Moisture-wicking, Anti-odor and Anti-microbial textile fabric blend and undergarments incorporating same

Abstract

A textile fabric blend is disclosed, combining chitosan having a degree of deacetylation of between 80% and 95% and a crosslinking degree of between 10% and 40%, and one or more natural fibers selected from the group consisting of viscose, modal, micromodal, lyocell, hemp, bamboo, and cotton. The chitosan may be extracted from crab shells or fungi and the content of chitosan in the blend is between 10% and 30% by weight. The other natural fibers are blended in proportions to enhance the moisture-wicking, anti-odor properties, and breathability of the textile fabric blend. The textile fabric blend has anti-bacterial and anti-fungal properties, and may be used to manufacture apparel such as undergarments, sports apparel, and other garments. In particular embodiments the textile fabric blend is incorporated as the interior lining of underwear.

Description

MOISTURE-WICKING, ANTI-ODOR AND ANTI-MICROBIAL TEXTILE FABRIC BLEND AND UNDERGARMENTS INCORPORATING SAMETECHNICAL FIELD

[0001] The present disclosure relates generally to textiles and garments having breathable, moisture-wicking, anti-odor, antibacterial and / or anti-fungal properties.RELATED APPLICATIONS

[0002] This application claims priority from US application No. 63 / 699,648 filed September 26, 2024 entitled “MOISTURE-WICKING, ANTI-ODOR AND ANTI-MICROBIAL TEXTILE FABRIC BLEND AND UNDERGARMENTS INCORPORATING SAME”. For the purposes of the United States, this application claims the benefit under 35 USC §119 of US application No.63 / 699,648 filed September 26, 2024 entitled “MOISTURE-WICKING, ANTI-ODOR AND ANTIMICROBIAL TEXTILE FABRIC BLEND AND UNDERGARMENTS INCORPORATING SAME”, which is incorporated herein by reference in its entirety.BACKGROUND

[0003] Conventional textile fabrics often suffer from limitations such as odor retention, poor moisture absorption, and susceptibility to microbial growth. To address these issues, various functional additives and treatments have been developed. However, many of these solutions rely on synthetic chemicals that may raise environmental and health concerns.

[0004] In addition, conventional underwear fabric may not provide sufficient antimicrobial protection, leading to potential skin irritation or infections, particularly in sensitive areas. Chemical treatments applied to underwear fabric can be harsh on the skin and lose itseffectiveness over time through frequent washing and use of the underwear. Maintaining hygiene and comfort in underwear is crucial for preventing infections and ensuring overall wellbeing.

[0005] Specialty underwear currently available in the market for providing leakproof protection (e.g., for periods or bladder leaks) typically utilizes synthetic waterproof materials (such as polyurethane) for the outer layer, and include an internal layer for absorbing a small amount of liquid. The internal layer may be made of synthetic and / or natural materials but as the focus is on absorbency and leakproof protection these specialty underwear generally do not limit microbial growth or prevent infections.

[0006] Specialty underwear also exists for wicking away sweat (e.g. during physical activity). However, such underwear is typically made of synthetic materials and provides limited protection against microbial growth or odors. The synthetic materials may also be irritating to the skin when in contact with the wearer’s intimate areas.

[0007] There is a need for sustainable and natural textile materials that provide superior functional performance (e.g. breathability, anti-odor, moisture-wicking, anti-bacterial and / or antifungal) without compromising on comfort or safety. There is also a need to provide textiles for garments, particularly undergarments, which address the need for providing improved hygiene and comfort without the use of chemical treatments. The present invention aims to provide solutions to the above-noted challenges.SUMMARY OF THE DISCLOSURE

[0008] The following embodiments and aspects thereof are described and illustrated in conjunction with apparatus and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.

[0009] One aspect of the invention relates to a textile fabric blend that overcomes the limitations of conventional fabrics by incorporating chitosan in a synergistic manner with natural fibers such as viscose, modal, micromodal, bamboo, hemp, lyocell and cotton. In particular embodiments, the chitosan is extracted from crab shells and / or fungi (including but not limited to mushrooms) and is processed to optimize the material’s antimicrobial characteristics when blended with other fibers. The textile fabric blend exhibits advantageous properties such as breathability and antibacterial, antifungal, moisture-wicking, and anti-odor properties.

