Antibacterial Polymer Coating on Textiles

Abstract

A composition having sodium pyrithione and a binder is provided. The composition may also have a softening agent. 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 effects and durability is also provided.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 344,190, filed May 20, 2022, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present invention relates to compositions and methods for treating textiles, and more particularly, to compositions and methods for imparting antibacterial and antifungal effects.

Background Art

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

Summary of the Invention

Problems to be Solved by the Invention

[0004] Instead, it is possible to use organic molecules such as quaternary ammonium silanes, phenols, azoles, etc. for the surface treatment of textiles. However, these compounds require extensive formulation efforts to reduce hydrophobicity and improve the durability of fiber materials.

[0005] Conventional chemicals used for the wash - durable treatment of textiles are usually insoluble chemical species. Examples include triclosan, silver chloride, zinc pyrithione, chitosan, etc.

Means for Solving the Problems

[0006] Therefore, the above - mentioned methods are not desirable, and the present invention solves and overcomes the problems of these methods.

[0007] The present invention provides a solution that imparts antifungal and antibacterial effects to textiles while meeting the new requirement of a heavy - metal - free composition.

[0008] In one aspect of the present invention, an antibacterial composition is provided that includes 6 wt% to 16 wt% sodium pyrithione, 10 wt% to 25 wt% binder, and water.

[0009] In some aspects, the antibacterial composition includes 8 wt% to 13 wt% sodium pyrithione. In some aspects, the antibacterial composition includes 10 wt% to 12 wt% sodium pyrithione.

[0010] In some aspects, the antibacterial composition includes 12 wt% to 22 wt% binder. In some aspects, the antibacterial composition includes 16 wt% to 19 wt% binder.

[0011] In some aspects, the antibacterial composition further includes 10 wt% to 30 wt% plasticizer. In some aspects, the antibacterial composition further includes 13 wt% to 25 wt% plasticizer. In some aspects, the antibacterial composition further includes 15 wt% to 20 wt% plasticizer.

[0012] In some aspects, the plasticizer is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based plasticizers, and combinations thereof.

[0013] In some aspects, the binder is selected from the group consisting of polyacrylic-based binders, polyurethane-based binders, and combinations thereof.

[0014] In one aspect, the antibacterial composition does not contain heavy metals.

[0015] In another aspect of the present invention, a method for treating a textile is disclosed. The method includes imparting an antibacterial effect to the textile by applying a composition to the textile, the composition comprising 6 wt% to 16 wt% sodium pyrithione, 10 wt% to 25 wt% binder, and water. In some embodiments, the composition does not contain heavy metals.

[0016] In some embodiments, the composition comprises 8 wt% to 13 wt% sodium pyrithione. In some embodiments, the composition comprises 10 wt% to 12 wt% sodium pyrithione.

[0017] In some embodiments, the composition comprises 12 wt% to 22 wt% binder. In some embodiments, the composition comprises 16 wt% to 19 wt% binder.

[0018] In some embodiments, the binder is selected from the group consisting of polyacrylic binders, polyurethane binders, and combinations thereof.

[0019] In some embodiments, the antibacterial composition further comprises 10 wt% to 30 wt% softening agent. In some embodiments, the antibacterial composition further comprises 13 wt% to 25 wt% softening agent. In some embodiments, the antibacterial composition further comprises 15 wt% to 20 wt% softening agent.

[0020] In some embodiments, the softening agent is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softening agents, and combinations thereof.

[0021] In some embodiments, the textile is a fabric.

[0022] In some embodiments, the composition is applied by a method selected from the group consisting of impregnation, spraying, roller coating, exhaustion, and combinations thereof.

[0023] In some embodiments, the composition is applied to the textile by impregnation in an impregnating liquid. In some embodiments, the impregnating liquid has a pH of 4 to 8.5. In some embodiments, after impregnation, the textile is cured at a temperature of 130°C to 180°C. In some embodiments, after impregnation, the textile is cured for at least 45 seconds.

[0024] In some embodiments, the composition is added together with a dye in the exhaustion dyeing stage. In some embodiments, the composition is added at a temperature of 60°C to 130°C. In some embodiments, the composition is exhausted over 20 minutes to 1 hour.

