UV Resistant Fabrics and Treatment Methods

Information

  • Patent Application
  • 20250116059
  • Publication Number
    20250116059
  • Date Filed
    October 09, 2024
    9 months ago
  • Date Published
    April 10, 2025
    3 months ago
  • Inventors
    • Ertem; Sedef Piril (Minneapolis, MN, US)
    • Jung; Healeam (Minneapolis, MN, US)
    • Ellefson; Aaron Marsicano (Minneapolis, MN, US)
  • Original Assignees
    • Claros Technologies Inc. (Minneapolis, MN, US)
Abstract
UV protective fabrics and methods of making UV protective fabrics having ferulic acid and/or ferulic acid derivatives such as ethyl ferulate, including soaking the fabric in an aqueous solution of ferulic acid and/or a ferulic acid derivative, removing the fabric from the aqueous solution, and drying the soaked fabric. The aqueous solution may optionally include one or more surfactants. The ferulic acid and/or ferulic acid derivatives may provide UVA protection such as a UVA transmission of less than 5% and improved UPF such as a UPF of 50 or more, including fabrics which may have a dye, without changing the color of the fabric.
Description
BACKGROUND OF THE INVENTION

The hazards associated with UV radiation from the sun are well known. For example, skin cancer is recognized as the most common cancer type worldwide. Skin cancer occurrence is known to be closely associated with UV radiation exposure.


UV radiation is defined as electromagnetic radiation ranging from 100-400 nm. It is arbitrarily divided into three regions; UVA (315-400 nm), UVB (280-315 nm) and UVC (100-280 nm). UVC and approximately 90% of UVB radiation are absorbed by the atmospheric components, such as ozone, water vapor, oxygen, and carbon dioxide. However, UVA radiation is less affected by the atmosphere. Therefore, the UV radiation reaching the Earth's surface is largely composed of UVA with a small UVB component.


Clothing is considered as one of the most effective methods of sun protection. According to the most recently implemented European Regulation (European PPE Regulation 2016/425), UV Protective clothing is considered a Category 1 Personal Protective Equipment (PPE) and must be capable of absorbing or reflecting the majority of radiated energy in the harmful wavelengths, i.e., UVB and UVA ranges. (Citation: Regulation (EU) 2016/425 [ec.europa.eu]). In accordance with these regulations, the European Standard for sun protective clothing (EN 13758-1) dictates UV protective clothing to have a UV protection factor (UPF) larger than 40 (UPF 40+), as well as less than 5% UVA transmittance. However, it is difficult to achieve such a low level of UVA transmittance.


Polyester and its blends are popular fabric choices for sun protective clothing due to their inherent ability to absorb UV radiation. Garments made from these fabrics generally provide UPF 50+, however, they still may transmit UVA radiation above the minimum limit 5%.


Some approaches for improving the UPF rating of garments include reliance on the fabric construction (knit or weave pattern, fabric density, and cover factor), the fabric chemical composition (e.g., synthetic fibers that are inherently capable of absorbing UVB radiation, such as polyester and blends of polyester fibers with other synthetic fibers, such as Spandex) and chemical additives or surface treatments such as UV absorbing dyes, finishes, optical brighteners, etc.


Most commercially available UV absorbing dyes and finishes for textiles are petroleum based synthetic aromatic compounds. These compounds are generally derivatives of benzotriazoles, phenyl triazines, phenyl salicylates, benzophenones, and oxalic acid dianilides. Most of the commercially available organic UV absorbers mainly absorb UVB radiation, and therefore do not provide desired levels of protection and do not conform with the new regulatory requirements.


In addition to providing inadequate protection against UVA radiation, textile dyeing and finishing products are significant sources of water pollution. Textile dyeing and finishing products are estimated to be responsible for about ⅕th of global water pollution. With greater need to conserve natural resources and fresh water supplies, it has become more important to find sustainable alternatives.





BRIEF DESCRIPTION OF THE FIGURES

The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.


The following drawings are illustrative of embodiments and do not limit the scope of the invention. The drawings are not necessarily to scale and are intended for use in conjunction with the following detailed description. Embodiments of the invention will be described with reference to the drawings, in which like numerals may represent like elements.



FIG. 1 is a graph of UPF versus cover factor for multiple fabric types;



FIG. 2 is a drawing of the chemical structure of ferulic acid;



FIG. 3 is a drawing of the chemical structure of cinnamic acid derivatives according to various embodiments;



FIG. 4 is a graph of the UV absorbance spectrum of ferulic acid in water;



FIG. 5 is a graph of the UV absorbance spectrum of tannic acid in water;



FIG. 6 is a graph of the UV absorbance spectrum of ferulic acid and tannic acid in water;



FIG. 7 is a graph of the UV absorbance spectrum of RAYOSAN C in water;



FIG. 8 is a picture of 100% polyester swatches before and after treatment with tannic acid and ferulic acid;



FIG. 9 is a picture of 93% polyester/7% Spandex swatches before and after treatment with tannic acid and ferulic acid;



FIG. 10 is a picture of 100% cotton swatches before and after treatment with tannic acid and ferulic acid;



FIG. 11 is a picture of 100% cotton swatches before and after treatment with Rayosan C and ferulic acid;



FIG. 12 is a graph of the diffuse transmittance spectra collected from 100% cotton swatches before and after treatment with Rayosan C and ferulic acid;



FIG. 13 is a photograph of dyed polyester/Spandex fabric swatches before and after treatment with ferulic acid;



FIG. 14 is a graph of the UVA transmittance achieved in dyed polyester/Spandex fabrics after treatment with ferulic acid and after numerous wash cycles;



FIG. 15 is a photograph of a multi fabric swatch before and after treatment with ferulic acid;



FIG. 16 is a graph of the response surface for room temperature bath application of ferulic acid;



FIG. 17 is a graph of the response surface for 70° C. bath application of ferulic acid;



FIG. 18 is a graph of solubilized ferulic acid versus surfactant concentration for various emulsifier blends;



FIG. 19 is a photograph of fabric swatches treated at room temperature in examples 10 and 11;



FIG. 20 is a photograph of fabric swatches treated at 130° C. in examples 12 and 13;



FIG. 21 is a graph of the UPF of fabrics with various cover factors before and after treatment with ferulic acid;



FIG. 22 is a graph of the UVA of fabrics with various cover factors before and after treatment with ferulic acid; and



FIG. 23 is photograph of undyed polyester/Spandex swatches after 130° C. treatment with commercially available UPF enhancers and ethyl ferulate.





SUMMARY

Various embodiments include method of treating a fabric to provide UV protection. The methods include soaking the fabric in an aqueous solution of ferulic acid and/or a ferulic acid derivative, removing the fabric from the aqueous solution, and drying the soaked fabric. In some embodiments, the aqueous solution includes ferulic acid and is at a temperature of between about 25 degrees C. to about 90 degrees C. during the soaking step. In some such embodiments, the aqueous solution is at a temperature of between about 75 degrees C. and about 90 degrees C. during the soaking step. In other embodiments, the aqueous solution includes ethyl ferulate and is at a temperature of between about 25 degrees C. and about 130 degrees C. during the soaking step. For example, in some such embodiments, the aqueous solution is at a temperature of between about 100 degrees C. and about 130 degrees C. during the soaking step. In various embodiments, the step of drying the soaked fabric includes heating the soaked fabric at a temperature of between about 80 degrees C. and about 180 degrees C.


In some embodiments, the aqueous solution also includes one or more surfactants, and the one or more surfactants together have a hydrophilic lipophilic balance (HLB) of between about 14 and about 20.


In some embodiments, the aqueous solution includes a ferulic acid derivative comprising ethyl ferulate, sinapic acid, chlorogenic acid, caffeic acid, rosmarinic acid, p-coumaric acid, and/or ethyl hexyl ferulate.


Various embodiments include UV protective fabric including a fabric having fibers with ferulic acid and/or a ferulic acid derivative absorbed by the fabric fibers, with the UV protective fabric protective fabric having a UVA transmittance of less than 5%. In some embodiments, ferulic acid is absorbed by the fabric fibers. In other embodiments, the ethyl ferulate is absorbed by the fabric fibers. In some embodiments, the fabric includes a polyester blend. Some such fabrics may be garments, for example. In some embodiments, the fabric has a color, which may include light colors such as white, which is unchanged by the ferulic acid and/or ferulic acid derivative absorbed by the fabric fiber.


Various embodiments include UV protective fabrics created by the process including soaking a fabric in an aqueous solution of ferulic acid and/or a ferulic acid derivative, removing the fabric from the aqueous solution, and drying the soaked fabric, to form a UV protective fabric such as a UV protective fabric having a UPF of about 50 or more. In some embodiments, the aqueous solution comprises ferulic acid or ethyl ferulate and one or more surfactants having an HLB of between about 13 and about 20. In some embodiments, the aqueous solution may further include a dye, and the color produced by the dye may not be affected by the ferulic acid or ferulic acid derivative.


