Antimicrobial polymer coatings on textiles

Abstract

A composition having a sodium pyrithione and a binder is provided. The composition may also have a softener. A method of using the composition is provided. The method includes applying the composition to a textile. A method of treating a textile with the composition to impart antibacterial and / or antifungal efficacy and durability is also provided.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 344,190 filed in the U.S. Patent and Trademark Office on May 20, 2022. The disclosure of that patent is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates to compositions and methods for treating textiles, and more particularly, to compositions and methods for imparting antimicrobial and antifungal effects. Background Art

[0004] Current bacterial and fungal control on textiles and garments relies heavily on the use of active substances containing metals such as zinc. The presence of "heavy metals" can cause many problems during processing in textile mills and is increasingly causing environmental concerns.

[0005] Alternatively, organic molecules such as quaternary ammonium silanes, phenols, and azoles can be used to treat textile surfaces. However, these compounds require extensive formulation efforts to reduce hydrophobicity and improve the durability of textile materials.

[0006] Conventional chemicals used for textile wash durability treatments are generally insoluble chemicals. Examples include triclosan, silver chloride, zinc pyrithione, and chitosan.

[0007] Therefore, the above methods are not ideal, and the present invention solves and overcomes the problems of these methods. Summary of the invention

[0008] The present invention provides a solution for providing antifungal and antibacterial efficacy on textiles while meeting the evolving demand for compositions that are free of heavy metals.

[0009] In one aspect of the present invention, an antimicrobial composition is provided. The antimicrobial composition comprises: 6 wt % to 16 wt % of sodium pyrithione, 10 wt % to 25 wt % of a binder, and the balance is water.

[0010] In some aspects, the antimicrobial composition comprises 8 wt% to 13 wt% sodium pyrithione. In some aspects, the antimicrobial composition comprises 10 wt% to 12 wt% sodium pyrithione.

[0011] In some aspects, the antimicrobial composition comprises 12 wt% to 22 wt% of the binder. In some aspects, the antimicrobial composition comprises 16 wt% to 19 wt% of the binder.

[0012] In some aspects, the antimicrobial composition further comprises 10% to 30% by weight of a softener. In some aspects, the antimicrobial composition further comprises 13% to 25% by weight of a softener. In some aspects, the antimicrobial composition further comprises 15% to 20% by weight of a softener.

[0013] In some aspects, the softener is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softeners, and combinations thereof.

[0014] In some aspects, the adhesive is selected from the group consisting of polyacrylic adhesives, polyurethane adhesives, and combinations thereof.

[0015] In some aspects, the composition is free of heavy metals.

[0016] In another aspect of the present invention, a method for treating textiles is disclosed. The method comprises applying a composition to the textile, thereby imparting antimicrobial efficacy to the textile; the composition comprises 6 wt % to 16 wt % of sodium pyrithione, 10 wt % to 25 wt % of a binder, and the balance is water. In some aspects, the composition does not contain heavy metals.

[0017] In some aspects, the composition comprises 8 wt% to 13 wt% sodium pyrithione. In some aspects, the composition comprises 10 wt% to 12 wt% sodium pyrithione.

[0018] In some aspects, the composition comprises 12 wt% to 22 wt% binder. In some aspects, the composition comprises 16 wt% to 19 wt% binder.

[0019] In some aspects, the adhesive is selected from the group consisting of polyacrylic adhesives, polyurethane adhesives, and combinations thereof.

[0020] In some aspects, the antimicrobial composition further comprises 10% to 30% by weight of a softener. In some aspects, the antimicrobial composition further comprises 13% to 25% by weight of a softener. In some aspects, the antimicrobial composition further comprises 15% to 20% by weight of a softener.

[0021] In some aspects, the softener is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softeners, and combinations thereof.

[0022] In some aspects, the textile is a fabric.

[0023] In some aspects, the composition is applied by a method selected from the group consisting of padding, spraying, roller coating, exhaustion, and combinations thereof.

[0024] In some aspects, the composition is applied to the textile by padding in a padding bath. In some aspects, the pH of the padding bath is 4 to 8.5. In some aspects, after padding, the textile is cured at a temperature of 130° C. to 180° C. In some aspects, after padding, the textile is cured for a minimum of 45 seconds.

[0025] In some aspects, the composition is added with the dye at an evacuated dyeing stage. In some aspects, the composition is added at a temperature of 60° C. to 130° C. In some aspects, the composition is evacuated for 20 minutes to 1 hour.