[0025] In another aspect of the present invention, an article is disclosed. The article includes a fibrous material treated with a composition, the composition including an effective amount of sodium pyrithione to reduce fungal growth on the textile and an effective amount of a binder to coat the textile. In some embodiments, the composition does not contain heavy metals.

[0026] In some embodiments, the composition includes 6 wt% to 16 wt% sodium pyrithione. In some embodiments, the composition includes 8 wt% to 13 wt% sodium pyrithione. In some embodiments, the composition includes 10 wt% to 12 wt% sodium pyrithione.

[0027] In some embodiments, the antimicrobial composition includes 10 wt% to 25 wt% binder. In some embodiments, the antimicrobial composition includes 12 wt% to 22 wt% binder. In some embodiments, the antimicrobial composition includes 16 wt% to 19 wt% binder.

[0028] In some embodiments, the binder is selected from the group consisting of polyacrylic binders, polyurethane binders, and combinations thereof.

[0029] In some embodiments, the antibacterial composition further comprises 10 wt% to 30 wt% of a softening agent. In some embodiments, the antibacterial composition further comprises 13 wt% to 25 wt% of a softening agent. In some embodiments, the antibacterial composition further comprises 15 wt% to 20 wt% of a softening agent.

[0030] In some embodiments, the softening agent is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softening agents, and combinations thereof.

[0031] In some embodiments, water is the balance of the total weight of the composition.

[0032] Further applicable areas of the present invention will become apparent from the following detailed description. It should be understood that the detailed description and specific examples, while indicating preferred embodiments of the present invention, are for purposes of illustration only and are not intended to limit the scope of the present invention.

Mode for Carrying Out the Invention

[0033] The following description of embodiments of the present invention is essentially exemplary only and is not intended to limit the present invention, its application, or uses. The following description is provided herein by way of example only for the purpose of providing an effective disclosure of the present invention and is not intended to limit the scope or content of the present invention.

[0034] Furthermore, 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 expression "X uses A or B" is intended to mean any of the natural inclusive permutations. That is, the expression "X uses A or B" is satisfied by any of "X uses A", "X uses B", or "X uses both A and B". Further, the articles "a" and "an" as used in this application and the appended claims should generally be construed to mean "one or more" unless otherwise specified or it is clear from the context that they refer to the singular form. In this specification and the claims, unless the context clearly indicates otherwise, the following terms shall take at least the meanings explicitly associated with them herein. The meanings specified below do not necessarily limit the terms, but merely provide examples of the terms. The meanings of "a", "an", and "the" may include plural references, and the meaning of "in" may include "in", "at", and / or "on" unless the context clearly indicates otherwise. The expression "in one embodiment" as used herein does not necessarily refer to the same embodiment, but it is possible.

[0035] In this specification, concentrations, amounts, and other numerical data may be presented or expressed in a range format. Such a range format is used merely for convenience and brevity, and thus should be construed flexibly as including not only the numerical values explicitly recited as the limits of the range, but also all individual numerical values or sub-ranges within the range as if each and every numerical value and sub-range within the range were explicitly recited. For example, a numerical range of "about 1 to about 5" should be construed to include not only the values explicitly recited as "about 1 to about 5", but also individual values and sub-ranges within the indicated range. Thus, this numerical range includes not only 1, 2, 3, 4, and 5, but also individual values such as 2, 3, and 4, and sub-ranges such as 1 - 3, 2 - 4, and 3 - 5. The same principle applies to ranges that indicate only one numerical value as the minimum or maximum value. Further, such an interpretation should apply regardless of the breadth of the range or the nature of the property being described.

[0036] The present invention relates to an antibacterial composition for imparting antibacterial properties and a method for treating a fiber material. The composition disclosed herein provides excellent antibacterial properties to the fiber material without using heavy metals. As used herein, the term "heavy metal" refers to any metal heavier than magnesium (atomic weight 24.3 grams / mol).

[0037] In one aspect of the present invention, an antibacterial composition comprising sodium pyrithione and a binder is provided. The antibacterial composition is heavy metal free (meaning it does not contain heavy metals). Sodium pyrithione is a water-soluble compound that does not contain particles and does not contain heavy metals. The binder is a polymer binder. The binder is preferably selected from the group consisting of polyacrylic binders, polyurethane binders, and combinations thereof. In one aspect of the present invention, a composition comprising sodium pyrithione, a binder, and a softening agent is provided.