Other embodiments include methods of treating a fabric to provide UV protection including soaking the fabric in an aqueous solution at a temperature of between about 25 degrees C. and about 130 degrees C. for between about 5 minutes and about 30 minutes, the aqueous solution including ferulic acid and/or a ferulic acid derivative and one or more surfactants having an HLB of between about 10 and about 20, removing the fabric from the aqueous solution, and drying the soaked fabric at a temperature of between about 80 degrees C. and about 180 degrees. In some embodiments, the HLB of the one or more surfactants is between about 14 and about 20, and the temperature of the aqueous solution is between about 75 degrees C. and about 90 degrees C. In some embodiments, the aqueous solution includes ethyl ferulate and the temperature of the aqueous solution is between about 100 degrees C. and about 130 degrees C.


DETAILED DESCRIPTION

The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention. Rather, the following description provides practical illustrations for implementing various exemplary embodiments. Utilizing the teachings provided herein, those skilled in the art may recognize that many of the examples have suitable alternatives.


Various embodiments described herein include methods of treating fabrics and treated fabrics which have UV protective properties including UVA and UVB protection. The fabrics may be treated using ferulic acid or its derivatives, including but not limited to ethyl ferulate, which may be a biobased, plant derived molecule, making it a natural, environmentally friendly, and sustainable alternative to other fabric treatments. In addition, treatment with ferulic acid and/or ethyl ferulate does not alter the color of the fabric. Fabrics treated with ferulic acid and/or ferulic acid derivatives such as ethyl ferulate as described herein absorbs UV radiation in the desired range of about 280 to about 400 nm. The treated fabric achieves a UPF of at least 50 and UVA transmittance of less than 5%. The treated fabrics block 98% or more of UV transmittance.


The methods and formulations including ferulic acid may be used as a textile finish to improve UV protective properties of natural and synthetic fibers, textile materials, and fabrics. The active ingredients, ferulic acid and/or its derivatives may be biobased, plant derived molecule (though if the ferulic acid was chemically synthesized, it could also be used in the methods and formulations described herein). In some embodiments, the methods and formulations do not change the color of fabric upon application. The resulting fabric is able to absorb UV radiation, specifically within the range of 280-400 nm. This UV protection results in an increased ultraviolet protection factor (UPF) and decreased UVA transmittance in the treated fabrics.


Ultraviolet protection factor (UPF) is a calculated value of the ratio of light transmitted through a fabric relative to amount of light transmitted through air. UPF calculations account for the power of solar irradiance and its erythemal effect on the skin, i.e. skin reddening, that is caused by the exposure to UV radiation. The equation to calculate UPF is shown below as Equation 1:






Equation


1










U

P

F

=





280


nm


400


nm





E
λ

×

S
λ

×
Δλ






280


nm


400


nm





E
λ

×

S
λ

×

T
λ

×
Δλ







Equation


1







in which Eλ is erythemal spectral effectiveness at wavelength λ, Sλ is solar spectral irradiance at wavelength λ, Tλ is transmittance value at wavelength λ, and Δλ is measured wavelength interval (nm).


UV transmittance may be measured using a spectrophotometer equipped with an integrated sphere at known wavelength intervals. UPF is then computed via an algorithm integrated within the software using the above equation. The variables E and S are determined based on the standard followed as part of the test method and can be EN 13758-1, AATCC TM183, or AS/NZS 4399.


This equation can be simplified to UPF=1/T, meaning that if UPF=50, only 2% of light is transmitted, or if UPF=20, 5% of all the UV light is transmitted. Table 1, below, shows the UPF Classification system according to AS/NZS 4399 and ASTM D6603.











TABLE 1







Effective UV Radiation


UPF range
Protection category
transmittance (%)







15-24
Good
6.7-4.2


25-39
Very Good
4.1-2.6


 40-50+
Excellent
2.5-≤2









One of the variables that affects light transmittance through fabric is its cover factor of the fabric, which is the ratio of the area occupied by fibers to the total area covered by the fabric. In other words, the higher the cover factor, the less empty space there is between the fibers making up the structure of the fabric such as the knit or woven structure of the fabric, and thus, less light is transmitted through the fabric. The cover factor of fabrics can be estimated via optical microscopy under light transmission mode followed by image analysis counting the number of pixels where light passes freely relative to the total number of pixels in the image. Cover factor is then reported as a percentage where 100% means no light passage.


Assuming all other factors (color, fiber material, final finish chemistry) are equal, UPF can be approximately related to cover factor using Equation 2, blow:










U

P

F



1
T



1

1
-

Cover


Factor
/
100







Equation


2







in which Tis transmittance. For example, a fabric with 98% cover factor theoretically will transmit only 2% of the incident light, and should achieve a theoretical amount of UPF 50. FIG. 1 shows the correlation between UPF and cover factor collected from multiple fabrics. Independent of fabric type, measured UPF values follow the theoretical UPF values, with fabrics reaching UPF values above 50 when cover factor of the fabric is ˜98% or higher. Compared to cotton-based fabrics with similar cover factor, polyester-based fabrics exhibit relatively higher UPF due to the UV absorbing repeat units in their polymer structure.


UPF measurement have limitations, however. UV-protective textiles may be worn in different manners, causing the fabric to be stretched, or wet. There is no standardized testing to replicate stretching of fabrics. The more a fabric is stretched, the more light will pass through. Thus, depending on testing conditions, UPF/UVA values will vary. In addition, UPF calculations are weighted for erythemal effectiveness, or skin reddening. Skin reddening is facilitated by the exposure to UVB radiation, rather than UVA. Therefore, even if a clothing is rated UPF 50+ (i.e. less than 2% transmittance in average for 280-400 nm range), it may still have high UVA transmittance. It is therefore useful to determine not only the UPF of a protective fabric but also the absorbance spectrum including both UVA and UVB. Another factor that affects UPF is the color of the fabric. Many dyes absorb UV radiation as well as visible light. Darker and/or deeply dyed fabrics with sufficiently high cover factors tend to reach UPF 50+. However, sun protection is generally needed in geographical areas where loosely knit clothing with light color shades. Existing colorless UV absorbing molecules were developed to be used as finishes and dyes to improve UPF of textiles without changing the color of the fabrics. However, most of these molecules are synthetic man-made compounds, and are designed to absorb mostly UVB radiation, and therefore lack the ability to protect from UVA radiation.


Various embodiments include a fabric finish or fabric treatment that uses ferulic acid and/or ferulic acid derivative as a UV absorbing component including protection from UVA radiation. Ferulic acid is an abundant plant polyphenol found in cell walls of plants, fruits, and vegetables. It is known for its antioxidant properties and are therefor used in therapeutic applications as well as in cosmetics, such as skin care products and sun screens. It has now been discovered that ferulic acid and ferulic acid derivatives act as UV absorbers, have an affinity towards fiber material, and can be applied at application temperatures relevant to textile industry. In some embodiments, the ferulic acid and/or ferulic acid derivative may be applied to fabric during dyeing process, such as together with dye molecules in the same treatment bath. In other embodiments, the ferulic acid and/or ferulic acid derivatives may be applied as a finish to the dyed fabric as a final step of the fabric manufacturing process after dying, such as after after dying and before drying the fabric, or alternatively after dying and drying the fabric. Application temperatures may vary from room temperature to 220 degrees C., for example, with the choice of temperature depending, for example, upon the application step and fabric type, as well as efficiency and cost considerations. For example, at higher temperatures, the ferulic acid and/or ferulic acid derivative molecules may diffuse into the fibers more quickly. However, the use of higher temperatures may be more expensive, and the process may also be used with lower temperatures.


Fabric treated with the ferulic acid and/or ferulic acid derivative solution exhibits excellent UPF protection and blocks both UVB and UVA transmittance. For example, the treated fabrics allow 5% or less transmittance of UVA, such as between 0 or 0.1% and 4.5%. The enhanced UV protection provided by the treated fabrics is present in both wet and dry fabric, and is durable after repeated washings. For example, the treated fabric may maintain a UPF of 50 or more and a UVA of less than 5% after at least 50 wash and dry cycles.


The treatment formulations described herein may be a solution including ferulic acid and/or a ferulic acid derivative such as ethyl ferulate. Ferulic acid is commercially available and may be naturally derived or chemically synthesized. Ethyl ferulate is the ethyl ester of ferulic acid, and typically obtained through a chemical synthesis, either through traditional organic chemistry practices or via enzyme assisted synthesis. The chemical structure of ferulic acid is shown in FIG. 2. In various embodiments, the treatment solution includes aqueous ferulic acid, in which ferulic acid may be present at a concentration of between about 1 and about 4 g/L, though other concentrations may also be used.


