Antibacterial fibers

Abstract

The present application relates to an antibacterial fiber. An apparatus and related manufacturing method to provide an antibacterial fiber are described. The manufacturing method includes adding an ultra-high molecular weight polyethylene structure into an extrusion device. The manufacturing method also includes feeding an antibacterial low-density polyethylene (LDPE) into the ultra-high molecular weight polyethylene at a predetermined temperature to produce a combined filament. The manufacturing method further includes passing the combined filament through a bath. The bath is configured to solidify the combined filament and extract a solvent. The manufacturing method still further includes drying the combined filament through an oven. The manufacturing method also includes heat stretching the combined filament. The combined filament is heated within the oven during the heat stretching and the resulting combined filament has antibacterial properties. A corresponding antibacterial fiber is also provided.

Description

TECHNICAL FIELD

[0001] Exemplary embodiments of the present application relate generally to high performance materials, and more particularly to antibacterial high performance material structures and composites. BACKGROUND

[0002] Most personal protective equipment is typically made of ultra-high molecular weight polyethylene that does not have antibacterial properties. Ultra-high molecular weight polyethylene is usually located near the skin and can become itchy and / or emit an unpleasant odor due to bacterial growth. Current methods of producing antibacterial materials include dipping gloves into antibacterial additives, such as Ag and Ag + , quaternary ammonium compounds, or other agents. However, the antibacterial properties of the dipped materials are non-permanent and add an extra step to manufacturing gloves. Furthermore, the antibacterial properties and longevity of the dipped materials are usually different for different materials. Additionally, the process to produce antibacterial materials is complex and creates pollution.

[0003] Applicants have identified a number of deficiencies and problems associated with high performance material structure data. Through efforts, creativity, and innovation, many of these identified problems have been solved by developing solutions included in embodiments of the present disclosure, many examples of which are described in detail herein. SUMMARY

[0004] Exemplary embodiments of the present disclosure relate to a cut-resistant, high antibacterial fiber structure and related manufacturing methods. In one exemplary embodiment, an antibacterial fiber is provided. The antibacterial fiber includes an ultra-high molecular weight polyethylene structure. The antibacterial fiber also includes an antibacterial low-density polyethylene (LDPE). The antibacterial LDPE includes polyhexamethylene guanidine (PHMG) grafted onto the LDPE structure. The ultra-high molecular weight polyethylene structure and the antibacterial LDPE are combined together to form the antibacterial fiber.

[0005] In some embodiments, the antibacterial low-density polyethylene is dissolved in oil. In some embodiments, the oil that dissolves the antibacterial low-density polyethylene includes coal oil. In some embodiments, the antibacterial LDPE has a weight that is about 1% of the total weight of the antibacterial fiber. In some embodiments, the ultra-high molecular weight polyethylene and the antibacterial LDPE are combined using gel spinning. In some embodiments, the antibacterial LDPE has a weight that is between 0.5% and 10% of the total weight of the antibacterial fiber.

[0006] In some embodiments, the ultra-high molecular weight polyethylene structure is extruded through an extrusion device. In some embodiments, the ultra-high molecular weight polyethylene structure is extruded through an extrusion device prior to being combined with the antibacterial LDPE. In some embodiments, the ultra-high molecular weight polyethylene structure and the antibacterial LDPE are extruded through a moderated flow device. In some embodiments, the antibacterial fiber can be configured as a garment material.

[0007] In another exemplary embodiment, a method of manufacturing an antibacterial fiber is provided. The method includes adding an ultra-high molecular weight polyethylene structure to an extrusion device. The method also includes feeding antibacterial low density polyethylene (LDPE) to the ultra-high molecular weight polyethylene at a predetermined temperature to create a combined filament. The method further includes passing the combined filament through a bath. The bath is configured to coagulate the combined filament and extract a solvent. The method still further includes drying the combined filament through an oven. The method also includes hot-drawing the combined filament. The combined filament is heated within the oven during the hot-drawing and the resulting combined filament has antibacterial properties.