[0010] A further aspect relates to undergarments incorporating the chitosan-based textile fabric blend described herein. The textile fabric blend may be used as an interior lining for the undergarment so that when the undergarment is worn, the lining is next to the user’s skin. The textile fabric blend provides enhanced antibacterial and antifungal properties, moisture-wicking and breathability characteristics, and a soft and comfortable feel and texture against the skin. The described embodiments can be used for women’s or men’s underwear, sports apparel, swimwear, socks, hat, diapers, and other garments, and are suited for everyday use and physical activities, providing enhanced hygiene, comfort, and protection, particularly in intimate areas.

[0011] According to particular embodiments of the textile fabric blend, the blend incorporates chitosan which has been processed to have a degree of deacetylation of between 80% and 95% and a crosslinking degree of between 10% and 40%, and one or more natural fibers selected from the group consisting of viscose, modal, micromodal, lyocell, hemp, bamboo, and cotton. The chitosan is extracted from crab shells and / or fungal sources, and the content of chitosan in the textile fabric blend is between 10% and 30% by weight. The other natural fibers are blended in proportions to enhance moisture-wicking, anti-odor, and breathable properties of the textile fabric blend.

[0012] A further aspect relates to a method of manufacturing such textile fabric blend, comprising the steps of: providing chitosan extracted from crab shells and / or fungal sources; processing the chitosan to generate a degree of deacetylation of between 80% and 95% and a crosslinking degree of between 10% and 40%; blending the chitosan with natural fibers; spinning the blended fibers into yarns; weaving or knitting the yarns into fabric; and applying finishing treatments.

[0013] A further aspect relates to the use of such textile fabric blend to make apparel such as undergarments, sports apparel, swimwear, socks, hats, and other garments.

[0014] A further aspect relates to an antimicrobial underwear lining including a blend of chitosan and natural fibers, wherein the natural fibers are selected from the group consisting of viscose, modal, micromodal, bamboo, hemp, lyocell, and cotton. The chitosan is extracted from crab shells and / or fungal sources and is processed to have a degree of deacetylation between 80% and 95% and a crosslinking degree of between 10% and 40%. The chitosan content in the antimicrobial underwear lining is between 10% and 30% by weight. The blend of chitosan and natural fibers is spun into yarns that are then woven or knitted into a textile.

[0015] A further aspect relates to an underwear garment incorporating such antimicrobial underwear lining, wherein the antimicrobial underwear lining is integrated into the underwear garment to provide coverage to areas prone to moisture and microbial growth.

[0016] In accordance with a particular embodiment, a method of manufacturing such antimicrobial underwear lining includes the steps of: providing chitosan extracted from crab shells and / or fungal sources; processing the chitosan to generate a degree of deacetylation of between 80% and 95% and a crosslinking degree of between 10% and 40%; blending the chitosan with viscose, modal, micromodal, bamboo, hemp, lyocell, and / or cotton fibers; spinning the blended fibers into yarn; and weaving or knitting the yarn into a fabric.

[0017] In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Features and advantages of the embodiments of the present invention will become apparent from the following detailed description, taken with reference to the appended drawings in which:

[0019] FIG. 1 illustrates a method for manufacturing a textile fabric blend according to one embodiment;

[0020] FIG. 2 illustrates a method for processing of chitin into chitosan for use in manufacturing a textile fabric blend according to one embodiment; and

[0021] FIGS. 3 and 4A and 4B show exemplary undergarments that incorporate the textile fabric blend manufactured in accordance with the method of FIG 1.DETAILED DESCRIPTION

[0022] The description which follows, and the embodiments described therein, are provided by way of illustration of examples of particular embodiments of the principles of the present invention. These examples are provided for the purposes of explanation, and not limitation, of those principles and of the invention.