The treatment solutions may include only aqueous ferulic acid and/or one or more ferulic acid derivatives. The treatment solution may not use or include any auxiliary chemicals such as salts, binders, pH adjusters or enzymes. For example, the treatment solution may include only ferulic acid and/or one or more ferulic acid derivatives such as ethyl ferulate and optionally one or more surfactants. Alternatively, the treatment solution may also include other components, such as antioxidants, radical scavengers, and/or antifouling agents, which may improve product shelf life.


In some embodiments, the treatment solution may optionally include one or more surfactants, including but not limited to, cetyltrimethylammonium bromide, sodiumdodecyl sulfate, Polysorbate 20, Polysorbate 40, Polysorbate 60, Polysorbate 80, Tween 20, Tween 40, Tween 60, Tween 80 Span 20, Span 40, Span 60, Span 80, Tergitol 15-S-12, Tergitol 15-S-20, Tergitol 15-S-40, and poloxamers. In some embodiments, the surfactant or the combination of surfactants used in the treatment solution may have a hydrophilic lipophilic balance (HLB), or a combined HLB, of 13 or more or 14 or more or 15 or more, such as 13-20, 14-20, or 15-20. In other embodiments, the surfactant or the combination of surfactants used in the treatment solution may have an HLB, or a combined HLB, of 10 or more, such as 10-13 or 10-20. For example, HLB values such as 10 or more may be used for alkyl modified ferulic acid derivatives such as alkyl ester ferulic acid derivatives.


In addition, the ferulic acid used in various embodiments may be a modified ferulic acid, which still imparts UV resistance. For example, the ferulic acid may be functionalized, such as on the acid end or on the hydroxyl end of the molecule. Ferulic acid and its derivatives may be used for the treatment solution, including but not limited to salts such as Sodium 3-(4-hydroxy-3-methoxyphenyl) acrylate, ester derivatives such as Ethyl 4-hydroxy-3-methoxycinnamate also known as ethyl ferulate or ferulate ethyl ester, phenyl ether derivatives such as 3,4-Dimethoxycinnamic acid, amide derivatives such as diferuloyl putrescin, and combinations of said derivatives.


Moreover, ferulic acid is a derivative of a group of chemicals that are known as cinnamic acid derivatives, that also impart UV absorbance in 280-400 nm. Various other cinnamic acid derivatives may be used to impart UV absorbance as described herein. These cinnamic acid derivatives include, but are not limited to, ethyl ferulate, sinapic acid, chlorogenic acid, caffeic acid, rosmarinic acid, p-coumaric acid, and ethyl hexyl ferulate. FIG. 3 shows examples of cinnamic acid derivatives which may be used in various embodiments, in which R1 may be —H, —OH, or —OCH3, R2 may be —H, —OH, or —OCH3, R3 may be —H, —OH, —OCH3, and R4 may be —H, —CH3, —CH2CH3, alkyl (C1-C12), —CH2CH(CH2CH3)(CH2)3CH3, ethyl-hexyl (—CH2CH(CH2CH3)(CH2)3CH3), or quinic acid.


Fabrics may be treated by soaking the fabric in the treatment formulation for a sufficient time for the fabric to be fully saturated with the treatment formulation. For example, the fabric may be soaked for at least 5 minutes, at least 10 minutes, or at least 15 minutes, such as about 30 minutes. The fabric may be soaked for about 5 minutes to about 60 minutes, or about 10 minutes to about 45 minutes, or about 15 to about 30 minutes. The fabric and/or solution may be stirred or agitated while soaking, or may be still. The fabric may then be removed from the treatment formulation. Excess treatment formulation may optionally be removed from the fabric, such as by rinsing, compressing, or blotting the fabric. The fabric may then be dried at room temperature via air drying or at a higher temperature such as between approximately 80° C. and approximately 180° C., or between approximately 100° C. and approximately 160° C., or between approximately 120° C. and approximately 140° C., or about 130° C. . . . The resulting dried fabric is a UVA and UVB protective fabric.


In some embodiments, the fabric may be soaked in the treatment solution at a temperature greater than room temperature. For example, the treatment formulation for ferulic acid, for example, may be between about room temperature (about 25° C.) and about 90° C., such as between about 60° C. and about 90° C., or between about 75° C. and about 90° C., or between about 85° C. and about 90° C., such as about 90° C. In some embodiments, such as treatment formulations for ethyl ferulate, the temperature may be between about room temperature (about 25° C.) and about 130° C., such as between about 80° C. and about 130° C., or between about 100° C. and about 130° C., or between about 120° C. and 130° C., or about 130° C. In some embodiments, such as embodiments in which the treatment solution includes ferulic acid and another component such as surfactant, the fabric may be soaked at the temperatures described above or alternatively at room temperature.


In some embodiments the bath pH of the treatment solution may be about 1 to about 14, such as preferably about 4 to about 5, which may be achieved without adjusting the pH.


In some embodiments, the treated fabric may be air dried at room temperature. In other embodiments, the fabric may be dried using a dryer, such as a tumble dryer or a dryer which blows room temperature air or heated air on the fabric, or other types of heated or room temperature fabric dryers, or tenter frames and conveyor belts at temperatures described above.


Fabrics which may be used in various embodiments include natural as well as synthetic fabrics including synthetic, semi-synthetic, or natural woven or non-woven textiles, fibers, or microfibers. Examples of textiles which may be used include cotton such as bleached cotton, polyester such as spun polyester, polyamide, nylon, Spandex, rayon, linen, cashmere, silk, wool such as worsted wool, acrylic such as spun acrylic, modacrylic, olefin, acetate, viscose such as spun viscose, polypropylene, polyvinyl chloride, lyocell, latex, and aramid, as well as blends or combinations of one or more of these or other materials or fibers. As such, the textile may be natural, such as silk including spun silk, wool, cotton, cellulosics, flax, jute or bamboo, may be synthetic, such as nylon, polyester, acrylic, Spandex, rayon, a polymer such polypropylene, polyurethane, or a combination of more than one of these. In some embodiments, the material may be a textile that is a blend of different materials including those listed above.


While the methods are described for use with fabric, the same method could alternatively be used for the treatment of natural or synthetic fabric precursors such as yarns, threads, or fibers. These treated fabric precursors may then be used to create a UV protective fabric, such as by knitting, weaving, felting, or bonding.


The fabrics may be treated using the treatment solution either before or after being constructed into a garment or other item. Treated materials according to various embodiments may be used as UV protective garments, such as hats, shirts, pants, jackets, scarves, and swim wear. In other embodiments, the UV protection of the treated material may reduce or prevent UV damage to the material itself, such as in products used outdoors and/or exposed to the sunshine, where the UV protection may reduce or prevent fading, for example. In some such embodiments, the treated materials may be used in furniture upholstery, car or other vehicle upholstery, tents, tarps, umbrellas, towels, blankets, bedding, drapery and other window treatments, and awnings, for example.


UV protection can be achieved using the treatment methods, without affecting the color of the fabric. It is therefore useful for white or light colored fabrics, which will maintain the same white or light color even after treatment. The color of dyed fabrics is also not affected by the ferulic acid and/or ferulic acid derivative treatment. The ferulic acid and/or ferulic acid derivative treatment therefore provides UV protection with no impact on the color of the fabric, whether natural or dyed, including white fabrics.


Treated fabric (and treated fabric garments) maintain a high level of UV protection, including a high UPF and low UVA transmittance, even after being washed in a washing machine with detergent using normal washing procedures. The treated fabric maintains UV protection after at least three wash cycles. In some embodiments, the treated fabric main UV protection for at least 10 wash cycles, at least 20 wash cycles, or at 50 wash cycles. For example, the treated fabric may maintain at least 90%, or at least 80%, or at least 70%, or at least 50% of its improvement in UPF and/or UVA transmittance over the control after the above noted number of wash cycles.


Aqueous solutions of ferulic acid absorb UV radiation. FIG. 4 shows the UV absorption spectrum of ferulic acid collected from an aqueous solution. The chemical absorbs UV radiation strongly between ˜260 nm-360 nm, with a maximum absorption at about 320 nm. This range covers the UVB (280-315 nm) and UVA (315-400 nm) regions.


Another biobased and plant derived UV absorbing substance is tannic acid. The UV absorbance spectrum of tannic acid is shown in FIG. 5. The chemical absorbs UV radiation at a range 250-320 nm, with a peak at about 275 nm. Thus, the chemical is effective in the UVB range but with little protection in the UVA range. In addition, tannic acid has a brown hue associated with it that can discolor the fabric upon application. As such, while tannic acid can be used to provide UV protection to fabrics, ferulic acid has significant advantages over tannic acid.


A comparison of the UV absorption spectrum of aqueous solutions of tannic acid and ferulic acid are shown in FIG. 6. This figure demonstrates the superior UVA absorbance of ferulic acid as compared to tannic acid.