[0008] In some embodiments, the predetermined temperature is about 80 degrees Celsius to 200 degrees Celsius. In some embodiments, the predetermined temperature is about 105 degrees Celsius. In some embodiments, the antibacterial LDPE fed to the extruded ultra-high molecular weight polyethylene is dissolved in an oil. In some embodiments, the oil that dissolves the antibacterial low density polyethylene includes coal distillate oil. In some embodiments, the weight of antibacterial LDPE is about 1% of the total weight of the antibacterial fiber. In some embodiments, the weight of the antibacterial LDPE is 0.5% to 10% of the total weight of the antibacterial fiber.

[0009] In some embodiments, the method also includes extruding the ultra-high molecular weight polyethylene structure and the antibacterial LDPE through a moderated flow device. In some embodiments, the high density polyethylene is extruded through an extrusion device prior to being combined with the antibacterial LDPE. In some embodiments, the method also includes threading the antibacterial fiber together to form an antibacterial garment material.

[0010] The above overview is provided merely to summarize some exemplary embodiments to provide a basic understanding of some aspects of the invention. Therefore, it will be understood that the above embodiments are merely illustrative and should not be construed as limiting the scope or spirit of the invention in any way. It will be understood that the scope of the invention includes many possible embodiments in addition to those summarized herein, some of which will be further described below. Attached Figure Description

[0011] The foregoing has provided a general overview of some exemplary embodiments of this disclosure, and reference will now be made to the accompanying drawings. The components shown in the drawings may or may not be present in some of the embodiments described herein. Some embodiments may include fewer (or more) components than those shown in the drawings.

[0012] Figure 1 An exemplary antimicrobial fiber structure of the present disclosure is shown in an exemplary antimicrobial glove;

[0013] Figure 2 An exemplary embodiment of the present disclosure is shown, which is an exemplary antimicrobial low-density polyethylene generated by grafting PHMG onto low-density polyethylene for use in combination with other polyethylene structures.

[0014] Figure 3 A simplified manufacturing method for producing antimicrobial fibers according to this disclosure is shown;

[0015] Figure 4 This is a flowchart illustrating an exemplary method for manufacturing antimicrobial fibers according to an exemplary embodiment of the present disclosure;

[0016] Figure 5 An exemplary method for manufacturing antimicrobial fibers according to an exemplary embodiment of the present disclosure is shown, for example... Figure 4 The methods discussed in the text; and

[0017] Figure 6A and 6B An exemplary embodiment is shown, which does not have antibacterial LDPE ( Figure 6A ) and LDPE with antibacterial properties Figure 6B Bacterial accumulation in high-performance polyethylene fibers. Detailed Implementation

[0018] Overview

[0019] The invention will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of the invention. In fact, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided to enable this disclosure to meet applicable legal requirements. The same numerals always denote the same elements. As used herein, terms such as “front,” “rear,” “top,” etc., are used for illustrative purposes in the examples provided below to describe the relative positions of certain components or portions of components. Furthermore, it will be apparent to those skilled in the art, based on this disclosure, that the terms “substantially” and “approximately” indicate that the referenced elements or related descriptions are accurate within applicable engineering tolerances.

[0020] The term "comprising / including / containing" means including / containing / containing but not limited to, and should be interpreted in the manner commonly used in the patent context. Phrases such as "in one embodiment," "according to one embodiment," etc., generally mean that the specific feature, structure, or characteristic following the phrase can be included in at least one embodiment of the invention, and may be included in more than one embodiment of the invention (importantly, such phrases do not necessarily refer to the same embodiment). If the specification describes something as "exemplary" or "example," it should be understood as referring to a non-exclusive example.