[0023] Described herein is a textile fabric blend that combines chitosan with one or more natural fibers selected from the group consisting of viscose, modal, micromodal, lyocell (e.g. Tencel™ lyocell), hemp, bamboo, cotton and the like. Chitosan is a natural polymer derivedfrom the shells of crustaceans, the exoskeleton of insects, and / or fungal cell walls. In particular embodiments, the chitosan that is used in the textile fabric blend can be sourced from crab shells and / or fungal sources.

[0024] The textile fabric blend according to the embodiments described herein exhibits enhanced antibacterial and antifungal properties while being moisture-wicking, anti-odor and breathable. The fabric may be used to manufacture men’s and women's undergarments, sports apparel, swim swear, socks, and hats as it offers superior comfort, hygiene, and durability. For example, the fabric may be incorporated as the inside lining of men’s or women’s underwear, offering long-lasting protection against bacterial or fungal infection without compromising comfort or breathability.

[0025] Turning to FIG. 1, a method 100 of manufacturing the textile fabric blend according to one embodiment is described below. Method 100 begins at processing stage 101 to produce processed chitosan 102. The chitosan 102 may be sourced from chitin 99, which is found in the exoskeletons of crustaceans like shrimp or crabs and cell walls of fungi, and it is processed using deacetylation, decalcification, and deproteinization. When the chitosan is processed and combined with other fibers, chitosan lends antimicrobial and moisture-wicking properties to the fabric. In particular embodiments, the chitosan 102 is processed to generate a degree of deacetylation in the chitosan of between 80% and 95% and a degree of crosslinking in the chitosan of between 10% and 40%. This is described in further detail below.

[0026] Chitin 99, sourced from crab shells and fungi such as mushrooms, undergoes purification and processing at stage 101 to remove impurities and produce high-purity chitosan 102 that can be spun into fibers. FIG. 2 shows in further detail the processing steps that are performed at stage 101 (such processing steps are referenced as 101 A, 101B, 101C, etc.) according to one embodiment based on crustacean-sourced chitosan. For chitosan sourced from crab shells (or other crustacean shells), the purification and processing stage may involvedeproteinization 101 A, demineralization 101B and deacetylation 101C. Deproteinization 101 A may be the first step in the purification process. In particular, the chitin 99 is treated with an alkaline solution (e.g. sodium hydroxide, NaOH) to remove proteins and other organic matter. Next, the chitin undergoes demineralization 101B by being subjected to an acid treatment (e.g. hydrochloric acid, HCI) to remove calcium carbonate and other minerals from the chitin. Finally, the purified chitin is subjected to deacetylation 101C, which is the chemical process by which chitosan is produced by removing acetyl groups (-COCH3) from chitin. This process increases the number of free amino groups (-NH2) along the polymer chain, which is crucial for its bioactivity.

[0027] In contrast, when chitosan is sourced from fungi, the process begins with an initial cell wall isolation step. For this step, mushrooms are dried, powdered, and treated with hot water or ethanol to remove soluble polysaccharides and lipids, thereby isolating the fungal cell wall material. This is followed by deproteinization, in which the isolated fungal cell walls are treated with an alkaline solution (e.g., sodium hydroxide, NaOH) to remove proteins and other organic matter. Subsequently, demineralization may be performed, using an acid treatment (e.g., hydrochloric acid, HCI) to remove any residual minerals. Since fungal cell walls contain little calcium carbonate or hard shell material compared to crustacean sources; the demineralization is minimal. Finally, deacetylation is performed, as described herein, to convert chitin to chitosan.

[0028] For deacetylation 101C, chitin is subjected to an alkali treatment (e.g. concentrated sodium hydroxide) at high temperatures (e.g. in the range of 80°C to 100°C) to remove acetyl groups and convert chitin into chitosan. The degree of deacetylation (DD) may be controlled during this process. The degree of deacetylation (DD) of chitosan refers to the percentage of amino groups that replace the acetyl groups. A higher DD increases the concentration of amino groups, which are responsible for chitosan's cationic charge in acidic environments. In terms ofimpact on antimicrobial properties of the fabric, the chitosan’s cationic charge is what allows chitosan to interact with negatively charged microbial cell walls, leading to cell membrane disruption and death of the microorganisms. In particular, the positively charged amino groups on deacetylated chitosan interact electrostatically with the negatively charged components (lipopolysaccharides) of bacterial cell membranes, destabilizing the membrane and leading to leakage of intracellular contents, ultimately killing the bacteria. A higher DD enhances the antimicrobial activity by increasing the density of cationic sites on chitosan, allowing for better interaction with bacterial cells. A DD in the range of 80% and 95% is optimal for effective antimicrobial properties in textiles.

