REPLACEABLE CURTAINS

Abstract

An improved removable curtain is described. One embodiment includes a curtain comprising an upper section; and a lower section, wherein at least one of the upper section or the lower section has anti-microbial properties, and wherein the lower section is connected to the upper section with a quick change mechanism such as a zipper or snaps. The anti-microbial properties of the curtain may be from anti-microbial fibers incorporated into the curtain, from an anti-microbial coating, or from both.

Description

PRIORITY

The present application is a continuation-in-part of commonly owned and assigned prior U.S. application Ser. No. 13/335,349, filed Dec. 22, 2011, which claims the benefit of commonly owned and assigned U.S. Provisional Application No. 61/426,618, filed Dec. 23, 2010, entitled “Fibers with Improving Anti-Microbial Performance,” each of which are each incorporated herein by reference.

FIELD OF THE INVENTION

The present invention relates to replaceable curtains, including hospital privacy curtains.

BACKGROUND

The basic features of replaceable curtains used in hospitals have not changed for many years. A typical curtain includes some means of connecting the top of the curtain to a guide track or rail allowing the curtain to be hung around, or across, a designated area. For example, hospital curtains commonly include a ventilation mesh at the top and swivel connectors to hang the curtain from a track to be able to pull the curtain around the patient or across a room opening.

One of the difficulties with replaceable curtains, such as hospital curtains, is the difficulty and time required to change the curtains. For example, hospital curtains often weigh 3-10 pounds each and are very difficult and time consuming to change, often requiring 1-2 hours resulting in infrequent changing of contaminated curtains.

It is widely believed that environmental contamination makes an important contribution to hospital infection. (See Journal of Hospital Infection, 2007 June; 65 Suppl 2:50-4.) Published literature in peer-reviewed medical journals reveals that fabrics in the healthcare setting (e.g., privacy curtains, upholstery, bedding) can serve as reservoirs of potential pathogens. (Journal of Clinical Microbiology, 2000 February; 38(2):724-6.) Privacy curtains in particular have been highlighted as potential problems as they are frequently touched by care-givers, patients, and others throughout the day, but are still laundered infrequently. (Infection Control and Hospital. Epidemiology, 2008 November; 29(11):1074-6.) PurThread Technologies funded a study at the University of Iowa in 2011 that studied both the frequency of conventional privacy curtain contamination as well as the speed with which the contamination takes place. Investigators revealed that 95% of the conventional curtains were contaminated at least once during the study period, and that 92% of previously clean curtains were contaminated within one week. (Ohl M. et al. 51st Interscience Conference on Antimicrobial Agents and Chemotherapy, 2011; Chicago.)

Although present devices and methods are functional, they are not sufficiently effective or otherwise satisfactory, especially in a busy, hospital environment. There is a need for curtains that can be changed more easily and that do not spread bacteria. Accordingly, a system and method are needed to address the shortfalls of present technology and to provide other new and innovative features.

SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention that are shown in the drawings are summarized below. These and other embodiments are more fully described in the Detailed Description section. It is to be understood, however, that there is no intention to limit the invention to the forms described in this Summary of the Invention or in the Detailed Description. One skilled in the art can recognize that there are numerous modifications, equivalents and alternative constructions that fall within the spirit and scope of the invention as expressed in the claims.

In one embodiment, the present invention comprises a curtain comprising an upper section; and an anti-microbial lower section, wherein the anti-microbial lower section is connected to the upper section with a quick change mechanism. The quick change mechanism may include a zipper—such as a large-tooth zipper, snaps, a hook and loop fastener (e.g., Velcro®), buttons, or other options. The anti-microbial lower section may comprise an anti-microbial fiber or the lower section may have anti-microbial properties from an anti-microbial coating, or both. Due to the repeated launderings of the lower section, in a preferred embodiment the anti-microbial fiber comprises a polymer; an anti-microbial agent; and a dispersion liquid, wherein the dispersion liquid is embedded in the anti-microbial fiber. In some embodiments, the upper section may also have anti-microbial properties. This may be due to an anti-microbial coating (such as a metallic anti-microbial coating) or anti-microbial fiber. The quick change mechanism comprises a zipper.