[0026] In another aspect of the present invention, an article is disclosed. The article includes an effective amount of sodium pyrithione to reduce fungal growth on a textile and an effective amount of an adhesive to coat the textile. In some aspects, the composition does not contain heavy metals.

[0027] In some aspects, the composition comprises 6 wt % to 16 wt % of sodium pyrithione. In some aspects, the composition comprises 8 wt % to 13 wt % of sodium pyrithione. In some aspects, the composition comprises 10 wt % to 12 wt % of sodium pyrithione.

[0028] In some aspects, the antimicrobial composition comprises 10% to 25% by weight of the binder. In some aspects, the antimicrobial composition comprises 12% to 22% by weight of the binder. In some aspects, the antimicrobial composition comprises 16% to 19% by weight of the binder.

[0029] In some aspects, the adhesive is selected from the group consisting of polyacrylic adhesives, polyurethane adhesives, and combinations thereof.

[0030] In some aspects, the antimicrobial composition further comprises 10% to 30% by weight of a softener. In some aspects, the antimicrobial composition further comprises 13% to 25% by weight of a softener. In some aspects, the antimicrobial composition further comprises 15% to 20% by weight of a softener.

[0031] In some aspects, the softener is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softeners, and combinations thereof.

[0032] In some aspects, water is the balance of the total weight of the composition.

[0033] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter.It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. DETAILED DESCRIPTION

[0034] The following description of the embodiments of the present invention is merely exemplary in nature and is in no way intended to limit the present invention, its application or use. The following description is provided herein only by way of example to provide an authorized disclosure of the present invention, but does not limit the scope or essence of the present invention.

[0035] In addition, the term "or" as used in this disclosure and the appended claims is intended to mean an inclusive "or" rather than an exclusive "or". That is, unless otherwise specified or clear from the context, the phrase "X employs A or B" is intended to mean any natural inclusive arrangement. That is, the phrase "X employs A or B" satisfies any of the following situations: X employs A; X employs B; or X employs both A and B. Unless otherwise specified or clear from the context to be in the singular form, the articles "a" and "an" used in this application and the appended claims should generally be interpreted to mean "one or more". Throughout the specification and claims, unless the context dictates otherwise, the following terms have at least the meanings explicitly associated herein. The meanings determined below do not necessarily limit the terms, but merely provide illustrative examples of the terms. Unless the context clearly indicates otherwise, the meaning of "a / a", "an", and "the" may include plural references, and the meaning of "in" may include "in / at / on". The phrase "in one embodiment" as used herein does not necessarily refer to the same embodiment, although it may.

[0036] Concentration, amount and other numerical data can be represented or presented in the format of range in this article.It should be understood that such range format is used only for convenience and simplicity, and therefore should be flexibly interpreted as not only including the numerical value clearly listed as the limit of the range, but also including all individual numerical values ​​or sub-ranges contained in the range, just as each numerical value and sub-range are clearly listed.As an example, the numerical range of "about 1 to 5" should be interpreted as not only including the value of about 1 to about 5 clearly listed, but also including the single value and sub-range in the indicated range.Therefore, included in this numerical range are individual values ​​(such as 2, 3 and 4), and sub-ranges (such as 1 to 3, 2 to 4 and 3 to 5, etc.) and individual 1, 2, 3, 4 and 5.The same principle applies to the scope of only listing one numerical value as the minimum or maximum value.In addition, no matter how wide the described range or feature is, this explanation should be applicable.

[0037] The present invention relates to an antimicrobial composition and method for treating textile materials to impart antimicrobial properties. The composition disclosed herein provides a textile material with excellent antimicrobial properties without the use of heavy metals. The term "heavy metal" as used herein refers to any metal heavier than magnesium (atomic weight 24.3 g / mol).

[0038] In one aspect of the present invention, an antimicrobial composition is provided, comprising sodium pyrithione and a binder. The antimicrobial composition does not contain heavy metals (meaning no heavy metals). Sodium pyrithione is a particle-free, heavy metal-free water-soluble compound. The binder is a polymer binder. Preferably, the binder is selected from polyacrylic acid binders, polyurethane binders and combinations thereof. In one aspect of the present invention, a composition is provided, comprising sodium pyrithione, a binder and a softener.

[0039] The antibacterial composition may include sodium pyrithione and a binder in a ratio of 1:1 to 1:5, 1:2 to 1:3, 1:2 to 1:5, 1:3 to 1:5, 1:1 to 1:4, 1:1 to 1:3, 1:1.5 to 1:3 or 1:25 to 1:35.