[0029] The conditions under which the chitosan is processed can be varied to achieve the desired degree of deacetylation. Adjusting the time and temperature of the alkali treatment will impact the DD. Longer treatment times and higher temperatures generally yield a higher DD, although the time and temperature need to be controlled and optimized so as to avoid overdegradation of the chitosan polymer. In addition, adjusting the sodium hydroxide concentration can control the extent of deacetylation. High concentrations typically accelerate deacetylation but require precise control to avoid over-degradation.

[0030] The deacetylated chitosan is then subjected to purification and washing at step 101D. For example, it can be repeatedly washed with distilled water to remove any remaining chemicals, ensuring the chitosan is pure and free of residual alkali or acid.

[0031] Once purified, chitosan is processed into fibers through wet spinning 101E to produce fibers suitable for blending with natural fabrics. Chitosan is insoluble in water but dissolves in acidic solutions. To prepare it for spinning, chitosan is dissolved in an aqueous solution of acetic acid (typically 1-2% concentration). The amino groups on the chitosan polymer chains become protonated (positively charged), allowing the polymer to dissolve.

[0032] The dissolved chitosan solution (chitosan dope solution) undergoes wet spinning 101E by being extruded through a spinneret. The spinneret is a device with fine holes through which the fibers are extruded. The fibers are extruded into a coagulation bath which may contain an alkaline solution (such as sodium hydroxide, NaOH) or an alcohol, which neutralizes the acid in the chitosan solution, precipitating the polymer into solid fibers.

[0033] The freshly coagulated fibers are stretched to align the polymer chains, improving mechanical properties like tensile strength and flexibility. The fibers are then washed to remove residual solvents and salts from the coagulation bath.

[0034] After this, the chitosan fibers may be subjected to further treatment or finishing at step 101F. For example, the chitosan fibers may undergo further neutralization (if necessary) to ensure that all acidic residues are removed, which is important for both durability and biocompatibility. Finally, the fibers are dried under controlled conditions to avoid shrinkage and to maintain their mechanical properties.

[0035] For added durability and resistance to washing, chitosan fibers may be chemically or ionically crosslinked at step 101G. This helps the fiber retain its structure and antimicrobial properties during prolonged use. The process for crosslinking of chitosan enhances the mechanical strength, durability, and antibacterial performance of the chitosan-based textiles. Crosslinking stabilizes chitosan within a fiber matrix, providing durability and wash fastness while retaining antimicrobial activity. An optimal crosslinking process enhances the mechanical stability of the textile while preserving the active sites (amino groups) responsible for antimicrobial effects.

[0036] In one embodiment, genipin is used to achieve crosslinking. Genipin, a natural crosslinker, is less toxic than other crosslinking agents such as glutaraldehyde, and can be used for textile and biomedical applications. It forms stable, flexible, and long-lasting crosslinks withchitosan through the reaction between genipin's reactive aldehyde groups and the amino groups of chitosan. For an optimal crosslinking process, moderate crosslinking is performed using crosslinking agents such as genipin at low concentrations to retain both flexibility and antimicrobial action.

[0037] This combination of 80%-95% deacetylation with 10%-40% crosslinking in the chitosan has been found by the inventors to optimize the antimicrobial properties of the chitosan. After wet spinning 101E, further treatment processes 101F and crosslinking 101G, chitosan fibers 102 are produced which are ready to be blended with other natural fibers, such as viscose, modal, micromodal, bamboo, hemp, lyocell, and / or cotton. The blending stage is discussed further below.