Commercially available UV absorbers may also provide little or no UV protection in the UVA spectrum. For example, RAYOSAN C is a commercially available fiber-reactive UV absorber for cellulosic and polyamide fibers and their blends. The UV absorbance spectrum of RAYOSAN C paste (Archroma) is shown in FIG. 7. FIG. 7 shows that the maximum UV absorbance of RAYOSAN C is in the UVB region, with little to no absorbance in the UVA region.


Experimental

These examples present the application procedure of ferulic acid and ferulic acid derivative formulations on different types of fabrics. Some examples also include comparative data utilizing the tannic acid and the commercial formulation, RAYOSAN C. Untreated fabric of the same type was used as the control sample. In all examples, the fabric swatches were colorless/undyed, unless otherwise indicated.


Test swatches of fabric were prepared using various treatment solutions as described in the Examples below.


In all examples, unless otherwise indicated, UV transmittance was measured on a Labsphere UV2000F equipped with an integrating sphere. UPF values and UVA transmittance were determined following AATCC TM 183 and reported as measured by the UV2000F Application software in accordance with the EN13758-1 method.


In all examples, unless otherwise indicated, swatches were subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate.


Example 1

In this example, an aqueous ferulic acid solution was used to treat fabric swatches including 100% polyester fabric swatches, 93% polyester/7% Spandex fabric swatches, and 100% cotton fabric swatches. All of the swatches were undyed, except for the 93% polyester/7% Spandex, which was dyed a pale blue.


In a 250 ml beaker equipped with a magnetic stir bar, 100 mL DI water and 0.4 g ferulic acid was added. The solution was heated to 70° C. while stirring at 180 rpm. Temperature was monitored with a temperature probe, and the beaker was covered with foil to prevent water evaporation. Once the temperature was reached and ferulic acid was completely dissolved, a 5-gram fabric swatch was immersed in the solution (20:1 liquor ratio). The stir bar was slowed to 60 rpm to maintain agitation while the fabric swatch was soaked in solution and treated for 15-30 minutes. The swatch was retrieved with tweezers and excess solution was squeezed out from the fabric until water stopped dropping. The swatch was dried in a Vastex D-100 Infrared Curing System at 80° C. for 10 minutes or until dry.


Dried swatches were let to cool to room temperature prior to UPF/UVA measurement.


Example 2

In this example, an aqueous solution of ferulic acid and cetyltrimethylammonium bromide was used to treat fabric swatches including 93% polyester/7% Spandex swatches and 100% cotton swatches. All of the swatches were undyed, except for the 93% polyester/7% Spandex, which was dyed a pale blue.


In a 250 ml beaker equipped with a magnetic stir bar, 100 mL DI water, 0.25 g ferulic acid, and 5.5 g cetyltrimethylammonium bromide was added. The solution was stirred at 25° C. temperature at 180 rpm until a clear solution formed. 5-gram fabric swatch was immersed in the solution (20:1 liquor ratio). The stir bar was slowed to 60 rpm to maintain agitation while the fabric swatch was soaked in solution and treated for 15-30-minutes. The swatch was retrieved with tweezers and excess solution was squeezed out from the fabric until water stopped dropping. The swatch was dried in a Vastex D-100 Infrared Curing System at 80° C. for 10 minutes or until dry.


Dried swatches were let to cool to room temperature prior to UPF/UVA measurement.


Example 3

In this example, an aqueous solution of tannic acid was used to treat fabric swatches including 100% polyester swatches, 93% polyester/7% Spandex swatches and 100% cotton swatches. All of the swatches were undyed, except for the 93% polyester/7% Spandex, which was dyed a pale blue.


In a 250 ml beaker equipped with a magnetic stir bar, 100 mL DI water and 0.8 g tannic acid was added. The room temperature solution was stirred at 180 rpm. Once tannic acid was completely dissolved, 5-gram fabric swatch was immersed in the solution (20:1 liquor ratio). The stir bar was slowed to 60 rpm to maintain agitation while the fabric swatch was soaked in solution and treated for 15-30-minutes. The swatch was retrieved with tweezers and excess solution was squeezed out from the fabric until water stopped dropping. The swatch was dried in a Vastex D-100 Infrared Curing System at 80° C. for 10 minutes or until dry.


Dried swatches were let to cool to room temperature prior to UPF/UVA measurement.



FIGS. 8-10 present photographs of the fabric swatches before (as shown in the control) and after treatment according to Example 1 (ferulic acid) and Example 3 (tannic acid). FIG. 8 is a photograph of the 100% polyester swatches. FIG. 9 is a photograph of the 93% polyester/7% Spandex swatches. FIG. 10 is a photograph of the 100% cotton swatches. In each case, with each type of material, the ferulic acid fabric swatches (labeled as example 1) exhibited no color change as compared to the control. In contrast, the tannic acid treated swatches (labeled as example 3) showed some discoloration. The undyed fabrics (FIGS. 8 and 10) took on a yellow/brown tint after treatment with tannic acid. The 93% polyester/7% Spandex swatch shown in FIG. 9 was a light blue before treatment. After treatment with tannic acid, the 93% polyester/7% Spandex swatch appears grayish or blue-brown, while the ferulic acid treated swatch appears identical in color to the control.


Example 4

In this example, a RAYOSAN C solution was used to treat 100% cotton swatches.


To achieve 4% solution of RAYOSAN C pa, 30 g sodium sulfate was dissolved in 500 mL deionized water while stirring. The solution was heated to 40° C. and 20 grams of RAYOSAN C pa was added. The solution was held at 40° C. for 10 minutes while the RAYOSAN C pa dissolved. Then 30 grams of sodium carbonate was added to the solution followed by a 25 gram swatch of fabric. The swatch was treated in solution for 30 minutes with periodic agitation and stirring. After treatment, the swatch was removed from solution and dried in a Vastex D-100 Infrared Curing System at 80° C. for 10 minutes. The swatch was rinsed by hand with hot deionized water then cold deionized water and left to hang dry.



FIG. 11 is a photograph of the 100% cotton swatches before and after treatment according to Example 1 (ferulic acid) and Example 4 (RAYOSAN C). Both treated samples appear to be the same color as the untreated control fabric. However, the UV protection data, presented below, demonstrate that the ferulic acid treatment was superior to the RAYOSAN C treated fabric, particularly in the UVA range.


Data collected from the test performed on the swatches from each of Examples 1-4 and the control are shown in the tables below.


Table 2 shows the results of UPF and UVA data collected from 100% polyester fabric before and after treatment with Example 1 and Example 3. These results show that both ferulic acid and tannic acid provided improved UV protection as compared to the control. However, ferulic acid treatment produced the best results, including higher UPF and lower UVA transmittance as compared to tannic acid.













TABLE 2







Condition
UPF
UVA (% T)









Control
88 ± 7
8.0 ± 0.5



Example 1 - ferulic acid
666 ± 73
1.8 ± 0.1



Example 3 - tannic acid
176 ± 14
4.3 ± 0.2







*UPF and UVA values were averaged between 9 separate spots on the same sample






Table 3 shows the results of UPF and UVA data collected from a 93% Polyester/7% Spandex fabric before and after treatment with Example 1, Example 2, and Example 3. Both of the ferulic acid solutions produced superior results. The UPF was slightly higher and the UVA transmittance was slightly lower in the fabric treated with the ferulic acid alone as compared to the ferulic acid with surfactant. However, it is believed that this is due to the much lower concentration of ferulic acid used in the combination with the surfactant in this example. In a subsequent example (see Example 5 below), the fabric treated with ferulic acid alone and with the same amount of ferulic acid in combination with surfactant produced similar results.













TABLE 3







Condition
UPF
UVA (% T)









Control
106 ± 6 
4.9 ± 0.1



Example 1 - ferulic acid
133 ± 11
2.1 ± 0.1



Example 2 - ferulic acid +
129 ± 11
3.1 ± 0.1



surfactant



Example 3 - tannic acid
92 ± 5
3.1 ± 0.1










Table 4 shows the UPF and UVA data collected from 100% cotton fabric before and after treatment with example 1, example 2, example 3, and example 4. Again, the ferulic acid solutions provided the best results for both UPF and UVA transmittance. While the RAYOSAN C provided UPF protection and a decrease in UVA transmission as compared to the control, the effect was much less than the ferulic acid solutions and the tannic acid.