[0021] As discussed herein, exemplary embodiments may be described with reference to fiber structures comprising various cores, filaments, yarns, coverings, etc. In this regard, in some instances, the described and claimed fiber structure may refer to a composite fiber structure. For clarity of description, exemplary embodiments of this application are described herein with reference to "antimicrobial fiber," but may be used equivalently and interchangeably to refer to a composite antimicrobial fiber structure. The term antimicrobial may indicate a substantial reduction of bacteria, may indicate a complete reduction and / or elimination of bacteria, may indicate fibers active against bacteria, and / or the like. Various embodiments of this disclosure enable the production of materials with antimicrobial properties without costly manufacturing and / or additional steps (e.g., coating, etc.). For example, some gloves currently use antimicrobial coatings on conventional gloves to reduce bacteria, but this approach is not only non-permanent but also adds additional steps to the manufacturing process.

[0022] refer to Figure 1 The illustration shows an antimicrobial glove 100 embodying an exemplary antimicrobial fiber and / or composed of an exemplary antimicrobial fiber. As shown, the antimicrobial glove 100 may be manufactured or formed from an antimicrobial fiber made according to an exemplary embodiment discussed herein. For example, the antimicrobial fiber may be used to produce yarns for manufacturing antimicrobial fabrics configured for clothing fabrics, etc.

[0023] See below for reference Figures 3-5 The antimicrobial fiber of this application may be produced by combining high-density polyethylene, such as ultra-high molecular weight polyethylene (UHMWPE) raw materials, and antimicrobial low-density polyethylene (LDPE) (for example, the antimicrobial LDPE is formed from PHMG grafted onto LDPE). Although this disclosure may refer to high-density polyethylene in association with UHMWPE, other high-density polyethylene structures are also contemplated.

[0024] Although the discussion is primarily based on gel spinning, the high-density polyethylene and the antimicrobial LDPE can be combined using various spinning techniques such as dry spinning, wet spinning, etc. While the description is based on the antimicrobial fiber structure used to form the antimicrobial glove 100, this disclosure contemplates that the antimicrobial fiber structure described herein can also be used to form any clothing (e.g., trousers, shirts, jackets, coverings, etc.) without limitation. In some embodiments, the antimicrobial fiber may have a light color (e.g., the antimicrobial fiber may be light yellow), allowing the antimicrobial fiber to be dyed in various colors for use.

[0025] Now for reference Figure 2 An exemplary antimicrobial LDPE is illustrated according to one exemplary embodiment. As shown, PHMG is grafted onto LDPE to form the antimicrobial LDPE 200 discussed herein. In various embodiments, the PHMG structure may be (C7H 15 N3) n It can also be configured to be grafted onto LDPE to produce the antimicrobial LDPE structure discussed in this paper.

[0026] Now for reference Figure 3 This illustrates a simplified manufacturing method for antibacterial fibers. As shown in the figure, the above reference... Figure 1 The antimicrobial fiber discussed can be manufactured by gel-spinning UHMWPE raw materials and antimicrobial LDPE (i.e., PHMG-grafted LDPE) to produce antimicrobial UHMWPE filaments (e.g., the antimicrobial fiber). In some embodiments, the amount of antimicrobial LDPE can vary based on the desired amount of antibacterial properties, the required cost, etc. In some embodiments, the antimicrobial LDPE can be approximately 0.5% to 10% of the total weight of the antimicrobial fiber. In some embodiments, the antimicrobial LDPE can be approximately 0.75% to 3% of the total weight of the antimicrobial fiber. In some embodiments, the antimicrobial LDPE can be approximately 0.8% to 1.5% of the total weight of the antimicrobial fiber. In some embodiments, the antimicrobial LDPE can be approximately 1% of the total weight of the antimicrobial fiber.

[0027] Figure 4An exemplary manufacturing method is illustrated according to one exemplary embodiment. Unless otherwise explicitly stated, various embodiments of the described method may be implemented in a different order than that described herein. Additional operations may also be included in the method of manufacturing antimicrobial fibers; therefore, the following steps are not exhaustive.

