, Mycoplasma fermentans, Mycoplasma genitalium, Mycoplasma haemofelis, Mycoplasma hominis, Mycoplasma hyopneumoniae, Mycoplasma hyorhinis. Mycoplasma pneumoniae'). In some embodiments, the antimicrobial properties include limiting, reducing, or inhibiting the infection or pathogenesis of multiple bacteria, e.g., a combination of two or more bacteria from the above list.

[0055] The antimicrobial activity of the AM/ AV materials may be measured by the standard procedure defined by ISO 20743:2013. This procedure measures antimicrobial activity by determining the percentage of a given bacterium or bacteria, e.g. Staphylococcus aureus, inhibited by a tested fiber. In one embodiment, the AM/ AV material inhibits the growth (growth reduction) of S. aureus in an amount ranging from 60% to 100%, e.g., from 60% to 99.999999%, from 60% to 99.99999%, from 60% to 99.9999%, from 60% to 99.999% from 60% to 99.999%, from 60% to 99.99%, from 60% to 99.9%, from 60% to 99%, from 60% to 98%, from 60% to 95%, from 65% to 99.999999%, from 65% to 99.99999%, from 65% to 99.9999%, from 65% to 99.999% from 65% to 99.999%, from 65% to 100%, from 65% to 99.99%, from 65% to 99.9%, from 65% to 99%, from 65% to 98%, from 65% to 95%, from 70% to 100%, from 70% to 99.999999%, from 70% to 99.99999%, from 70% to 99.9999%, from 70% to 99.999% from 70% to 99.999%, from 70% to 99.99%, from 70% to 99.9%, from 70% to 99%, from 70% to 98%, from 70% to 95%, from 75% to 100%, from 75% to 99.99%, from 75% to 99.9%, from 75% to 99.999999%, from 75% to 99.99999%, from 75% to 99.9999%, from 75% to 99.999% from 75% to 99.999%, from 75% to 99%, from 75% to 98%, from 75% to 95%, %, from 80% to 99.999999%, from 80% to 99.99999%, from 80% to 99.9999%, from 80% to 99.999% from 80% to 99.999%, from 80% to 100%, from 80% to 99.99%, from 80% to 99.9%, from 80% to 99%, from 80% to 98%, or from 80% to 95%. In terms of lower limits, the AM/ AV material may inhibit greater than 60% growth of S. aureus, e.g., greater than 65%, greater than 70%, greater than 75%, greater than 80%, greater than 85%, greater than 90%, greater than 95%, greater than 98%, greater than 99%, greater than 99.9%, greater than 99.99%, greater than 99.999%, greater than 99.9999%, greater than 99.99999%, or greater than 99.999999%.

[0056] Klebsiella pneumoniae efficacy may also be determined using the aforementioned tests. In some embodiments, a product formed from the polymer composition inhibits the growth (growth reduction) of Klebsiella pneumoniae, as measured by the test mentioned above. Escherichia coli may be determined using ASTM E3160 (2018). The ranges and limits for Staph Aureus are applicable to Escherichia coli and/or Klebsiella pneumoniae and/or SARS-CoV-2 as well.

[0057] Efficacy may be characterized in terms of log reduction. In terms of Escherichia coli log reduction, the composition/fibers/fabrics may be determined via ASTM 3160 (2018) and may demonstrate a coli log reduction greater than 1.5, e.g., greater than 2.0, greater than 2.15, greater than 2.5, greater than 2.7, greater than 3.0, greater than 3.3, greater than 4.0, greater than 4.1, greater than 5.0, or greater than 6.0.

[0058] In terms of Staph Aureus log reduction, the composition/fibers/fabrics may be determined via ISO 20743:2013 and may demonstrate a microbial log reduction greater than 1.5, e.g., greater than 2.0, greater than 2.5, greater than 2.7, greater than 3.0, greater than 4.0, greater than 5.0, or greater than 6.0.

[0059] In terms of Klebsiella pneumoniae log reduction, the composition/fibers/fabrics may be determined via ISO 20743:2013 and may demonstrate a microbial log reduction greater than 1.5, e.g., greater than 2.0, greater than 2.5, greater than 2.6, greater than 3.0, greater than 4.0, greater than 5.0, or greater than 6.0.

[0060] In terms of SARS-CoV-2 log reduction, the composition/fibers/fabrics may be determined via ISO 18184:2019 and may demonstrate a viral log reduction greater than 1.5, e.g., greater than 2.0, greater than 2.5, greater than 2.6, greater than 1.7, greater than 3.0, greater than 4.0, greater than 5.0, or greater than 6.0.

[0061] The AM/ AV properties may include any antiviral effect. In some embodiments, for example, the antiviral properties of the AM/ AV material include limiting, reducing, or inhibiting infection of a virus. In some embodiments, the antiviral properties of the AM/ AV material include limiting, reducing, or inhibiting pathogenesis of a virus. In some cases, the polymer composition may limit, reduce, or inhibit both infection and pathogenesis of a virus.

[0062] The virus affected by the antiviral properties of the AM/ AV material is not particularly limited. In some embodiments, for example, the virus is an adenovirus, a herpesvirus, an ebolavirus, a poxvirus, a rhinovirus, a coxsackievirus, an arterivirus, an enterovirus, a morbillivirus, a coronavirus, an influenza A virus, an avian influenza virus, a swine-origin influenza virus, or an equine influence virus. In some embodiments, the antiviral properties include limiting, reducing, or inhibiting the infection or pathogenesis of one of virus, e.g., a virus from the above list. In some embodiments, the antiviral properties include limiting, reducing, or inhibiting the infection or pathogenesis of multiple viruses, e.g., a combination of two or more viruses from the above list.

[0063] In some cases, the virus is a coronavirus, e.g., severe acute respiratory syndrome coronavirus (SARS-CoV), Middle East respiratory syndrome coronavirus (MERS-CoV), or severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2) (e.g., the coronavirus that causes CO VID-19). In some cases, the virus is structurally related to a coronavirus.

[0064] In some cases, the virus is an influenza virus, such as an influenza A virus, an influenza B virus, an influenza C virus, or an influenza D virus, or a structurally related virus. In some cases, the virus is identified by an influenza A virus subtype, e.g., H1N1, H1N2, H2N2, H2N3, H3N1, H3N2, H3N8, H5N1, H5N2, H5N3, H5N6, H5N8, H5N9, H6N1, H7N1, H7N4, H7N7, H7N9, H9N2, or H10N7.

[0065] In some cases, the virus is a bacteriophage, such as a linear or circular single-stranded DNA virus (e.g., phi X 174 (sometimes referred to as XI 74)), a linear or circular doublestranded DNA, a linear or circular single-stranded RNA, or a linear or circular double-stranded RNA. In some cases, the antiviral properties of the polymer composition may be measured by testing using a bacteriophage, e.g., phi X 174.

[0066] In some cases, the virus is an ebolavirus, e.g., Bundibugyo ebolavirus (BDBV), Reston ebolavirus (RESTV), Sudan ebolavirus (SUDV), Tai Forest ebolavirus (TAFV), or Zaire ebolavirus (EBOV). In some cases, the virus is structurally related to an ebolavirus.

[0067] The antiviral activity may be measured by a variety of conventional methods. For example, ISO 18184:2019 may be utilized to assess the antiviral activity. In one embodiment, the AM/ AV material inhibits the pathogenesis (e.g., growth) of a virus in an amount ranging from 60% to 100%, e.g., from 60% to 99.999999%, from 60% to 99.99999%, from 60% to 99.9999%, from 60% to 99.999% from 60% to 99.999%, from 60% to 99.99%, from 60% to 99.9%, from 60% to 99%, from 60% to 98%, from 60% to 95%, from 65% to 99.999999%, from 65% to 99.99999%, from 65% to 99.9999%, from 65% to 99.999% from 65% to 99.999%, from 65% to 100%, from 65% to 99.99%, from 65% to 99.9%, from 65% to 99%, from 65% to 98%, from 65% to 95%, from 70% to 100%, from 70% to 99.999999%, from 70% to 99.99999%, from 70% to 99.9999%, from 70% to 99.999% from 70% to 99.999%, from 70% to 99.99%, from 70% to 99.9%, from 70% to 99%, from 70% to 98%, from 70% to 95%, from 75% to 100%, from 75% to 99.99%, from 75% to 99.9%, from 75% to 99.999999%, from 75% to 99.99999%, from 75% to 99.9999%, from 75% to 99.999% from 75% to 99.999%, from 75% to 99%, from 75% to 98%, from 75% to 95%, %, from 80% to 99.999999%, from 80% to 99.99999%, from 80% to 99.9999%, from 80% to 99.999% from 80% to 99.999%, from 80% to 100%, from 80% to 99.99%, from 80% to 99.9%, from 80% to 99%, from 80% to 98%, or from 80% to 95%. In terms of lower limits, a AM/ AV material may inhibit greater than 60% of pathogenesis of the virus, e.g., greater than 65%, greater than 70%, greater than 75%, greater than 80%, greater than 85%, greater than 90%, greater than 95%, greater than 98%, greater than 99%, greater than 99.9%, greater than 99.99%, greater than 99.999%, greater than 99.9999%, greater than 99.99999%, or greater than 99.999999%.

[0068] In addition, the use of the polymer compositions disclosed herein provides for biocompatibility advantages. For example, the overall softness of the aforementioned fabrics, along with the compositional characteristics, provides for unexpected reductions in irritation and sensitivity. Beneficially, the disclosed fibers and fabric do not demonstrate the biocompatibility issues associated with conventional fabrics, e.g., those that employ metals with toxicity problems such as silver. For example, the AM/ AV polymer compositions demonstrate passing results with regard to irritation and sensitization, as tested in accordance with ISO 10993-10 and 10993-12. AM/ AV Polymer Composition

[0069] As noted above, the AM/ AV materials of the present disclosure may comprise polymer compositions that beneficially exhibit antimicrobial and/or antiviral properties. For example, the fabric sheet may be made from and/or may comprise an antimicrobial/antiviral polymer composition as described herein.

[0070] AM/ AV polymer compositions suitable for use in the AM/ AV materials described herein generally comprise a polymer and one or more AM/ AV compounds, e.g., metals (e.g., metallic compounds). In some embodiments, the polymer compositions comprise a polymer, zinc (provided to the composition via a zinc compound), and/or phosphorus (provided to the composition via a phosphorus compound). In some embodiments, the polymer compositions comprise a polymer, copper (provided to the composition via a copper compound), and phosphorus (provided to the composition via a phosphorus compound).