TABLE 4







Condition
UPF
UVA (% T)









Control
 9.9 ± 0.4
15.6 ± 0.4 



Example 1 - ferulic acid
1399 ± 32
 0.6 ± 0.04



Example 2 - ferulic acid +
1044 ± 24
 1.1 ± 0.05



surfactant



Example 3 - tannic acid
 465 ± 28
2.2 ± 0.2



Example 4 - RAYOSAN C
124 ± 6
8.8 ± 0.4







*UPF and UVA values were averaged between 9 separate locations on the same sample






The data from the transmittance testing of the 100% cotton swatches produced in Example 1 and Example 4 is presented in the graph shown as FIG. 12. The control swatches exhibited significant transmittance of UV radiation, particularly in the UVA spectrum. The RAYOSAN C treated swatches blocked UVB transmission but performed poorly at blocking UVA transmittance. In contrast, the ferulic acid treated swatches exhibited excellent blocking of both UVB and UVA transmittance.


Example 5

In this example, an aqueous solution of ferulic acid alone or ferulic acid and cetyltrimethylammonium bromide was used to treat fabric swatches including 93% polyester/7% Spandex swatches.


In a 250 ml beaker equipped with a magnetic stir bar, 100 mL DI water, 0.25 g or 0.4 g ferulic acid was added, alone or along with 5.5 g cetyltrimethylammonium bromide, as indicated in Table 5, below. The solution was stirred at either 25° C. or 70° C. temperature at 180 rpm until a clear solution formed. 5-gram fabric swatch was immersed in the solution (20:1 liquor ratio). The stir bar was slowed to 60 rpm to maintain agitation while the fabric swatch was soaked in solution and treated for 15-30-minutes. The swatches was retrieved with tweezers and excess solution was squeezed out from the fabric until water stopped dropping. The swatch was dried in a Vastex D-100 Infrared Curing System at 80° C. for 10 minutes or until dry.


Dried swatches were let to cool to room temperature prior to UPF/UVA measurement.


The dried treated swatches were then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. Washed swatches were dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after three washing and drying cycles, and after 5 washing and drying cycles.


The results are shown in Table 5, below, which compares the UPF and UVA transmittance of 93% polyester/7% Spandex fabric swatches treated with and without surfactant, with the treatment solution at various concentrations and temperatures as indicated. In this example, when the amount of ferulic acid was the same in treatment solutions with and without surfactant, the UPF and the UVA transmittance was comparable.












TABLE 5














Bath













temp
UNWASHED
3× WASHED
5× WASHED














Formulation
(° C.)
UPF
UVA (% T)
UPF
UVA (% T)
UPF
UVA (% T)





Control
NA
106 ± 6 
4.9 ± 0.1
NA
NA
NA
NA


Ferulic acid-4 g/L
70
133 ± 11
2.1 ± 0.1
179 ± 19
1.9 ± 0.1
NA
NA


Ferulic acid-2.5 g/L
70
131 ± 7 
2.5 ± 0.1
157 ± 8 
2.4 ± 0.1
157 ± 4 
2.4 ± 0.0


Ferulic acid-2.5 g/L
70
129 ± 14
3.1 ± 0.2
146 ± 13
3.5 ± 0.1
146 ± 17
3.5 ± 0.2


CTAB-55 g/L


Ferulic acid-2.5 g/L
25
112 ± 14
3.1 ± 0.2
NA
NA
145 ± 13
3.3 ± 0.1


CTAB-55 g/L









Example 6

In this example, an aqueous solution of ferulic acid alone was used to treat colored fabric swatches including a blue swatche of 93% polyester/7% Spandex and a green swatch of 90% polyester/10% Spandex.


The fabric swatches were prepared using 4 g/L of ferulic acid following the procedure described in Example 1.


The fabric swatches were sent for third party testing of the control and treated samples. UPF and UVA values were collected following AATCC TM 183. Swatches were evaluated as received, in dry and wet condition. Treated samples were also laundered per ISO 6330/AATCC LP1 using IEC-W Liquid Wool detergent without aluminum, at normal cycle (cold wash 27±3° C.). Washed samples were tumble dried low.


Testing was performed at the baseline before washing, after 10, 20 and 50 washing and drying cycles, under both wet and dry conditions. The results are shown in Tables 6 and 7, below, and in FIGS. 13 and 14.



FIG. 13 shows a picture of the fabrics before (control, left column) and after treatment (right column). Both swatches look the same, before and after treatment with ferulic acid. There was no impact on the visual appearance of the dyed materials for either color or material.


The results shown in Table 6 are for the blue 93% polyester/7% Spandex fabric swatches, and the results shown in Table 7 are for the green 90% polyester/10% Spandex fabric swatches. Both dyed swatches achieved high levels of UV protection from the ferulic acid treatment. They also retained high level of UV protection, in both wet and dry conditions, even after 50 wash cycles. These results show that the UV protection provided by the treatment solution is long lasting and work in both wet and dry conditions, including on dyed fabrics, making ferulic acid treatment useful for many purposes including garments which will be used when wet such as all types of swim wear, or other recreational garments such as fishing or surfing gear.











TABLE 6







Light Blue
Dry
Wet











93% polyester/7% Spandex
UPF
UVA (%)
UPF
UVA (%)





Control (untreated)
61 ± 1.2 
 7.6 ± 0.03
55.77 ± 1.1 
11.5 ± 0.1 


Treated - 0 wash
90 ± 0.9 
3.07 ± 0.01
  92 ± 2.2
4.99 ± 0.06


Treated - 10x wash
90 ± 1.75
2.88 ± 0.03
96.72 ± 1.89
4.22 ± 0.03


Treated - 20x wash
83 ± 1.47
2.98 ± 0.03
80.18 ± 0.77
4.02 ± 0.01


Treated - 50x wash
86 ± 2.62
2.74 ± 0.08
72.86 ± 0.92
4.03 ± 0.02


















TABLE 7







Green
Dry
Wet











90% polyester/10% Spandex
UPF
UVA (%)
UPF
UVA (%)





Control (untreated)
67 ± 0.5
 6.8 ± 0.01
69 ± 1.2
10.1 ± 0.4 


Treated - 0 wash
109 ± 2.0 
 2.5 ± 0.03
123 ± 5.3 
4.10 ± 0.07


Treated - 10x wash
103 ± 2.2 
2.57 ± 0.03
105 ± 2.6 
3.99 ± 0.07


Treated - 20x wash
112 ± 1.49
2.38 ± 0.03
113 ± 01.8
3.26 ± 0.04


Treated - 50x wash
 94 ± 1.38
2.44 ± 0.05
 84 ± 1.68
3.54 ± 0.12









The above results are presented as a graph in FIG. 14, which shows the UVA transmittance results for both fabrics after treatment and after each period of wash cycles. The upper line is the blue 93% polyester/7% Spandex, and the lower line is the green 90% polyester/10% Spandex. The graph shows that the ferulic acid treatment resulted in substantially blocking of UVA transmission, which remained relatively steady even after 50 wash cycles.


Example 7

In this example, a multifiber test strip including multiple fabric swatches was treated using ferulic acid. The test strip included acetate, cotton, polyamide, acrylic, silk, viscose, and wool, stitched together into a single strip.


The test strip, TestFabrics MFF 49, was treated according to the procedure described in example 1, with an aqueous solution of 4 g/L ferulic acid. The test strip was soaked in the treatment solution at 70° C. for 15-30 minutes, and then dried at 80° C.


The dried test trip was tested for UPF and UVA transmittance.


The test strip was then washed according to the washing protocol described in Example 5, above. A photograph of the control test strip and the treated test strip is shown in FIG. 15. No color change was observed in any of the fabrics


The UPF and UVA transmittance results are shown in Table 8, below. All of the materials showed substantially improvement as UV absorbers with a significant reduction in UVA transmittance.













TABLE 8










After treatment -
After treatment- 3×



Before treatment
unwashed
washed













Fabric Type
UPF
UVA (% T)
UPF
UVA (% T)
UPF
UVA (% T)
















Bleached Cotton
54.7
4.74
1270
0.71
105.
5.68


Polyamide
59.9
6.79
1566
0.38
1115
0.75


Spun polyester
266
5.24
1076
1.00
1046
1.05


Spun polyacrylic
347
3.97
959
1.22
505
1.6


Spun Silk
673
1.69
1513
0.41
1003
1.01


Spun Viscose
138
3.12
1362
0.59
155
3.92


Worsted Wool
116
4.79
1438
0.5
681
1.76









Example 8

In this example, application parameters were refined with a goal of minimizing UVA (% T) using a three-factor central composite design methodology. The variables evaluated were bath duration, bath temperature, and oven temperature, where bath duration ranged from 10 to 60 minutes, bath temperatures of 25° C. and 70° C., and oven temperature ranged from 70° C. to 110° C. The list of experimental conditions is shown in Table 10. Each run was conducted with three 3″×6″ swatches of undyed fabric of composition 87% rPET (recycled polyester) and 13% Spandex with a cover factor of approximately 97%. Each swatch was treated in a beaker equipped with a magnetic stir bar containing a solution of 4 g/L of ferulic acid and 80 g/L Tween 20 at a 1:10 liquor ratio to the fabric, meaning that for every 1 g fabric, 10 g water was used. After treatment, the fabric was gently squeezed to remove excess liquid before curing in the oven. Each swatch was measured for UVA (% T) on a UV Spectrophotometer Labsphere 2000F using method EN 13758-1:2007 on the 9 location ISO Mask. The dried treated swatches were then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after one washing and drying cycle. The results are presented in Table 9.















