ACTIVE FORCE ELECTRIC FIELD ANTI-PATHOGENIC FABRIC AND ASSOCIATED METHOD OF FABRICATION

Abstract

Described herein relates to an active force electric field anti-pathogenic fabric and methods thereof used to remove pathogens from an environment surrounding the fabric. The device may be woven into daily clothing items, personal protective equipment, and/or other clothing items typically worn by a user. The device may include a current-carrying mesh that may be coated with active materials used to remove pathogens from the air. As such, the device may operate as an anti-pathogenic material that may be used to remove harmful particles from an area surrounding a user. Accordingly, microorganisms, smoke particles, industrial pollutants, odor molecules, and/or allergens may be structurally disassociated into harmless protein fragments and/or natural molecules when encountering the purifying agents in the device.

Claims

1. An anti-pathogenic fabric, the anti-pathogenic fabric comprising: a user-facing side opposite a surrounding environment-facing side, the user-facing side configured to reside adjacent to at least a portion of a surface of a user; a first fiber layer disposed proximate to the user-facing side; a second fiber layer disposed proximate to the surrounding environment-facing side; at least one copper naphthenate particle distributed on a surface of the second fiber layer, wherein the second fiber layer is positioned between the first fiber layer and the at least one copper naphthenate particle; and wherein the second fiber layer, the first fiber layer and the at least one copper naphthenate particle are configured to capture at least one electrically charged pathogenic particle to prevent the at least one electrically charged pathogenic particle from traversing beyond the first fiber layer.

2. The anti-pathogenic fabric of claim 1, wherein the first fiber layer and the second fiber layer are spaced apart from each other to provide space for generation of an electric field to capture the at least one electrically charged pathogenic particle to prevent the at least one electrically charged pathogenic particle from traversing beyond the first fiber layer.

3. The anti-pathogenic fabric of claim 1, wherein the first fiber layer includes a plurality of interwoven fiber strands forming a first mesh.

4. The anti-pathogenic fabric of claim 2, wherein at least one of the plurality of interwoven fiber strands of the first fiber layer is made of hemp.

5. The anti-pathogenic fabric of claim 1, wherein the second fiber layer includes a plurality of interwoven fiber strands forming a second mesh.

6. The anti-pathogenic fabric of claim 4, wherein at least one of the plurality of interwoven fiber strands of the second fiber layer is made of hemp.

7. The anti-pathogenic fabric of claim 1, further comprising a photocatalytic layer coating the second fiber layer, wherein the photocatalytic layer is disposed between the second fiber layer and the at least one naphthenate particle.

8. The anti-pathogenic fabric of claim 6, wherein the at least one copper naphthenate particle, the photocatalytic layer, or both are configured to impart an electrical charge onto at least one pathogenic particle translating in a direction toward the surrounding environment-facing side of the fabric.

9. The anti-pathogenic fabric of claim 1, further comprising a first tetrafluoroethylene layer coating at least a portion of a surface of the first fiber layer, wherein the first tetrafluoroethylene layer is disposed between the first fiber layer and the second fiber layer.

10. The anti-pathogenic fabric of claim 1, further comprising a second tetrafluoroethylene layer coating at least a portion of a surface of the second fiber layer, wherein the second tetrafluoroethylene layer is disposed between the second fiber layer and the photocatalytic layer.

11. The anti-pathogenic fabric of claim 1, further comprising a plurality of microcapsules incorporated into the first fiber layer, the second fiber layer, or both, wherein at least one of the plurality of microcapsules comprises an amount of a microbial substance.

12. The anti-pathogenic fabric of claim 1, wherein the anti-pathogenic fabric is a face mask configured to cover a respiratory tract of the user.

13. A method of making an anti-pathogenic fabric, the method comprising the steps of: interweaving a first plurality of fiber strands into a first fiber layer; interweaving a second plurality of fiber strands into a second fiber layer; and distributing at least one copper naphthenate particle on a surface of the second fiber layer, wherein the second fiber layer is positioned between the first fiber layer and the at least one copper naphthenate particle.

14. The method of claim 13, wherein the first fiber layer and the second fiber layer are spaced apart from each other to provide space for generation of an electric field to capture at least one electrically charged pathogenic particle to prevent the at least one electrically charged pathogenic particle from traversing beyond the first fiber layer.

