Fiber with odor control component

Abstract

The present disclosure provides a fiber and fabrics made therefrom. In an embodiment, a fiber is provided and includes an odor control composition. The odor control composition includes (A) from 85 wt % to 99.5 wt % of an olefin-based polymer and (B) from 15 wt % to 0.5 wt % of an odor suppressant. The odor suppressant includes: (i) an ionomer, (ii) particles of zinc oxide, and (iii) particles of copper oxide.

Claims

1. A fiber comprising: an odor control composition, the odor control composition comprising: (A) from 85 wt % to 99.5 wt % of an olefin-based polymer (B) from 15 wt % to 0.5 wt % of an odor suppressant comprising a blend of: (i) an ionomer; (ii) particles of zinc oxide; and (iii) particles of copper oxide.

2. The fiber of claim 1 wherein the odor control composition has a methyl mercaptan odor suppression value of greater than 45% as measured in accordance with ASTM D5504-12.

3. The fiber of claim 1, wherein the olefin-based polymer is an ethylene/alpha-olefin copolymer.

4. The fiber of claim 1 wherein the ionomer is a zinc salt of a polymer selected from the group of ethylene/methyl-methacrylic acid, ethylene/vinyl acrylic acid, ethylene/methacrylate, ethylene/n-butyl acrylic acid, and ethylene acrylic acid.

5. The fiber of claim 1, wherein the ionomer is a zinc ionomer.

6. The fiber of claim 1, wherein the particles of zinc oxide have a D50 particle size from 100 nm to 3000 nm.

7. The fiber of claim 1, wherein the particles of zinc oxide have a surface area from 1 m.sup.2/g to 9 m.sup.2/g; and a porosity less than 0.020 m.sup.3/g.

8. The fiber of claim 1, wherein the particles of copper oxide are selected from the group of copper (I) oxide and copper (II) oxide.

9. The fiber of claim 1, wherein a weight percent ratio between the ionomer (Bi) the zinc oxide (Bii) and the copper oxide (Biii) is from 150:100:1 to 2.9:2.5:1.

10. The fiber of claim 1 wherein the fiber is a mono-component fiber.

11. The fiber of claim 1 wherein the fiber is a bi-component fiber comprising: a first component that is the odor control composition; a second component that is a polymeric material different than the odor control composition.

12. The fiber of claim 11 wherein the bi-component fiber has a sheath-core structure.

13. The fiber of claim 11 wherein the first component is present in a sheath.

14. A fabric comprising: a plurality of fibers, the fibers comprising an odor control composition, the odor control composition comprising (A) from 85 wt % to 99.5 wt % of an olefin-based polymer (B) from 15 wt % to 0.5 wt % of an odor suppressant comprising a blend of: (i) an ionomer; (ii) particles of zinc oxide; and (iii) particles of copper oxide.

15. The fabric of claim 14 wherein the odor control composition has a methyl mercaptan odor suppression value of greater than 45% as measured in accordance with ASTM D5504-12.

Description

DETAILED DESCRIPTION

(1) The present disclosure provides a fiber. In an embodiment, a fiber is provided and includes an odor control composition. The odor control composition includes: (A) from 85 wt % to 99.5 wt % of an olefin-based polymer, and (B) from 15 wt % to 0.5 wt % of an odor suppressant comprising a blend of: (i) an ionomer; (ii) particles of zinc oxide; and (iii) particles of copper oxide.

(2) Fiber

(3) A “fiber” is a single, continuous strand of elongated material having a generally round cross-section and a length to diameter ratio of greater than 10.

(4) Odor Control Composition

(5) The present fiber includes an odor control composition. In an embodiment, the odor control composition includes from 85 wt %, or 90 wt % to 95 wt %, or 97 wt %, 99 wt %, or 99.5 wt % component (A) that is an olefin-based polymer. The odor control composition includes a reciprocal amount of component (B), or from 15 wt %, or 10 wt % to 5 wt %, or 3 wt %, 1 wt % or 0.5 wt % of an odor suppressant.

(6) The odor control composition has an odor suppression value from 45%, or 46%, or 50%, or 60%, or 70% to 75%, or 80%, or 85%, or 90%, as measured in accordance with ASTM D5504-12.

