Fibrous antimicrobial materials, structures, and barrier applications

Abstract

Fibrous antimicrobial materials for use in structures and barrier applications, such as face masks and wound dressings, have been developed from antimicrobial polymeric materials. The fibrous antimicrobial materials also are particularly suitable for use in air and water filtration. The antimicrobial polymeric materials are prepared from solid solutions of antimicrobial bisguanide compounds blended with certain thermoplastic polymers. The antimicrobial polymeric materials may be extruded into fibers or used in the particulate form for preparation of the nonwoven antimicrobial materials. The antimicrobial bisguanide compound, such as chlorhexidine, are distributed at the molecular level within at least one thermoplastic polymer, such as a polyolefin in which the antimicrobial bisguanide compound is soluble, to form a miscible blend. Methods for their formation and use also are provided.

1 . A bicomponent antimicrobial fiber comprising:
 a first region of the fiber comprising a miscible blend of an antimicrobial bisguanide compound and at least one thermoplastic polymer; and   a second region of the fiber comprising a second polymer,   wherein at least a portion of the first region of the fiber is disposed on the exterior surface of the fiber.   
     
     
         2 . The fiber of  claim 1 , wherein the second region is a core of the fiber and the first region is a coating on the core. 
     
     
         3 . The fiber of  claim 1 , wherein the antimicrobial bisguanide compound comprises chlorhexidine. 
     
     
         4 . The fiber of  claim 1 , wherein the at least one thermoplastic polymer comprises a polyolefin. 
     
     
         5 . The fiber of  claim 1 , wherein the second polymer comprises a polyolefin. 
     
     
         6 . The fiber of  claim 1 , wherein the miscible blend is from about 1% to about 25% by weight antimicrobial bisguanide compound. 
     
     
         7 . A fiber of  claim 1 , wherein the fiber is in a woven or nonwoven material. 
     
     
         8 . A barrier structure comprising:
 at least one layer of a woven or nonwoven fibrous antimicrobial material which comprises an antimicrobial polymeric material comprising a miscible blend of an antimicrobial bisguanide compound and at least one thermoplastic polymer, the miscible blend being from about 1% to about 25% by weight antimicrobial bisguanide compound,   wherein the at least one layer is spray impact and fluid penetration resistant.   
     
     
         9 . The barrier structure of  claim 8 , wherein the woven or nonwoven fibrous antimicrobial material comprises a bicomponent antimicrobial fiber. 
     
     
         10 . The barrier structure of  claim 8 , wherein the antimicrobial bisguanide compound comprises chlorhexidine. 
     
     
         11 . The barrier structure of  claim 8 , wherein the at least one thermoplastic polymer comprises a polyolefin. 
     
     
         12 . The barrier structure of  claim 8 , wherein the miscible blend is from about 5% to about 15% by weight antimicrobial bisguanide compound. 
     
     
         13 . The barrier structure of  claim 8 , wherein the fibrous antimicrobial material further comprises particles of the antimicrobial polymeric material dispersed throughout the fibrous antimicrobial material. 
     
     
         14 . The barrier structure of  claim 8 , wherein the fibrous antimicrobial material is porous. 
     
     
         15 . A protective article comprising the barrier structure of  claim 8 , wherein the protective article is a garment including a gown, robe, face mask, head cover, shoe cover, or glove. 
     
     
         16 . A protective article comprising the barrier structure of  claim 8 , wherein the protective article is a surgical drape, surgical fenestration or cover, drape, sheet, linen, padding, or gauze dressing. 
     
     
         17 . A protective article comprising the barrier structure of  claim 8 , wherein the protective article is a wipe cloth or sponge. 
     
     
         18 . An antimicrobial face mask comprising:
 a fibrous antimicrobial material which comprises an antimicrobial polymeric material and comprising a miscible blend of an antimicrobial bisguanide compound blended with at least one thermoplastic polymer, the miscible blend being from about 1% to about 25% by weight antimicrobial bisguanide compound, wherein the fibrous antimicrobial material is woven or nonwoven; and   a means for securing the fibrous material over a person's mouth and/or nose.   
     
     
         19 . The antimicrobial face mask of  claim 18 , wherein the antimicrobial bisguanide compound comprises chlorhexidine. 
     
     
         20 . The antimicrobial face mask of  claim 18 , wherein the at least one thermoplastic polymer comprises a polyolefin. 
     
     
         21 . An antimicrobial wound dressing comprising:
 a fibrous antimicrobial material which comprises an antimicrobial polymeric material comprising a miscible blend of an antimicrobial bisguanide compound blended with at least one thermoplastic polymer, the miscible blend being from about 1% to about 25% by weight antimicrobial bisguanide compound, the fibrous antimicrobial material being woven or nonwoven; and   a means for securing the fibrous antimicrobial material over a wound of a human or animal.   
     
     
         22 . The antimicrobial wound dressing of  claim 21 , wherein the antimicrobial bisguanide compound comprises chlorhexidine. 
     
     
         23 . The antimicrobial wound dressing of  claim 21 , wherein the at least one thermoplastic polymer comprises a polyolefin. 
     
     
         24 . A device for antimicrobial treatment of a fluid comprising a filter core with at least one fibrous antimicrobial material wound around the filter core, wherein the fibrous antimicrobial material comprises an antimicrobial polymeric material comprising a miscible blend of an antimicrobial bisguanide compound blended with at least one thermoplastic polymer, the miscible blend being from about 1% to about 25% by weight antimicrobial bisguanide compound. 
     
     
         25 . The device of  claim 24 , wherein the antimicrobial bisguanide compound comprises chlorhexidine. 
     
     
         26 . The device of  claim 24 , wherein the at least one thermoplastic polymer comprises a polyolefin. 
     
     
         27 . The device of  claim 24 , wherein the at least one fibrous antimicrobial material comprises a bicomponent antimicrobial fiber. 
     
     
         28 . The device of  claim 24 , wherein the fibrous antimicrobial material has a linear density from about 0.1 to about 30 denier.