[0038] Referring back to FIG. 1 , method 100 proceeds to blending stage 105 wherein the processed chitosan 102 is blended with one or more natural fibers 103 selected from the group of modal, micromodal, lyocell, hemp, bamboo, and cotton fibers. The natural fibers 103 are blended with chitosan 102 in specific proportions to achieve the desired balance of properties such as antimicrobial efficacy, moisture management and comfort. In particular embodiments, the chitosan content in the fabric blend is between 10% and 30% by weight; when the chitosan is processed and combined with other natural fibers as described herein, this chitosan content has been found by the inventors to provide effective antibacterial and antifungal protection (e.g. against pathogenic Staphylococcus aureus, Gardnerella vaginalis, and Candida albicans (yeast)). In addition to the natural fibers 103, spandex or elastane (or other similar elastic fibers such as natural rubber (latex) may optionally be incorporated into the blend to provide some elasticity to the textile blend. In particular embodiments, the spandex content in the fabric blend is between 3% and 10% by weight, with the remaining content comprised of the combination of chitosan 102 and natural fibers 103. The blending process at stage 105 yields a mixture ofblended fibers 106 with an even distribution of chitosan throughout the fabric, maximizing its antimicrobial efficacy.

[0039] The chitosan fibers can be physically blended with other natural fibers in one of the following ways. In staple fiber blending, chitosan is processed into short staple fibers, which are blended with the staple fibers of natural materials. The blended fiber mix is then spun into yarns. Staple fiber blending may be used for blending chitosan with cotton and modal fibers. In filament blending, chitosan is processed into filaments (longer fibers). Lyocell (and other natural fibers) may be processed through a wet spinning process to yield filaments made from such natural fibers. The chitosan filaments may be spun together with such natural fiber filaments to create a blended yarn.

[0040] Chitosan can blend with viscose, modal, micromodal, bamboo, hemp, lyocell, and / or cotton to yield different blends. Each blend has different characteristics. Chitosan is naturally hydrophilic, which complements the moisture-wicking properties of fibers such as modal, micromodal and lyocell. Modal, micromodal and lyocell are cellulosic fibers made from wood. Their production process generally requires less than half the water as for the production of cotton fibers. Modal and micromodal are made from reconstituted cellulose sourced primarily from beech trees. Modal is characterized by its softness and moisture-wicking properties. Micromodal has similar properties but is made from finer ground cellulosic fiber. Blending chitosan with modal creates a fabric that retains these qualities of modal while incorporating the antimicrobial functionality of chitosan. Lyocell is made from wood, such as eucalyptus wood, that is used to create a pulp. The pulp is dissolved in a solvent and pushed through a spinneret to form fiber strands. Lyocell is a sustainable, biodegradable fiber with good moisture management through its moisture-wicking characteristics. Blending chitosan with lyocell results in a fabric that has enhanced antimicrobial properties while maintaining lyocell’s characteristics. Cotton has a similar hydrophilicity to chitosan, and therefore blends well with chitosan. Blendingchitosan with cotton yields a fabric which combines the softness of cotton with the antimicrobial properties of chitosan.

[0041] Chitosan's antimicrobial activity can be retained in fabric blends, protecting against bacteria, fungi, and odors. This makes chitosan-natural fiber blends beneficial for applications in medical textiles, undergarments, sportswear, and hygiene products. In addition, blending chitosan with natural fibers such as viscose, modal, micromodal, bamboo, hemp, lyocell, and cotton results in environmentally friendly textiles that are biodegradable and sustainable. Depending on the blending ratio and the degree of fiber alignment, the mechanical strength of chitosan-natural fiber blends can be optimized for durability, softness, and comfort.

[0042] In particular embodiments, the fabric blend is composed of between 10% and 30% chitosan by weight, with the remainder of the fabric blend comprised of a combination of natural fibers (such as modal) and spandex. Some exemplary proportions (by weight) for the textile fabric blend include: 10% chitosan, 80% modal and 10% spandex; 20% chitosan, 75% modal and 5% spandex; 30% chitosan, 60% modal and 10% spandex. The fabric blend may be used as the interior crotch lining for underwear as described below with reference to FIGS. 3 and 4A, 4B.

[0043] While exemplary proportions of the textile fabric blend are described herein, the proportions of chitosan and natural fibers (and spandex, if used) may be adjusted to achieve the desired balance of properties. For example, a higher concentration of chitosan may be used for applications requiring enhanced antimicrobial protection, while a lower concentration may be suitable for applications emphasizing breathability and comfort.