(7) A. Olefin-Based Polymer

(8) The present composition includes an olefin-based polymer. The olefin-based polymer can be a propylene-based polymer or an ethylene-based polymer. Non-limiting examples of propylene-based polymer include propylene copolymer, propylene homopolymer, and combinations thereof. In an embodiment, the propylene-based polymer is a propylene/α-olefin copolymer. Non-limiting examples of suitable α-olefins include C.sub.2 and C.sub.4-C.sub.20 α-olefins, or C.sub.4-C.sub.10 α-olefins, or C.sub.4-C.sub.8 α-olefins. Representative α-olefins include ethylene, 1-butene, 1-pentene, 1-hexene, 1-heptene and 1-octene.

(9) In an embodiment, the propylene/α-olefin copolymer is a propylene/ethylene copolymer containing greater than 50 wt % units derived from propylene, or from 51 wt %, or 55 wt %, or 60 wt % to 70 wt %, or 80 wt %, or 90 wt %, or 95 wt %, or 99 wt % units derived from propylene, based on the weight of the propylene/ethylene copolymer. The propylene/ethylene copolymer contains a reciprocal amount of units derived from ethylene, or from less than 50 wt %, or 49 wt %, or 45 wt %, or 40 wt % to 30 wt %, or 20 wt %, or 10 wt %, or 5 wt %, or 1 wt % units derived from ethylene, based on the weight of the propylene/ethylene copolymer.

(10) In an embodiment, the olefin-based polymer is an ethylene-based polymer. The ethylene-based polymer can be an ethylene homopolymer or an ethylene/α-olefin copolymer.

(11) In an embodiment, the ethylene-based polymer is an ethylene/α-olefin copolymer. Non-limiting examples of suitable α-olefins include C.sub.3-C.sub.20 α-olefins, or C.sub.4-C.sub.10 α-olefins, or C.sub.4-C.sub.8 α-olefins. Representative α-olefins include propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene and 1-octene.

(12) In an embodiment, the ethylene/α-olefin copolymer is an LLDPE that is an ethylene/C.sub.4-C.sub.8 α-olefin copolymer. The LLDPE has one, some, or all of the following properties:

(13) (i) a density from 0.910 g/cc to 0.930 g/cc, or from 0.915 g/cc to 0.926 g/cc; and/or

(14) (ii) a melt index from 0.5 g/10 min, or 1.0 g/10 min, or 2.0 g/10 min to 3.0 g/10 min, or 4.0 g/10 min, or 5.0 g/10 min.

(15) B. Odor Suppressant

(16) The present composition includes an odor suppressant. The odor suppressant is composed of a (Bi) an ionomer, (Bii) particles of zinc oxide, and (Biii) particles of copper oxide.

(17) (Bi) Ionomer

(18) The present composition includes an ionomer. An “ionomer,” as used herein, is an ion-containing polymer. An “ion” is an atom that has an electrical charge, either positive or negative. The ionomer has a majority weight percent (generally 85% to 90%) of repeating monomer units that are non-ionic (non-polar), and a minority weight percent (generally 10% to 15%) of repeating comonomer units that are ionic, or polar (i.e., positively-charged or negatively-charged). The positive charges of the ionic groups attract the negative charges of the ionic groups, creating ionic bonds. Ionomer resins exhibit what is known as “reversible crosslinking” behavior, i.e. when an ionomer is heated, the polymer chains have increased mobility, and the ionic bonds cannot stay intact because the positive charges and negative charges are pulled away from each other.

(19) Non-limiting examples of the monomers and comonomers from which an ionomer is derived include a copolymer of at least one alpha-olefin and at least one ethylenically unsaturated carboxylic acid and/or anhydride. Non-limiting examples of suitable alpha-olefins include ethylene, propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, and 3-methylbutene. Non-limiting examples of suitable carboxylic acids and anhydrides include acrylic acid, methacrylic acid, ethacrylic acid, maleic acid, fumaric acid, and maleic anhydride.

(20) In an embodiment, the ionomer is a copolymer of ethylene and methacrylic acid.

(21) In an embodiment, the ionomer is a copolymer of ethylene and acrylic acid.

(22) In an embodiment, the ionomer is a metal ionomer. A “metal ionomer,” as used herein, refers to a copolymer based on a metal salt of a copolymer of an alpha-olefin and an ethylenically unsaturated carboxylic acid and/or anhydride. The metal ionomer may be fully or partially neutralized by a metal ion. Non-limiting examples of metals suitable for neutralizing an ionomer include the alkali metals, i.e., cations such as sodium, lithium, and potassium; alkaline earth metals, i.e., cations such as calcium, magnesium; and transition metals such as zinc. A non-limiting example of a metal ionomer is Surlyn® 8660, which is a sodium salt of an ethylene and methacrylic acid copolymer, available from Dow-DuPont.