[0028] Now for reference Figure 4 The manufacturing method, as described in box 400, involves incorporating ultra-high molecular weight polyethylene (e.g., having a molecular weight of 1×10⁻⁶) into a container. 6 -2×10 7 The UHMWPE (polyethylene with a viscosity-average molecular weight of g / mol) structure is added to the extrusion apparatus. In some embodiments, the UHMWPE is added to the extrusion apparatus using a mixing container or the like. In some embodiments, the mixing container may include an agitator (e.g., agitator blades, etc.). In some embodiments, the UHMWPE may be combined with one or more additional substances (e.g., the UHMWPE may be suspended in a first solvent such as white oil or chlorofluorocarbon, and in some cases, additional substances such as surfactants, dispersants) to form a UHMWPE solution to assist the extrusion process. In various embodiments, the UHMWPE structure may be suspended in a non-volatile first solvent at a given concentration. In some embodiments, the UHMWPE concentration may be about 5% to 20% of the UHMWPE solution, preferably about 6% to 15%, more preferably about 8%. In various embodiments, the extrusion apparatus 510 may be a twin-screw extruder configured to rotate during operation. In some embodiments, the extrusion apparatus 510 may also heat the UHMWPE raw material during operation.

[0029] Now for reference Figure 4 According to block 410, the manufacturing method includes feeding coal tar containing antimicrobial LDPE into extruded high-density polyethylene. In some embodiments, the added antimicrobial LDPE may be about 0.5% to 3% of the total weight of the combined filaments, preferably about 0.75% to 2%, more preferably about 1% of the total weight. In some embodiments, the antimicrobial LDPE solution may be added to the UHMWPE solution. For example, in the case where coal tar is then added to the extruded UHMWPE at a predetermined temperature, the antimicrobial LDPE can be dissolved in the coal tar.

[0030] In some examples, coal tar containing antimicrobial LDPE can be added to UHMWPE at a predetermined temperature. In some embodiments, the predetermined temperature of the UHMWPE when adding the antimicrobial LDPE can be from about 80 degrees Celsius to 200 degrees Celsius, preferably from about 80 degrees Celsius to 160 degrees Celsius, and more preferably from about 105 degrees Celsius. In some embodiments, the coal tar can be shale oil, such as kerosene. In some embodiments, other solvents can be used to dissolve the antimicrobial LDPE, such as decahydronaphthalene.

[0031] Now for reference Figure 4 Block 420, the manufacturing method includes processing the assembled filaments using a flow control device 530. In various embodiments, the flow control device 530 may be configured to extrude the assembled filaments. In some embodiments, the flow control device 530 may be in communication with a spinneret 540, which is configured to separate the assembled filaments into multiple strands or fibers once the assembled filaments are extruded. The extrusion speed and subsequent processing through the spinneret 540 may be based on the application type, the equipment used, the desired fiber size, and / or etc. In some embodiments, the strands or fibers produced by the spinneret 540 continue through a bath 550 for solidification.

[0032] Now for reference Figure 4 According to block 430, the manufacturing method includes passing the assembled filaments through a bath 550. In various embodiments, bath 550 may act as a coagulation bath, allowing the assembled filaments to be quenched (e.g., the polymer chains of the assembled filaments may be quenched). In various embodiments, bath 550 may contain a quenching liquid, such as water. In some embodiments, the quenching liquid in bath 550 may be water at ambient temperature (e.g., approximately 20 to 30 degrees Celsius). In some embodiments, bath 550 may contain a second solvent, such as xylene or dichloromethane. In various embodiments, the second solvent may be used to extract a first solvent from the assembled filaments. In various embodiments, the first solvent may be extracted within bath 550. In some embodiments, the assembled filaments may also undergo cold stretching within bath 550. For example, bath 550 may have one or more rollers configured to feed the assembled filaments through bath 550. In some embodiments, the one or more rollers may operate in a manner with little to no tension on the assembled filaments.

[0033] Now for reference Figure 4According to block 440, the manufacturing method includes providing heat to the assembled filaments via an oven 560. In various embodiments, after the assembled filaments have passed through a bath 550 to quench the fibers and remove a first solvent, the fibers may then enter an oven 560 configured to provide heat to the fibers. In various embodiments, the oven 560 may be configured to remove a portion (e.g., a majority) of a second solvent from the fibers during the drying process. In various embodiments, the oven 560 may be a dedicated oven configured for the process described herein. In some embodiments, the oven 560 may be a convection oven.