TABLE 9









Bath
Bath
Oven
UVA (%)_before wash
UVA (%)_after 1× wash

















Temp
Duration
Temp
Swatch
Swatch
Swatch
Swatch
Swatch
Swatch


Run
(° C.)
(min)
(° C.)
1
2
3
1
2
3



















1
34
20
78
5.65
5.65
5.54
7.48
7.66
7.26


2
34
50
78
5.43
5.37
5.24
6.88
6.83
6.95


3
61
20
78
5.35
5.20
5.32
6.52
6.41
6.47


4
61
50
78
4.99
5.04
5.35
6.09
6.1
6.27


5
34
20
102
5.01
5.00
4.87
5.11
5.17
5.27


6
34
50
102
4.96
4.87
4.81
4.99
5.03
5.1


7
61
20
102
4.87
4.64
4.31
4.91
4.69
4.35


8
61
50
102
4.66
4.23
4.42
4.73
4.12
4.37


9
48
35
70
5.31
5.36
5.7
6.87
7
7.4


10
48
35
110
3.91
4.13
3.99
4.19
4.34
3.98


11
25
35
90
5.35
5.27
5.22
6.11
6.26
6.13


12
70
35
90
5.17
5.32
5.26
5.66
5.81
5.98


13
48
10
90
5.55
5.16
5.09
6.82
5.95
6.19


14
48
60
90
4.32
4.72
4.79
4.78
5.34
5.19


15
48
35
90
4.72
5.48
5.49
5.82
6.67
6.49









The results were used to generate FIGS. 16 and 17, which show the response surface for predicted UVA values given any combination of factors within the parameters of the study. Response surface is a statistical methodology to show the relationships between variables. In this case the response surface shows the UVA response to change in bath duration, bath temperature, and oven temperature. FIG. 16 shows the response surface for room temperature (25° C.) bath application, while FIG. 17 shows the response surface for 70° C. bath application.


From these results, it was discovered that oven temperature was the greatest contributor toward lowering UVA (% T) values and the durability of those values through laundering cycle. Bath duration and bath temperature were also significant contributors in resulting low UVA (% T) values. The results suggest using the highest oven temperature without degrading the UV active component, depending upon the duration of exposure, which still allows for some flexibility in bath duration and bath temperature. Based on this study and information gathered from the industry, an optimized application condition for ferulic acid formulation may include a bath temperature of about 60° C., a bath duration of about 30 minutes, and an oven temperature (drying temperature) of about 130° C. for about 6 minutes, though this is highly dependent on the type of oven or dryer used and other optimal conditions may apply in other situations.


Example 9

In this example, solubilization of ferulic acid with surfactants was studied. Surfactants TWEEN 20 and SPAN 20 were used as model compounds to find an optimal hydrophilic-lipophilic balance (HLB) value to solubilize ferulic acid. The HLB system is an empirical system that assigns a number on the scale of 0 to 20 to describe how the proportion of the hydrophilic and lipophilic parts of the surfactant will affect its behavior in emulsions. In other words, the HLB number indicates the degree of water or oil solubility of a particular surfactant. HLB numbers higher than 10 indicate better water solubility while HLB numbers lower than 10 indicate better oil solubility. SPAN 20 is a lipophilic molecule with a HLB value of 8.6 and TWEEN 20 a hydrophilic molecule with HLB of 16.7. They possess similar chemical structures with lauric acid forming the hydrophobic tail and sorbitan forming the hydrophilic head, with an only difference of polyethylene oxide group in TWEEN 20 that enables it to be more hydrophilic. Table 10 shows the surfactant blend compositions used to reach HLB values ranging from 13-16.7.












TABLE 10









Emulsifier Blend
Final












Sample #
SPAN 20
TWEEN 20
HLB
















1

100% 
16.7



2
 9%
91%
16



3
21%
79%
15



4
33%
67%
14



5
46%
54%
13










To the different blends of SPAN 20 and TWEEN 20, ferulic acid was added at 10:1 (w:w) surfactant to ferulic acid weight ratio. The mixture was further diluted to arrive at a ferulic acid concentration of 4 g/L. Out of the five solutions, HLB 13 and 14 were not able to fully solubilize ferulic acid, therefore only sample choices having an HLB of 14 or greater were considered for further evaluation.


Next, the maximum amount of ferulic acid dissolved was determined for each surfactant blend and their solutions in water with concentrations ranging from 5 mM to 300 mM. The results are shown in FIG. 18, which demonstrates the correlation between HLB and ferulic acid solubility for each surfactant blend. The amount of solubilized ferulic acid increased with increasing surfactant concentration and increasing HLB, indicating that the more hydrophilic the surfactant the better is solubility in this example.


Example 10

Examples 10-13 demonstrate the impact of the application temperature on UPF/UVA. In some cases, UV enhancing compounds may be added during the dye cycle of the fabric manufacturing process, as opposed to being applied as a finish onto a dyed fabric. This way, the number of process steps may be reduced, and thus, cost of production may be improved. Textile finishes are typically applied using a treatment bath at room temperature, while dye baths are run at higher temperatures. Specifically for polyesters, dyeing bath temperatures may be as high as 130° C., above the glass transition of the fiber, to allow for diffusion of small molecules into the fiber material. For the studies shared in Examples 10-13, ferulic acid and ethyl ferulate were used as UV absorbing compounds, and application was performed at room temperature or at 130° C. An Ahiba IR dyeing machine was used to reach this high application temperature. The UPF/UVA results are summarized in Table 11.


In this example, an aqueous solution containing ferulic acid and Tween 20 was used to treat three undyed fabric swatches with a composition of 97% polyester/3% Spandex.


A treatment concentrate was prepared by mixing Tween 20 and ferulic acid at 20:1 weight ratio and stirred thoroughly at room temperature until no ferulic acid particle was observed. The concentrate was then diluted in water at room temperature to prepare a treatment solution at a 4 g/L ferulic acid concentration. 100 mL treatment solution was then transferred to a 300 mL steel beaker designed for the Ahiba IR dyeing machine. A 10-gram fabric swatch was immersed in the treatment solution (10:1 liquor ratio). The beaker was then installed into the Ahiba IR dyeing machine and treated for 30 minutes at room temperature. After the treatment process, the fabric swatch was retrieved with a tweezer and rolled through a manual wringer to remove excess solution. The swatch was dried and cured in a Thermo Scientific oven at 130° C. for 5-10 minutes. The dried swatch was let to cool to room temperature prior to UPF/UVA measurement. An image of the dried swatch is shown in FIG. 19 (labeled as example 10), along with a swatch from the following Example 11 and an untreated fabric swatch as a control. The color of the fabric swatch was unchanged after treatment as compared to the control.


Each swatch was measured for UPF/UVA (% T) before and after wash on a UV Spectrophotometer Labsphere 2000F using method EN 13758-1:2007 on the 9 location ISO Mask. The dried treated swatches were then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after three washing and drying cycles. The results are shown in Table 11, along with the results of Examples 11-13.


Example 11

In this example, an aqueous solution containing ethyl ferulate and Tween 20 was used to treat three undyed fabric swatches with a composition of 97% polyester/3% Spandex.


A treatment concentrate was prepared by mixing Tween 20 and ethyl ferulate at 20:1 weight ratio at 70° C. to until ethyl ferulate was completely dissolved. The concentrate was then diluted in water at room temperature to prepare a treatment solution at a final 4 g/L ethyl ferulate concentration. 100 mL treatment solution was then transferred to a 300 mL steel beaker designed for the Ahiba IR dyeing machine. A 10-gram fabric swatch was immersed in the treatment solution (10:1 liquor ratio). The beaker was then installed into the Ahiba IR dyeing machine and treated for 30 minutes at room temperature. After the treatment process, the fabric swatch was retrieved with a tweezer and rolled through a manual wringer to remove excess solution. The swatch was dried and cured in a Thermo Scientific oven at 130° C. for 5-10 minutes. An image of the dried swatch is shown in FIG. 19 (labeled as example 11), along with a swatch from the preceding Example 11 and an untreated fabric swatch as a control. The color of the fabric swatch was unchanged after treatment as compared to the control.


Dried swatches were let to cool to room temperature prior to UPF/UVA measurement on a UV Spectrophotometer Labsphere 2000F using method EN 13758-1:2007 on the 9 location ISO Mask. The dried treated swatches were then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after three washing and drying cycles. The results are shown in table 11, along with the results of Examples 10, 12 and 13.