[0071] Exemplary polymer compositions are disclosed in US Patent Application No. 17/192,491, filed March 4, 2021, and US Patent Application No. 17/192,533, filed on March 4, 2021, both of which are incorporated herein by reference. Polymer

The polymer compositions comprise a polymer, which, in some embodiments, is a polymer suitable for producing fibers and fabrics. In one embodiment, the polymer composition comprises a polymer in an amount ranging from 50 wt.% to 100 wt.%, e.g., from 50 wt.% to 99.99 wt.%, from 50 wt.% to 99.9 wt.%, from 50 wt.% to 99 wt.% from 55 wt.% to 100 wt.%, from 55 wt.% to 99.99 wt.%, from 55 wt.% to 99.9 wt.%, from 55 wt.% to 99 wt.%, from 60 wt.% to 100 wt.%, from 60 wt.% to 99.99 wt.%, from 60 wt.% to 99.9 wt.%, from 60 wt.% to 99 wt.%., from 65 wt.% to 100 wt.%, from 65 wt.% to 99.99 wt.%, from 65 wt.% to 99.9 wt.%, or from 65 wt.% to 99 wt.%. In terms of upper limits, the polymer composition may comprise less than 100 wt.% of the polymer, e.g., less than 99.99 wt.%, less than 99.9 wt.%, or less than 99 wt.%. In terms of lower limits, the polymer composition may comprise greater than 50 wt.% of the polymer, e.g., greater than 55 wt.%, greater than 60 wt.%, or greater than 65 wt.%.

[0072] The polymer of the polymer composition may vary widely. The polymer may include but is not limited to, a thermoplastic polymer, polyester, nylon, rayon, polyamide 6, polyamide 6,6, polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), co-PET, polybutylene terephthalate (PBT) polylactic acid (PLA), and polytrimethylene terephthalate (PTT). In some embodiments, the polymer composition may comprise PET, for its strength, longevity during washing, ability to be made permanent press, and ability to be blended with other fibers. In some embodiments, the polymer may be PA6,6. In some cases, nylon is known to be a stronger fiber than PET and exhibits a non-drip burning characteristic that is beneficial, e.g., in military or automotive textile applications, and is more hydrophilic than PET. The polymer used in the present disclosure can be a polyamide, polyether amide, polyether ester or polyether urethane or a mixture thereof.

[0073] In some cases, the polymer compositions may comprise polyethylene. Suitable examples of polyethylene include linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), medium-density polyethylene (MDPE), high-density polyethylene (HDPE), and ultra-high-molecular-weight polyethylene (UHMWPE).

[0074] In some cases, the polymer compositions may comprise polycarbonate (PC). For example, the polymer composition may comprise a blend of polycarbonate with other polymers, e.g., a blend of polycarbonate and acrylonitrile butadiene styrene (PC-ABS), a blend of polycarbonate and polyvinyl toluene (PC-PVT), a blend of polycarbonate and polybutylene terephthalate (PC-PBT), a blend of polycarbonate and polyethylene terephthalate (PC-PET), or combinations thereof.

[0075] In some cases, the polymer composition may comprise polyamides. Common polyamides include nylons and aramids. For example, the polyamide may comprise PA-4T/4I; PA-4T/6I; PA-5T/5I; PA-6; PA6,6; PA6,6/6; PA6,6/6T; PA-6T/6I; PA-6T/6I/6; PA-6T/6; PA- 6T/6I/66; PA-6T/MPMDT (where MPMDT is polyamide based on a mixture of hexamethylene diamine and 2-methylpentamethylene diamine as the diamine component and terephthalic acid as the diacid component); PA-6T/66; PA-6T/610; PA-10T/612; PA-10T/106; PA-6T/612; PA- 6T/10T; PA-6T/10I; PA-9T; PA-10T; PA-12T; PA-10T/10I; PA-10T/12; PA-10T/11; PA-6T/9T; PA-6T/12T; PA-6T/10T/6I; PA-6T/6V6; PA-6T/61/12; and copolymers, blends, mixtures and/or other combinations thereof. Additional suitable polyamides, additives, and other components are disclosed in US Patent Application No. 16/003,528.

[0076] In some embodiments, the polymer compositions comprise a thermoplastic polymer, polyester, nylon, rayon, polyamide, polyamide, poly olefin, polyolefin terephthalate, polyolefin terephthalate glycol, co-PET, or polylactic acid, or combinations thereof.

[0077] In other embodiments, the polymer composition is blended with an absorbent fiber, such as rayon, lyocell, and/or a natural fiber, such as cotton or hemp. For instance, the polymer composition may be PA-66 blended with rayon or lyocell.

[0078] The polymer composition may, in some embodiments, comprise a combination of polyamides. By combining various polyamides, the final composition may be able to incorporate the desirable properties, e.g., mechanical properties, of each constituent polyamides. For example, in some embodiments, the polyamide comprises a combination of PA-6, PA6,6, and PA6,6/6T. In these embodiments, the polyamide may comprise from 1 wt.% to 99 wt.% PA-6, from 30 wt.% to 99 wt.% PA6,6, and from 1 wt.% to 99 wt.% PA6,6/6T. In some embodiments, the polyamide comprises one or more of PA-6, PA6,6, and PA6,6/6T. In some aspects, the polymer composition comprises 6 wt.% of PA-6 and 94 wt.% of PA6,6. In some aspects, the polymer composition comprises copolymers or blends of any of the polyamides mentioned herein.

[0079] The polymer composition may also comprise polyamides produced through the ringopening polymerization or polycondensation, including the copolymerization and/or copolycondensation, of lactams. Without being bound by theory, these polyamides may include, for example, those produced from propriolactam, butyrolactam, valerolactam, and caprolactam. For example, in some embodiments, the polyamide is a polymer derived from the polymerization of caprolactam. In those embodiments, the polymer comprises at least 10 wt.% caprolactam, e.g., at least 15 wt.%, at least 20 wt.%, at least 25 wt.%, at least 30 wt.%, at least 35 wt.%, at least 40 wt.%, at least 45 wt.%, at least 50 wt.%, at least 55 wt.%, or at least 60 wt.%. In some embodiments, the polymer includes from 10 wt.% to 60 wt.% of caprolactam, e.g., from 15 wt.% to 55 wt.%, from 20 wt.% to 50 wt.%, from 25 wt.% to 45 wt.%, or from 30 wt.% to 40 wt.%. In some embodiments, the polymer comprises less than 60 wt.% caprolactam, e.g., less than 55 wt.%, less than 50 wt.%, less than 45 wt.%, less than 40 wt.%, less than 35 wt.%, less than 30 wt.%, less than 25 wt.%, less than 20 wt.%, or less than 15 wt.%. Furthermore, the polymer composition may comprise the polyamides produced through the copolymerization of a lactam with a nylon, for example, the product of the copolymerization of a caprolactam with PA6,6. [0080] In some aspects, the polymer can formed by conventional polymerization of the polymer composition in which an aqueous solution of at least one diamine-carboxylic acid salt is heated to remove water and effect polymerization to form an antiviral nylon. This aqueous solution is preferably a mixture which includes at least one polyamide-forming salt in combination with the specific amounts of a zinc compound, a copper compound, and/or a phosphorus compound described herein to produce a polymer composition. Conventional polyamide salts are formed by reaction of diamines with dicarboxylic acids with the resulting salt providing the monomer. In some embodiments, a preferred polyamide-forming salt is hexamethylenediamine adipate (nylon 6,6 salt) formed by the reaction of equimolar amounts of hexamethylenediamine and adipic acid.

AM A V (Metallic) Compounds

[0081] As noted above, the polymer composition may include one or more AM/ AV compounds, which may be in the form of a metallic compound. In some embodiments, the polymer composition includes zinc, e.g., in a zinc compound, optionally phosphorus, e.g., in a phosphorus compound, optionally copper, e.g., in a copper compound, optionally silver, e.g., in a silver compound, or combinations thereof. As used herein, a metallic compound refers to a compound having at least one metal molecule or ion, e.g., a “zinc compound” refers to a compound having at least one zinc molecule or ion. [0082] Some conventional polymer compositions, fibers and fabrics utilize AM/ AV compounds to inhibit viruses and other pathogens. For example, some fabrics may include antimicrobial additives, e.g., silver, coated or applied as a film on an exterior surface. However, it has been found that these treatments or coatings often present a host of problems. For example, the coated additives may extract out of the fibers/fabric during dyeing or washing processes, which adversely affects the antimicrobial and/or antiviral properties. As it relates to conventional products, while in constant use, some coatings, e.g., silver, may contribute to health and/or even environmental problems. In contrast to conventional formulations, the polymer compositions disclosed herein comprise a unique combination of AM/ AV compounds (e.g., metallic compounds) rather than simply coating the AM/ AV compounds on a surface. Stated another way, the polymer composition may have certain amounts of a metallic compound embedded in the polymer matrix such that the polymer composition retains AM/ AV properties during and after dyeing and/or washing.

[0083] In one embodiment, AM/ AV compounds can be added as a masterbatch. The masterbatch may include a polyamide such as nylon 6 or nylon 6,6. Other masterbatch compositions are contemplated.

[0084] The polymer composition may comprise metallic compounds, e.g., a metal or a metallic compound, dispersed within the polymer composition. In one embodiment, the polymer composition comprises metallic compounds in an amount ranging from 5 wppm to 20,000 wppm, e.g., from 5 wppm to 17,500 wppm, from 5 wppm to 17,000 wppm, from 5 wppm to 16,500 wppm, from 5 wppm to 16,000 wppm, from 5 wppm to 15,500 wppm, from 5 wppm to 15,000 wppm, from 5 wppm to 12,500 wppm, from 5 wppm to 10,000 wppm, from 5 wppm to 5000 wppm, from 5 wppm to 4000 wppm, e.g., from 5 wppm to 3000 wppm, from 5 wppm to 2000 wppm, from 5 wppm to 1000 wppm, from 5 wppm to 500 wppm, from 10 wppm to 20,000 wppm, from 10 wppm to 17,500 wppm, from 10 wppm to 17,000 wppm, from 10 wppm to 16,500 wppm, from 10 wppm to 16,000 wppm, from 10 wppm to 15,500 wppm, from 10 wppm to 15,000 wppm, from 10 wppm to 12,500 wppm, from 10 wppm to 10,000 wppm, from 10 wppm to 5000 wppm, from 10 wppm to 4000 wppm, from 10 wppm to 3000 wppm, from 10 wppm to 2000 wppm, from 10 wppm to 1000 wppm, from 10 wppm to 500 wppm, from 50 wppm to 20,000 wppm, from 50 wppm to 17,500 wppm, from 50 wppm to 17,000 wppm, from 50 wppm to 16,500 wppm, from 50 wppm to 16,000 wppm, from 50 wppm to 15,500 wppm, from 50 wppm to 15,000 wppm, from 50 wppm to 12,500 wppm, from 50 wppm to 10,000 wppm, from 50 wppm to 5000 wppm, from 50 wppm to 4000 wppm, from 50 wppm to 3000 wppm, from 50 wppm to 2000 wppm, from 50 wppm to 1000 wppm, from 50 wppm to 500 wppm, from 100 wppm to 20,000 wppm, from 100 wppm to 17,500 wppm, from 100 wppm to 17,000 wppm, from 100 wppm to 16,500 wppm, from 100 wppm to 16,000 wppm, from 100 wppm to 15,500 wppm, from 100 wppm to 15,000 wppm, from 100 wppm to 12,500 wppm, from 100 wppm to 10,000 wppm, from 100 wppm to 5000 wppm, from 100 wppm to 4000 wppm, from 100 wppm to 3000 wppm, from 100 wppm to 2000 wppm, from 100 wppm to 1000 wppm, from 100 wppm to 500 wppm, from 200 wppm to 20,000 wppm, from 200 wppm to 17,500 wppm, from 200 wppm to 17,000 wppm, from 200 wppm to 16,500 wppm, from 200 wppm to 16,000 wppm, from 200 wppm to 15,500 wppm, from 200 wppm to 15,000 wppm, from 200 wppm to 12,500 wppm, from 200 wppm to 10,000 wppm, from 200 wppm to 5000 wppm, from 200 wppm to 4000 wppm, from 200 wppm to 3000 wppm, from 200 wppm to 2000 wppm, from 200 wppm to 1000 wppm, or from 200 wppm to 500 wppm.