(23) In an embodiment, the metal ionomer is a zinc ionomer. The term “zinc ionomer,” (or “ZnI/O”) as used herein, refers to a copolymer based on a zinc salt of a copolymer of ethylene and a vinyl comonomer with carboxylic acid/or anhydride. Non-limiting examples of suitable comonomer having vinyl comonomer with an acid group include methyl/methacrylic acid, vinyl acrylic acid, methacrylate, n-butyl acrylic acid, and acrylic acid.

(24) Non-limiting examples of suitable zinc ionomer include zinc salt of ethylene/acrylic acid comonomer, zinc salt of ethylene/methyl-methacrylic acid copolymer, zinc salt of ethylene/vinyl acrylic acid copolymer, zinc salt of ethylene/methacrylate copolymer, zinc salt of ethylene/n-butyl acrylic acid copolymer, and any combination thereof.

(25) In an embodiment, the zinc ionomer is a zinc salt of ethylene/acrylic acid copolymer. Non-limiting examples of a suitable zinc ionomer include Surlyn® 9150, which is a zinc salt of an ethylene and methacrylic acid copolymer, available from Dow-DuPont.

(26) B(ii) Particles of Zinc Oxide

(27) The odor suppressant includes particles of zinc oxide (or “ZnO”). The ZnO particles have a D50 particle size from 100 nm to 3000 nm, a surface area from 1 m.sup.2/g to less than 10 m.sup.2/g, and a porosity less than 0.020 m.sup.3/g.

(28) In an embodiment, the ZnO particles have one, some, or all of the following properties (i)-(iii) below:

(29) (i) a particle size D50 from 100 nm, or 200 nm, or 300 nm, or 400 nm to 500 nm, or 600 nm, or 700 nm, or 800 nm, or 900 nm, or 1000 nm, or 2000 nm, or 3000 nm; and/or

(30) (ii) a surface area from 1 m.sup.2/g, or 2 m.sup.2/g, or 3 m.sup.2/g, or 4 m.sup.2/g to 5 m.sup.2/g, or 6 m.sup.2/g, or 7 m.sup.2/g, or 8 m.sup.2/g, or 9 m.sup.2/g; and/or

(31) (iii) a porosity from 0.005 m.sup.3/g, or 0.006 m.sup.3/g, or 0.008 m.sup.3/g, or 0.010 m.sup.3/g to 0.012 m.sup.3/g, or 0.013 m.sup.3/g, or 0.015 m.sup.3/g, or less than 0.020 m.sup.3/g.

(32) Non-limiting examples of suitable ZnO particles include 800HSA (Zinc Oxide, LLC), ZnO micropowder (US Research Nanomaterials), and Zoco102 (Zochem, Inc.).

(33) (Biii) Particles of Copper Oxide

(34) The odor suppressant also includes particles of copper oxide. The copper oxide can be either “Cu.sub.2O” (copper I oxide) or “CuO” (copper II oxide), or a mix of both. In an embodiment, the copper oxide particles have a D50 particle size from 100 nm to 3000 nm and a surface area from 1 m.sup.2/g to less than 10 m.sup.2/g. Bounded by no particular theory, it is believed that the copper oxide particles contribute as a sulfur scavenger for hydrogen sulfide and mercaptans in particular.

(35) In an embodiment, the copper oxide particles have a particle size D50 from 100 nm, or 200 nm, or 300 nm, or 400 nm to 500 nm, or 600 nm, or 700 nm, or 800 nm, or 900 nm, or 1000 nm, or 2000 nm, or 3000 nm. Non-limiting examples of suitable copper oxide particles include Cu.sub.2O 325 mesh powder and CuO 325 mesh powder available from Reade Advanced Materials.

(36) C. Composition

(37) The present composition includes (A) from 85 wt % to 99.5 wt % of the olefin-based polymer and (B) from 15 wt % to 0.5 wt % of the odor suppressant, based on total weight of the composition (hereafter, Composition 1). The odor suppressant is mixed, or otherwise blended, into the olefin-based polymer matrix, and is a blend of (Bi) an ionomer, (Bii) particles of zinc oxide, and (Biii) particles of copper oxide. The composition has an odor suppression value of greater than 45%. In an embodiment, the composition has an odor suppression value from 46%, or 49%, or 50% or 60% or 70% to 75%, or 80%, or 85%, or 90%.