[0034] Now for reference Figure 4 The manufacturing method, as described in block 450, involves hot-stretching filament fibers through an oven 560. In some embodiments, the hot stretching may be divided into multiple stages. For example, the hot stretching may be divided into three stages or stretching, such that each stretch uses rollers within the oven to change the orientation of the combined filaments. In various embodiments, the required heat applied to the fibers can affect the number of stretches. In various embodiments, the stretching temperature can range from about 110 degrees Celsius to 200 degrees Celsius, preferably from about 110 degrees Celsius to 160 degrees Celsius, and more preferably from about 140 degrees Celsius.

[0035] Now for reference Figure 4 In block 460, the manufacturing method includes winding the finished antimicrobial fiber 570 onto a spool (e.g., a roller). In this embodiment, the antimicrobial fiber is intended for use, for example, in... Figure 1 The antimicrobial glove 100 is shown in the figure. In various embodiments, the finished antimicrobial fiber can be used in a manner similar to other fibers currently in use. For example, the antimicrobial fiber can be used in a variety of applications, such as gloves (e.g., antimicrobial glove 100), upper shoe materials, clothing fabrics, ropes, and / or articles like these. Furthermore, the antimicrobial fiber can be configured to have antimicrobial properties without any additional manufacturing steps (e.g., the antimicrobial fiber itself has antimicrobial properties and does not require additional coating).

[0036] Exemplary manufacturing method

[0037] like Figure 5As shown, a UHMWPE structure can be incorporated into an extrusion apparatus 510, which extrudes UHMWPE suspended in a first solvent via a twin-screw extruder, etc. Antimicrobial LDPE can be incorporated into high-density polyethylene at a predetermined temperature, for example, about 110 degrees Celsius. In some embodiments, the antimicrobial LDPE 200 can be dissolved in oil 500, such as coal tar. In some embodiments, oil 500 containing dissolved antimicrobial LDPE 200 can be combined with UHMWPE at point 520. Once combined, the combined filaments can be passed through a flow control device 530, which extrudes the combined filaments and transfers them to a spinneret 540 configured to separate the combined filaments into individual filaments. After individual filaments have been produced by the spinneret 540, the combined filaments can then enter a bath 550, which acts as a coagulation bath (e.g., water in the bath that quenches the combined filaments) and an extraction bath (e.g., a second solvent present in the bath to extract the first solvent). In various embodiments, the assembled filaments may undergo cold stretching within bath 550. In some embodiments, the assembled filaments may pass through oven 560 to dry the assembled filaments, thereby evaporating the second solvent. Furthermore, within oven 560, the filament fibers may undergo hot stretching (e.g., to achieve high orientation and high crystallinity of the polymer chains) before being wound for use as antimicrobial fiber 570.

[0038] Exemplary antibacterial test results

[0039] Figures 6A-6B The study showed a reduction in bacteria from a typical UHMWPE without antimicrobial LDPE. Figure 6A The study showed bacteria accumulation on conventional UHMWPE fibers that do not contain antibacterial LDPE, while Figure 6B Bacteria accumulated on an antimicrobial fiber according to an exemplary embodiment discussed herein are shown. Figure 6A and 6B These are results from tests conducted according to GB / T 20944.3-2008 at different bacterial loads. As shown in the figure, conventional UHMWPE fibers (e.g., slides 600A, 610A, 620A, and 630A) can accumulate a significant amount of bacteria that pass through the fibers and are then exposed to various environments that allow bacterial growth. In various embodiments, as shown in the figure, the amount of bacteria accumulating on antimicrobial fibers can be significantly less than that on conventional UHMWPE fibers. As shown in the figure, where the fiber environment allows 10 4 In the case of colony-forming units (CFU) / ml bacterial growth, slide 600B showed a significant reduction in bacteria accumulation due to the antimicrobial fibers compared to the conventional UHMWPE fibers shown in slide 600A. This was achieved when the fiber environment allowed for 10... 3As shown in the CFU / ml case, slide 610B exhibits a significant reduction in bacteria buildup due to the antimicrobial fibers compared to the conventional UHMWPE fibers shown in slide 610A. This is exemplified by the fiber environment allowing for 10... 2 As shown in the CFU / ml case, slide 620B exhibits a significant reduction in bacteria buildup due to the antimicrobial fibers compared to the conventional UHMWPE fibers shown in slide 620A. Within this fiber environment, 10 2 In another case with CFU / ml, slide 630B shows a significant reduction in bacteria buildup from the antimicrobial fibers compared to the conventional UHMWPE fibers shown in slide 630A. In one exemplary embodiment, the bacterial buildup reduction of antimicrobial fibers with 1% total weight antimicrobial LDPE can be approximately 96.6% compared to conventional UHMWPE fibers without antimicrobial LDPE.