In another embodiment, the invention may comprise a curtain comprising an anti-microbial upper section; and a lower section, wherein the lower section is connected to the anti-microbial upper section with a quick change mechanism. In some embodiment, the lower section may be an anti-microbial lower section. The anti-microbial properties of the curtain may come from anti-microbial fibers incorporated into the curtain, from an anti-microbial coating on the curtain, from a combination of both, or from other anti-microbials.

In yet another embodiment, the invention may comprise a curtain comprising: an upper section, wherein the upper section comprises anti-microbial fibers; and a lower section, wherein the lower section comprises anti-microbial fibers, wherein the lower section is connected to the upper section via a quick change mechanism. In a preferred embodiment, the anti-microbial fibers comprise: a polymer; an anti-microbial agent; and a dispersion liquid, wherein the dispersion liquid is embedded in the anti-microbial fiber.

As previously stated, the above-described embodiments and implementations are for illustration purposes only. Numerous other embodiments, implementations, and details of the invention are easily recognized by those of skill in the art from the following descriptions and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Various objects and advantages and a more complete understanding of the present invention are apparent and more readily appreciated by reference to the following Detailed Description and to the appended claims when taken in conjunction with the accompanying Drawing wherein:

FIG. 1 illustrates a standard hospital curtain consistent with the prior art;

FIG. 2 illustrates a replaceable curtain consistent with one embodiment of the present invention;

FIG. 3 illustrates a large tooth zipper that may be used in embodiments of the present invention;

FIG. 4 illustrates a replaceable curtain with the lower section removed but with the upper section (in this case comprising a mesh) still attached to a hanging mechanism;

FIG. 5 illustrates a type of snap that may be used in embodiments of the present invention;

FIG. 6 illustrates a type of compression snap that may be used in embodiments of the present invention;

FIG. 7 illustrates a quick change mechanism consistent with one embodiment of the present invention;

FIG. 8 includes a flow chart for an exemplary method of producing fibers that may be used consistent with an embodiment of the present invention; and

FIGS. 9A and 9B are illustrations of an anti-microbial fiber that may be used in embodiments of the present invention.

DETAILED DESCRIPTION

As a partial solution to the issues with replaceable curtains, it is possible to design a replaceable curtain that includes an upper section that connects to a guide rail or track, and a removable lower section connected to the upper section, wherein the upper and lower sections are connected with a quick change mechanism such as a zipper. This solution, however, does not adequately address at least two issues. First, in practice it is not realistic for the removable lower section to be changed after every use. Given the frequency at which patients, healthcare workers, and other individuals who may come in contact with a curtain, the curtain needs additional protection beyond the fact that the lower section can be changed more frequently. Second, although the removable lower section can be changed more easily, and more frequently (because the quick change mechanism provides a faster option for curtain removal and replacement), the top section would not be removed often as it faces many of the same difficulties as in the prior art. In fact, the upper section may be removed less frequently than in the prior art because the comparative ease of just removing the lower section. Accordingly, a design would result in leaving an upper section that would still be changed infrequently.

The present invention provides improvements to known replaceable curtains, including hospital curtains. In a preferred embodiment, the present invention includes a replaceable curtain with an upper section that is designed for connection with a hanging mechanism, such as a guide track, curtain rod, or rail, and an anti-microbial lower section connected to the upper section, wherein the upper and lower sections are connected with a quick change mechanism such as a zipper. In one embodiment, the anti-microbial lower section comprises anti-microbial fibers to provide its anti-microbial properties. In another embodiment, the anti-microbial lower section may be treated, such as with an anti-microbial coating, in order to provide its anti-microbial properties. This anti-microbial lower section may be combined with any type of upper section, including the anti-microbial upper section discussed below.

