MEDICINAL FABRIC FOR DERMATOLOGICAL USE CASES AND ASSOCIATED METHOD FOR MANUFACTURING THE SAME

Abstract

A method for manufacturing medicinal fabric that provides enhanced dermatological comfort for the user/patient, especially those with sensitive skin conditions (e.g., acne, contact dermatitis, atopic dermatitis, eczema, psoriasis, rosacea, urticaria, etcetera) including the steps of: (1) selecting a cotton fiber, wherein the cotton fiber is long staple cotton and 100 percent organic; (2) processing the cotton fiber as greige cotton; (3) optionally verifying that the cotton fiber is organic per Global Organic Textile Standards or comparable standards; (4) fermenting or otherwise naturally preparing an herb or plant into a medicinally potent agent/substance and hypoallergenic dyeing agent; (5) using a skin-friendly binding technique, such as binderless dyeing the cotton fiber with the agent/substance via ultrasonic energy or using a technique that similarly uses no irritative chemical binders; (6) selecting a suitable weave type for the specific use/case to reduce mechanical irritation to the user/patient; (7) optionally verifying that the woven cotton fiber has not been contaminated during the manufacturing process through toxicological verification methods; and (8) optionally verifying that the woven cotton fiber passes the standardized dermatological Human Repeat Insult Patch Test.

Claims

1. A method for manufacturing medicinal fabric that provides enhanced dermatological comfort for those with sensitive skin conditions, comprising the steps of: selecting a cotton fiber, wherein the cotton fiber is long staple cotton and 100 percent organic; processing the cotton fiber as greige cotton; optionally verifying that the cotton fiber is organic per Global Organic Textile Standards or comparable standards; fermenting or otherwise naturally preparing an herb or plant into a medicinally potent agent/substance and hypoallergenic dyeing agent; using a skin-friendly binding technique, such as binderless dyeing the cotton fiber with the agent/substance via ultrasonic energy or using a technique that similarly uses no irritative chemical binders; selecting a suitable weave type for the specific use/case to reduce mechanical irritation to the user/patient; optionally verifying that the woven cotton fiber has not been contaminated during the manufacturing process through toxicological verification methods; and optionally verifying that the woven cotton fiber passes the standardized dermatological Human Repeat Insult Patch Test.

2. The method according to claim 1, wherein the step of selecting the cotton fiber includes selecting Gossypium barbadense cotton fiber.

3. The method according to claim 1, wherein the step of selecting the cotton fiber includes selecting cotton fiber that is free from any residual pesticides.

4. The method according to claim 1, wherein the step of processing the cotton fiber occurs in the absence of bleach.

5. The method according to claim 1, wherein the step of producing the herbal dye includes a medicinal active agent/substance that benefits the user/patient.

6. The method according to claim 1, wherein the step of fermenting a product includes fermenting at least one of the products selected from the group consisting of indigo leaf, pomegranate, gardenia, madder, onion, mango, jackwood, sandalwood, and combinations thereof.

7. The method according to claim 1, wherein the step of dyeing the cotton fiber via ultrasonic energy includes the step of dyeing via dual-frequency, dual-intensity ultrasonic energy or using a similar method that avoids the use of binding chemicals that may cause irritations to sensitive skin.

8. The method according to claim 1, further comprising the step of verifying that the woven cotton fiber comprises an antibacterial index of greater than 2.

9. The method according to claim 1, further comprising the step of verifying that the woven cotton fiber comprises an antibacterial index of greater than 5.

10. A method for manufacturing medicinal fabric that provides enhanced dermatological comfort for those with sensitive skin conditions, comprising the steps of: selecting a cotton fiber, wherein the cotton fiber is long staple, Gossypium barbadense and 100 percent organic; processing the cotton fiber as greige cotton in the absence of bleach; optionally verifying that the cotton fiber is organic per Global Organic Textile Standards; fermenting indigo leaf into an antibacterial and hypoallergenic dyeing agent; dyeing the cotton fiber with the indigo leaf dyeing agent via dual-frequency, dual-intensity ultrasonic energy or similar technique that avoids irritative chemicals; sateen weaving the cotton fiber; optionally verifying that the woven cotton fiber has not been contaminated during the manufacturing process; and optionally verifying that the woven cotton fiber passes the standardized Human Repeat Insult Patch Test.