[0040] The antimicrobial composition may comprise: 6 wt % to 16 wt % of sodium pyrithione. Preferably, the antimicrobial composition comprises 8 wt % to 13 wt % of sodium pyrithione. More preferably, the antimicrobial composition comprises 10 wt % to 12 wt % of sodium pyrithione.

[0041] The antimicrobial composition may comprise 10 wt % to 25 wt % of the binder. Preferably, the antimicrobial composition comprises 12 wt % to 22 wt % of the binder. More preferably, the antimicrobial composition comprises 16 wt % to 19 wt % of the binder.

[0042] The antimicrobial composition may comprise 10% to 30% by weight of a softener. Preferably, the antimicrobial composition comprises 13% to 25% by weight of a softener. More preferably, the antimicrobial composition comprises 15% to 20% by weight of a softener.

[0043] Preferably, the softener is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softeners, and combinations thereof.

[0044] Other non-limiting examples of additives that may be incorporated into the compositions of the present invention include, but are not limited to, surfactants, dispersants, pH adjusters, hygroscopic aids, and combinations thereof.

[0045] The composition is suitable for treating textiles, thereby imparting antibacterial and antifungal properties to the textiles. The composition also improves fabric properties such as color fastness and hand feel.

[0046] The combination of sodium pyrithione and a binder has a synergistic effect, which is even greater when a softener is further added.

[0047] In one aspect of the present invention, a method of using a composition is provided. The method comprises applying the composition to a textile, wherein the composition comprises sodium pyrithione and a binder, thereby imparting to the textile a property selected from the group consisting of antibacterial efficacy, antifungal efficacy, and combinations thereof. The composition may further comprise a softener.

[0048] The composition can be applied to the textile material or fabric by any conventional or other technique known to those of ordinary skill in the art, including but not limited to padding, spraying, roller coating or other types of coating, evacuation and combinations thereof, followed by a curing step to ensure the polymer formation process, wherein padding and evacuation are preferred.

[0049] For padding, a padding bath including sodium pyrithione and a binder and / or a softener is prepared. Examples of binders include, but are not limited to, polyacrylic acid binders, polyurethane binders, or combinations thereof. The pH of the padding bath is preferably between 4 and 8.5. The pH range should be within an ideal range to maintain the integrity of the textile and to maintain an ideal tactile feel on the textile surface.

[0050] Once the padding bath is prepared or obtained, the padding bath is applied to the textile. The padding textile is preferably cured at a curing temperature of 130°C to 180°C for a minimum of 45 seconds.

[0051] Regarding evacuation, sodium pyrithione and binder are added at the pre-dyeing stage together with sodium benzoate and carboxylic acids (citric acid, lactic acid) at a temperature of 60°C to 85°C for 20 minutes to 1 hour.

[0052] Textiles can be made from various types of fibers, including but not limited to synthetic fibers, natural fibers, and combinations thereof.

[0053] Textiles can be used in a variety of articles including, but not limited to, yarns, filaments, fabrics, garments, apparel, footwear, bedding, drapes, uniforms, carpets, upholstery, face masks, robes, carpets, upholstery, foams, and nonwoven filters.

[0054] Example of operation

[0055] Example 1 - Antibacterial Performance

[0056] The following examples demonstrate the durability of the treatments of the present invention. As used herein, the term "durability" generally refers to the ability of the antibacterial properties of the treated textile fabric to withstand extended periods of laundering or home laundering (HL).

[0057] Tests were performed according to AATCC TM 100 to demonstrate antibacterial properties. Table 1 below clearly shows that when sodium pyrithione, adhesives or softeners were used alone, they did not have antibacterial properties after 25 washes, and for sodium pyrithione, including data after one wash, even after only one home wash, little efficacy was shown because sodium pyrithione did not have any fastness on textiles due to its water solubility, and adhesives or softeners did not have antibacterial capabilities. However, when sodium pyrithione and adhesives were used together, synergy and very good antibacterial properties were shown after 25 home washes because an invisible polymer coating was formed. When sodium pyrithione and adhesives were mixed together with softeners and then applied to fabrics, it showed enhanced synergy and even greater antibacterial efficacy. When tested against AATCCTM 8, the wet friction fastness of the treated article was also increased from 3.5 to 4.5. Because the softener reduces surface roughness and friction.

[0058] The synergistic effect of sodium pyrithione and the binder forms an invisible polymer film on the fabric surface, making the treatment durable. The uniqueness of the selected binder is that it is compatible with the ionic properties of sodium pyrithione and effectively prevents its rapid dissolution during the washing process and multiple washing cycles. In addition, the addition of a softener improves the quality of the adhesive film. The softener can reduce surface roughness and friction, further increasing the friction and touch of the treated textiles.