[0044] Method 100 then proceeds to carding and spinning stage 107 wherein the blended fibers undergo carding (to disentangle and clean the fibers and make them ready for spinning), and are spun into yarns 108 to create a yarn that can be woven or knitted. The spinning ensures that the chitosan is evenly distributed throughout the yarns 108. The resulting yarns 108 retainthe beneficial properties of each fiber, including the antimicrobial effects of chitosan. Suitable spinning techniques that may be used at stage 107 include ring spinning or open-end spinning.

[0045] Subsequently, at weaving / knitting stage 109 of method 100, the yarns are woven or knitted into a fabric 110. The resulting blended fabric 110 exhibits a uniform texture with enhanced durability, breathability, and comfort. For underwear lining applications, the fabric is constructed to be lightweight, breathable, and soft against the skin.

[0046] Finally, at finishing stage 111 of method 100, the blended fabric 110 undergoes optional additional finishing treatments to enhance its softness, appearance, and performance. These treatments are selected to maintain the fabric's natural properties and ensure the longevity of its antimicrobial effects. The resulting finished textile fabric blend 112 is then ready for use to produce garments, such as the garments described herein.

[0047] The textile fabric blend 112 manufactured in accordance with method 100 has inherent antibacterial and antifungal protection from the chitosan content, reducing the risk of infections and odors, especially in moist environments (e.g. moisture due to sweat). The natural antimicrobial properties of chitosan prevent the growth of odor-causing bacteria, keeping the fabric fresh for extended periods. The inclusion of natural fibers 103 such as modal and lyocell in the textile fabric blend 112 enhances the fabric’s breathability, allowing for better air circulation and temperature regulation, and provides for moisture management, keeping the skin dry and comfortable during sports and other physical activities. Furthermore, the use and incorporation of chitosan, a byproduct of the seafood industry, combined with natural fibers, makes the textile fabric blend more environmentally friendly and sustainable than other textile fabrics.

[0048] The textile fabric blend described herein is well-suited for men’s and women's undergarments and sports apparel. The textile fabric blend’s antibacterial and antifungalproperties help prevent odor and infections, while its moisture-wicking and breathable qualities ensure comfort while wearing the garment.

[0049] Each of FIGS. 3 and 4A, 4B show an exemplary underwear garment 200 incorporating a chitosan and natural fiber-based textile fabric blend 112 as the interior lining of a portion of the underwear garment 200. Textile fabric blend 112 may be made in accordance with method 100 of FIG. 1. To construct the underwear garment 200, the textile fabric blend 112 is cut into a shape so as to provide an interior lining for the crotch portion of the underwear garment 200. This lining (made from textile fabric blend 112) is then sewn into the underwear garment 200 and covers the areas of the body most susceptible to moisture, odors, fungal and bacterial growth. The lining is securely attached to the outer fabric of the underwear garment 200, creating a seamless, comfortable fit.

[0050] Underwear garment 200 is designed for daily use, providing ongoing antibacterial and antifungal protection, moisture and odor management, and comfort through the textile fabric blend 112 used to line the garment. It is particularly beneficial for those with sensitive skin or those prone to infections. Further, the moisture-wicking, anti-odor and breathable properties of the lining make the underwear ideal for sports and physical activities, ensuring comfort and hygiene throughout the day.

[0051] The inventors have found that undergarments lined with a chitosan and natural fibers textile fabric blend as described herein exhibit enhanced antibacterial properties against Staphylococcus aureus, Escherichia coli (E. coli) and Gardenerella vaginalis. In particular, testing of the lining has found it to reduce bacterial growth by at least 80-99% compared to conventional natural fiber fabrics. The textile fabric blend exhibits antifungal properties effective against common fungi including Candida albicans that cause infections in intimate areas. The lining is integrated into men’s and women's underwear garments in a manner that ensures full coverage of areas prone to moisture and microbial growth.

