Processes for producing antitoxic fibers and fabrics

Abstract

The invention provides a novel method for producing an antitoxic nonwoven fabric by molecularly grafting the antitoxic molecule thereto. The method comprises immersing a fibrous media comprising a material having a melt flow index of less than 150 MFI in a stable antitoxin solution comprising an antitoxin, preferably triiodide. The wet media is processed through rollers, thereby forcing the antitoxic molecule (e.g., iodine) to penetrate the media. The wet media is dried, and the fabric isolated therefrom. The invention further provides products incorporating the antitoxic media formed by this molecularly grafting method, including a wound dressing, surgical drape, privacy curtain, facemask, gown, article of protective clothing, shoe covering, hair covering, air filter, medical tape, and wipe.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This applications claims the benefit of U.S. provisional application 61 / 568,982, filed on Dec. 9, 2011, the entirety of which is incorporated herein.FIELD OF THE INVENTION[0002]The present invention relates to antitoxic fibers and fabrics and methods for their manufacture, most particularly, to methods for molecular grafting of antitoxins to fibers and media formed therefrom. The invention also relates to products comprising the antitoxic fibers and fabrics so formed.BACKGROUND OF THE INVENTION[0003]Various methods for producing antimicrobials for use in both nonwoven and woven fabrics are known. However, improvements in the production of antitoxins or antimicrobials and in the products that incorporate them, so that they exhibit both low toxicity and high efficacy, are still needed.[0004]A woven or nonwoven material can be loaded with antitoxin in different ways and at different points during or after processing of the material. For exam...

AI Technical Summary

Benefits of technology

The present invention is about a new manufacturing process for producing fibers and fabrics that contain antitoxins. This process is cost-effective and efficient. The resultant fabrics have a high capacity for antitoxins and are effective in reducing toxicity. The invention also provides products made from the antitoxic fibers and fabrics, such as wound dressings, gowns, and air filters. The manufacturing process involves a molecular grafting technique that increases the amount of active antitoxic agent in the fibers and reduces the amount of antitoxin lost during the process. Overall, this invention allows for efficient and cost-effective production of high-quality antitoxic fibers and fabrics.

Problems solved by technology

However, improvements in the production of antitoxins or antimicrobials and in the products that incorporate them, so that they exhibit both low toxicity and high efficacy, are still needed.

Although methods described above produce efficacious materials, a significant loss of the antitoxic agent may be encountered during the various processing steps.

In the meltblown procedure, for instance, it is found that the steps of heating and extrusion may result in sublimation or leeching of the antitoxic agent from the web.

While the addition of an immersion step in the post-processing of the nonwoven was found to increase the amount of antitoxin in the product, and thus increase the measured kill performance, this additive step was also found to increase the amount of leaching and toxicity.

In addition, the added immersion step increases the overall cost.

Although methods described above for entrapping antitoxic agents into the three-dimensional matrix or into the fibers of a nonwoven web produce efficacious materials, it is found that significant loss of the antitoxic agent may be encountered during processing.

In the meltblown procedure, for instance, it is found that the steps of heating and extrusion may result in sublimation or leeching of the antitoxic agent from the web.

The loss of antitoxic agent during the manufacturing process is costly.

In addition, the unused antitoxins constitute undesirable hazardous waste materials that must be properly disposed of.

Images