Example 12

In this example, an aqueous solution containing ferulic acid and Tween 20 was used to treat three undyed fabric swatches with a composition of 97% polyester/3% Spandex.


A treatment concentrate was prepared by mixing Tween 20 and ferulic acid at 20:1 weight ratio and stirred thoroughly at room temperature until no ferulic acid particle was observed. The concentrate was then diluted in water at room temperature to prepare a treatment solution at a 4 g/L ferulic acid concentration. 100 mL treatment solution was then transferred to a 300 mL steel beaker designed for the Ahiba IR dyeing machine. A 10-gram fabric swatch was immersed in the treatment solution (10:1 liquor ratio). The beaker was then installed into the Ahiba IR dyeing machine and treated for 30 minutes at 130° C. After the treatment process, the fabric swatch was retrieved with a tweezer and rolled through a manual wringer to remove excess solution. The swatch was dried and cured in a Thermo Scientific oven at 130° C. for 5-10 minutes. The dried swatch was let to cool to room temperature prior to UPF/UVA measurement. An image of the dried swatch is shown in FIG. 20 (labeled as example 12), along with a swatch from the following Example 13 and an untreated fabric swatch as a control. The color of the fabric swatch was tinted yellow after treatment as compared to the control.


UPF/UVA measurement of treated swatches were collected on a UV Spectrophotometer Labsphere 2000F using method EN 13758-1:2007 on the 9 location ISO Mask. The swatches were then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after three washing and drying cycles. The results are shown in the table 11, along with the results of Examples 10-11 and 13.


Example 13

In this example, an aqueous solution containing ethyl ferulate and Tween 20 was used to treat three undyed fabric swatches with a composition of 97% polyester/3% Spandex.


A treatment concentrate was prepared by mixing Tween 20 and ethyl ferulate at a 20:1 weight ratio at 70° C. until the ethyl ferulate was completely dissolved. The concentrate was then diluted in water at room temperature to prepare a treatment solution at a 4 g/L ethyl ferulate concentration. 100 mL treatment solution was then transferred to a 300 mL steel beaker designed for the Ahiba IR dyeing machine. A 10-gram fabric swatch was immersed in the treatment solution (10:1 liquor ratio). The beaker was then installed into the Ahiba IR dyeing machine and treated for 30 minutes at 130° C. After the treatment process, the fabric swatch was retrieved with a tweezer and rolled through a manual wringer to remove excess solution. The swatch was dried and cured in a Thermo Scientific oven at 130° C. for 5-10 minutes. The dried swatch was left to cool to room temperature prior to UPF/UVA measurement. An image of the dried swatch is shown in FIG. 20 (labeled as example 13), along with a swatch from the previous Example 12 and an untreated fabric swatch as a control. The color of the fabric swatch was unchanged after treatment as compared to the control.


UPF/UVA measurement of treated swatches were collected on a UV Spectrophotometer Labsphere 2000F using method EN 13758-1:2007 on the 9 location ISO Mask. The treated swatches were then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after three washing and drying cycles. The results are shown in the table 11, below, along with the results of Examples 10-12.













TABLE 11









Bath
UNWASHED
3X WASHED













temp

UVA

UVA


Formulation
(° C.)
UPF
(% T)
UPF
(% T)





Control
NA
28 ± 1
9.9 ± 0.2
51 ± 6
7.3 ± 0.4


Ferulic acid +
25
41 ± 2
6.2 ± 0.2
89 ± 8
4.8 ± 0.1


Tween 20


(Example 10)


Ethyl Ferulate +
25
 51 ± 11
4.4 ± 0.6
102 ± 24
5.4 ± 0.5


Tween 20


(Example 11)


Ferulic acid +
130
112 ± 28
3.8 ± 0.7
100 ± 5 
4.4 ± 0.1


Tween 20


(Example 12)


Ethyl Ferulate +
130
92 ± 8
2.7 ± 0.2
109 ± 9 
3.8 ± 0.2


Tween 20


(Example 13)









The results of Examples 10-13 show that both formulations improved UPF and UVA values. The improvement was more pronounced with increasing bath temperature, likely due to more efficient diffusion of the UV absorbing compounds into the fiber material. It was observed that the color of fabric was unchanged when the treatments were applied at room temperature, in both cases. When applied at 130° C., fabrics treated with ethyl ferulate maintained their color, while those treated with ferulic acid turned yellow. This color change indicates a change in chemical structure of ferulic acid, likely hydrolytic degradation or condensation induced by elevated temperature.


Example 14

In this example, an aqueous caffeic acid solution was used to treat fabric swatches with a composition of 87% recycled polyester/13% spandex.


In a 200 mL beaker equipped with a magnetic stir bar, 100 mL deionized water and 0.4 g caffeic acid were added to reach a 4 g/L concentration of caffeic acid. The solution was heated to 70° C. while stirring at 180 rpm. Temperature was monitored with a temperature probe, and the beaker was covered with foil to prevent water evaporation. Once the temperature was reached and ferulic acid was completely dissolved, a 5-gram fabric swatch was immersed in the solution (20:1 liquor ratio). The stir bar was slowed to 60 rpm to maintain agitation while the fabric swatch was soaked in solution and treated for 15-30 minutes. The swatch was retrieved with tweezers and excess solution was squeezed out from the fabric until water stopped dropping. The swatch was dried in a Vastex D-100 Infrared Curing System at 80° C. for 10 minutes or until dry.


The dried swatch was let to cool to room temperature prior to UPF/UVA measurement.


The dried treated swatch was then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after three washing and drying cycles. The results are shown in the table below.













TABLE 12









Bath
UNWASHED
3X WASHED













temp

UVA

UVA


Formulation
(° C.)
UPF
(% T)
UPF
(% T)





Control
NA
 97 ± 5
  9 ± 0.2




Caffeic acid
70
235 ± 8
1.8 ± 0.0
216 ± 33
3.3 ± 0.5









Example 15

In this example, an aqueous chlorogenic acid solution was used to treat fabric swatches with a composition of 87% recycled polyester/13% spandex.


In a 200 ml beaker equipped with a magnetic stir bar, 100 mL deionized water and 0.2 g chlorogenic acid were added to reach a 2 g/L concentration of chlorogenic acid. The solution was heated to 70° C. while stirring at 180 rpm. Temperature was monitored with a temperature probe, and the beaker was covered with foil to prevent water evaporation. Once the temperature was reached and ferulic acid was completely dissolved, a 5-gram fabric swatch was immersed in the solution (20:1 liquor ratio). The stir bar was slowed to 60 rpm to maintain agitation while the fabric swatch was soaked in solution and treated for 15-30 minutes. The swatch was retrieved with tweezers and excess solution was squeezed out from the fabric until water stopped dropping. The swatch was dried in a Vastex D-100 Infrared Curing System at 80° C. for 10 minutes or until dry.


The dried swatch was let to cool to room temperature prior to UPF/UVA measurement.


The dried treated swatch was then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after three washing and drying cycles. The results are shown in the table below.













TABLE 13









Bath
UNWASHED
5X WASHED













temp

UVA

UVA


Formulation
(° C.)
UPF
(% T)
UPF
(% T)





Control
NA
97 ± 5 
  9 ± 0.2




Caffeic acid
70
400 ± 163
2.2 ± 0.2
228 ± 24
2.9 ± 0.5









Example 16

In this example, an aqueous solution of ferulic acid and chlorogenic acid was used to treat fabric swatches with a composition of 87% recycled polyester/13% spandex.


In a 200 mL beaker equipped with a magnetic stir bar, 100 mL deionized water, 0.2 g ferulic acid, and 0.1 g p-coumaric acid were added. The solution was heated to 70° C. while stirring at 180 rpm. Temperature was monitored with a temperature probe, and the beaker was covered with foil to prevent water evaporation. Once the temperature was reached and ferulic acid was completely dissolved, a 5-gram fabric swatch was immersed in the solution (20:1 liquor ratio). The stir bar was slowed to 60 rpm to maintain agitation while the fabric swatch was soaked in solution and treated for 15-30 minutes. The swatch was retrieved with tweezers and excess solution was squeezed out from the fabric until water stopped dropping. The swatch was dried in a Vastex D-100 Infrared Curing System at 80° C. for 10 minutes or until dry.


The dried swatch was let to cool to room temperature prior to UPF/UVA measurement.


The dried treated swatch was then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after three washing and drying cycles. The results are shown in the table below.