11. A product manufactured according to the process of claim 10.

12. A product manufactured according to the process of claim 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0028] While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and described herein in detail several specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.

[0029] The present invention is directed to a method for manufacturing medicinal fabric that provides enhanced dermatological comfort for those with sensitive skin conditions, comprising the following general steps: (1) selecting cotton that is preferably long staple cotton, such as Gossypium barbadense; (2) selecting cotton that is preferably 100% organic; (3) processing as greige virgin cotton (unbleached); (4) certifying the source as GOTS (Global Organic Textile Standard) grade organic or comparable; (5) fermenting or otherwise naturally preparing herbal dye agents/substances, such as indigo leaf (or other plant) dye; (6) dyeing using sonic sound waves or utilizing other skin-friendly binding techniques; (7) using suitable weave type for the respective body parts the fabric will be in touch with to reduce mechanical irritation; (8) no chemical finishing; (9) passing toxicological fabric test and verify properties; and (10) passing dermatological HRIPT Test.

[0030] The above-identified manufacturing and/or production process avoids any sources for dermatological irritation typical seen with fabrics. Step-1-3 ensure the correct sourcing of fibers: Long staples in the cotton, such as Gossypium barbadense (Step 1) reduce mechanical irritation as cotton fibers can stretch more before frailing. A long staple fiber is preferably between 1? and 1? long. 100% of organic cotton (Step 2) guarantees no residual pesticides remain that could irritate sensitive skin. Using greige cotton (Step 3) eliminates the chance of irritations from residual bleach. Raw, virgin lint, which is ginned cotton that has not been washed and bleached, is referred to by the industry as greige cotton. The correct sourcing of the cotton (Steps 1-3) is verified by the strict GOTS Transaction Certification with the requirements to be labeled as greige cotton and graded as 100% organic. If the GOTS label is not available, other third-party verification for the cotton quality may be used. This step verifies that no accidental mix-up of organic on non-organic cotton has occurred. If the test fails, the production should be terminated. It is common that supply chains are so opaque that even organic labeled products are not or just partially organic.

[0031] GOTS is recognized as the world's leading processing standard for textiles made from organic fibers. It defines high-level environmental criteria along the entire organic textiles supply chain and requires compliance with social criteria as well. Only textile products that contain a minimum of 70% organic fibers can become GOTS certified. All chemical inputs, such as dyestuffs and auxiliaries used must meet certain environmental and toxicological criteria. The choice of accessories is limited in accordance with ecological aspects as well. A functional wastewater treatment plant is mandatory for any wet-processing unit involved and all processors must comply with minimum social criteria.

[0032] Step 4 is a test to verify that sourced cotton passes these specific requirements. Steps 5-8 disclose preferred dyeing and finishing process. For example, Indigo Naturalis (which may be used in Step 5) is a plant that can be fermented into a medicinal/antibacterial and hypoallergenic dyeing agent/substance. Sonic wave dyeing (Step 6) does two things: (1) eliminates the chance of chemical irritation due to synthetic dyes or mordants; (This is a physical dyeing process in which the color is fixed into the textile using physical force rather than a chemical reaction.); and (2) keeps the skin-beneficial properties (such as the anti-bacterial properties of indigo and other medicinal agents such as Tryptanthrin) of the plant dye. This replicates the traditional hand-made process in which the properties are transferred into the fabric. For this, a dual-frequency mechanism is preferably used: In the dyeing process, the ultrasonic wave range is 20 KHz-28 KHz. Dyeing temperature is as low as 15? C. and not higher than 35? C. and dyeing time is 10-60 minutes. In the dyeing process, the multi-frequency ultrasonic intensity is 0.1-0.8 W/cm. During the soaping process, the frequency selection range of ultrasonic waves is 28 KHz-55 KHz, and the soaping temperature is between 20? C.-35? C. Soaping time is 5-30 minutes, while multi-frequency ultrasonic intensity is 0.2-1 W/cm.sup.2. This process also uses almost no water, and produces no toxic wastewater like most other fabric dyeing processes. Sateen weaving (Step 7) creates the smoothest surface possible for cotton for textiles such as bedsheets, which significantly reduces mechanical irritation to skin. Shirts which need to allow for stretching and higher breathability because they enclose the torso should be made from jersey knitted fabric. Any finishing agents (Step 8) should be avoided or need to fulfill the criteria of being plant-based and have hypoallergenic properties. Step 9 and 10 are a set of tests that help qualify the fabric according to the framework of this invention. Step 9 is an assessment process according to strict standards of toxicology: Quantitation of azo/pigment forming specific amine compounds, formaldehyde, pH, and colorfastness to verify that no impurification has happened during the production process. Step 10 is a Human Repeat Insult Patch Test (HRIPT Test), a clinical study on human subjects to verify that textile is Hypo-allergenic, Dermatologist-tested, Non-irritating and Suitable for sensitive skin, a final test to rule out that any skin irritating substances have tainted the fabric.