Depending on the environment, and design of the curtain, the upper section may not be easily reachable in normal use and may not need anti-microbial properties. However, in many environments (and due to likely contact with the upper section while changing out the lower section) the upper section may also be exposed to contamination. Accordingly, in some embodiments the present invention includes a replaceable curtain with an anti-microbial upper section that is designed for connection with a hanging mechanism, such as a guide track, curtain rod, or rail, and a lower section connected to the upper section, wherein the upper and lower sections are connected with a quick change mechanism such as a zipper. The anti-microbial upper section may be treated with an anti-microbial coating and/or may comprise anti-microbial fibers for the destruction of pathogens such as bacteria, mold, mildew, fungus, spores, and viruses.

In embodiments that include an anti-microbial upper section, it is preferred (and recommended) that the lower section also be an anti-microbial lower section because the lower section is easily contaminated. However, it is not required. Because the lower section may be changed more easily and more frequently than the anti-microbial upper section, and given the higher cost of anti-microbial fabrics as compared to typical fibers, some embodiments of the present invention need not include anti-microbial fibers in the lower section.

FIG. 1 illustrates a standard hospital curtain commonly used in hospitals and other healthcare facilities. FIG. 1 shows a hanging mechanism 2000—in this case a guide track 2100 built into the ceiling to which hooks 2200 are used to secure the curtain 1000. The upper portion of the curtain shows an open mesh, in accordance with fire codes, for ventilation. Because hospital rooms are positively ventilated, the mesh is needed to allow air to escape from the room without the curtain blowing up in a vertical motion. The bottom portion of the hospital curtain is typically comprised of an opaque fabric in order to provide for privacy.

Referring next to FIG. 2, there is an illustration of an exemplary embodiment consistent with the present invention. The exemplary replaceable curtain in FIG. 2 includes an upper section 1100 which is configured for connection with a hanging mechanism 2000 such as a guide track, hanging rod, or rail. In one embodiment, the upper section 1100 may include pre-configured holes or grommets that permit connection to the hanging mechanism (e.g., guide track, hanging rod, rail) using a clip or hook. In another embodiment, the hanging mechanism 2000 could be pre-configured to incorporate hardware that is designed to directly connect with the upper section 1100 of the curtain.

Consistent with the present invention, the upper section 1100 further includes a quick change mechanism 1300 configured to detachably connect the upper section 1100 to the lower section 1200 of the replaceable curtain. As discussed above, at least one of the upper section or lower section, and preferably both, are anti-microbial sections.

In one embodiment, the quick change mechanism 1300 includes a zipper 1310 that allows for faster, and easier, connection and removal of the lower section 1200 of the replaceable curtain 1000. FIG. 3 shows an exemplary large-tooth zipper that may be used consistent with the present invention. The zipper in FIG. 3 has large intermeshing teeth 1311 (also known as elements) made of durable plastic (typically nylon) with a slider 1312 (also referred to as an operator or traveler) to open and close the zipper. This type of zipper is designed to withstand multiple operations including a wet environment (such as laundering). In one example, the large-tooth zipper could be similar or the same as a plastic boat zipper, such as the #10 plastic boat zipper made by YKK.

As shown in FIG. 4, in some embodiments the slider 1312 of the zipper 1310 remains on the upper section 1100 of the curtain. This prevents the slider 1312 from having to go through as frequent launderings. It is noted that as used herein, the term quick change mechanism may refer to the complete assembly or the component parts used to detachably connect the upper section 1100 to the lower section 1200. For example, in the embodiments in FIGS. 3 and 4 quick change mechanism 1100 may refer to the portion of the teeth of the zipper that are on the lower section 1200 of the curtain. In the embodiments in FIGS. 3 and 4, quick change mechanism 1300 may refer to both the portion of the teeth on the upper section 1100 of the curtain, and the slider 1312. In the embodiments in FIGS. 3 and 4, quick change mechanism 1300 may refer to the intermeshing teeth on the upper section 1100 and lower section 1200 of the curtain and the slider 1312. For example, those of skill in the art will understand that a lower section 1100 of a replaceable curtain which includes a quick change mechanism 1300 should include a lower portion of a curtain that includes the zipper elements (or teeth) that are configured to connect with zipper elements (or teeth) on a separate portion of the curtain.