[0052] Tests have also shown that the textile fabric blend described herein maintains its antimicrobial efficacy after 180 washes, providing for long-lasting protection and durability. The textile fabric blend is free of synthetic chemicals and dyes, ensuring hypoallergenic properties suitable for sensitive skin. The chitosan content contributes to the fabric’s ability to neutralize odors, providing a fresh feel throughout prolonged wear.

[0053] To demonstrate the antimicrobial efficacy of the textile fabric blends described herein, antimicrobial activity testing was conducted on representative fabric samples incorporating chitosan and natural fibers and manufactured in accordance with the processes described herein. The following summarizes the results of two laboratory tests performed by SGS-CSTC Standards Technical Services, using the AATCC 100-2019 Test Method for Antibacterial Finishes on Textile Material.

[0054] Sample 1 - Chitosan Blend Fabric: A fabric sample comprising 9.2% chitosan, 82.8% Lenzing / Tencel modal, and 8% spandex by weight was tested for antimicrobial activity against representative bacterial and fungal organisms. The test organisms included Candida albicans (ATCC 10231), Escherichia coli (ATCC 8739), and Staphylococcus aureus (ATCC 6538). The test yielded the following results:

[0055] Table 1

[0056] These results demonstrate that the chitosan blend fabric achieved a reduction in viable microorganism counts of at least 98.2% after 24 hours of contact, compared to untreatedcontrol fabrics. The reduction achieved was 99.8% for Staphylococcus aureus, 99.2% for Escherichia coli, and 98.2% for Candida albicans.

[0057] Sample 2 - Women’s Underwear Lining (Chitosan Blend): A further test was conducted on a women’s underwear lining sample incorporating a chitosan-based textile fabric blend manufactured in accordance with the methods described herein, and comprising 9.2% chitosan, 82.8% Lenzing / Tencel modal, and 8% spandex by weight. The sample was tested for antimicrobial activity against Gardnerella vaginalis (ATCC 14018), a bacterium associated with bacterial vaginosis and intimate area infections. The test yielded the following results:

[0058] Table 2

[0059] The chitosan blend underwear lining demonstrated a greater than 99.9% reduction in viable Gardnerella vaginalis after 24 hours of contact, with the treated sample showing undetectable levels of viable bacteria (<100 CFU / sample) compared to the untreated control.

[0060] All antimicrobial activity tests were performed in accordance with AATCC 100-2019, which assesses the reduction in viable microorganism counts on textile materials after a 24-hour contact period. The reduction percentage (R) is calculated as R = 100 x (B - A) / B, where A is the number of bacteria recovered from the treated specimen after 24 hours, and B is the number recovered from the untreated control specimen after 24 hours. Test swatches were 3.8 x 3.8 cm, 1.0 g each. For the underwear lining sample, the treated specimen was sterilized by autoclaving prior to testing.

[0061] These test results demonstrate that textile fabric blends comprising chitosan and natural fibers, as described in the present disclosure, provide effective antimicrobial protectionby inhibiting the growth of common bacterial and fungal pathogens associated with odor, irritation and infection.

[0062] In addition to undergarments and underwear, textile fabric blend 112 can be incorporated into other types of garments. It may be used to construct garments or to line areas of garments where moisture-wicking, breathability, anti-odor, anti-bacterial and anti-fungal characteristics are desired. Garments that may benefit from incorporating textile fabric blend 112, include, for example, socks, children’s and infant wear, and sports apparel and the like.

[0063] The overall process for manufacturing a finished undergarment 200 incorporating a textile fabric blend 112 may include several steps including: (i) material selection and fabric blend ratio determination for the textile fabric blend 112; (ii) fabric production (comprising spinning, processing, finishing, and blending, followed by weaving or knitting); (iii) dyeing of the fabric; (iv) pattern-making; (v) design development; (vi) size grading; (vii) cutting (e.g. laser and / or manual), (viii) sewing; (viiii) quality control; (x); trimming and pressing; and (xi) packaging of the finished garment.

[0064] The examples and corresponding diagrams used herein are for illustrative purposes only. Different configurations and terminology can be used without departing from the principles expressed herein.