(38) The ZnI/O (Bi) is present in component (B) in an amount of 1 to 90 wt % based on the total weight of component (B). The ratio of ZnO to ZnI/O (hereafter “ZnO to ZnI/O ratio”) is from 3:1 to 1:7 based on the total weight of the odor suppressant (B). The ZnO to ZnI/O ratio can be from 3:1, or 2:1, or 1:1 to 1:2, or 1:3, or 1:4, or 1:5, or 1:6, or 1:7. The particles of copper oxide (Biii) are present in component (B) in an amount of from 0.01 wt % to 30 wt % based on the total weight of component (B). The particles of copper oxide can be copper (I) oxide (Cu.sub.2O), copper (II) oxide (CuO), or a mix of both. In an embodiment, the weight percent ratio between the ionomer (Bi), the zinc oxide (Bii), and the copper oxide (Biii) is from 150:100:1 to 2.9:2.5:1 based on the total weight of the odor suppressant (B) (hereafter, Composition 1).

(39) In an embodiment, the weight percent ratio between the ionomer (Bi), the zinc oxide (Bii), and the copper oxide (Biii) is from 100:75:1 to 3:2.5:1 based on the total weight of the odor suppressant (B).

(40) In an embodiment, the present composition includes from 85 wt %, or 90 wt % to 95 wt %, or 97 wt %, 99 wt %, or 99.4 wt %, or 99.5 wt % component (A) that is an ethylene-based polymer. The present composition includes a reciprocal amount of the odor suppressant, component (B), or from 15 wt %, or 10 wt % to 5 wt %, or 3 wt %, 1 wt %, or 0.6 wt %, or 0.5 wt % odor suppressant wherein Zn I/O to ZnO to Cu.sub.2O ratio is from 12.5:12.5:1 to 2.5:2.5:1. The odor suppressant (B) can be any odor suppressant as previously disclosed herein (hereafter, Composition 2).

(41) The composition (i.e. Composition 1 and/or Composition 2) has an odor suppression value from 46%, or 50%, or 60%, or 70% to 75%, or 80%, or 85%, or 90%.

(42) While the combination of ZnO and ionomer improve OSV for methyl mercaptan, the addition of copper oxide, and in particular Cu.sub.2O, has been observed to further improve overall OSV. In fact, Applicant surprisingly discovered that the addition of from 0.01 wt % to 0.1 wt % of Cu.sub.2O to a ZnO/ionomer odor suppressing composition (based on the total weight of odor suppressant composition (B), for example) can more than double the OSV performance compared to ZnO/ionomer odor suppressing compositions that lack the copper oxide particles.

(43) D. Blend

(44) Components (A) and (B) are mixed, or otherwise blended, together to form the present composition so that the particles of zinc oxide and the particles of copper oxide are (i) dispersed within the olefin-based polymer (A) and/or (i) dispersed within the ionomer (Bi).

(45) In an embodiment, the present composition is produced as an odor control masterbatch wherein component (B) is formed by dispersing the zinc oxide particles (Bii) and the copper oxide particles (Biii) into the ionomer (Bi). The dispersing may be accomplished by physical mixing and/or melt blending of components (Bi), (Bii), and (Biii) in order to uniformly disperse the particles (zinc oxide and copper oxide) throughout the ionomer. The resultant component (B) is subsequently mixed, or otherwise blended, with the olefin-based polymer, component (A). The mixing of component (B) and component (A) may be accomplished by physical mixing and/or melt blending (hereafter odor control masterbatch 1).

(46) In an embodiment, the present composition is produced as an odor control masterbatch by dispersing the zinc oxide particles (Bii) into the ionomer (Bi). The dispersing may be accomplished by physical mixing and/or melt blending of components (Bi) and (Bii) in order to uniformly disperse the zinc particles throughout the ionomer (Bi) (“Bi-Bii blend”). The Bi-Bii blend and the copper oxide particles are subsequently added to the olefin-based polymer component (A) by physical mixing and/or melt blending to form the present composition of a homogeneous blend of olefin-based polymer (A), ionomer (Bi), zinc oxide particles (Bii), and copper oxide particles (Biii). (hereafter odor control masterbatch 2)

(47) In an embodiment, the present composition is produced as an odor control masterbatch by mixing the ionomer (Bi), the zinc oxide particles (Bii), the copper oxide particles (Biii) and the the olefin-based polymer (A). The mixing may be accomplished by physical mixing and/or melt blending of components (A), (Bi), (Bii), and (Biii) in order to uniformly disperse the ionomer (Bi), the zinc oxide particles (Bii), and the copper oxide particles (Biii) throughout the olefin-based polymer (A) (hereafter odor control masterbatch 3).