In another embodiment, the quick change mechanism 1300 may be a snap 1320. FIG. 5 shows an exemplary snap design 1320 that may be used as the quick change mechanism in the present invention. The snaps 1320 in FIG. 5 are designed for repeated use, wherein the male portion 1321 of the snap is held in a receiving socket portion 1322 of the snap. The corresponding portions (1321, 1322) of the snaps can be mechanically attached to the upper section 1100 of the curtain and the lower section 1200 of the curtain. For example, in one embodiment of the present invention, an upper section 1100 of the curtain comprising a quick change mechanism may include a mesh section of the curtain with receiving socket portions 1322 of a snap assembly spread along the length. In a further embodiment, compression snaps, such as those illustrated in FIG. 6, can be attached to the upper section 1100 and lower section 1200 of the curtain with a compression tool.

In another embodiment, as shown in FIG. 7, the quick change mechanism 1300 may include a channel 1341 on one side and an extrusion profile 1342 on the other side, wherein the extrusion is designed to slide within the channel in a horizontal direction, but is prevented from moving in a vertical direction. Due the friction in this type of situation, it may be preferential to include a handle attached to the lower section 1200 in order to pull the curtain into the proper position. Numerous alternative cross-section shapes will be readily available to those of skill in the art. In yet further embodiments, the quick change mechanism may comprise Velcro® between the upper section 1100 and lower sections 1200 of the curtain. Those of skill in the art will recognize further quick change mechanisms 1300 consistent with present invention.

In a preferred embodiment of the present invention the replaceable curtain 1000 is a hospital curtain used for privacy and separation between patients. The upper section 1100 of the curtain may be comprised of a large mesh in order to allow for positive ventilation of a hospital room while minimizing curtain movement. Because most contamination of hospital curtains is due to contact contamination that occurs during typical use—e.g., contamination caused by hospital staff grabbing the curtain to open or shut the curtain—the upper section 1100 of the curtain is not exposed to as much contamination and does not require as frequent changes. In contrast, the lower section 1200—which is typically comprised of a much tighter weave in order to provide patient privacy—should be changed frequently in order to ensure safe, sanitary conditions. In this embodiment, the change between the large mesh and the tight weave offers a natural transition point for the zipper quick change mechanism. This is further advantageous because while the large mesh makes up a lower percentage of the volume of the curtain, it can account for a larger portion of the cost.

It is noted, however, that the position of the quick change mechanism 1300 does not have to be at a transition point between two different fabric types. Nor does the upper section 1100 have to include any fabric portion of the replaceable curtain. In one embodiment, the upper section 1100 may be comprised entirely of one portion of the quick change mechanism 1300 used to connect to the lower section of the curtain. For example, the upper section 1100 may be comprised of the tape portion 1313 of a zipper, the elements 1311 (or teeth), and (optionally) the slider 1312. In this embodiment, the tape portion 1313 would include means for connecting to the hanging mechanism (e.g., a guide track, hanging rod, or rail).

It is further noted that in order to reduce the risk of contamination caused by transfer from the replaceable curtain, the upper section 1100 and lower section 1200 may be comprised of anti-microbial fibers that have been infused with an anti-microbial agent and a dispersion liquid, and which exhibit improved performance with repeated launderings. This is of particular importance for an anti-microbial lower section 1200 because the lower section 1200 will be changed and laundered more frequently so the anti-microbial properties should not degrade quickly over time.

Referring now to FIG. 8, there is an illustration of a method for generating the fibers with improved anti-microbial properties and characteristics. At Step 100 a mixture is created, the mixture including a polymer, an anti-microbial alloy powder, and a dispersion liquid. As used herein, a polymer refers to a compound suitable for fiber and fabric generation including, but not limited to, a thermoplastic polymer, polyester, nylon, rayon, polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), co-PET, polylactic acid (PLA), and polytrimethylene terephthalate (PTT). In a preferred embodiment, the polymer may be PET, for its strength, longevity during washing, ability to be made permanent press, and ability to be blended with other fibers. In another embodiment, the polymer may be Nylon 6,6 may. Nylon is known to be a stronger fiber than PET and exhibits a non-drip burning characteristic that is beneficial in military applications, and is more hydrophilic than PET.