[0085] In terms of lower limits, the polymer composition may comprise greater than 5 wppm metallic compounds, e.g., greater than 10 wppm, greater than 50 wppm, greater than 100 wppm, greater than 200 wppm, or greater than 300 wppm. In terms of upper limits, the polymer composition may comprise less than 20,000 wppm metallic compounds, e.g., less than 17,500 wppm, less than 17,000 wppm, less than 16,500 wppm, less than 16,000 wppm, less than 15,500 wppm, less than 15,000 wppm, less than 12,500 wppm, less than 10,000 wppm, less than 5000 wppm, less than less than 4000 wppm, less than 3000 wppm, less than 2000 wppm, less than 1000 wppm, or less than 500 wppm. As noted above, the metallic compounds are preferably embedded in the polymer formed from the polymer composition.

[0086] As noted above, the polymer composition includes zinc in a zinc compound and phosphorus in a phosphorus compound, preferably in specific amounts in the polymer composition, to provide the aforementioned structural and antiviral benefits. As used herein, “zinc compound” refers to a compound having at least one zinc molecule or ion (likewise for copper compounds). As used herein, “phosphorus compound” refers to a compound having at least one phosphorus molecule or ion. Zinc content may be indicated by zinc or zinc ion (the same is true for copper). The ranges and limits may be employed for zinc content and for zinc ion content, and for other metal content, e.g., copper content. The calculation of zinc ion content based on zinc or zinc compound can be made by the skilled chemist, and such calculations and adjustments are contemplated.

[0087] The polymer composition may comprise zinc, e.g., in a zinc compound or as zinc ion, e.g., zinc or a zinc compound, dispersed within the polymer composition. In one embodiment, the polymer composition comprises zinc in an amount ranging from 5 wppm to 20,000 wppm, e.g., from 5 wppm to 17,500 wppm, from 5 wppm to 17,000 wppm, from 5 wppm to 16,500 wppm, from 5 wppm to 16,000 wppm, from 5 wppm to 15,500 wppm, from 5 wppm to 15,000 wppm, from 5 wppm to 12,500 wppm, from 5 wppm to 10,000 wppm, from 5 wppm to 5000 wppm, from 5 wppm to 4000 wppm, e.g., from 5 wppm to 3000 wppm, from 5 wppm to 2000 wppm, from 5 wppm to 1000 wppm, from 5 wppm to 500 wppm, from 10 wppm to 20,000 wppm, from 10 wppm to 17,500 wppm, from 10 wppm to 17,000 wppm, from 10 wppm to

16.500 wppm, from 10 wppm to 16,000 wppm, from 10 wppm to 15,500 wppm, from 10 wppm to 15,000 wppm, from 10 wppm to 12,500 wppm, from 10 wppm to 10,000 wppm, from 10 wppm to 5000 wppm, from 10 wppm to 4000 wppm, from 10 wppm to 3000 wppm, from 10 wppm to 2000 wppm, from 10 wppm to 1000 wppm, from 10 wppm to 500 wppm, from 50 wppm to 20,000 wppm, from 50 wppm to 17,500 wppm, from 50 wppm to 17,000 wppm, from 50 wppm to 16,500 wppm, from 50 wppm to 16,000 wppm, from 50 wppm to 15,500 wppm, from 50 wppm to 15,000 wppm, from 50 wppm to 12,500 wppm, from 50 wppm to 10,000 wppm, from 50 wppm to 5000 wppm, from 50 wppm to 4000 wppm, from 50 wppm to 3000 wppm, from 50 wppm to 2000 wppm, from 50 wppm to 1000 wppm, from 50 wppm to 500 wppm, from 100 wppm to 20,000 wppm, from 100 wppm to 17,500 wppm, from 100 wppm to 17,000 wppm, from 100 wppm to 16,500 wppm, from 100 wppm to 16,000 wppm, from 100 wppm to 15,500 wppm, from 100 wppm to 15,000 wppm, from 100 wppm to 12,500 wppm, from 100 wppm to 10,000 wppm, from 100 wppm to 5000 wppm, from 100 wppm to 4000 wppm, from 100 wppm to 3000 wppm, from 100 wppm to 2000 wppm, from 100 wppm to 1000 wppm, from 100 wppm to 500 wppm, from 200 wppm to 20,000 wppm, from 200 wppm to

17.500 wppm, from 200 wppm to 17,000 wppm, from 200 wppm to 16,500 wppm, from 200 wppm to 16,000 wppm, from 200 wppm to 15,500 wppm, from 200 wppm to 15,000 wppm, from 200 wppm to 12,500 wppm, from 200 wppm to 10,000 wppm, from 200 wppm to 5000 wppm, from 200 wppm to 4000 wppm, 5000 wppm to 20000 wppm, from 200 wppm to 3000 wppm, from 200 wppm to 2000 wppm, from 200 wppm to 1000 wppm, from 200 wppm to 500 wppm, from 10 wppm to 900 wppm, from 200 wppm to 900 wppm, from 425 wppm to 600 wppm, from 425 wppm to 525 wppm, from 350 wppm to 600 wppm, from 375 wppm to 600 wppm, from 375 wppm to 525 wppm, from 480 wppm to 600 wppm, from 480 wppm to 525 wppm, from 600 wppm to 750 wppm, or from 600 wppm to 700 wppm.

[0088] In terms of lower limits, the polymer composition may comprise greater than 5 wppm of zinc, e.g., greater than 10 wppm, greater than 50 wppm, greater than 100 wppm, greater than 200 wppm, greater than 300 wppm, greater than 350 wppm, greater than 375 wppm, greater than 400 wppm, greater than 425 wppm, greater than 480 wppm, greater than 500 wppm, or greater than 600 wppm.

[0089] In terms of upper limits, the polymer composition may comprise less than 20,000 wppm of zinc, e.g., less than 17,500 wppm, less than 17,000 wppm, less than 16,500 wppm, less than 16,000 wppm, less than 15,500 wppm, less than 15,000 wppm, less than 12,500 wppm, less than 10,000 wppm, less than 5000 wppm, less than less than 4000 wppm, less than 3000 wppm, less than 2000 wppm, less than 1000 wppm, less than 500 wppm, less than 400 wppm, less than 330 wppm, less than 300. In some aspects, the zinc compound is embedded in the polymer formed from the polymer composition.

[0090] The ranges and limits are applicable to both zinc in elemental or ionic form and to zinc compound. The same is true for other ranges and limits disclosed herein relating to other metals, e.g., copper. For example, the ranges may relate to the amount of zinc ions dispersed in the polymer.

[0091] The zinc of the polymer composition is present in or provided via a zinc compound, which may vary widely. The zinc compound may comprise zinc oxide, zinc ammonium adipate, zinc acetate, zinc ammonium carbonate, zinc stearate, zinc phenyl phosphinic acid, or zinc pyrithione, or combinations thereof. In some embodiments, the zinc compound comprises zinc oxide, zinc ammonium adipate, zinc acetate, or zinc pyrithione, or combinations thereof. In some embodiments, the zinc compound comprises zinc oxide, zinc stearate, or zinc ammonium adipate, or combinations thereof. In some aspects, the zinc is provided in the form of zinc oxide. In some aspects, the zinc is not provided via zinc phenyl phosphinate and/or zinc phenyl phosphonate.

[0092] The inventors have also found that the polymer compositions surprisingly may benefit from the use of specific zinc compounds. In particular, the use of zinc compounds prone to forming ionic zinc (e.g., Zn²⁺) may increase the antiviral properties of the polymer composition. It is theorized that the ionic zinc disrupts the replicative cycle of the virus. For example, the ionic zinc may interfere with, e.g., inhibit viral protease or polymerase activity. Further discussion of the effect of ionic zinc on viral activity is found in Velthuis et al., Zn Inhibits Coronavirus and Arterivirus RNA Polymerase Activity In Vitro and Zinc Ionophores Block the Replication of These Viruses in Cell Culture, PLoS Pathogens (Nov. 2010), which is incorporated herein by reference.

[0093] The amount of the zinc compound present in the polymer compositions may be discussed in relation to the ionic zinc content. In one embodiment, the polymer composition comprises ionic zinc, e.g., Zn²⁺, in an amount ranging from 1 wppm to 30,000 wppm, e.g., from 1 wppm to 25,000 wppm, from 1 wppm to 20,000 wppm, from 1 wppm to 15,000 wppm, from 1 wppm to 10,000 wppm, from 1 wppm to 5,000 wppm, from 1 wppm to 2,500 wppm, from 50 wppm to 30,000 wppm, from 50 wppm to 25,000 wppm, from 50 wppm to 20,000 wppm, from 50 wppm to 15,000 wppm, from 50 wppm to 10,000 wppm, from 50 wppm to 5,000 wppm, from 50 wppm to 2,500 wppm, from 100 wppm to 30,000 wppm, from 100 wppm to 25,000 wppm, from 100 wppm to 20,000 wppm, from 100 wppm to 15,000 wppm, from 100 wppm to 10,000 wppm, from 100 wppm to 5,000 wppm, from 100 wppm to 2,500 wppm, from 150 wppm to 30,000 wppm, from 150 wppm to 25,000 wppm, from 150 wppm to 20,000 wppm, from 150 wppm to 15,000 wppm, from 150 wppm to 10,000 wppm, from 150 wppm to 5,000 wppm, from 150 wppm to 2,500 wppm, from 250 wppm to 30,000 wppm, from 250 wppm to 25,000 wppm, from 250 wppm to 20,000 wppm, from 250 wppm to 15,000 wppm, from 250 wppm to 10,000 wppm, from 250 wppm to 5,000 wppm, or from 250 wppm to 2,500 wppm. In some cases, the ranges and limits mentioned above for zinc may also be applicable to ionic zinc content.