TABLE 14









Bath
UNWASHED
3X WASHED













temp

UVA

UVA


Formulation
(° C.)
UPF
(% T)
UPF
(% T)





Control
NA
97 ± 5
 9 ± 0.2




Ferulic acid +
70
237 ± 24
3.9 ± 0.04
237 ± 27
4.5 ± 0.1


p-coumaric acid









Example 17

In this example, fabrics with various cover factors were treated with ferulic acid at room temperature, and are applied following method described in Example 1 or Example 10. The fabrics were selected from a range of material and cover factor selections. Fabric materials were grouped based on the composition of the majority component. Polyester group contains fabrics with compositions 100% polyester, or blends with 93%/7%, 90%/10%, or 87%/13% Polyester/Spandex by weight, or 76% recycled polyester, 19% tencel lyocell, 5% elastane, or 94% Polyester, 4% Nylon, 2% Spandex. Nylon fabric was composed of 100% Nylon. Cotton fabrics were composed of 100% cotton or 96% Modal 4% Spandex, by weight. The colors of the fabrics were light shades, such as White, light blue, or light green. The UPF and UVA data presented was collected from swatches before and after treatment. The fabrics were not washed prior to measurements.


The results are shown in FIGS. 21 and 22, in which the UPF and UVA of all fabric types improved after the treatment. FIG. 21 shows the UPF of fabrics with various cover factors before and after application. FIG. 22 shows the UVA of fabrics with various cover factors before and after application. Once applied with a ferulic acid containing finish, the UPF of the fabrics increased above 50 for a broad range of cover factors (50-100%). Similarly, UVA transmittance of fabrics was significantly reduced. For fabrics with cover factors 94% or higher, less than 5% UVA transmittance was achieved, meeting requirements of the EU regulations.


Example 18

In this example, undyed fabric swatches with a composition of 97% polyester/3% Spandex were treated with commercially available UPF enhancers Rayosan PES (Archroma), Jintex TUV (Jintex), and Fadex F (Archroma). Solutions were prepared according to technical data sheets of each product. To prepare a 3% solution, 0.6 g Rayosan PES was dissolved in 200 mL deionized water. Similarly, 0.8 g Jintex TUV or Fadex F was added to 200 mL deionized water, to prepare a 4% solution. Each solution was stirred at room temperature for 10 minutes until fully incorporated. 100 mL of treatment solution was then transferred to a 300 mL steel beaker designed for the Ahiba IR dyeing machine. Two swatches per treatment condition were prepared. A 10-gram fabric swatch was immersed in the treatment solution (10:1 liquor ratio). The beaker was then installed into the Ahiba IR dyeing machine and treated for 30 minutes at 130° C. After the treatment process, the fabric swatch was retrieved with a tweezer and gently squeezed by hand to remove excess solution. The swatch was rinsed by hand under cold running water and excess was again squeezed out by hand before curing in a Thermo Scientific oven at 130° C. for 20 minutes until dry. The dried swatch was left to cool to room temperature prior to UPF/UVA measurement.


UPF/UVA measurement of treated swatches were collected on a UV Spectrophotometer Labsphere 2000F using method EN 13758-1:2007 on the 9 location ISO Mask. The treated swatches were then subjected to the following washing protocol. Laundering was performed on an SDL Atlas Vortex M6 washing machine following AATCC LP1 protocol for Delicate Cold wash using 1993 AATCC Standard Reference Detergent WOB. The washed swatch was dried using SDL Atlas Vortex M6D with Fabric Selector set to Delicate and dry cycle set to the middle indicator between “More Dry” and “Less Dry” for Automatic Regular/Delicate. UPF/UVA measurements were obtained after three washing and drying cycles. The results are shown in the table below in comparison with the Ethyl Ferulate and Tween 20 treatment at the same temperature on the same composition of fabric. (Example 13)













TABLE 15









Bath
UNWASHED
3X WASHED













temp

UVA

UVA


Formulation
(° C.)
UPF
(% T)
UPF
(% T)





Control
control
28 ± 1
9.9 ± 0.2
51 ± 6
7.3 ± 0.4


Rayosan PES
130
177 ± 18
2.70 ± 0.09
152 ± 45
2.97 ± 0.33


Jintex TUV
130
211 ± 15
0.62 ± 0.02
209 ± 37
0.57 ± 0.10


Fadex F
130
169 ± 31
0.79 ± 0.09
153 ± 13
0.83 ± 0.05


Ethyl Ferulate +
130
92 ± 8
2.7 ± 0.2
109 ± 9 
3.8 ± 0.2


Tween 20


(Example 13)









The treated swatches can be seen in FIG. 23. The fabric swatches include, from left to right, the control, Rayosan PES, Jintex TUV, Fadex F, and Ethyl Ferulate and Tween 20 treatment. These results show that the ethyl ferulate and Tween 20 treatment produced results comparable to the commercial products without changing the color of the fabric. In the foregoing description, the inventions have been described with reference to specific embodiments. However, it may be understood that various modifications and changes may be made without departing from the scope of the inventions.

Claims
  • 1. A method of treating a fabric to provide UV protection, the method comprising: soaking the fabric in an aqueous solution of ferulic acid and/or a ferulic acid derivative;removing the fabric from the aqueous solution; anddrying the soaked fabric.
  • 2. The method of claim 1 wherein the aqueous solution comprises ferulic acid and wherein the aqueous solution is at a temperature of between about 25 degrees C. to about 90 degrees C. during the soaking step.
  • 3. The method of claim 2 wherein the aqueous solution is at a temperature of between about 75 degrees C. and about 90 degrees C. during the soaking step.
  • 4. The method of claim 1 wherein the aqueous solution comprises ethyl ferulate and wherein the aqueous solution is at a temperature of between about 25 degrees C. and about 130 degrees C. during the soaking step.
  • 5. The method of claim 4 wherein the aqueous solution is at a temperature of between about 100 degrees C. and about 130 degrees C. during the soaking step.
  • 6. The method of claim 1 wherein the aqueous solution further comprises one or more surfactants, the one or more surfactants together have a hydrophilic lipophilic balance (HLB) of between about 14 and about 20.
  • 7. The method of claim 1 wherein the aqueous solution comprises a ferulic acid derivative comprising sinapic acid, chlorogenic acid, caffeic acid, rosmarinic acid, p-coumaric acid, and/or ethyl hexyl ferulate.
  • 8. The method of claim 1 wherein the drying the soaked fabric comprises heating the soaked fabric at a temperature of between about 80 degrees C. and about 180 degrees C.
  • 9. A UV protective fabric comprising a fabric having fibers with ferulic acid and/or a ferulic acid derivative absorbed by the fabric fibers, wherein the UV protective fabric protective fabric has a UVA transmittance of less than 5%.
  • 10. The UV protective fabric of claim 9, wherein the UV protective fabric is created by the process comprising: soaking a fabric in an aqueous solution of ferulic acid and/or a ferulic acid derivative;removing the fabric from the aqueous solution; anddrying the soaked fabric;wherein the UV protective fabric has a UPF of about 50 or more.
  • 11. The fabric of claim 10 wherein the aqueous solution comprises ferulic acid or ethyl ferulate and one or more surfactants having an HLB of between about 13 and about 20.
  • 12. The fabric of claim 10 wherein the aqueous solution further comprises a dye, and wherein the UV protective fabric has a color produced by the dye wherein the color is not affected by the ferulic acid or ferulic acid derivative.
  • 13. The fabric of claim 9 wherein the fabric has ferulic acid absorbed by the fabric fibers.
  • 14. The fabric of claim 9 wherein the fabric has ethyl ferulate absorbed by the fabric fibers.
  • 15. The fabric of claim 9 wherein the fabric comprises a polyester blend.
  • 16. The fabric of claim 9 wherein the fabric comprises a garment.
  • 17. The fabric of claim 9 wherein the fabric has a color and wherein the color is unchanged by ferulic acid and/or ferulic acid derivative absorbed by the fabric fibers.
  • 18. A method of treating a fabric to provide UV protection, the method comprising: soaking the fabric in an aqueous solution at a temperature of between about 25 degrees C. and about 130 degrees C. for between about 5 minutes and about 30 minutes, the aqueous solution comprising ferulic acid and/or a ferulic acid derivative and one or more surfactants having an HLB of between about 10 and about 20;removing the fabric from the aqueous solution; anddrying the soaked fabric at a temperature of between about 80 degrees C. and about 180 degrees.
  • 19. The method of claim 18 wherein the aqueous solution comprises ferulic acid, wherein the HLB of the one or more surfactants is between about 14 and about 20, and wherein the temperature of the aqueous solution is between about 75 degrees C. and about 90 degrees C.
  • 20. The method of claim 18 wherein the aqueous solution comprises ethyl ferulate and wherein the temperature of the aqueous solution is between about 100 degrees C. and about 130 degrees C.
CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application 63/588,855, filed Oct. 9, 2023, entitled UV Resistant Fabrics and Treatment Methods, the disclosure of which is hereby incorporated by reference in the entirety.

Provisional Applications (1)
Number Date Country
63588855 Oct 2023 US