(48) In an embodiment, the present composition is produced as an odor control masterbatch by mixing the ionomer (Bi), the zinc oxide particles (Bii), and the olefin-based polymer (A). The mixing may be accomplished by physical mixing and/or melt blending of components (Bi), (Bii), and (A) in order to uniformly disperse (Bi) and (Bii) throughout (A) (hereafter, A-Bi-Bii blend). Copper oxide particles (Biii) are mixed with component (A). The mixing may be accomplished by physically mixing and/or melt blending in order to uniformly disperse the copper oxide particles (Biii) into (A) (hereafter, A-Biii blend). The A-Bi-Bii blend is then mixed with the A-Biii blend. The mixing may be accomplished by physical mixing and/or melt blending to form a homogeneous composition composed of olefin-based polymer (A), ionomer (Bi), zinc oxide particles (Bii), and copper oxide particles (Biii) (hereafter, odor control masterbatch 4).

(49) In an embodiment, the odor control masterbatch (i.e., any of odor control masterbatch 1, 2, 3, or 4) includes from 20 wt % to 30 wt % ionomer, from 20 wt % to 30 wt % particles of zinc oxide, from 5 wt % to 15 wt % particles of copper oxide, and from 30 wt % to 60 wt % LLDPE, with the aggregate of the components amounting to 100 wt % odor control composition.

(50) The present fiber may be a mono-component fiber, a homofil fiber, or a bi-component fiber.

(51) In an embodiment, the fiber is a mono-component fiber. A “mono-component fiber” (also known as “monofiber” or “homofil fiber”) is a fiber that is a continuous strand of a single material. The mono-component fiber can have either an indefinite (i.e., not predetermined) length, or a definite length (i.e., a “staple fiber” which is a discontinuous strand of material which has been cut or otherwise divided into segments of a predetermined length). A mono-component fiber is a fiber that has a single polymer region or domain, and that does not have any other distinct polymer regions (as does a bi-component fiber).

(52) In an embodiment, the fiber is a bi-component fiber. A “bi-component fiber” is a fiber that has two or more distinct polymeric components. Bi-component fibers are also known as conjugated or multicomponent fibers. The polymers are usually different from each other although two or more components may comprise the same polymer. The polymeric components are arranged in distinct zones across the cross-section of the bi-component fiber. The different components of the bi-component fiber usually extend continuously along the length of the bi-component fiber. The configuration of a bi-component fiber can be, for example, a sheath-core arrangement (in which one polymer is surrounded by another), a segmented pie arrangement, or an “islands-in-the sea” arrangement.

(53) The bi-component fiber includes a first component and a second component, wherein the first component is the odor control composition.

(54) Non-limiting examples of suitable materials for the second component include olefin-based polymer (i.e. propoylene-based polymer and ethylene-based polymer), polyesters such as polyethylene terephthalate, glycol-modified polyethylene terephthalate, polybutylene terephthalate, polylactic acid, polytrimethylene terephthalate (e.g., SORONA® available from DuPont), polyethylene 2,5-furandicarboxylate, polyhydroxybutyrate, polyamide, polylactic acid (e.g., NatureWorks available from Cargill-Dow and LACEA® from Mistui Chemical), diacid/diol aliphatic polyester (e.g. BIONOLLE® 1000 and BIONELLE® 3000 available from Showa High Polymer Company, Ltd.), and aliphatic/aromatic copolyester (e.g. EASTAR™ BIO Copolyester from Eastman Chemical or ECOFLEX™ from BASF), and combinations thereof.

(55) The polyester may have a density ranging from 1.2 g/cc to 1.5 g/cc, or from 1.35 g/cc to 1.45 g/cc.

(56) The polyester may have a molecular weight equivalent to an intrinsic viscosity (IV) from 0.5 dl/g to 1.4 dl/g, as determined according to ASTM D4603 or ASTM D2857.

(57) In an embodiment, the bi-component fiber has a sheath-core configuration whereby the core (composed of the second component) is either centrally or non-centrally located within the sheath (composed of the odor control composition), with the sheath completely surrounding the core.

(58) In an embodiment, the bi-component fibers have a segmented pie configuration. The fiber is composed of a plurality of first pie segments. The first pie segments are composed of the first component that is the odor control composition. The fiber also includes a plurality of second pie segments. The second pie segments are composed of the second component. Each pie segment extends from a center point of the fiber and extends radially outward to the outer surface of the fiber. The volume of the fiber is filled by an alternating arrangement of first pie segments and second pie segments. The alternating first pie segments and second pie segments extend along the length, or along the entire length, of the fiber, and are integral and inseparable.