[0094] The zinc may be embedded in the polymer matrix. For example, the fibers may comprise a polyamide polymer matrix embedded with zinc, for instance ionic zinc (Zn²⁺).

[0095] In some cases, the use of zinc provides for processing and or end use benefits. Other antiviral agents, e.g., copper or silver, may be used, but these often include adverse effects (e.g., on the relative viscosity of the polymer composition, toxicity, and health or environmental risk). In some situations, the zinc does not have adverse effects on the relative viscosity of the polymer composition. Also, the zinc, unlike other antiviral agents, e.g., silver, does not present toxicity issues (and in fact may provide health advantages, such as immune system support). In addition, as noted herein, the use of zinc provides for the reduction or elimination of leaching into other media and/or into the environment. This both prevents the risks associated with introducing zinc into the environment and allows the polymer composition to be reused - zinc provides surprising “green” advantages over conventional, e.g., silver-containing, compositions.

[0096] As noted above, the polymer composition, in some embodiments, includes copper (provided via a copper compound). As used herein, “copper compound” refers to a compound having at least one copper molecule or ion.

[0097] In some cases, the copper compound may improve, e.g., enhance the antiviral properties of the polymer composition. In some cases, the copper compound may affect other characteristics of the polymer composition, e.g., antimicrobial activity or physical characteristics. [0098] The polymer composition may comprise copper (e.g., in a copper compound), e.g., copper or a copper compound, dispersed within the polymer composition. In one embodiment, the polymer composition comprises copper in an amount ranging from 5 wppm to 20,000 wppm, e.g., from 5 wppm to 17,500 wppm, from 5 wppm to 17,000 wppm, from 5 wppm to 16,500 wppm, from 5 wppm to 16,000 wppm, from 5 wppm to 15,500 wppm, from 5 wppm to 15,000 wppm, from 5 wppm to 12,500 wppm, from 5 wppm to 10,000 wppm, from 5 wppm to 5000 wppm, from 5 wppm to 4000 wppm, e.g., from 5 wppm to 3000 wppm, from 5 wppm to 2000 wppm, from 5 wppm to 1000 wppm, from 5 wppm to 500 wppm, from 5 wppm to 100 wppm, from 5 wppm to 50 wppm, from 5 wppm to 35 wppm, from 10 wppm to 20,000 wppm, from 10 wppm to 17,500 wppm, from 10 wppm to 17,000 wppm, from 10 wppm to 16,500 wppm, from 10 wppm to 16,000 wppm, from 10 wppm to 15,500 wppm, from 10 wppm to 15,000 wppm, from 10 wppm to 12,500 wppm, from 10 wppm to 10,000 wppm, from 10 wppm to 5000 wppm, from 10 wppm to 4000 wppm, from 10 wppm to 3000 wppm, from 10 wppm to 2000 wppm, from 10 wppm to 1000 wppm, from 10 wppm to 500 wppm, from 50 wppm to 20,000 wppm, from 50 wppm to 17,500 wppm, from 50 wppm to 17,000 wppm, from 50 wppm to 16,500 wppm, from 50 wppm to 16,000 wppm, from 50 wppm to 15,500 wppm, from 50 wppm to 15,000 wppm, from 50 wppm to 12,500 wppm, from 50 wppm to 10,000 wppm, from 50 wppm to 5000 wppm, from 50 wppm to 4000 wppm, from 50 wppm to 3000 wppm, from 50 wppm to 2000 wppm, from 50 wppm to 1000 wppm, from 50 wppm to 500 wppm, from 100 wppm to 20,000 wppm, from 100 wppm to 17,500 wppm, from 100 wppm to 17,000 wppm, from 100 wppm to 16,500 wppm, from 100 wppm to 16,000 wppm, from 100 wppm to 15,500 wppm, from 100 wppm to 15,000 wppm, from 100 wppm to 12,500 wppm, from 100 wppm to 10,000 wppm, from 100 wppm to 5000 wppm, from 100 wppm to 4000 wppm, from 100 wppm to 3000 wppm, from 100 wppm to 2000 wppm, from 100 wppm to 1000 wppm, from 100 wppm to 500 wppm, from 200 wppm to 20,000 wppm, from 200 wppm to 17,500 wppm, from 200 wppm to 17,000 wppm, from 200 wppm to 16,500 wppm, from 200 wppm to 16,000 wppm, from 200 wppm to 15,500 wppm, from 200 wppm to 15,000 wppm, from 200 wppm to 12,500 wppm, from 200 wppm to 10,000 wppm, from 200 wppm to 5000 wppm, from 200 wppm to 4000 wppm, from 200 wppm to 3000 wppm, from 200 wppm to 2000 wppm, from 200 wppm to 1000 wppm, or from 200 wppm to 500 wppm.

[0099] In terms of lower limits, the polymer composition may comprise greater than 5 wppm of copper, e.g., greater than 10 wppm, greater than 50 wppm, greater than 100 wppm, greater than 200 wppm, or greater than 300 wppm. In terms of upper limits, the polymer composition may comprise less than 20,000 wppm of copper, e.g., less than 17,500 wppm, less than 17,000 wppm, less than 16,500 wppm, less than 16,000 wppm, less than 15,500 wppm, less than 15,000 wppm, less than 12,500 wppm, less than 10,000 wppm, less than 5000 wppm, less than less than 4000 wppm, less than 3000 wppm, less than 2000 wppm, less than 1000 wppm, less than 500 wppm less than 100 wppm, less than 50 wppm, less than 35 wppm. In some aspects, the copper compound is embedded in the polymer formed from the polymer composition.

[0100] The composition of the copper compound is not particularly limited. Suitable copper compounds include copper iodide, copper bromide, copper chloride, copper fluoride, copper oxide, copper stearate, copper ammonium adipate, copper acetate, or copper pyrithione, or combinations thereof. The copper compound may comprise copper oxide, copper ammonium adipate, copper acetate, copper ammonium carbonate, copper stearate, copper phenyl phosphinic acid, or copper pyrithione, or combinations thereof. In some embodiments, the copper compound comprises copper oxide, copper ammonium adipate, copper acetate, or copper pyrithione, or combinations thereof. In some embodiments, the copper compound comprises copper oxide, copper stearate, or copper ammonium adipate, or combinations thereof. In some aspects, the copper is provided in the form of copper oxide. In some aspects, the copper is not provided via copper phenyl phosphinate and/or copper phenyl phosphonate.

[0101] In some cases, the polymer composition includes silver (optionally provided via a silver compound). As used herein, “silver compound” refers to a compound having at least one silver molecule or ion. The silver may be in ionic form. The ranges and limits for silver may be similar to the ranges and limits for copper (discussed above).

[0102] In one embodiment, the molar ratio of the copper to the zinc is greater than 0.01 : 1, e.g., greater than 0.05: 1, greater than 0.1 : 1, greater than 0.15: 1, greater than 0.25: 1, greater than 0.5:1, or greater than 0.75: 1. In terms of ranges, the molar ratio of the copper to the zinc in the polymer composition may range from 0.01 : 1 to 15: 1, e.g., from 0.05: 1 to 10: 1, from 0.1 : 1 to 9: 1, from 0.15: 1 to 8: 1, from 0.25: 1 to 7: 1, from 0.5: 1 to 6: 1, from 0.75: 1 to 5: 1 from 0.5: 1 to 4: 1, or from 0.5: 1 to 3: 1. In terms of upper limits, the molar ratio of zinc to copper in the polymer composition may be less than 15: 1, e.g., less than 10: 1, less than 9: 1, less than 8: 1, less than 7: 1, less than 6: 1, less than 5: 1, less than 4: 1, or less than 3: 1. In some cases, copper is bound in the polymer matrix along with zinc.

[0103] In some embodiments, the use of cuprous ammonium adipate has been found to be particularly effective in activating copper ions into the polymer matrix. Similarly, the use of silver ammonium adipate has been found to be particularly effective in activating silver ions into the polymer matrix. It is found that dissolving copper (I) or copper (II) compounds in ammonium adipate is particularly efficient at generating copper (I) or copper (II) ions. The same is true for dissolving Ag (I) or Ag (III) compounds in ammonium adipate to generate Agl+ or Ag3+ ions. [0104] The polymer composition may comprise silver (e.g., in a silver compound), e.g., silver or a silver compound, dispersed within the polymer composition. In one embodiment, the polymer composition comprises silver in an amount ranging from 5 wppm to 20,000 wppm, e.g., from 5 wppm to 17,500 wppm, from 5 wppm to 17,000 wppm, from 5 wppm to 16,500 wppm, from 5 wppm to 16,000 wppm, from 5 wppm to 15,500 wppm, from 5 wppm to 15,000 wppm, from 5 wppm to 12,500 wppm, from 5 wppm to 10,000 wppm, from 5 wppm to 5000 wppm, from 5 wppm to 4000 wppm, e.g., from 5 wppm to 3000 wppm, from 5 wppm to 2000 wppm, from 5 wppm to 1000 wppm, from 5 wppm to 500 wppm, from 10 wppm to 20,000 wppm, from 10 wppm to 17,500 wppm, from 10 wppm to 17,000 wppm, from 10 wppm to 16,500 wppm, from 10 wppm to 16,000 wppm, from 10 wppm to 15,500 wppm, from 10 wppm to 15,000 wppm, from 10 wppm to 12,500 wppm, from 10 wppm to 10,000 wppm, from 10 wppm to 5000 wppm, from 10 wppm to 4000 wppm, from 10 wppm to 3000 wppm, from 10 wppm to 2000 wppm, from 10 wppm to 1000 wppm, from 10 wppm to 500 wppm, from 50 wppm to 20,000 wppm, from 50 wppm to 17,500 wppm, from 50 wppm to 17,000 wppm, from 50 wppm to 16,500 wppm, from 50 wppm to 16,000 wppm, from 50 wppm to 15,500 wppm, from 50 wppm to 15,000 wppm, from 50 wppm to 12,500 wppm, from 50 wppm to 10,000 wppm, from 50 wppm to 5000 wppm, from 50 wppm to 4000 wppm, from 50 wppm to 3000 wppm, from 50 wppm to 2000 wppm, from 50 wppm to 1000 wppm, from 50 wppm to 500 wppm, from 100 wppm to 20,000 wppm, from 100 wppm to 17,500 wppm, from 100 wppm to 17,000 wppm, from 100 wppm to 16,500 wppm, from 100 wppm to 16,000 wppm, from 100 wppm to 15,500 wppm, from 100 wppm to 15,000 wppm, from 100 wppm to 12,500 wppm, from 100 wppm to 10,000 wppm, from 100 wppm to 5000 wppm, from 100 wppm to 4000 wppm, from 100 wppm to 3000 wppm, from 100 wppm to 2000 wppm, from 100 wppm to 1000 wppm, from 100 wppm to 500 wppm, from 200 wppm to 20,000 wppm, from 200 wppm to 17,500 wppm, from 200 wppm to 17,000 wppm, from 200 wppm to 16,500 wppm, from 200 wppm to 16,000 wppm, from 200 wppm to 15,500 wppm, from 200 wppm to 15,000 wppm, from 200 wppm to 12,500 wppm, from 200 wppm to 10,000 wppm, from 200 wppm to 5000 wppm, from 200 wppm to 4000 wppm, from 200 wppm to 3000 wppm, from 200 wppm to 2000 wppm, from 200 wppm to 1000 wppm, or from 200 wppm to 500 wppm.