An anti-microbial agent may be any suitable anti-microbial, such as silver, copper, zinc and/or gold in metallic forms (e.g., particulates, alloys and oxides), salts (e.g., sulfates, nitrates, acetates, citrates, and chlorides) and/or in ionic forms. In some embodiments, the anti-microbial agent is an anti-microbial alloy powder with a particle size of less than of less than 3 μ. (micron) and preferable between 0.7 and 2μ.

The anti-microbial agent may be comprised of an anti-microbial powder formed from alloys of one or more metals that exhibit anti-microbial properties. Anti-microbial alloys made of two or more element alloys can have superior anti-microbial properties compared to one element particles. Embodiments of the present invention can include an anti-microbial alloy which includes a combination of: transition metals of the periodical table such as chromium, manganese, iron, cobalt, nickel, copper, zinc, silver, and/or gold; rare earth metals from the lanthanides such as cerium, neodymium, samarium, gadolinium, terbium, dysprosium, holmium, and/or erbium; and/or alkali metals such as lithium, sodium, potassium, magnesium, and/or calcium. The combination may comprise a binary combination, ternary combination, quaternary combination, or even higher order combination. The selected alloys, and the relative percentages of each alloy, may be selected depending on the intended use of the fiber or other selection criteria. Different combinations will result in different anti-microbial classes that may be used with the present invention.

For example, different classes of anti-microbial alloys have been produced by QuarTek Corporation as described in various patent applications (U.S. Provisional Application Nos. 60/888,343 and 60/821,497 filed on Aug. 4, 2006 and U.S. patent application Ser. Nos. 11/868,475 filed on Oct. 06, 2007, 11/858,157 filed on Sep. 20, 2007, and 11/671,675 filed on Feb. 6, 2007). These anti-microbial alloys have been produced by varying the elemental composition of the alloys, the elemental ratios within the same alloy, or by changing parameters in the synthesis process. As needed, these anti-microbial alloys may be synthesized in various size ranges from 5 nm to 2000 nm, preferably less than 1000 nm, or even within the range of 100-500 nm.

A dispersion liquid, as introduced above, is a liquid additive used to disperse the anti-microbial agent and assist with the combination of the anti-microbial agent and the polymer. This allows for more uniform dispersion of the anti-microbial agent throughout the eventual fiber. Further, this combination “welds” the anti-microbial within the polymer to help prevent or limit the active anti-microbial ingredients from being washed from the fiber. The dispersion liquid itself is embedded in the fiber during manufacture but at least a portion of the dispersion liquid dissolves from the fiber during treatments, or launderings, creating cracks and/or striations in the fiber and further exposing the anti-microbial agent in the fiber to any pathogens. For example, FIGS. 9A-9B show illustrations of an anti-microbial fiber consistent with embodiments of the present invention. FIG. 9A illustrates a fiber just after manufacture, while FIG. 9B illustrates cracks and/or striations in the fiber after treatments, or launderings, that dissolve or otherwise remove some of the dispersion liquid. These cracks or striations in the fiber further expose the anti-microbial agent embedded in the fiber to any surrounding pathogens.

Exemplary dispersion liquids include anti-stats, anionic anti-stat oils, phosphate esters, vegetable oils, and other liquids. In one embodiment, the dispersion liquid may be comprised of predominately a phosphate ester with 10-30% water. In another embodiment, the dispersion liquid may be comprised of certain waxes, such as Montan Wax that operates to carry powders into fiber. The selection of the dispersion liquid may also relate to other desired characteristics of the fiber, including the desired tenacity, color, feel, etc.

Referring again to Step 100 in FIG. 8, in one embodiment creating the mixture may comprise first adding the dispersion liquid to polymer pellets in a tumbling mixer (similar to a concrete mixer) and then adding the anti-microbial agent. In another embodiment, the anti-microbial agent may be first mixed with the dispersion liquid and then added to the polymer. In another embodiment, the dispersion liquid may be sprayed on the polymer and an anti-microbial alloy powder mixed in as the dispersion liquid makes the polymer chips tacky and the powder adheres uniformly. Further variations and methods of combining the dispersion liquid, polymer and anti-microbial will be understood by those of skill in the art in view of the present disclosure.