(59) In an embodiment, the bi-component fibers have an “islands-in-the-sea configuration.” The fiber is composed of a plurality of cores (formed from the second component). The plurality of cores are separated from each other and are disposed in a sheath composed of the first component that is the odor control composition. The plurality of cores form discrete “islands” within the “sea,” which is the sheath. The material of the sheath (the odor control composition, first component) separates the plurality of cores (second component) from each other. The material of the sheath also surrounds, or otherwise encases, the plurality of cores. The plurality cores (“islands”) and sheath (“sea”) extend along the length, or along the entire length, of the fiber, and are integral and inseparable.

(60) The fiber (mono-component or bi-component) may be a melt-spun fiber or a meltblown fiber.

(61) In an embodiment, the fiber (mono-component or bi-component) is a melt-spun fiber. A “melt-spun fiber,” as used herein, is a fiber produced by a melt-spinning process. Melt-spinning is a process whereby a polymer melt is extruded through a plurality of fine die capillaries (such as a spinnerette, for example) as molten filaments while simultaneously applying an extensional force which reduces the density of the molten filaments. The molten filaments solidify upon cooling below their melt temperature to form fibers. The term “melt spinning” encompasses staple fiber spinning (including short spinning and long spinning) and bulk continuous filament fiber. Melt-spun fibers may be cold-drawn.

(62) In an embodiment, the fiber is a meltblown fiber. A “meltblown fiber” is a fiber formed by extruding a molten thermoplastic polymer composition through a plurality of fine, usually circular, die capillaries as molten threads or filaments into converging high velocity gas streams (e.g. air) which function to attenuate the threads or filaments to reduced density. The filaments or threads are carried by the high velocity gas streams and deposited on a collecting surface to form a web of randomly dispersed fibers with average thickness generally smaller than 10 microns.

(63) In an embodiment, the fiber has a density with a lower limit of 15 denier and an upper limit of 100 denier.

(64) In an embodiment, the fiber has a ramp-to-break from 2600 meters per minute (mpm) to 3200 mpm.

(65) In an embodiment, the fiber has a tensile strength from 30 g/5 cm, or 50 g/5 cm to 100 g/5 cm.

(66) In an embodiment, the fiber has a tenacity of at least 2 cn/Tex.

(67) The fiber may optionally include one or more other additives. Non-limiting examples of suitable additives include stabilizers, antioxidants, fillers, colorants, nucleating agents, mold release agents, dispersing agents, catalyst deactivator, UV light absorbent, flame retardant, coloring agent, mold release agent, lubricant, anti-static agent, pigment, and any combination of the foregoing.

(68) The present fiber may comprise two or more embodiments disclosed herein.

(69) Fabric

(70) The present disclosure provides a fabric. In an embodiment, the fabric includes a plurality of fibers. The fibers include an odor control component. The odor control component includes: (A) from 85 wt % to 99.5 wt % of an olefin-based polymer and (B) from 15 wt % to 0.5 wt % of an odor suppressant. The odor suppressant is composed of a blend of: (i) an ionomer, (ii) particles of zinc oxide, and (iii) particles of copper oxide.

(71) In an embodiment, the odor control composition has a methyl mercaptan odor suppression value of greater than 45% as measured in accordance with ASTM D5504-12.

(72) A “fabric” is a woven structure or a non-woven structure formed from individual fibers or yarn.

(73) A “woven fabric” is an assembly of interlaced fibers (or yarns). The woven fabric is fabricated by weaving two distinct sets of fibers—the warp fibers (or “warp”) and the weft fibers (or “weft”). The warp is the set of fibers in place in a loom before the weft is introduced. The weft is the set of fibers introduced during the weaving process. The lengthwise or longitudinal warp fibers are held stationary in tension on a frame or a loom while the transverse weft fibers are drawn through and inserted over-and-under the warp. The warp and the weft are interlaced at right angles to form the fabric. Non-limiting examples of interlaced woven fabric structures include lock-stitch knitted fabric.

(74) As used herein a “non-woven” or a “non-woven fabric” or “non-woven material” is an assembly of fibers (for example, sheath-core, segmented pie, or “islands-in-the-sea”) held together in a random web such as by mechanical interlocking or by fusing at least a portion of the fibers. The non-woven fabrics according to the present disclosure may be fabricated via different techniques. Such methods include, but are not limited to, spunbond process, melt-blowing process, carded web process, air laid process, thermo-calendaring process, adhesive bonding process, hot air bonding process, needle punch process, hydroentangling process, electrospinning process, and combinations thereof.