[0105] In terms of lower limits, the polymer composition may comprise greater than 5 wppm of silver, e.g., greater than 10 wppm, greater than 50 wppm, greater than 100 wppm, greater than 200 wppm, or greater than 300 wppm. In terms of upper limits, the polymer composition may comprise less than 20,000 wppm of silver, e.g., less than 17,500 wppm, less than 17,000 wppm, less than 16,500 wppm, less than 16,000 wppm, less than 15,500 wppm, less than 15,000 wppm, less than 12,500 wppm, less than 10,000 wppm, less than 5000 wppm, less than less than 4000 wppm, less than 3000 wppm, less than 2000 wppm, less than 1000 wppm, or less than 500 wppm. In some aspects, the silver compound is embedded in the polymer formed from the polymer composition.

[0106] The composition of the silver compound is not particularly limited. Suitable silver compounds include silver iodide, silver bromide, silver chloride, silver fluoride, silver oxide, silver stearate, silver ammonium adipate, silver acetate, or silver pyrithione, or combinations thereof. The silver compound may comprise silver oxide, silver ammonium adipate, silver acetate, silver ammonium carbonate, silver stearate, silver phenyl phosphinic acid, or silver pyrithione, or combinations thereof. In some embodiments, the silver compound comprises silver oxide, silver ammonium adipate, silver acetate, or silver pyrithione, or combinations thereof. In some embodiments, the silver compound comprises silver oxide, silver stearate, or silver ammonium adipate, or combinations thereof. In some aspects, the silver is provided in the form of silver oxide. In some aspects, the silver is not provided via silver phenyl phosphinate and/or silver phenyl phosphonate. In some aspects, the silver is provided by dissolving one or more silver compounds in ammonium adipate.

[0107] The polymer composition may comprise phosphorus (in a phosphorus compound), e.g., phosphorus or a phosphorus compound is dispersed within the polymer composition. In one embodiment, the polymer composition comprises phosphorus in an amount ranging from 50 wppm to 10000 wppm, e.g., from 50 wppm to 5000 wppm, from 50 wppm to 2500 wppm, from 50 wppm to 2000 wppm, from 50 wppm to 800 wppm, 100 wppm to 750 wppm, 100 wppm to 1800 wppm, from 100 wppm to 10000 wppm, from 100 wppm to 5000 wppm, from 100 wppm to 2500 wppm, from 100 wppm to 1000 wppm, from 100 wppm to 800 wppm, from 200 wppm to 10000 wppm, 200 wppm to 5000 wppm, from 200 wppm to 2500 wppm, from 200 wppm to 800 wppm, from 300 wppm to 10000 wppm, from 300 wppm to 5000 wppm, from 300 wppm to 2500 wppm, from 300 wppm to 500 wppm, from 500 wppm to 10000 wppm, from 500 wppm to 5000 wppm, or from 500 wppm to 2500 wppm. In terms of lower limits, the polymer composition may comprise greater than 50 wppm of phosphorus, e.g., greater than 75 wppm, greater than 100 wppm, greater than 150 wppm, greater than 200 wppm greater than 300 wppm or greater than 500 wppm. In terms of upper limits, the polymer composition may comprise less than 10000 wppm (or 1 wt.%), e.g., less than 5000 wppm, less than 2500 wppm, less than 2000 wppm, less than 1800 wppm, less than 1500 wppm, less than 1000 wppm, less than 800 wppm, less than 750 wppm, less than 500 wppm, less than 475 wppm, less than 450 wppm, less than 400 wppm, less than 350 wppm, less than 300 wppm, less than 250 wppm, less than 200 wppm, less than 150 wppm, less than 100 wppm, less than 50 wppm, less than 25 wppm, or less than 10 wppm.

[0108] In some aspects, the phosphorus or the phosphorus compound is embedded in the polymer formed from the polymer composition. As noted above, because of the overall make-up of the disclosed composition low amounts, if any, phosphorus may be employed, which in some cases may provide for advantageous performance results (see above).

[0109] The phosphorus of the polymer composition is present in or provided via a phosphorus compound, which may vary widely. The phosphorus compound may comprise bezene phosphinic acid, diphenylphosphinic acid, sodium phenylphosphinate, phosphorous acid, benzene phosphonic acid, calcium phenylphosphinate, potassium B-pentylphosphinate, methylphosphinic acid, manganese hypophosphite, sodium hypophosphite, monosodium phosphate, hypophosphorous acid, dimethylphosphinic acid, ethylphosphinic acid, diethylphosphinic acid, magnesium ethylphosphinate, triphenyl phosphite, diphenylrnethyl phosphite, dimethylphenyl phosphite, ethyldiphenyl phosphite, phenylphosphonic acid, methylphosphonic acid, ethylphosphonic acid, potassium phenylphosphonate, sodium methylphosphonate, calcium ethylphosphonate, and combinations thereof. In some embodiments, the phosphorus compound comprises phosphoric acid, benzene phosphinic acid, or benzene phosphonic acid, or combinations thereof. In some embodiments, the phosphorus compound comprises benzene phosphinic acid, phosphorous acid, or manganese hypophosphite, or combinations thereof. In some aspects, the phosphorus compound may comprise benzene phosphinic acid.

[0110] Advantageously, it has been discovered that adding the above identified zinc compounds and phosphorus compounds may result in a beneficial relative viscosity (RV) of the polymer composition. In some embodiments, the RV of the polymer composition ranges from 5 to 80, e.g., from 5 to 70, from 10 to 70, from 15 to 65, from 20 to 60, from 30 to 50, from 10 to 35, from 10 to 20, from 60 to 70, from 50 to 80, from 40 to 50, from 30 to 60, from 5 to 30, or from 15 to 32. In terms of lower limits, the RV of the polymer composition may be greater than 5, e.g., greater than 10, greater than 15, greater than 20, greater than 25, greater than 27.5, or greater than 30. In terms of upper limits, the RV of the polymer composition may be less than 70, e.g., less than 65, less than 60, less than 50, less than 40, or less than 35.

[OHl] To calculate RV, a polymer is dissolved in a solvent (usually formic or sulfuric acid), the viscosity is measured, then the viscosity is compared to the viscosity of the pure solvent. This give a unitless measurement. Solid materials, as well as liquids, may have a specific RV. The fibers/fabrics produced from the polymer compositions may have the aforementioned relative viscosities, as well.

[0112] It has been determined that a specific amount of the zinc compound and the phosphorus compound can be mixed in a polymer composition, e.g., polyamide composition, in finely divided form, such as in the form of granules, flakes and the like, to provide a polymer composition that can be subsequently formed, e.g., extruded, molded or otherwise drawn, into various products (e.g., high-contact products, surtopsheet layers of high-contact products) by conventional methods to produce products having substantially improved antimicrobial activity. The zinc and phosphorus are employed in the polymer composition in the aforementioned amounts to provide a fiber with improved antimicrobial activity retention (near-permanent). Additional Components

[0113] In some embodiments, the polymer composition may comprise additional additives. The additives include pigments, hydrophilic or hydrophobic additives, anti-odor additives, additional antiviral agents, and antimicrobial/anti-fungal inorganic compounds, such as copper, zinc, tin, and silver.

[0114] In some embodiments, the polymer composition can be combined with color pigments for coloration for the use in fabrics or other components formed from the polymer composition. In some aspects, the polymer composition can be combined with UV additives to withstand fading and degradation in fabrics exposed to significant UV light. In some aspects, the polymer composition can be combined with additives to make the surface of the fiber hydrophilic or hydrophobic. In some aspects, the polymer composition can be combined with a hygroscopic material, e.g., to make the fiber, fabric, or other products formed therefrom more hygroscopic. In some aspects, the polymer composition can be combined with additives to make the fabric flame retardant or flame resistant. In some aspects, the polymer composition can be combined with additives to make the fabric stain resistant. In some aspects, the polymer composition can be combined with pigments with the antimicrobial compounds so that the need for conventional dyeing and disposal of dye materials is avoided.

[0115] In some embodiments, the polymer composition may further comprise additional additives. For example, the polymer composition may comprise a delusterant. A delusterant additive may improve the appearance and/or texture of the synthetic fibers and fabric produced from the polymer composition. In some embodiments, inorganic pigment-like materials can be utilized as delusterants. The delusterants may comprise one or more of titanium dioxide, barium sulfate, barium titanate, zinc titanate, magnesium titanate, calcium titanate, zinc oxide, zinc sulfide, lithopone, zirconium dioxide, calcium sulfate, barium sulfate, aluminum oxide, thorium oxide, magnesium oxide, silicon dioxide, talc, mica, and the like. In preferred embodiments, the delusterant comprises titanium dioxide. It has been found that the polymer compositions that include delusterants comprising titanium dioxide produce synthetic fibers and fabrics that greatly resemble natural fibers and fabrics, e.g., synthetic fibers and fabrics with improved appearance and/or texture. It is believed that titanium dioxide improves appearance and/or texture by interacting with the zinc compound, the phosphorus compound, and/or functional groups within the polymer.

[0116] In one embodiment, the polymer composition comprises the delusterant in an amount ranging from 0.0001 wt.% to 3 wt.%, e.g., 0.0001 wt.% to 2 wt.%, from 0.0001 to 1.75 wt.%, from 0.001 wt.% to 3 wt.%, from 0.001 wt.% to 2 wt.%, from 0.001 wt.% to 1.75 wt.%, from 0.002 wt.% to 3 wt.%, from 0.002 wt.% to 2 wt.%, from 0.002 wt.% to 1.75 wt.%, from 0.005 wt.% to 3 wt.%, from 0.005 wt.% to 2 wt.%, from 0.005 wt.% to 1.75 wt.%. In terms of upper limits, the polymer composition may comprise less than 3 wt.% delusterant, e.g., less than 2.5 wt.%, less than 2 wt.% or less than 1.75 wt.%. In terms of lower limits, the polymer composition may comprise greater than 0.0001 wt.% delusterant, e.g., greater than 0.001 wt.%, greater than 0.002 wt.%, or greater than 0.005 wt.%.