As indicated by Step 200 in FIG. 9, once the mixture is created, the mixture may be extruded in order to create a fiber. The extrusion process itself depends on the temperature of the mixture being sufficiently high to melt the mixture. A melting step may be a separate step in FIG. 9 or it may be part of either the mixing process or the extruding process. When the mixture is at a sufficiently high temperature, the mixture may be extruded using conventional mechanisms such as a spinneret. The fiber may then be drawn, crimped, cut and spun into a yarn or other fabric depending on the intended end use.

In one embodiment, fibers consistent with the present invention will be between 0.5 to 20 denier, and preferably between 0.5 and 4.5 denier. The length of the fiber may vary depending on the intended use of the fiber, but a preferred range of lengths for the fibers may be 10 to 180 mm in length. The present invention further allows for a range of tenacities. In one preferred embodiment the tenacity is greater than four (4) grams per denier, while other embodiments will be greater than 6.2 grams per denier. Due to the advantages of the present invention, higher tenacity fibers (greater than 6.2, or even greater than 6.8 grams per denier) may be manufactured.

In another embodiment, the anti-microbial powder and the dispersion liquid are mixed together and injected into the continuous polymerization of the polymer and then directly spun into fiber without the extrusion step.

There are numerous post-fiber-creation techniques (Step 300) that may be used in order to further enhance the characteristics of the fiber. In one embodiment, an air jet spinning method may be used on the anti-microbial fibers in order to increase the bulkiness of the yarn and to make the yarn fuzzier. These air jet spun yarns expose more surface area of the fiber to bacteria in order to improve the anti-microbial characteristics of the fiber. In another embodiment, the anti-microbial fiber may be blended with cellulosic fibers such as cotton, rayon, Tencel®, etc. to enhance the moisture available near the anti-microbial fiber, improving the efficacy of the fibers at killing pathogens.

After the fibers have been converted to yarns and then to fabrics, post finishing in hot water (85° C. or greater) to remove the weaving starch and start the emulsion of the dispersion liquid. A topical finish (or coating) containing additional copper, silver, and/or zinc with a latex binder, such as Ethylene Vinyl Acetate (EVA) or Acrylic, may be applied to create a chemical bond with the active additives in the fiber. The effect of creating striations on the fiber after initial washing to remove starch, provides a unique chemical and mechanical bond of the binder with the fiber, connecting the antimicrobial additives.

The present invention permits fibers that are infused with anti-microbial compounds to be heat set at 180° C. to make the fabrics permanent press without degradation of the anti-microbial properties. Being able to permanent press a fabric according the present invention offers numerous advantages beyond just improving appearance or reducing laundering time. For example, permanent press sheets are less likely to wrinkle, which can improve patient comfort and potentially reduce bed sores.

Fibers consistent with the present invention are able to meet the Clorox 5X test, and can even exhibit improved bacteria killing performance after repeated washing with Clorox bleach and tide. The Clorox-5X test uses the common bleaching agent and the bleaching agent found in Clorox® bleach, sodium hypochlorite, in a series of bleaching cycles to determine whether the fabric will withstand chlorine bleaching. The Clorox-5X test refers to bleaching of the fabric through five (5) cycles. The Clorox-1X test refers to bleaching of the fabric through one (1) cycle. A cycle includes bleach washing a test sample with the bleaching chemical known by the trade name Clorox, in water with Clorox and detergent at 40° C., for 20 minutes.

During a laundering process, such as the Clorox-5X test, some of the dispersion liquid within the fiber may be dissolved and removed, leaving cracks in the fiber that further expose the anti-microbial imbedded within the fiber to any pathogens. Accordingly, the laundering process can increase the anti-microbial effectiveness of the fiber.