[0033] A laboratory test against strict toxicological standard verifies the correct dyeing and processing (Steps 5-8) methods have been applied. The final HRIPT Test is the last check that no chemicals or plant materials have entered the fabrics that could cause dermatological adverse effects. A failure of any of the gates should halt the production process. By following the above-listed steps, in the order listed, a fabric avoids or highly limits any form of irritations that can cause discomfort to sensitive skin.

[0034] Organic cotton and herbal dyes, such as natural indigo dye are preferred ingredients. The absence of any other added processing chemicals that could have unwanted side-effects is also preferred. The toxicological and the HRIPT tests are preferred to verify the dermatological quality of products and rule out impurities and scientifically back the claim hypoallergenic. The GOTS certification is optional, but it allows to stop the process at an early stage through an independent third party. Plant-based and hypoallergenic finishing could be added if it improves the positive properties of the fabric.

[0035] Steps 5-7 can be reversed depending when dyeing is done on cotton bolls, yarn, or woven/knitted fabric. Other weave types could produce similarly gentle fabrics while giving fabric additional properties that sateen does not have (e.g., stretchability). Instead of indigo leaf dye, other plant dyes that also have positive dermatological effects could be used such as pomegranate, gardenia, madder, onion, mango, or different woods (e.g., Jackwood, sandalwood).

Example

[0036] The Japanese Industrial Standard (JIS) issued a testing method to determine the antibacterial activity (expressed as an Index), of antimicrobial-treated (compounded) materials or articles. The antibacterial activity is calculated dividing the number of bacteria present after 24 hours of cultivation onto a testing treated article/product (C) into the number of bacteria present after 24 hours of cultivation onto the corresponding untreated (without antimicrobial agent) article/product (B). An antibacterial index of >2.0 (?99% killing ratio) of a treated article with antimicrobial agent might be considered as Antibacterial Article.

[0037] The test result shown below illustrates the medicinal/antibacterial properties of the inventive process.

TABLE-US-00001 Common logarithm for the number of bacteria Common logarithm for (Max-Min) the number of bacteria Immediately after (Max-Min) Antibacterial Sample inoculation After 18 h incubation activity value Conventional Original 4.54 (0.0) 7.14 (0.0) ?0.1 Fabric Aizome Original 4.38 (0.1) 1.30 (0.0) 5.7 Bedding Fabric Control Fabric 4.55 (0.0) 7.03 (0.1) Growth value F: 2.5

[0038] The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention.

[0039] While certain embodiments have been illustrated and described, it should be understood that changes and modifications can be made therein in accordance with ordinary skill in the art without departing from the technology in its broader aspects as defined in the following claims.

[0040] The embodiments, illustratively described herein may suitably be practiced in the absence of any element or elements, limitation or limitations, not specifically disclosed herein. Thus, for example, the terms comprising, including, containing, etcetera shall be read expansively and without limitation. Additionally, the terms and expressions employed herein have been used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the claimed technology. Additionally, the phrase consisting essentially of will be understood to include those elements specifically recited and those additional elements that do not materially affect the basic and novel characteristics of the claimed technology. The phrase consisting of excludes any element not specified.

[0041] The present disclosure is not to be limited in terms of the particular embodiments described in this application. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and compositions within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds compositions or biological systems, which can of course vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

[0042] In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0043] As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etcetera. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etcetera. As will also be understood by one skilled in the art all language such as up to, at least, greater than, less than, and the like, include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member.

[0044] All publications, patent applications, issued patents, and other documents referred to in this specification are herein incorporated by reference as if each individual publication, patent application, issued patent, or other document was specifically and individually indicated to be incorporated by reference in its entirety. Definitions that are contained in text incorporated by reference are excluded to the extent that they contradict definitions in this disclosure.

[0045] Other embodiments are set forth in the following claims.