[0117] In some embodiments, the polymer composition may further comprise colored materials, such as carbon black, copper phthalocyanine pigment, lead chromate, iron oxide, chromium oxide, and ultramarine blue.

[0118] In some embodiments, the polymer composition may include additional antiviral agents other than zinc. The additional antimicrobial agents may be any suitable antiviral. Conventional antiviral agents are known in the art and may be incorporated in the polymer composition as the additional antiviral agent or agents. For example, the additional antiviral agent may be an entry inhibitor, a reverse transcriptase inhibitor, a DNA polymerase inhibitor, an m-RNA synthesis inhibitor, a protease inhibitor, an integrase inhibitor, or an immunomodulator, or combinations thereof. In some aspects, the additional antimicrobial agent or agents are added to the polymer composition.

[0119] In some embodiments, the polymer composition may include additional antimicrobial agents other than zinc. The additional antimicrobial agents may be any suitable antimicrobial, such as silver, copper, and/or gold in metallic forms (e.g., particulates, alloys and oxides), salts (e.g., sulfates, nitrates, acetates, citrates, and chlorides) and/or in ionic forms. In some aspects, further additives, e.g., additional antimicrobial agents, are added to the polymer composition.

[0120] In some embodiments, the polymer composition (and the fibers or fabric formed therefrom) may further comprise an antimicrobial or antiviral coating. For example, a fiber or fabric formed from the polymer composition may include a coating of zinc nanoparticles (e.g., nanoparticles of zinc oxide, zinc ammonium adipate, zinc acetate, zinc ammonium carbonate, zinc stearate, zinc phenyl phosphinic acid, or zinc pyrithione, or combinations thereof). To produce such a coating, the surface of polymer composition (e.g., the surface of the fiber and/or fabric formed therefrom) may be cationized and coated layer-by layer by stepwise dipping the polymer composition into an anionic polyelectrolyte solution (e.g., comprising poly 4- styrenesulfonic acid) and a solution comprising the zinc nanoparticles. Optionally, the coated polymer composition may be hydrothermally treated in a solution of NH4OH at 9 °C for 24 h to immobilize the zinc nanoparticles.

[0121] In some cases, the AM/ AV materials described herein do not require the use or inclusion of acids, e.g., citric acid, and/or acid treatment to be effective. Such treatments are known to create static charge/static decay issues. Advantageously, the elimination of the need for acid treatment, thus eliminates the static charge/static decay issues associated with conventional configurations.

[0122] In some embodiments, any or some of the components disclosed herein may be considered optional. In some cases, the disclosed compositions may expressly exclude any or some of the aforementioned additives in this description, e.g., via claim language. For example claim language may be modified to recite that the disclosed compositions, materials processes, etc., do not utilize or comprise one or more of the aforementioned additives, e.g., the disclosed materials do not comprise a flame retardant or a delusterant. As another example, the claim language may be modified to recite that the disclosed materials do not comprise long chain polyamide component, e.g., PA-12.

Metal Retention Rate

[0123] As noted, the AM/ AV materials described herein have permanent, e.g., nearpermanent, antimicrobial and/or antiviral properties. The permanence of these properties allows the AM/ AV materials to be reused, e.g., after washing, further extending the usefulness of the article.

[0124] One metric for assessing the permanence, e.g., near-permanence, of the antimicrobial and/or antiviral properties of the AM/ AV material is metal retention. As discussed above, the AM/ AV materials may be prepared from the disclosed polymer compositions, which may include various metallic compounds, e.g., zinc compound, phosphorus, copper compound, and/or silver compound. The metallic compounds of the polymer compositions may provide antimicrobial and/or antiviral properties to the AM/ AV material. Thus, retention of the metallic compounds, e.g., after one or more cycles of washing, may provide permanent, e.g., nearpermanent, antimicrobial and/or antiviral properties.

[0125] Beneficially, AM/ AV materials formed from the disclosed polymer compositions demonstrate relatively high metal retention rate. The metal retention rate may relate to the retention rate of a specific metal in the polymer composition, e.g., zinc retention, copper retention, or to the retention rate of all metals in the polymer composition, e.g., total metal retention.

[0126] In some embodiments, the AM/ AV materials formed from the disclosed polymer compositions have a metal retention greater than 65% as measured by a dye bath test, e.g., greater than 75%, greater than 80%, greater than 90%, greater than 95%, greater than 97%, greater than 98%, greater than 99%, greater than 99.9%, greater than 99.99%, greater than 99.999%, greater than 99.9999%, greater than 99.99999% or greater than 99.999999%. In terms of upper limits, the AM/ AV materials may have a metal retention of less than 100%, e.g., less than 99.9%, less than 98%, or less than 95%. In terms of ranges, the AM/ AV materials may have a metal retention may be from 60% to 100%, e.g., from 60% to 99.999999%, from 60% to 99.99999%, from 60% to 99.9999%, from 60% to 99.999% from 60% to 99.999%, from 60% to 99.99%, from 60% to 99.9%, from 60% to 99%, from 60% to 98%, from 60% to 95%, from 65% to 99.999999%, from 65% to 99.99999%, from 65% to 99.9999%, from 65% to 99.999% from 65% to 99.999%, from 65% to 100%, from 65% to 99.99%, from 65% to 99.9%, from 65% to 99%, from 65% to 98%, from 65% to 95%, from 70% to 100%, from 70% to 99.999999%, from 70% to 99.99999%, from 70% to 99.9999%, from 70% to 99.999% from 70% to 99.999%, from 70% to 99.99%, from 70% to 99.9%, from 70% to 99%, from 70% to 98%, from 70% to 95%, from 75% to 100%, from 75% to 99.99%, from 75% to 99.9%, from 75% to 99.999999%, from 75% to 99.99999%, from 75% to 99.9999%, from 75% to 99.999% from 75% to 99.999%, from 75% to 99%, from 75% to 98%, from 75% to 95%, %, from 80% to 99.999999%, from 80% to 99.99999%, from 80% to 99.9999%, from 80% to 99.999% from 80% to 99.999%, from 80% to 100%, from 80% to 99.99%, from 80% to 99.9%, from 80% to 99%, from 80% to 98%, or from 80% to 95%. In some cases, the ranges and limits relate to dye recipes having lower pH values, e.g., less than (and/or including) 5.0, less than 4.7, less than 4.6, or less than 4.5. In some cases, the ranges and limits relate to dye recipes having higher pH values, e.g., greater than (and/or including) 4.0, greater than 4.2, greater than 4.5, greater than 4.7, greater than 5.0, or greater than 5.2.

[0127] In some embodiments, the AM/ AV materials formed from the disclosed polymer compositions have a metal retention greater than 40% after a dye bath, e.g., greater than 44%, greater than 45%, greater than 50%, greater than 55%, greater than 60%, greater than 65%, greater than 70%, greater than 75%, greater than 80%, greater than 90%, greater than 95%, or greater than 99%. In terms of upper limits, the AM/ AV materials may have a metal retention of less than 100%, e.g., less than 99.9%, less than 98%, less than 95% or less than 90%. In terms of ranges, the AM/ AV materials may have a metal retention in a range from 40% to 100%, e.g., from 45% to 99.9%, from 50% to 99.9%, from 75% to 99.9%, from 80% to 99%, or from 90% to 98%. In some cases, the ranges and limits relate to dye recipes having higher pH values, e.g., greater than (and/or including) 4.0, greater than 4.2, greater than 4.5, greater than 4.7, greater than 5.0, or greater than 5.2.

[0128] In some embodiments, the AM/ AV materials formed from the polymer compositions have a metal retention greater than 20%, e.g., greater than 24%, greater than 25%, greater than 30%, greater than 35%, greater than 40%, greater than 45%, greater than 50%, greater than 55%, or greater than 60%. In terms of upper limits, the AM/ AV materials may have a metal retention of less than 80%, e.g., less than 77%, less than 75%, less than 70%, less than 68%, or less than 65%. In terms of ranges, the AM/ AV materials may have a metal retention ranging from 20% to 80%, e.g., from 25% to 77%, from 30% to 75%, or from 35% to 70%. In some cases, the ranges and limits relate to dye recipes having lower pH values, e.g., less than (and/or including) 5.0, less than 4.7, less than 4.6, or less than 4.5.

[0129] Stated another way, in some embodiments, the AM/ AV materials formed from the polymer composition demonstrate an extraction rate of the metal compound less than 35% as measured by the dye bath test, e.g., less than 25%, less than 20%, less than 10%, or less than 5%. In terms of upper limits, the AM/ AV materials may demonstrate an extraction rate of the metal compound greater than 0%, e.g., greater than 0.1%, greater than 2% or greater than 5%. In terms of ranges, the AM/ AV materials may demonstrate an extraction rate of the metal compound from 0% to 35%, e.g., from 0% to 25%, from 0% to 20%, from 0% to 10%, from 0% to 5%, from 0.1% to 35%, from 0.1% to 25%, from 0.1% to 20%, from 0.2% to 10%, from 0.1% to 5%, from 2% to 35%, from 2% to 25%, from 2% to 20%, from 2% to 10%, from 2% to 5%, from 5% to 35%, from 5% to 25%, from 5% to 20%, or from 5% to 10%.

[0130] The metal retention of a AM/ AV material may be measured by a dye bath test according to the following standard procedure. A sample is cleaned (all oils are removed) by a scour process. The scour process may employ a heated bath, e.g., conducted at 71 °C for 15 minutes. A scouring solution comprising 0.25% on weight of fiber (“owf ’) of Sterox (723 Soap) nonionic surfactant and 0.25 % owf of TSP (trisodium phosphate) may be used. The samples are then rinsed with cold water.

[0131] The cleaned samples may be tested according a chemical dye level procedure. This procedure may employ placing them in a dye bath comprising 1.0% owf of C.I. Acid Blue 45, 4.0% owf of MSP (monosodium phosphate), and a sufficient % owf of di sodium phosphate or TSP to achieve a pH of 6.0, with a 28: 1 liquor to sample ratio. For example, if a pH of less than 6 is desired, a 10% solution of the desired acid may be added using an eye dropper until the desired pH was achieved. The dye bath may be preset to bring the bath to a boil at 100 °C. The samples are placed in the bath for 1.5 hours. As one example, it may take approximately 30 minutes to reach boil and hold one hour after boil at this temperature. Then the samples are removed from the bath and rinsed. The samples are then transferred to a centrifuge for water extraction. After water extraction, the samples were laid out to air dry. The component amounts are then recorded.

[0132] In some embodiments, the metal retention of a fiber formed from the polymer composition may be calculated by measuring metal content before and after a dye bath operation. The amount of metal retained after the dye bath may be measured by known methods. For the dye bath, an Ahiba dyer (from Datacolor) may be employed. In a particular instance, twenty grams of un-dyed fabric and 200 ml of dye liquor may be placed in a stainless steel can, the pH may be adjusted to the desired level, the stainless steel can may be loaded into the dyer; the sample may be heated to 40 °C then heated to 100 °C (optionally at 1.5 °C/minute). In some cases a temperature profile may be employed, for example, 1.5 °C/minute to 60 °C, 1 °C/minute to 80 °C, and 1.5 °C/minute to 100 °C. The sample may be held at 100 °C for 45 minutes, followed by cooling to 40 °C at 2 °C/minute, then rinsed and dried to yield the dyed product. Method of Forming Fibers and Nonwoven Fabrics

[0133] As described herein, the fibers or fabrics of the AM/ AV material are made by forming the AM/ AV polymer composition into the fibers, which are arranged to form the fabric or structure.

[0134] In some aspects, fibers, e.g., polyamide fibers, are made by spinning a polyamide composition formed in a melt polymerization process. During the melt polymerization process of the polyamide composition, an aqueous monomer solution, e.g., salt solution, is heated under controlled conditions of temperature, time and pressure to evaporate water and effect polymerization of the monomers, resulting in a polymer melt. During the melt polymerization process, sufficient amounts of zinc and, optionally, phosphorus, are employed in the aqueous monomer solution to form the polyamide mixture before polymerization. The monomers are selected based on the desired polyamide composition. After zinc and phosphorus are present in the aqueous monomer solution, the polyamide composition may be polymerized. The polymerized polyamide can subsequently be spun into fibers, e.g., by melt, solution, centrifugal, or electro-spinning.

[0135] In some embodiments, the process for preparing fibers having permanent AM/ AV properties from the polyamide composition includes preparing an aqueous monomer solution, adding less than 20,000 wppm of one or more metallic compounds dispersed within the aqueous monomer solution, e.g., less than 17,500 wppm, less than 17,000 wppm, less than 16,500 wppm, less than 16,000 wppm, less than 15,500 wppm, less than 15,000 wppm, less than 12,500 wppm, less than 10,000 wppm, less than 5000 wppm, less than less than 4000 wppm, less than 3000 wppm, less than 2000 wppm, less than 1000 wppm, or less than 500 wppm, polymerizing the aqueous monomer solution to form a polymer melt, and spinning the polymer melt to form an AM/ AV fiber. In this embodiment, the polyamide composition comprises the resultant aqueous monomer solution after the metallic compound(s) are added.

[0136] In some embodiments, the process includes preparing an aqueous monomer solution. The aqueous monomer solution may comprise amide monomers. In some embodiments, the concentration of monomers in the aqueous monomer solution is less than 60 wt%, e.g., less than 58 wt%, less than 56.5 wt%, less than 55 wt%, less than 50 wt%, less than 45 wt%, less than 40 wt%, less than 35 wt%, or less than 30 wt%. In some embodiments, the concentration of monomers in the aqueous monomer solution is greater than 20 wt%, e.g., greater than 25 wt%, greater than 30 wt%, greater than 35 wt%, greater than 40 wt%, greater than 45 wt%, greater than 50 wt%, greater than 55 wt%, or greater than 58 wt%. In some embodiments, the concentration of monomers in the aqueous monomer solution is in a range from 20 wt% to 60 wt%, e.g., from 25 wt% to 58 wt%, from 30 wt% to 56.5 wt%, from 35 wt% to 55 wt%, from 40 wt% to 50 wt%, or from 45 wt% to 55 wt%. The balance of the aqueous monomer solution may comprise water and/or additional additives. In some embodiments, the monomers comprise amide monomers including a diacid and a diamine, i.e., nylon salt.

[0137] In some embodiments, the aqueous monomer solution is a nylon salt solution. The nylon salt solution may be formed by mixing a diamine and a diacid with water. For example, water, diamine, and dicarboxylic acid monomer are mixed to form a salt solution, e.g., mixing adipic acid and hexamethylene diamine with water. In some embodiments, the diacid may be a dicarboxylic acid and may be selected from the group consisting of oxalic acid, malonic acid, succinic acid, glutaric acid, pimelic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, undecanedioic acid, dodecandioic acid, maleic acid, glutaconic acid, traumatic acid, and muconic acid, 1,2- or 1,3 -cyclohexane dicarboxylic acids, 1,2- or 1,3 -phenyl enediacetic acids, 1,2- or 1,3- cyclohexane diacetic acids, isophthalic acid, terephthalic acid, 4,4'-oxybisbenzoic acid, 4,4- benzophenone dicarboxylic acid, 2,6-napthalene dicarboxylic acid, p-t-butyl isophthalic acid and 2,5-furandicarboxylic acid, and mixtures thereof. In some embodiments, the diamine may be selected from the group consisting of ethanol diamine, trimethylene diamine, putrescine, cadaverine, hexamethyelene diamine, 2-methyl pentamethylene diamine, heptamethylene diamine, 2-methyl hexamethylene diamine, 3 -methyl hexamethylene diamine, 2,2-dimethyl pentamethylene diamine, octamethylene diamine, 2,5-dimethyl hexamethylene diamine, nonamethylene diamine, 2,2,4- and 2,4,4-trimethyl hexamethylene diamines, decamethylene diamine, 5 -methylnonane diamine, isophorone diamine, undecamethylene diamine, dodecamethylene diamine, 2,2,7,7-tetramethyl octamethylene diamine, bis(p- aminocyclohexyl)methane, bis(aminomethyl)norbomane, C2-C16 aliphatic diamine optionally substituted with one or more Cl to C4 alkyl groups, aliphatic poly ether diamines and furanic diamines, such as 2,5-bis(aminomethyl)furan, and mixtures thereof. In preferred embodiments, the diacid is adipic acid and the diamine is hexamethylene diamine which are polymerized to form PA6,6. [0138] It should be understood that the concept of producing a polyamide from diamines and diacids also encompasses the concept of other suitable monomers, such as, aminoacids or lactams. Without limiting the scope, examples of aminoacids can include 6-aminohaxanoic acid, 7-aminoheptanoic acid, 11-aminoundecanoic acid, 12-aminododecanoic acid, or combinations thereof. Without limiting the scope of the disclosure, examples of lactams can include caprolactam, enantholactam, lauryllactam, or combinations thereof. Suitable feeds for the disclosed process can include mixtures of diamines, diacids, aminoacids and lactams.

[0139] After the aqueous monomer solution is prepared, a metallic compound (e.g., a zinc compound, a copper compound, and/or a silver compound) is added to the aqueous monomer solution to form the polyamide composition. In some embodiments, less than 20,000 wppm of the metallic compound is dispersed within the aqueous monomer solution. In some aspects, further additives, e.g., additional AM/ AV agents, are added to the aqueous monomer solution. Optionally, phosphorus (e.g., a phosphorus compound) is added to the aqueous monomer solution.

[0140] In some cases, the polyamide composition is polymerized using a conventional melt polymerization process. In one aspect, the aqueous monomer solution is heated under controlled conditions of time, temperature, and pressure to evaporate water, effect polymerization of the monomers and provide a polymer melt. In some aspects, the particular weight ratio of zinc to phosphorus may advantageously promote binding of zinc within the polymer, reduce thermal degradation of the polymer, and enhance its dyeability.

[0141] In one embodiment, a nylon is prepared by a conventional melt polymerization of a nylon salt. Typically, the nylon salt solution is heated under pressure, e.g. 250 psig/1825* 10³ n/m²,to a temperature of, for example, about 245° C. Then the water vapor is exhausted off by reducing the pressure to atmospheric pressure while increasing the temperature to, for example, about 270° C. Before polymerization, zinc and, optionally, phosphorus be added to the nylon salt solution. The resulting molten nylon is held at this temperature for a period of time to bring it to equilibrium prior to being extruded into a fiber. In some aspects, the process may be carried out in a batch or continuous process.

[0142] In some embodiments, during melt polymerization, zinc, e.g., zinc oxide is added to the aqueous monomer solution. The AM/ AV fiber may comprise a polyamide that is made in a melt polymerization process and not in a master batch process. In some aspects, the resulting fiber has permanent AM/ AV properties. The resulting fiber can be used in the topsheet layer and/or the pad layer of the AM/ AV material.

[0143] The AM/ AV agent may be added to the polyamide during melt polymerization, for example as a master batch or as a powder added to the polyamide pellets, and thereafter, the fiber may be formed from spinning. The fibers are then formed into a nonwoven structure.

[0144] In some aspects, the AM/ AV nonwoven structure is melt blown. Melt blowing is advantageously less expensive than electrospinning. Melt blowing is a process type developed for the formation of microfibers and nonwoven webs. Until recently, microfibers have been produced by melt blowing. Now, nanofibers may also be formed by melt blowing. The nanofibers are formed by extruding a molten thermoplastic polymeric material, or polyamide, through a plurality of small holes. The resulting molten threads or filaments pass into converging high velocity gas streams which attenuate or draw the filaments of molten polyamide to reduce their diameters. Thereafter, the melt blown nanofibers are carried by the high velocity gas stream and deposited on a collecting surface, or forming wire, to form a nonwoven web of randomly disbursed melt blown nanofibers. The formation of nanofibers and nonwoven webs by melt blowing is well known in the art. See, e.g., U.S. Pat. Nos. 3,704,198; 3,755,527; 3,849,241; 3,978,185; 4,100,324; and 4,663,220.

[0145] One option, “Island-in-the-sea,” refers to fibers forming by extruding at least two polymer components from one spinning die, also referred to as conjugate spinning.

[0146] As is well known, electrospinning has many fabrication parameters that may limit spinning certain materials. These parameters include: electrical charge of the spinning material and the spinning material solution; solution delivery (often a stream of material ejected from a syringe); charge at the jet; electrical discharge of the fibrous membrane at the collector; external forces from the electrical field on the spinning jet; density of expelled jet; and (high) voltage of the electrodes and geometry of the collector. In contrast, the aforementioned nanofibers and products are advantageously formed without the use of an applied electrical field as the primary expulsion force, as is required in an electrospinning process. Thus, the polyamide is not electrically charged, nor are any components of the spinning process. Importantly, the dangerous high voltage necessary in electrospinning processes, is not required with the presently disclosed processes/products. In some embodiments, the process is a non-electrospin process and resultant product is a non-electrospun product that is produced via a non-electrospin process. [0147] Another embodiment of making the nanofiber nonwovens is by way of 2-phase spinning or melt blowing with propellant gas through a spinning channel as is described generally in U.S. Patent No. 8,668,854. This process includes two phase flow of polymer or polymer solution and a pressurized propellant gas (typically air) to a thin, preferably converging channel. The channel is usually and preferably annular in configuration. It is believed that the polymer is sheared by gas flow within the thin, preferably converging channel, creating polymeric film layers on both sides of the channel. These polymeric film layers are further sheared into nanofibers by the propellant gas flow. Here again, a moving collector belt may be used and the basis weight of the nanofiber nonwoven is controlled by regulating the speed of the belt. The distance of the collector may also be used to control fineness of the nanofiber non woven.

[0148] Beneficially, the use of the aforementioned polyamide precursor in the melt spinning process provides for significant benefits in production rate, e.g., at least 5% greater, at least 10% greater, at least 20% greater, at least 30% greater, at least 40% greater. The improvements may be observed as an improvement in area per hour versus a conventional process, e.g., another process that does not employ the features described herein. In some cases, the production increase over a consistent period of time is improved. For example, over a given time period, e.g,, one hour, of production, the disclosed process produces at least 5% more product than a conventional process or an electrospin process, e.g., at least 10% more, at least 20% more, at least 30% more, or at least 40% more.

[0149] Still yet another methodology which may be employed is melt blowing. Melt blowing involves extruding the polyamide into a relatively high velocity, typically hot, gas stream. To produce suitable nanofibers, careful selection of the orifice and capillary geometry as well as the temperature is required as is seen in: Hassan et al., J Membrane Sci., 427, 336-344, 2013 and Ellison et al., Polymer, 48 (11), 3306-3316, 2007, and, International Nonwoven Journal, Summer 2003, pg 21-28.

[0150] US Patent No. 7,300,272 (incorporated herein by reference) discloses a fiber extrusion pack for extruding molten material to form an array of nanofibers that includes a number of split distribution plates arranged in a stack such that each split distribution plate forms a layer within the fiber extrusion pack, and features on the split distribution plates form a distribution network that delivers the molten material to orifices in the fiber extrusion pack. Each of the split distribution plates includes a set of plate segments with a gap disposed between adjacent plate segments. Adjacent edges of the plate segments are shaped to form reservoirs along the gap, and sealing plugs are disposed in the reservoirs to prevent the molten material from leaking from the gaps. The sealing plugs can be formed by the molten material that leaks into the gap and collects and solidifies in the reservoirs or by placing a plugging material in the reservoirs at pack assembly. This pack can be used to make nanofibers with a melt blowing system described in the patents previously mentioned. The systems and method of US Patent No. 10,041,188 (incorporated herein by reference) are also exemplary.

[0151] In one embodiment, a process for preparing the AM/ AV nonwoven polyamide structure, e.g., for use in the fabric sheet, is disclosed. The process comprising the step of forming a (precursor) polyamide (preparation of monomer solutions are well known), e.g., by preparing an aqueous monomer solution. During preparation of the precursor, a metallic compound, such as zinc, is added (as discussed herein). In some cases, the metallic compound is added to (and dispersed in) the aqueous monomer solution. Phosphorus may also be added. In some cases, the precursor is polymerized to form a polyamide composition. The process further comprises the steps of forming polyamide fibers and forming the AM/ AV polyamide fibers into a structure. In some cases, the polyamide composition is melt spun, spunlaced, spunbonded, electrospun, solution spun, or centrifugally spun. The resulting fibers can be melt spun fibers, spunlace fiber, sponbond fibers, electrospun fibers, solution spun fibers, centrifugal spun fibers, or staple fibers.

[0152] A fabric can be made from the fibers by conventional means.

[0153] As used herein, “greater than” and “less than” limits may also include the number associated therewith. Stated another way, “greater than” and “less than” may be interpreted as “greater than or equal to” and “less than or equal to.” It is contemplated that this language may be subsequently modified in the claims to include “or equal to.” For example, “greater than 4.0” may be interpreted as, and subsequently modified in the claims as “greater than or equal to 4.0.” Embodiments

[0154] As used below, any reference to a series of embodiments is to be understood as a reference to each of those embodiments disjunctively (e.g., “Embodiments 1-4” is to be understood as “Embodiments 1, 2, 3, or 4”). [0155] Embodiment l is a wet wipe fabric sheet comprising fibers comprising a polymer and zinc; and a lotion composition comprising less than 0.5 wt% preservative, based on the total weight of the lotion composition, wherein the fibers retain greater than 200 wt% liquid; and the fibers inhibit mold formation.

[0156] Embodiment 2 is the wet wipe fabric sheet of embodiment 1, wherein the fabric comprises a single sheet of fibers.

[0157] Embodiment 3 is the wet wipe fabric sheet of embodiment 1, wherein the polymer comprises polyamide.

[0158] Embodiment 4 is the wet wipe fabric sheet of embodiment 3, wherein the polyamide is a PA66.

[0159] Embodiment 5 is the wet wipe fabric sheet of embodiment 1, wherein the fibers comprises a polyamide polymer matrix embedded with ionic zinc (Zn²⁺).

[0160] Embodiment 6 is the wet wipe fabric sheet of embodiment 3, wherein the polymer comprises a polyamide blended with an absorbent fiber selected from the group consisting of rayon, lyocell, and a natural fiber.

[0161] Embodiment 7 is the wet wipe fabric sheet of embodiment 1, wherein the wet wipe fabric sheet comprises less than 0.5 wt% phenoxyethanol.

[0162] Embodiment 8 is the wet wipe fabric sheet of embodiment 1, wherein the wet wipe fabric sheet is free of any synthetic preservatives.

[0163] Embodiment 9 is the wet wipe fabric sheet of embodiment 1, wherein the lotion composition further comprises water and one or more surfactant, moisturizer, and/or fragrant. [0164] Embodiment 10 is the wet wipe fabric sheet of embodiment 1, wherein the fibers comprise staple fibers.

[0165] Embodiment 11 is the wet wipe fabric sheet of embodiment 1, wherein the fibers comprise spunlace fibres.

[0166] Embodiment 12 is the wet wipe fabric sheet of embodiment 1, wherein the fibers further prevent odor.

[0167] Embodiment 13 is a package of wet wipes, comprising a plurality of wet wipe fabric sheets of embodiment 1, enclosed by packaging.

[0168] Embodiment 14 is a preservative-free wet wipe fabric sheet comprising fibers comprises a polyamide polymer matrix embedded with ionic zinc (Zn²⁺); and a lotion composition comprising less than 0.5 wt% of a synthetic preservative; wherein the fibers retain greater than 200 wt% liquid, based on the total weight of the lotion composition; and the fibers inhibit mold formation.

[0169] Embodiment 15 is the wet wipe fabric sheet of embodiment 14, wherein the wet wipe fabric sheet comprises between 0.1-0.5 wt% of a non-synthetic preservative.

[0170] Embodiment 16 is a method of inhibiting or preventing mold and/or odor in a wet wipe fabric sheet, without the use of synthetic preservatives, comprising the steps of introducing fibers comprising a polymer and zinc into a wet wipe fabric sheet, and adding a lotion composition to the wet wipe fabric sheet; wherein the fibers inhibit or prevent mold and/or odor in the wet wipe fabric sheet without the need for synthetic preservatives.

[0171] Embodiment 17 is the method of embodiment 16, wherein the polymer comprises polyamide.

[0172] Embodiment 18 is the method of embodiment 17, wherein the polyamide is a PA66.

[0173] Embodiment 19 is the method of embodiment 16, wherein the fibers comprises a polyamide polymer matrix embedded with ionic zinc (Zn²⁺).

[0174] Embodiment 20 is the method of embodiment 16, wherein the fibers comprise spunlace fibres.

[0175] Embodiment 21 is the method of embodiment 16, wherein the wet fabric comprises less than 0.5 wt% phenoxyethanol.

Claims

We claim:

1. A wet wipe fabric sheet comprising: fibers comprising a polymer composition comprising a polymer and zinc; and a lotion composition comprising less than 0.5 wt% preservative, based on the total weight of the lotion composition; wherein: the fibers retain greater than 200 wt% liquid; and the fibers inhibit mold formation.

2. The wet wipe fabric sheet of claim 1, wherein the fabric comprises a single sheet of fibers.

3. The wet wipe fabric sheet of claim 1, wherein the wet wipe fabric sheet is free of any synthetic preservatives.

4. The wet wipe fabric sheet of claim 1, wherein the wet wipe fabric sheet comprises less than 0.5 wt% phenoxyethanol.

5. The wet wipe fabric sheet of claim 1, wherein the polymer comprises polyamide.

6. The wet wipe fabric sheet of claim 3, wherein the polyamide is PA66.

7. The wet wipe fabric sheet of claim 1, wherein the fibers comprises a polyamide polymer matrix embedded with ionic zinc (Zn²⁺).

8. The wet wipe fabric sheet of claim 3, wherein the polymer comprises a polyamide blended with an absorbent fiber selected from the group consisting of rayon, lyocell, and a natural fiber.

46

9. The wet wipe fabric sheet of claim 1, wherein the lotion composition further comprises water and one or more surfactant, moisturizer, and/or fragrant.

10. The wet wipe fabric sheet of claim 1, wherein the fibers comprise staple fibers.

11. The wet wipe fabric sheet of claim 1, wherein the fibers comprise spunlace fibres.

12. A package of wet wipes, comprising a plurality of wet wipe fabric sheets of claim 1, enclosed by packaging.

13. A preservative-free wet wipe fabric sheet comprising: fibers comprising a polyamide polymer matrix embedded with ionic zinc (Zn²⁺); and a lotion composition comprising less than 0.5 wt% synthetic preservative, based on the total weight of the lotion composition; wherein: the fibers retain greater than 200 wt% liquid; and the fibers inhibit mold formation.

14. The wet wipe fabric sheet of claim 13, wherein the wet wipe fabric sheet comprises between 0.1-0.5 wt% of a non-synthetic preservative.

15. A method of inhibiting or preventing mold and/or odor in a wet wipe fabric sheet, without the use of synthetic preservatives, comprising the steps of introducing fibers comprising a polymer and zinc into a wet wipe fabric sheet, and adding a lotion composition to the wet wipe fabric sheet; wherein the fibers inhibit or prevent mold and/or odor in the wet wipe fabric sheet without the need for synthetic preservatives.

16. The method of claim 15, wherein the polymer comprises polyamide.

17. The method of claim 16, wherein the polyamide is a PA66.

47

18. The method of claim 16, wherein the fibers comprises a polyamide polymer matrix embedded with ionic zinc (Zn²⁺).

19. The method of claim 15, wherein the fibers comprise spunlace fibers.

20. The method of claim 15, wherein the wet fabric sheet comprises less than 0.5 wt% phenoxyethanol.

48