In some embodiments, fibers consistent with the present invention may be further treated with an anti-microbial post fabrication. In this manner, although the effectiveness of the post-fabrication anti-microbial treatment may decrease over time, the effectiveness of the fibers will remain constant or increase over time due to the increased exposed surface area of the fiber as the dispersion liquid disintegrates away.

An exemplary fiber consistent with embodiments of the present invention was made using 99.3% Polyester (PET) resin of 0.64 IV blended with 0.4% QuarTek Alloy QSM-ACL73, 0.1% Phosphate Ester Anti Stat, and 0.2% pthalo blue pigment. The alloy was a powder with particle sizes of 0.4-0.6 microns. The alloy powder was dried in a convection oven at 150° C. for 24 hours. The hot PET resin was removed from the desiccant drier at 125° C. FibroChem Anti-Stat 101A (an anionic anti-stat oil) was added to the PET pellets at a rate of 0.5 liter per 1,000 pounds by carefully drizzling the oil with a brush. The powder alloy was then added slowly to the mixture of PET pellets and anti-stat oil in a tumbling mixer (similar to a concrete mixer) and mixed for 5 minutes.

The compounds were extruded at a melt temperature of 290° C. and pumped through a spinneret to produce a fiber of 5.5 denier. The fiber was then drawn to 1.3 denier, crimped, and cut to 1.5″ (38 mm). During the drawing, a draw ratio was increased from a typical 3.3:1 to 3.7:1 which produced a fiber with a tenacity of 6.2 grams/denier.

In this exemplary embodiment, the fibers were then spun into a yarn and knitted in a tube. The knitted tubes were tested for bacteria using AATCC test #100. Unwashed the knitted tubes showed a 99.9% kill rate. The knitted tubes were then washed twenty-five (25) times using hot water, chlorine bleach, and detergent. After being washed, the knitted tubes were again tested, this time showing a 99.999% kill rate.

In another exemplary embodiment, similar fibers were generated in a production run of 5,000 pounds. The fibers were spun using air-jet yarn spinning to produce yarns which were bulky and allowed fibers to be available on the surface. The yarns were woven in different constructions using starch (PVA) to aid in the weaving.

The woven fabrics were scoured in a finishing mill at 85° C. to remove the starch, dried at 150° C. and then heat set at 180° C. to make the fabric “permanent press”. The fabric was then post-finished with a solution containing copper, silver & zinc with an acrylic latex binder that attached to the fibers providing dual protection-inside and outside the fibers. Because the anti-stat oil started to dissolve in the hot water, there were small cracks formed in the surface of the fiber that provided a chemical and mechanical bond.

Fabrics consistent with this embodiment were made into sheets, pillow cases, privacy curtains, isolation gowns, scrubs, doctor's coats, and blankets. Once again, these fabrics were tested using the AATCC 100 test. All fabrics provided results better than 99.99% kill rates and most were 99.999% after 25 launderings with Clorox, detergent, and hot water. The fibers are also suitable for use in nonwovens.

As described therein, the antimicrobial fiber in the anti-microbial upper section may include synthetic fiber comprising a polymer, an anti-microbial agent, and a dispersion liquid, wherein the dispersion liquid is embedded in the fiber. The anti-microbial agent may be comprised of silver and/or copper and/or zinc and/or gold in metallic form, salt form or ionic form and the dispersion liquid may be selected from the group consisting of an anti-stat, an anionic anti-stat oil, a phosphate ester, a wax, and a vegetable oil. The fiber may range from 0.5 to 20 denier, or preferably from 1.0 to 3.0 denier. The synthetic fiber can be a portion of an air jet spun yarn. In some embodiments, the synthetic fiber may further comprise cellulosic fibers and/or a metallic anti-microbial coating.

The improved hospital curtain described herein consistent with the present invention may be used in Emergency Rooms; Outpatient Treatment facilities such as CAT Scan, X-Ray, Magnetic Imaging, etc; Doctor's Offices; and Nursing Homes.