[0038] The antibacterial composition may contain 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.

[0039] The antibacterial composition may contain 6% to 16% by weight of sodium pyrithione. Preferably, the antibacterial composition contains 8% to 13% by weight of sodium pyrithione. More preferably, the antibacterial composition contains 10% to 12% by weight of sodium pyrithione.

[0040] The antibacterial composition may contain 10% to 25% by weight of a binder. Preferably, the antibacterial composition contains 12% to 22% by weight of a binder. More preferably, the antibacterial composition contains 16% to 19% by weight of a binder.

[0041] The antibacterial composition may contain 10% to 30% by weight of a softening agent. Preferably, the antibacterial composition contains 13% to 25%. More preferably, the antibacterial composition contains 15% to 20%.

[0042] The softening agent is preferably selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softening agents, and combinations thereof.

[0043] Other non-limiting examples of additives that may be included in the composition of the present invention include surfactants, dispersants, pH adjusters, wicking aids, and combinations thereof, but are not limited thereto.

[0044] The composition is suitable for use in treating textiles, imparting antibacterial properties and antifungal effects to the textiles. The composition also improves fabric properties such as color fastness and handfeel.

[0045] There is a synergistic effect in the combination of sodium pyrithione and the binder, and the effect is further enhanced when a softening agent is further added.

[0046] In one aspect of the present invention, a method of using the composition is provided. This method includes applying a composition containing sodium pyrithione and a binder to a textile to impart to the textile a property selected from the group consisting of antibacterial effects, antifungal effects, and combinations thereof. The composition may further contain a softening agent.

[0047] The composition may be applied to the fiber material or fabric by any conventional or other techniques known to those skilled in the art, including but not limited to impregnation, spraying, roller coating or other types of coating, exhaustion, and combinations thereof, and then a curing step is performed to ensure the polymer formation process. In particular, impregnation and exhaustion are preferred.

[0048] In impregnation, an impregnating solution containing sodium pyrithione and a binder and / or a softening agent is prepared. Examples of the binder include, but are not limited to, polyacrylic binders, polyurethane binders, or combinations thereof. The pH range of the impregnating solution is preferably 4 to 8.5. The pH range should be a desirable range to maintain the integrity of the textile and the desirable tactile feeling on the surface of the textile.

[0049] Once the impregnating solution is prepared or obtained, the impregnating solution is applied to the textile. The impregnated textile is preferably cured at a curing temperature in the range of 130°C to 180°C for at least 45 seconds.

[0050] In exhaustion, in the pre-dyeing stage, sodium pyrithione and the binder are added 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.

[0051] The textile article may be made of various types of fibers including, but not limited to, synthetic fibers, natural fibers, and combinations thereof.

[0052] The textile article can be used in numerous articles including, but not limited to, yarns, filaments, fabrics, clothing, decorations, footwear, bedding, curtains, uniforms, carpets, upholstery, face masks, gowns, carpets, upholstery, foams, non-woven filters.

[0053] (Examples)

[0054] Example 1 - Antibacterial performance

[0055] The following examples demonstrate the durability of the treatment 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 repeated washing or home laundering (HL).

[0056] To demonstrate the antibacterial performance, tests were conducted in accordance with AATCC TM 100. As is evident from Table 1 below, when sodium pyrithione, binder, and softener were used alone, no antibacterial performance was shown after 25 washes. For sodium pyrithione, the data after 1 wash is included, which indicates that since sodium pyrithione is water-soluble, it has no fastness to textiles and has little effect even after just 1 home wash. The binder and softener had no antibacterial performance. However, when sodium pyrithione and binder were used in combination, an invisible polymer film was formed, and even after 25 home washes, it showed very excellent antibacterial performance due to the synergistic effect. When sodium pyrithione and binder were mixed with the softener and applied to the fabric, the synergistic effect was enhanced and the antibacterial effect was further improved. Furthermore, in the test against AATCC TM 8, the wet crocking fastness of the treated article improved from 3.5 to 4.5 points. This is because the softener reduced the surface roughness and friction.

[0057] Due to the synergistic effect of the combination of sodium pyrithione and binder, an invisible polymer film is formed on the fabric surface, making the treatment durable. The specificity of the selected binder is that it has good compatibility with the ionic nature of sodium pyrithione and can effectively prevent its rapid dissolution even during washing or multiple wash cycles. Furthermore, adding the softener improves the quality of the binder film. The softener can reduce the surface roughness and friction, and can further improve the crocking and tactile feel of the treated textiles.

[0058]

Table 1

[0059] Example 2 - Antifungal Performance

[0060] (a) Untreated control fabric, (b) fabric treated with sodium pyrithione and a binder, and (c) fabric treated with sodium pyrithione, a binder, and a softening agent were each used to conduct tests. The tests were conducted in accordance with AATCC TM 30-III. The higher the score, the worse the antifungal result.

[0061] (a) Untreated control group, score = 2

[0062] (b) Sodium pyrithione and a binder, score = 1

[0063] (c) Sodium pyrithione, a binder, and a softening agent, score = 0

[0064] The performance was significantly improved in (b) and further significantly improved in (c).

[0065] Therefore, those skilled in the art will readily understand that the present invention enables broad utility and application. Many embodiments and adaptations of the present invention, as well as many variations, modifications, and equivalent configurations other than those described herein, will be apparent from or reasonably suggested by the present invention and the foregoing description without departing from the content or scope of the present invention. Accordingly, although the present invention has been described in detail herein in connection with its preferred embodiments, it is to be understood that the present disclosure is merely exemplary and illustrative of the present invention and is made for the purpose of providing a complete and effective disclosure of the present invention. It should be understood that the foregoing disclosure is not intended to limit the present invention nor should it be construed as doing so, nor is it intended to exclude other embodiments, adaptations, variations, modifications, and equivalent configurations nor should it be construed as doing so.

Claims

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

2. The antibacterial composition according to claim 1, further comprising 10% to 30% by weight of a softening agent.

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

4. The antibacterial composition according to claim 1, wherein the binder is selected from the group consisting of polyacrylic binders, polyurethane binders, and combinations thereof.

5. The antibacterial composition according to claim 2, wherein the softening agent is selected from the group consisting of sulfated fatty alcohols, anionic fatty acid polysiloxanes, nonionic fatty acid polysiloxanes, ethoxylated polysiloxanes, polyethylene-based softening agents, and combinations thereof.

6. A method for treating a textile, comprising applying to the textile a composition comprising 6% to 16% by weight of sodium pyrithione, 10% to 25% by weight of a binder, and water to impart an antibacterial effect to the textile.

7. The method according to claim 6, wherein the composition does not contain heavy metals.

8. The method according to claim 6, wherein the composition further comprises 10% to 30% by weight of a softening agent.

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

10. The method according to claim 6, wherein the binder is selected from the group consisting of polyacrylic binders, polyurethane binders, and combinations thereof.

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

12. The method according to claim 6, wherein the composition is applied by a method selected from the group consisting of impregnation, spraying, roller coating, exhaustion, and combinations thereof.

13. The method according to claim 12, wherein the composition is applied to the textile by impregnation in an impregnating solution.

14.

14. The method according to claim 13, wherein the textile is cured at a curing temperature in the range of 130°C to 180°C after impregnation.

15. The method according to claim 13, wherein the textile is cured for at least 45 seconds after impregnation.

16. The method according to claim 12, wherein the composition is added during the exhaustion dyeing stage.

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

18. The method according to claim 12, wherein the composition is exhausted over 20 minutes to 1 hour.

19. An article, wherein the article comprises a fibrous material, the fibrous material has been treated with a composition, the composition is, an effective amount of sodium pyrithione to reduce fungal growth on the textile, and an effective amount of a binder to coat the textile, and comprises an article.

20. The article according to claim 19, wherein the sodium pyrithione is present at 6% to 16% by weight.

21. The article according to claim 19, wherein the binder is present at 10% to 25% by weight.

22. The article according to claim 19, wherein the composition does not contain heavy metals.

23. The article according to claim 19, wherein the binder is selected from the group consisting of polyacrylic binders, polyurethane binders, and combinations thereof.

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

25. Water is the balance of the total weight of the composition, according to the article of claim 19.

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