[0040] Embodiments of this disclosure include antimicrobial fibers or fabrics that may be governed by, tested against, or otherwise associated with antimicrobial-related standards. In some cases, these standards may be prescribed and / or enforced by standards bodies or government agencies. It will be apparent to those skilled in the art that these standards may be updated or modified from time to time to change the requirements for meeting the standards (e.g., to reduce injury or other accidents). As an example, Figure 6A and 6B The test results are shown. Furthermore, antibacterial standards can be updated in response to incident statistical analysis and / or in response to improved technologies. The antibacterial fiber structures described herein incorporate combinations of different technologies to achieve enhanced antibacterial properties. Using a combination of technologies, rather than simply using a single technology, can facilitate achieving multiple at least partially antagonistic objectives and / or balancing the performance of a given design. For example, the antibacterial fiber can be configured to meet the ASTM E2149 antibacterial standard. When tested using AATCC 100-2012 testing, HMPE yarn made from the antibacterial fiber of one exemplary embodiment resulted in a reduction of Escherichia coli exceeding 99.9% according to ATCC 8739 and a reduction of Staphylococcus aureus exceeding 99.9% according to ATCC 6538. Furthermore, the antibacterial fiber of one exemplary embodiment resulted in a reduction of Escherichia coli exceeding 99% according to ASTM 2149-2013a.

[0041] Benefiting from the teachings presented in the foregoing description and the accompanying drawings, those skilled in the art will conceive of many modifications and other embodiments of the invention set forth herein. Therefore, it will be understood that the invention is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are used herein, they are used only in a general and descriptive sense and not for the purpose of limitation.

Claims

1. A method of manufacturing an antimicrobial fiber, the method comprising: suspending ultra-high molecular weight polyethylene (UHMWPE) in a solvent to form a UHMWPE solution; adding the UHMWPE solution to an extrusion apparatus; dissolving an antimicrobial low-density polyethylene (LDPE) in an oil to form an antimicrobial LDPE solution; adding the antimicrobial LDPE solution to the UHMWPE solution at a temperature of 80 degrees Celsius to 200 degrees Celsius to produce a combined filament, wherein the antimicrobial LDPE comprises polyhexamethylene guanidine (PHMG) grafted onto the LDPE structure; passing the combined filament through a bath, wherein the bath is configured to solidify the combined filament and extract the solvent; drying the combined filament through an oven; and heat stretching the combined filament, wherein the combined filament is heated within the oven during the heat stretching, wherein the produced combined filament has antimicrobial properties.

2. The method of claim 1, wherein the temperature is 105 degrees Celsius.

3. The method of claim 1, wherein the oil dissolving the antimicrobial low-density polyethylene comprises coal distillate oil.

4. The method of claim 1, wherein the weight of the antimicrobial LDPE is 1% of the total weight of the antimicrobial fiber.

5. The method of claim 1, wherein the weight of the antimicrobial LDPE is 0.5% to 10% of the total weight of the antimicrobial fiber.

6. The method of claim 1, further comprising extruding the antimicrobial LDPE solution and the UHMWPE solution through a flow regulating apparatus.

7. The method of claim 1, further comprising threading the antimicrobial fiber together to form an antimicrobial apparel material.

Images