[0059] Table 1

[0060]

[0061]

[0062] * Premix 11 wt% sodium pyrithione, 18 wt% polyacrylic acid binder and 17 wt% polysilicone softener, then apply 2.2% owf (percentage by fabric weight) of the premixed formulation to the polyester material.

[0063] Example 2 - Antifungal Properties

[0064] The test used: (a) untreated control fabric; (b) fabric treated with sodium pyrithione and adhesive (c) fabric treated with sodium pyrithione, adhesive and softener. The test followed AATCC TM 30-III. The higher the grade, the worse the antifungal effect.

[0065] (a) Untreated control group, level = 2

[0066] (b) Sodium pyrithione and binder, grade = 1

[0067] (c) Sodium pyrithione and binders and softeners, grade = 0

[0068] The performance is significantly improved in (b) and even more significantly improved in (c).

[0069] Therefore, it will be readily understood by those skilled in the art that the present invention has wide practicality and applicability. Without departing from the essence or scope of the present invention, in addition to those described herein, many embodiments and adjustments of the present invention and many changes, modifications and equivalent arrangements will be apparent from the present invention and its foregoing description or reasonably implied. Therefore, although the preferred embodiments of the present invention have been described in detail herein, it should be understood that the present disclosure is only illustrative and exemplary of the present invention, and is only used to provide a complete and feasible disclosure of the present invention. The foregoing disclosure is not intended to or should not be interpreted as limiting the present invention, or excluding any such other embodiments, adjustments, changes, modifications and equivalent arrangements.

Claims

1. An antibacterial composition comprising: 6 to 16% by weight of sodium pyrithione, 10 to 25 wt % of a binder, and The remaining water, The weight percentages are based on the total weight of the composition.

2. The antibacterial composition according to claim 1, further comprising 10 wt% to 30 wt% of a softener.

3. The antimicrobial composition according to claim 1, wherein the composition does not contain heavy metals.

4. The antimicrobial composition according to claim 1, wherein the adhesive is selected from the group consisting of polyacrylic adhesives, polyurethane adhesives, and combinations thereof.

5. The antimicrobial composition of claim 2, wherein the softener is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softeners, and combinations thereof.

6. A method for treating a textile, the method comprising: applying a composition onto a textile, wherein the composition comprises 6 to 16 wt % of sodium pyrithione, 10 to 25 wt % of a binder and the balance is water, This gives the textiles an antibacterial effect.

7. The method of claim 6, wherein the composition is free of heavy metals.

8. The method of claim 6, wherein the composition further comprises 10 to 30 weight percent of a softener.

9. The method of claim 6, wherein the textile is a fabric.

10. The method of claim 6, wherein the adhesive is selected from the group consisting of polyacrylic adhesives, polyurethane adhesives, and combinations thereof.

11. The method of claim 8, wherein the softener is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softeners, and combinations thereof.

12. The method of claim 6, wherein the composition is applied by a method selected from the group consisting of padding, spraying, rolling, evacuation, and combinations thereof.

13. The method of claim 12, wherein the composition is applied to the textile by padding in a padding bath.

14. The method of claim 13, wherein the padded textile is cured at a curing temperature of 130°C to 180°C.

15. The method of claim 13, wherein the textile is cured for a minimum of 45 seconds after padding.

16. The method of claim 12, wherein the composition is added during an evacuated dyeing stage.

17. The method of claim 12, wherein the composition is added at a temperature of 60°C to 130°C.

18. The method of claim 12, wherein the composition is evacuated for 20 minutes to 1 hour.

19. An article comprising a textile material, wherein the textile material is treated with a composition comprising: an effective amount of sodium pyrithione to reduce fungal growth on textiles, and An effective amount of adhesive is applied to the textile.

20. The article of claim 19, wherein the sodium pyrithione is present in an amount of 6 wt% to 16 wt%.

21. The article of claim 19, wherein the binder is present in an amount of 10 wt% to 25 wt%.

22. The article of claim 19, wherein the composition is free of heavy metals.

23. The article of claim 19, wherein the adhesive is selected from the group consisting of polyacrylic adhesives, polyurethane adhesives, and combinations thereof.

24. The article of claim 19, wherein the composition further comprises 10% to 30% by weight of a softener.

25. The article of claim 19, wherein water comprises the balance of the total weight of the composition.

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