[0065] Although the invention has been described with reference to certain specific embodiments, various modifications thereof will be apparent to those skilled in the art without departing from the scope of the invention. The scope of the claims should not be limited by the illustrative embodiments set forth in the examples, but should be given the broadest interpretation consistent with the description as a whole. For example, various features are described herein as being present in “some embodiments” or in “one embodiment”. Such features are not mandatory and may not be present in all embodiments. Embodiments of theinvention may include zero, any one or any combination of two or more of such features. This is limited only to the extent that certain ones of such features are incompatible with other ones of such features in the sense that it would be impossible for a person of ordinary skill in the art to construct a practical embodiment that combines such incompatible features. Consequently, the description that “some embodiments” possess feature A and “some embodiments” possess feature B should be interpreted as an express indication that the inventors also contemplate embodiments which combine features A and B (unless the description states otherwise or features A and B are fundamentally incompatible).

Claims

CLAIMS1. A textile fabric blend comprising: a) chitosan which has been processed to have a degree of deacetylation of between 80% and 95% and a crosslinking degree of between 10% and 40%; and b) one or more natural fibers selected from the group consisting of viscose, modal, micromodal, lyocell, hemp, bamboo, and cotton.

2. The textile fabric blend according to claim 1 wherein the chitosan content is between 10% and 30% by weight.

3. The textile fabric blend according to any one of claims 1 or 2, wherein the natural fibers are blended in proportions to enhance moisture-wicking, anti-odor, and breathable properties of the textile fabric blend.

4. The textile fabric blend according to any one of claims 1 to 3, wherein the chitosan is extracted from crab shells, fungi, or a combination thereof.

5. The textile fabric blend according to any one of claims 1 to 4 wherein the textile fabric blend incorporates spandex, natural elastic fibers, or a combination thereof.

6. The textile fabric blend according to claim 5 comprising one of the following content proportions by weight: 10% chitosan, 80% modal and 10% spandex; 20% chitosan, 75% modal and 5% spandex; and 30% chitosan, 60% modal and 10% spandex.

7. The textile fabric blend according to any one of claims 1 to 6 wherein the chitosan is crosslinked using genipin at low concentration.

8. A method of manufacturing the textile fabric blend of any one of claims 1 to 7, comprising the steps of: processing chitosan to have a degree of deacetylation of between 80% and 95% and a crosslinking degree of between 10% and 40%; blendingthe chitosan with natural fibers; spinning the blended fibers into yarns; weaving or knitting the yarns into fabric; and applying finishing treatments.

9. Use of the textile fabric blend of any one of claims 1 to 7 to manufacture apparel such as undergarments, sports apparel, swim wear, socks, hats, and diapers.

10. An antimicrobial underwear lining comprising a blend of chitosan and natural fibers, wherein the natural fibers are selected from the group consisting of viscose, modal, micromodal, bamboo, hemp, lyocell, and cotton.

11. The antimicrobial underwear lining according to claim 10, wherein the chitosan is extracted from crab shells or fungi and has a degree of deacetylation between 80% and 95% and a crosslinking degree of between 10% and 40%.

12. The antimicrobial underwear lining according to any one of claims 10 or 11 , wherein the chitosan content in the antimicrobial underwear lining is between 10% and 30% by weight.

13. The antimicrobial underwear lining according to any one of claims 10 to 12, wherein the blend of chitosan and natural fibers is spun into yarns that are then woven or knitted into a textile.

14. An underwear garment incorporating the antimicrobial underwear lining of any one of claims 10 to 13, wherein the antimicrobial underwear lining is integrated into the underwear garment to provide coverage to areas prone to moisture and microbial growth.

15. A method of manufacturing the antimicrobial underwear lining of any one of claims 10 to 13, comprising the steps of: processing chitosan to have a degree of deacetylationbetween 80% and 95% and a crosslinking degree of between 10% and 40%; blending the chitosan with viscose, modal, micromodal, bamboo, hemp, lyocell, and / or cotton fibers; spinning the blended fibers into yarn; and weaving or knitting the yarn into a fabric.

16. A textile fabric blend, underwear lining, or garment having any new and inventive feature, combination of features, or sub-combination of features as described herein.

17. A method having any new and inventive step, act, combination of steps and / or acts or sub-combination of steps and / or acts as described herein.

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