15. The method of claim 13, further comprising coating the second fiber layer with a photocatalytic layer, wherein the second fiber layer is positioned between the photocatalytic layer and the first fiber layer.

16. The method of claim 13, wherein the first fiber layer, the second fiber layer, the photocatalytic layer, and the at least one copper naphthenate particle form a wearable device configured to be positioned adjacent to at least a portion of a surface of a user.

17. The method of claim 13, further comprising coating at least a portion of a surface of the first fiber layer with a first tetrafluoroethylene layer, wherein the first tetrafluoroethylene layer is disposed between the first fiber layer and the second fiber layer.

18. The method of claim 17, further comprising coating at least a portion of a surface of the second fiber layer with a second tetrafluoroethylene layer, wherein the second tetrafluoroethylene layer is disposed between the second fiber layer and the photocatalytic layer.

19. The method of claim 13, further comprising incorporating a plurality of microcapsules into the first fiber layer, the second fiber layer, or both, wherein at least one of the plurality of microcapsules comprises an amount of a microbial substance.

20. The method of claim 13, further comprising forming the anti-pathogenic fabric into a face mask configured to cover a respiratory tract of the user.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] For a fuller understanding of the invention, reference should be made to the following detailed description, taken in connection with the accompanying drawings, in which:

[0027] FIG. 1 is a graphical illustration depicting a fabric device that is coated with a plurality of layers designed to charge and deactivate pathogen particles interacting with the fabric device, such that the pathogen particles do not reach a respiratory tract of the wearer, according to an embodiment of the present disclosure.

[0028] FIG. 2 is a process-flow diagram describing a method of removing pathogens from an ambient environment surrounding a charged fabric material of a fabric device, according to an embodiment of the present disclosure.

[0029] FIG. 3 is a graphical illustration depicting a fabric device including a plurality of antimicrobial microcapsules distributed among electrically charged fibers of the fabric device, according to an embodiment of the present disclosure.

[0030] FIG. 4 is a plot depicting measured results of the efficacy of a fabric device employing charged and/or coated fabrics, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0031] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part thereof, and within which are shown by way of illustration specific embodiments by which the invention may be practiced. It is to be understood that one skilled in the art will recognize that other embodiments may be utilized, and it will be apparent to one skilled in the art that structural changes may be made without departing from the scope of the invention.

[0032] As such, elements/components shown in diagrams are illustrative of exemplary embodiments of the disclosure and are meant to avoid obscuring the disclosure. Any headings, used herein, are for organizational purposes only and shall not be used to limit the scope of the description or the claims.

[0033] Furthermore, the use of certain terms in various places in the specification, described herein, are for illustration and should not be construed as limiting. For example, any reference to an element herein using a designation such as first, second, and so forth does not limit the quantity or order of those elements, unless such limitation is explicitly stated. Rather, these designations may be used herein as a convenient method of distinguishing between two or more elements or instances of an element. Therefore, a reference to first and/or second elements does not mean that only two elements may be employed there or that the first element must precede the second element in some manner. Also, unless stated otherwise a set of elements may comprise one or more elements

[0034] Reference in the specification to one embodiment, preferred embodiment, an embodiment, or embodiments means that a particular feature, structure, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the disclosure and may be in more than one embodiment. The appearances of the phrases in one embodiment, in an embodiment, in embodiments, in alternative embodiments, in an alternative embodiment, or in some embodiments in various places in the specification are not necessarily all referring to the same embodiment or embodiments. The terms include, including, comprise, and comprising shall be understood to be open terms and any lists that follow are examples and not meant to be limited to the listed items.

[0035] Referring in general to the following description and accompanying drawings, various embodiments of the present disclosure are illustrated to show its structure and method of operation. Common elements of the illustrated embodiments may be designated with similar reference numerals.

[0036] Accordingly, the relevant descriptions of such features apply equally to the features and related components among all the drawings. For example, any suitable combination of the features, and variations of the same, described with components illustrated in FIG. 1, can be employed with the components of FIG. 2, and vice versa. This pattern of disclosure applies equally to further embodiments depicted in subsequent figures and described hereinafter. It should be understood that the figures presented are not meant to be illustrative of actual views of any particular portion of the actual structure or method but are merely idealized representations employed to more clearly and fully depict the present invention defined by the claims below.

[0037] As used in this specification and the appended claims, the singular forms a, an, and the include plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term or is generally employed in its sense including and/or unless the context clearly dictates otherwise.

[0038] In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present technology. It will be apparent, however, to one skilled in the art that embodiments of the present technology may be practiced without some of these specific details.

[0039] As used herein, the term mechanical communication refers to any coupling mechanism configured to transmit and/or exchange any force known in the art using any methods and/or device known in the art. Non-limiting examples of mechanical communication may include mechanical coupling, clamps, universal joint, sleeve coupling, roller chain coupling, flange coupling, and/or flange couplings. For ease of reference, the exemplary embodiment described herein refers to mechanical coupling, but this description should not be interpreted as exclusionary of other mechanical coupling mechanisms.

[0040] As used herein, the term coupling mechanism refers to any apparatus known in the art configured to temporarily affix one object to at least one alternative object. Non-limiting examples of the coupling mechanism may include a screw, a nail, a rivet, a magnet, and/or an adhesive. For ease of reference, the exemplary embodiment described herein refers to a screw, but this description should not be interpreted as exclusionary of other coupling mechanisms.

[0041] As used herein, the terms about, approximately, or roughly refer to being within an acceptable error range (i.e., tolerance) for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined (e.g., the limitations of a measurement system) (e.g., the degree of precision required for a particular purpose, such as imparting a charge on surrounding particles, including pathogens, to remove the pathogens from a surrounding area). As used herein, about, approximately, or roughly refer to within 25% of the numerical.

[0042] All numerical designations, including ranges, are approximations which are varied up or down by increments of 1.0, 0.1, 0.01 or 0.001 as appropriate. It is to be understood, even if it is not always explicitly stated, that all numerical designations are preceded by the term about. It is also to be understood, even if it is not always explicitly stated, that the compounds and structures described herein are merely exemplary and that equivalents of such are known in the art and can be substituted for the compounds and structures explicitly stated herein.

[0043] Wherever the term at least, greater than, or greater than or equal to precedes the first numerical value in a series of two or more numerical values, the term at least, greater than or greater than or equal to applies to each of the numerical values in that series of numerical values. For example, greater than or equal to 1, 2, or 3 is equivalent to greater than or equal to 1, greater than or equal to 2, or greater than or equal to 3.

[0044] Wherever the term no more than, less than, or less than or equal to precedes the first numerical value in a series of two or more numerical values, the term no more than, less than or less than or equal to applies to each of the numerical values in that series of numerical values. For example, less than or equal to 1, 2, or 3 is equivalent to less than or equal to 1, less than or equal to 2, or less than or equal to 3.

[0045] The present invention includes the use of an active force electric field anti-pathogenic fabric device (hereinafter fabric device) to remove pathogens from an environment surrounding the fabric. In an embodiment, the fabric device may be woven into daily clothing items, personal protective equipment, and/or any other clothing items known in the art typically worn by a user. The fabric device may also include a current-carrying mesh that may be coated with active materials used to remove pathogens from the air. As such, the fabric device may be configured to operate as an anti-pathogenic material, such that the fabric device may be used to remove harmful particles from an area surrounding a user. In this manner, in this embodiment, the purifying agents disposed within at least one portion of the fabric device may act on microorganisms, smoke particles, industrial pollutants, odor molecules, and/or allergens, such that the fabric device may structurally disassociate the particulates into harmless protein fragments and/or natural molecules.

[0046] As shown in FIG. 1, in an embodiment, the fabric device may include a plurality of layers arranged, such that wearer-facing side 2 of the fabric may be comprised of a fiber mesh, and/or such that surrounding environment-facing side 4 of the fabric device may be comprised of a coating designed to capture and/or deactivate airborne particles prior to interacting with the wearer's respiratory tract. In this manner, wearer-facing side 2 may be opposite surrounding environment-facing side 4, with the plurality of layers disposed between wearer-facing side 2 and surrounding environment-facing side 4.

[0047] In an embodiment, first fiber layer 10a may be disposed proximate to wearer-facing side 2, forming a fabric mesh material that may be designed to rest upon and/or be disposed adjacent to a wearer's skin. As such, in this embodiment, first fiber layer 10a may be formed of a plurality of fibers forming a mesh. In this manner, at least one of the plurality of fibers may be a hemp fiber. Hemp is known to control microorganism propagation, and/or textiles can be formed from hemp fibers since hemp fibers are cellulosic fibers. Hemp fibers have excellent fiber length and strength, absorbency and durability, and anti-microbial (e.g., anti-fungal and/or anti-bacterial) properties. In addition, hemp fibers contain cannabinoids, which are potent antimicrobials that have been used to fight superbugs, including antibiotic-resistant bacteria and common fungal infections, such as candidiasis. In addition, cannabinoids help treat certain types of viral infections. [1]. Certain cannabinoids have been found to inhibit the replication of the COVID-19 causing SARS-CoV-2 virus. However, hemp is a poor conductor of electricity; as such, hemp fibers must be treated to be used within the current-carrying mesh of the fabric, as will be discussed in greater detail below.

[0048] Additionally, as shown in FIG. 1, in an embodiment, first fiber layer 10a of the fabric device may be coated with first tetrafluoroethylene layer 12a, which may be configured to generate a layer of disinfectant ions to intercept particles prior to reaching first fiber layer 10a during the processes described in greater detail below. As such, in this embodiment, first fiber layer 10a and/or first tetrafluoroethylene layer 12a may form an attraction screen designed to capture particles prior to interaction with a user. The attraction screen formed by first fiber layer 10a and/or first tetrafluoroethylene layer 12a may have a charge opposite of the particles, such that the particles may be attracted to the attraction screen, preventing the particles from interaction with the user.

[0049] Moreover, as shown in FIG. 1, in an embodiment, second fiber layer 10b and/or second tetrafluoroethylene layer 12b of the fabric device may be disposed proximate to surrounding environment-facing side 4, and/or may be spaced apart from first fiber layer 10a and/or first tetrafluoroethylene layer 12a. In this manner, the distance between second fiber layer 10b and first tetrafluoroethylene layer 12a may provide a space for the existence of electric field 14 therebetween, which will be discussed in greater detail below; however, in an embodiment, second fiber layer 10b may be disposed proximate to first tetrafluoroethylene layer 12a.

[0050] Additionally, in an embodiment, second tetrafluoroethylene layer 12b may be disposed proximate to surrounding environment-facing side 4 of the fabric. Similar to the attraction screen formed by first fiber layer 10a and/or first tetrafluoroethylene layer 12a, in this embodiment, second fiber layer 10b and/or second tetrafluoroethylene layer 12b may comprise a charge opposite that of the particles, such that second fiber layer 10b and/or second tetrafluoroethylene layer 12b may be configured to capture particles prior to entering the fabric.

[0051] As shown in FIG. 1, in an embodiment, second tetrafluoroethylene layer 12b may also be coated on surrounding environment-facing side 4 with photocatalytic material 16. Nonlimiting examples of photocatalytic material 16 may include titanium dioxide, including sulfur-doped nano-titanium dioxide. In addition, in this embodiment, at least one particle of copper naphthenate 18 (CuN) may also be distributed on at least one portion of photocatalytic material 16, forming a coating on surrounding environment-facing side 4 of the fabric. Copper naphthenate 18 is the copper salt of naphthenic acid, and/or copper naphthenate 18 may be used to treat at least one of the plurality of fibers of the fabric device, such as the at least one hemp fiber. As such, in this embodiment, by applying the Copper naphthenate 18 coating on at least one of the plurality of fibers (e.g., the at least one hemp fiber) may improve and/or optimize the electrical conductivity of the fibers while enhancing the biocidal effects, making it suitable for a wide range of applications. Copper naphthenate 18 may not only be permanently effective, but it may also be compatible with human skin and/or the environment, such that the coating may be safe and/or effective for use by humans without risking harmful side effects. Accordingly, in this embodiment, the fabric devices (e.g., protective clothing), as disclosed above and/or herein, may be useful in hospitals, nursing homes, schools, hotels, and/or crowded public areas to prevent infection from pathogens.

[0052] Moreover, in some embodiments, the fabric device may be used as a hemp-incorporated nanofibrous polyurethane membrane and/or an asymmetric chitosan membrane prepared by electrospinning as wound dressings. Additionally, in some embodiments, the fabric device may also be durable through multiple cleaning cycles and/or outdoor exposure, and/or the fabric device may have no adverse effects on other fabric properties including wear comfort and/or aesthetic of the fabric device.