In yet another embodiment, the present invention includes methods for changing the replaceable curtains described herein by using the quick change mechanism. In certain embodiments, after removing the lower section, a wipe containing anti-microbial solution may be rubbed over a portion of the anti-microbial upper section. The portion of the anti-microbial upper section that is cleansed or recharged with the wipe may be the portion that is most contacted while changing out the lower section. It is also understood that different anti-microbial techniques may be used in combination. For example, both anti-microbial fibers and anti-microbial treatment (such as a coating) may be used for one of, or both, the anti-microbial upper section and the anti-microbial lower section.

In conclusion, the present invention provides, among other things, a system and method for replaceable hospital curtains, and methods for replacing hospital curtains. Those skilled in the art can readily recognize that numerous variations and substitutions may be made in the invention, its use and its configuration to achieve substantially the same results as achieved by the embodiments described herein. Accordingly, there is no intention to limit the invention to the disclosed exemplary forms. Many variations, modifications and alternative constructions fall within the scope and spirit of the disclosed invention as expressed in the claims.

Claims

1. A curtain comprising:

an upper section; and

an anti-microbial lower section, wherein the anti-microbial lower section is connected to the upper section with a quick change mechanism.

2. The curtain of claim 1, wherein the lower section comprises an anti-microbial fiber.

3. The curtain of claim 2, wherein the anti-microbial fiber comprises:

a polymer;

an anti-microbial agent; and

a dispersion liquid, wherein the dispersion liquid is embedded in the anti-microbial fiber.

4. The curtain of claim 1, wherein the upper section comprises an anti-microbial upper section.

5. The curtain of claim 4, wherein the anti-microbial upper section comprises a metallic anti-microbial coating.

6. The curtain of claim 5, wherein the metallic anti-microbial coating comprises:

a solution containing copper, silver, gold or zinc; and

a binder.

7. The curtain of claim 4, wherein the anti-microbial upper section comprises an anti-microbial fiber, the anti-microbial fiber comprising:

a polymer;

an anti-microbial agent; and

a dispersion liquid, wherein the dispersion liquid is embedded in the fiber.

8. The curtain of claim 1, wherein the upper section includes grommets to assist with connecting the upper section to a hanging mechanism.

9. The curtain of claim 1, wherein the anti-microbial upper section includes pre-configured attachments configured to connect to a hanging mechanism.

10. The curtain of claim 1, wherein the quick change mechanism comprises a zipper.

11. The curtain of claim 1, wherein the quick change mechanism comprises a snap.

12. The curtain of claim 1, wherein the quick change mechanism comprises:

a channel attached to the anti-microbial upper section; and

an extrusion profile attached to the lower section, wherein the extrusion profile is designed to slide within the channel in a horizontal direction, but is prevented from moving in a vertical direction.

13. The curtain of claim 1, wherein the anti-microbial section comprises a mesh.

14. A curtain comprising:

an anti-microbial upper section; and

a lower section, wherein the lower section is connected to the anti-microbial upper section with a quick change mechanism.

15. The curtain of claim 14, wherein the anti-microbial upper section comprises an anti-microbial fiber, the anti-microbial fiber comprising:

a polymer;

an anti-microbial agent; and

a dispersion liquid, wherein the dispersion liquid is embedded in the fiber.

16. The curtain of claim 14, wherein the lower section comprises an anti-microbial fiber.

17. The curtain of claim 16, wherein the anti-microbial fiber comprises:

a polymer;

an anti-microbial agent; and

a dispersion liquid, wherein the dispersion liquid is embedded in the anti- microbial fiber.

18. The curtain of claim 17, wherein the dispersion liquid is selected from the group consisting of an anti-stat, an anionic anti-stat oil, a phosphate ester, a wax, and a vegetable oil.

19. The curtain of claim 14, wherein the quick change mechanism comprises a zipper.

20. A curtain comprising:

an upper section, wherein the upper section comprises anti-microbial fibers; and

a lower section, wherein the lower section comprises anti-microbial fibers, wherein the lower section is connected to the upper section via a quick change mechanism.

21. The curtain of claim 20, wherein the anti-microbial fibers comprise:

a polymer;

an anti-microbial agent; and

a dispersion liquid, wherein the dispersion liquid is embedded in the anti- microbial fiber.