(75) In an embodiment, the present fabric is produced by way of a spunbond process. In a spunbond process, the fabrication of non-woven fabric includes the following steps: (a) extruding strands of the odor control composition from a spinneret; (b) quenching the strands with a flow of air which is generally cooled in order to hasten the solidification of the molten strands; (c) attenuating the filaments by advancing the filaments through the quench zone with a draw tension that can be applied by either pneumatically entraining the filaments in an air stream or by winding the filaments around mechanical draw rolls of the type commonly used in the textile fibers industry; (d) collecting the drawn strands into a web on a foraminous surface, e.g. moving screen or porous belt; and (e) bonding the web of loose strands into the non-woven fabric. Bonding can be achieved by a variety of means including, but not limited to, thermo-calendaring process, adhesive bonding process, hot air bonding process, needle punch process, hydroentangling process, and combinations thereof.

(76) The spunbond non-woven fabric can be formed into multilayer or laminate structures. Such multilayer structures comprise at least two or more layers, wherein at least one or more layers are spunbond non-woven fabrics according to the present disclosure, and one or more other layers are selected from one or more melt blown non-woven layers, one or more wet-laid non-woven layers, one or more air-laid non-woven layers, one or more webs produced by any non-woven or melt spinning process, one or more film layers, such as cast film, blown film, one or more coating layers derived from a coating composition via, for example, extrusion coating, spray coating, gravure coating, printing, dipping, kiss rolling, or blade coating. The laminate structures can be joined via any number of bonding methods; thermal bonding, adhesive lamination, hydroentangling, needle punching. Structures can range from S to SX, or SXX, or, SXXX, or SXXXX, or SXXXXX, whereby the X can be a film, coating, or other non-woven material in any combination. Additional spunbond layers can be made from the ethylene-based polymer composition, as described herein, and optionally in combinations with one or more polymers and/or additives.

(77) The spunbond non-woven fabric can be used in various end-use applications including, but not limited to, hygiene absorbent products such diapers, feminine hygiene articles, adult incontinence products, wipes, bandages and wound dressings, and disposable slippers and footwear, medical application such isolation gowns, surgical gowns, surgical drapes and covers, surgical scrub suits, caps, masks, and medical packaging.

(78) In the case of staple or binder fibers, the present fibers composed of the odor control composition can be mixed with a variety of other fibers including synthetic fibers such as polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), or natural fibers such as cellulose, rayon, or cotton. Such fibers can be wet laid, air laid or carded into a non-woven web. The non-woven web can then be laminated to other materials.

(79) In an embodiment, the plurality of fibers of the non-woven fabric have a diameter from 0.2 microns to 10 microns.

(80) In an embodiment, the present fiber can be used with a carding line to produce fabric.

(81) By way of example, and not limitation, some embodiments of the present disclosure will now be described in detail in the following Examples.

EXAMPLES

(82) Materials used in the examples are provided in Table 1 below.

(83) TABLE-US-00001 TABLE 1 Material/Description Properties Source Ethylene/octene 0.9 melt flow rate (I2) (g/10 min) The Dow (LLDPE 1) 0.923 g/cc Chemical Company ZnO 800HSA ZnO D50 particle size 3000 nm; density = 5.61 g/cc; Zinc Oxide, LLC Zinc Oxide Porosity 0.0131 g/m.sup.3, surface area 4.46 m.sup.2/g micro-powder (ZnO-1) Zinc Oxide ZnO D50 particle size 500 nm; density = 5.61 g/cc; 500 nm (US micro-powder Porosity 0.008 m.sup.3/g, surface area 3.36 m.sup.2/g Research (ZnO-2) Nanomaterials) Zoco102 ZnO D50 particle size 200 nm; density = 5.61 g/cc; Zochem, Inc. Zinc Oxide Porosity 0.012 m.sup.3/g, surface area 4.4 m.sup.2/g micro-powder (ZnO-3) Ampacet 110069 70 wt % TiO.sub.2 in Carrier Resin LLDPE Ampacet White PE MB (MI 2.3, d- 0.917 g/cc) Corporation Titanium dioxide Masterbatch Specific gravity: 2.03 (TiO.sub.2) Masterbatch Surlyn ® 9150 Ethylene/Methacrylic Acid Copolymer, zinc cation Dow-DuPont (Zinc Ionomer) Density 0.970 g/cc, melt flow 4.5 g/10 min Cu.sub.2O 325 mesh Reade Advanced Materials

(84) 1. Films

(85) Master batch processing. Two master batches were prepared to ease feeding the odor suppressing compositions into a subsequent film line. The master batches were prepared on a Coperion ZSK 26 twin screw extruder using a general purpose screw. The residence time of material was controlled by the screw design, feed rate of 20 lbs/hr, and a screw speed of 300 revolutions per minute (RPM). No oil was injected. There was no side arm feeder. No vacuum was pulled. The compounded material was sent through a water bath before being cut by a strand cut pelletizer. After collection the pelletized materials were N.sub.2 purged, then sealed in an aluminum bag.