[0053] Referring now to FIG. 2, in conjunction with FIG. 1, an exemplary process-flow diagram is provided, depicting a method of removing pathogens from an ambient environment surrounding a charged fabric material. The steps delineated in the exemplary process-flow diagram of FIG. 2 are merely exemplary of an order of removing pathogens by charging particles using an electric field created on a wearable fabric. The steps may be carried out in another order, with or without additional steps included therein.

[0054] As noted above, in an embodiment, the fabric device may comprise a current-carrying mesh. As shown in FIG. 2, in this embodiment, the mesh may be coated with tetrafluoroethylene (step 20) and/or further may be over-coated with an active photocatalytic material (step 22). In this manner, the photocatalytic material may also then be energized to create powerful dismantling agents on surface, including hydroxyl radicles, from natural ambient air (step 24). As such, in this embodiment, the material may utilize the ambient air to create dismantling agents that may be used to remove pathogens from the surrounding environment.

[0055] Additionally, as shown in FIG. 2, in conjunction with FIG. 1, in an embodiment, due to the current in the mesh, the fabric device may be configured to impart and/or enhance positive and/or negative electrostatic charges on surrounding particles to increase decontamination (step 26). Furthermore, in this embodiment, the charged particles of the fabric device may migrate to an activated dismantling mesh within the fabric device that may include an internal oppositely-charged attraction screen (step 28). In this manner, multiple dismantling meshes may be used within the fabric device to capture positively charged particles and/or negatively charged particles, as well as neutral particles.

[0056] In an embodiment, suspended water molecules may also be configured to be drawn to the mesh in the same way, providing a supply of raw material of water molecules that may be used to create the decontaminating agents. As such, in this embodiment, the resulting material may be formed into a current-carrying mesh in accordance with the process flow diagram described in detail above. In this manner, a resin precondensate may be included on at least one of the plurality of fibers (e.g., the at least one hemp fiber) to improve laundering durability, as well as an antimicrobial material used to further improve the efficacy of the fabric.

[0057] Referring now to FIG. 3, in conjunction with FIG. 1 and FIG. 2, in an embodiment, the fabric device may comprise at least one antimicrobial microcapsule 30, such that the at least one antimicrobial microcapsule 30 may be incorporated into at least one of the plurality of fibers (e.g., the at least one hemp fiber) of first fiber layer 10a and/or second fiber layer 10b, such as during primary spinning of the first fiber layer 10a and/or second fiber layer 10b, and/or as a coating on the surface of the first fiber layer 10a and/or second fiber layer 10b. As such, in this embodiment, the at least one antimicrobial microcapsule 30 may accomplish the controlled release of antimicrobials contained therein, which may be particularly useful in the cases of personal protective equipment employing the fabrics described herein.

[0058] In some embodiments, in the case of viruses, even a small electric field may result from a hydrodynamically controlled rotation of the axes to align the overall electric dipoles with the applied field. This results in time-dependent electric birefringence in the virus leading to the field-induced structural changes. In this manner, such field-induced structural transitions may render the virus harmless to the wearer of the fabric device, derived in part from the controlled release of antimicrobials from the at least one antimicrobial microcapsule 30.

[0059] The following example is provided for the purpose of exemplification and is not intended to be limiting. In an exemplary embodiment, a wearable anti-pathogenic fabric device provided the following lab study results.

[0060] As shown in FIG. 4, lab studies were performed using screen printing required for printing the circuits on the fabric device to assess the electric field strength as well as the fabric's ability to denature virus simulants (e.g., exosomes and/or other protein nano-particles). FIG. 4 graphically depicts that minimal pressure drops were detected through the fabric device, which was implemented in a facemask, showing the effectiveness of the charged fabrics described herein in the destruction of all proteinaceous nano-particles. However, it should be appreciated that the fabric device can be implemented in wearable and/or non-wearable items other than facemasks, such as medical scrubs, carpets, tablecloths, bed sheets, fitted sheets, and any other fabric commonly interacted with by humans and animals.

[0061] The advantages set forth above, and those made apparent from the foregoing description, are efficiently attained. Since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

INCORPORATION BY REFERENCE

[0062] [1] Nguyen, L. C. et al. (2021). Cannabidiol Inhibits SARS-CoV-2 Replication and Promotes the Host Innate Immune Response. bioRxiv: the preprint server for biology, 2021.03.10.432967.

[0063] All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. To the extent publications and patents or patent applications incorporated by reference contradict the disclosure contained in the specification, the specification is intended to supersede and/or take precedence over any such contradictory material.

[0064] It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.