(86) The composition of the first master batch (MB1) was 50 wt % LLDPE 1, 25 wt % ZnO, and 25 wt % Surlyn 9150. The composition of the second master batch (MB2) was 90 wt % LLDPE 1 and 10 wt % Cu.sub.2O. Examples and counter example formulations were generated using the appropriate amount of pure LLDPE 1, MB1 and MB2 to achieve the target weight % of each composition listed.

(87) TABLE-US-00002 TABLE 2 Blown film line process parameters Films without Films containing Parameter Units TiO.sub.2 MB TiO.sub.2 MB Takeoff m/min 15 15 Layflat cm 23.5 23.5 Frostline cm 14 14 B.U.R ratio 2.5 2.5 Die gap mm 2.0 2.0 Melt temperature - Ext. A ° C. 218 218 Melt temperature - Ext. B ° C. 226 226 Melt temperature - Ext. C ° C. 215 215 RPM - Ext. A rpm 51 51 RPM - Ext. B rpm 50 50 RPM - Ext. C rpm 32 32 Total Output kg/hr 8.8 8.8 Film Total Thickness mm 0.023 0.056

(88) 2. Odor Suppression

(89) The compositions of comparative samples (CS) and inventive examples (IE) are shown in Table 3.

(90) The odor suppression values (OSV) for are provided in Table 3 below. Concentrations were measured using the reference sample (CS 1) as the calibration standard after two days, concentrations in the reference sample might change after two days, so the concentrations in the samples should be considered as the relative change to the reference sample.

(91) TABLE-US-00003 TABLE 3 Odor Suppression Values and Blown Film Properties OSV of Methyl Mercaptan Methyl Mercaptan Sample Components OSV (%) CS 1 99% LLDPE 1 + 1% TiO.sub.2 MB 12 CS 2 97.5% LLDPE 1 + 2.5% TiO.sub.2 MB 2 CS 3 99% LLDPE 1 + 0.5 wt % ZnO + 0.5 wt % Zinc 28 Ionomer CS 4 97.5% LLDPE 1 + 1.25 wt % ZnO + 1.25 wt % 44 Zinc Ionomer IE 1 97.4% LLDPE 1 + 1.25 wt % ZnO + 1.25 wt % 80 Zinc Ionomer + 0.1% Cu.sub.2O IE 2 98.9% LLDPE 1 + 0.5 wt % ZnO + 0.5 wt % 64 Zinc Ionomer + 0.1% Cu.sub.2O IE 3 99.4% LLDPE 1 + 0.25 wt % ZnO + 0.25 wt % 49 Zinc Ionomer + 0.1% Cu.sub.2O Zinc ionomer used in Table 3 is Surlyn 9150 *TiO.sub.2 MB—titanium dioxide masterbatch 70 wt % TiO.sub.2 powder in 30 wt % LLDPE carrier, added for white color

(92) In Table 3, component amounts for each sample yield 100 wt % total sample composition. It can readily be observed that the ZnO/zinc ionomer combination is effective in improving OSV as compared to a composition that lacks any odor suppressing technology by comparing the OSV for CS 3 (28%) to the OSVs for CS 1 & 2 (12% and 2% respectively). However, it is surprising to see that although Cu.sub.2O is added at very low loadings as part of the present odor suppressant (i.e., at <10% of the combination of ZnO, zinc ionomer, and Cu.sub.2O in IE2), it can further improve the OSV to 64% as compared to CS 3 OSV of 28%, (i.e., the sample with zinc ionomer and ZnO, and without Cu.sub.2O present). The addition of Cu.sub.2O unexpectedly allows for a reduction in ZnO/zinc ionomer concentrations by 50% in the composition while maintaining an OSV that is almost 50% higher than the ZnO/zinc ionomer combination that does not have Cu.sub.2O present, as can be observed by comparing the OSV for 1E3 (49%) to the OSV of CS3 (28%). It is further observed that the ZnO/zinc ionomer combination still exhibits a significant influence on OSV in that higher loadings of these materials in combination with 0.1 wt % Cu.sub.2O exhibits the highest OSV of the inventive examples 1E1 (80%) and IE2 (64%) shown in Table 3.

(93) It is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims.