CZ204894A3 - Multilayer non-woven composite cloth - Google Patents

Abstract

A multi-layered nonwoven composite web has a first and third (12'; 20) layers of fibrous material selected from the group consisting of man-made, thermoplastic man-made staple fibres and combinations thereof and weighting between 0.05 and 10 ounces per square yard and having a second layer (14') of non-wood cellulose base staple fibre of between 0.1 to 10 ounces per square yard sandwiched between and all thermobonded into a coherent web with the area of bonding to being between 5-75% of the area of the web and having an air permeability of 25-37 cubic feet per minute per square yard. Also claimed are a composite where the first and third layers have a void volume in excess of 85% and a web having a wick rate of water of 0.01-0.05 grammes per second and a water retention value of 3 kPa of between 7 and 15.

Description

The present invention relates to fibrous fabrics and in particular to novel composite fabrics consisting of one or more layers of thermoplastic nonwoven material and one layer of cellulose-based fibers (hereinafter cellulose fibers).

BACKGROUND OF THE INVENTION

Nonwoven fabrics are defined as planar or nonwoven structures made by joining or intertwining short or long fibers or yarns by mechanical, thermal or chemical means or by solvent. These fabrics do not require the fibers to be converted into yarn. Nonwovens are also called spun or technical and are called nonwovens because they are made by processes other than spinning, weaving, or knitting. The basis of all nonwoven fabrics is a fibrous structure which may consist of only one type of fiber. Fibers that are measured in centimeters or inches, or fractions thereof, are called staple fibers. Very long fibers are called filaments and are typically measured in kilometers or miles. In fact, they are not easy to measure because they can be tens or hundreds of yards in length. For fibers, their length must be much greater than their diameter, eg the length-to-width (diameter) ratio must be at least 100, but is much greater. The length of the cotton fibers may be less than 1/2 inch and may be up to more than 2 inches with a typical length to diameter ratio of approximately 1400. Other natural fibers exhibit the following typical ratios: linen -1200, ramie-3000 and wool-3000.

In the present application, the terms fiber or fibers will refer to both short and long fibers, ie staple fibers and filaments, unless explicitly stated otherwise in the text. E.g. spunbonded fabrics are made up of filaments, while meltblown fabrics consist of fibers of different lengths so that both staple fibers and filaments can be found. The individual fibers in the nonwoven can be arranged in an organized or random fashion. Each fabric has mechanical, tensile and contact properties that result from the type of bonding and the degree of bonding of the fibers as well as the overall reinforcement of the fabric by its components. The nonwoven fabrication technology comprises the following primary steps: fibers of different lengths and diameters; fabric structure according to production and processing method; bonding the fiber in the structure and reinforcing the individual components. By combining one or more of these elements, a huge number of types of nonwoven fibrous webs can be produced. By selecting the type and length of the fibers and the bonding process and selecting the optimum production process, a highly technical yet extremely flexible combination of variants can be achieved.

Nonwovens have been successfully used in healthcare as disposable replacements of earlier cotton, reusable medical and surgical gowns, surgical drapes, face masks, shoe covers, sterile packs, and other items, and are estimated to be more than $ 1 billion a year . In addition, nonwoven fabrics have found application in the manufacture of medical products such as sanitary napkins, sanitary napkins, disposable diapers and other similar articles. One of the advantages of nonwovens compared to woven fabrics has so far been their relatively low cost. The difference between the price of nonwoven and woven fabrics has so far been so great that end users were able to throw away the nonwoven after one use, yet they were economically worthwhile compared to reusable woven fabrics.

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Among the excellent properties of nonwovens for medical and hygienic use are their pleasant feel (softness and flowability), wicking capacity, liquid retention capacity, absorbency and strength. End users also appreciate the extent to which the properties of nonwovens are close to those of fabrics, especially cotton. In general, nonwoven fabrics are believed not to have a number of properties that distinguish fabrics, in particular pleasant feel, capillarity and the ability to absorb and retain liquids. For example, blown nonwoven fabrics have an air volume of about 85%, spunbonded nonwoven fabrics of about 90 to 95%. In addition, these structures have undesirable chemical properties, e.g., they are hydrophobic and thus not very suitable, for example, for medical applications. In addition, the surface

-3these nonwovens smooth, so it is slick and greasy to look and feel. The fibrous material of prior art nonwoven fabrics usually exhibits a low surface tension, so that it does not attract water, and consequently these fabrics have a low ability to absorb and retain water-containing liquids. These fabrics are also difficult to impregnate with liquid formulations. Further, due to the lengths of the fibers and the method for producing the fibers, the fibers lie in the structure such that their length is substantially oriented parallel to the plane of the fabric, thereby giving the fabrics a low liquid absorption capacity. Therefore, considerable efforts have been made to improve these properties of the nonwoven and to change the technology of their production and / or processing. However, these improvements increase the cost of the nonwoven fabric and may negatively affect its financial advantage over woven fabrics. In addition, nonwoven fibers are made from petroleum and are therefore subject to substantial fluctuations in the price of this raw material and, moreover, their final disposal after use has to be addressed.

The essence of the invention *

The present invention provides a brand new multilayer composite fabric, all layers of which are nonwoven, which exhibits the same properties as a woven fabric, while maintaining / economical to the nonwoven. The fabric of the present invention is multilayered. Its first layer is of man-made fibrous material selected from the group consisting of thermoplastic blown artificial fibers, thermoplastic spun synthetic fibers, thermoplastic man-made staple fibers and combinations thereof, and is light in weight, ranging from about 0.05 to 10 ounces / yard2. The second layer consists of cellulose staple fibers with the exception of wood fibers and has a basis weight of between 0.1 and 10 ounces / yard2. The fibers of the second layer have a length in the range of about 0.5 to 3 inches and a fineness (size) between 3 and 5 Micronaire units. The layers are most often thermally bonded to form a unitary structure, with the joints between the layers constituting about 5 to 75% of the area of one of the planar surfaces of the composite fabric. The type of bonding contemplated in the present invention does not adversely affect the feel and other physical properties of the fabric, such as the degree of capillarity and fluid retention. Therefore, the joining is performed only from one side of the laminate. In an optimum embodiment, the composite fabric has at least one (third) layer of fibrous material selected from the group consisting of thermoplastic blown man-made fibers, thermoplastic spun man-made fibers, thermoplastic man-made staple fibers, and combinations thereof. The third layer is also light in weight, having a basis weight of between about 0.05 and 10 oz (yard), touching the second layer on the side facing away from the first layer, and thermally bonding to at least the second layer such that the second layer a layer is sandwiched between the first and third layers. The composite fabric may further comprise other similar layers of similar materials.

Regardless of the number of layers of the entire structure, the proposed composite fabric should optimally have a total basis weight of between about 0.5 and 24 oz / yd ^ to bring it as close as possible to the woven fabrics to the touch, drape and other properties. This goal can be achieved by carefully selecting individual low basis weight layers. Other desirable or desired properties such as strength, capillarity, fluid uptake and retention properties, and barrier capability (the ability to eliminate liquid while allowing or even promoting) can also be achieved. vapor or gas transfer through the entire thickness of the structure).

The composite fabric of the present invention is particularly suitable for the manufacture of disposable medical products due to its ability to form a barrier, pleasant feel, airiness, strength, capillarity, the ability to absorb and retain liquids and other great properties.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a schematic representation of one embodiment of a fabric incorporating various features of the present invention.

Fig. 2 is a schematic representation of another embodiment of a fabric incorporating various features of the present invention.

Figure 3 is a schematic representation of a fabric forming process incorporating various features of the present invention.

Fig. 4 is a schematic representation of another fabric manufacturing process incorporating various features of the present invention.

Fig. 5 is a schematic representation of yet another fabric manufacturing process and fabric manufacturing apparatus included in the process.

6 shows an apparatus for measuring the absorbency and retention properties of textiles.

7 shows a fabric wicking test apparatus.

Giant. Figures 8 to 34 show graphs of wicking values of samples according to the data in Table X.

Fig. 35 shows a graph of the wicking values of the laminates of the present invention at different weights of the cotton core.

Fig. 35 is a graph of capillarity of non-laminate cotton fabrics 11i.

Figure 37 shows a graphical comparison of the capillarity of cotton core laminates and ramie core laminates.

DETAILED DESCRIPTION OF THE INVENTION

The composite fabric 10 of FIG. 1 consists of a first layer 12 and a second layer 14. As shown in the figure, these layers are connected to each other by diamond-like bonding faces 16 that are substantially the same size and equidistant from each other. Optimally, these bonding surfaces should extend substantially over the entire surface of the composite fabric, thereby joining the individual layers into a unitary structure. Figure 2 shows another embodiment of the fabric 10, which also consists of the first and second layers 12 'and 14' respectively, and in addition the third layer 20.

At least one layer of the composite fabric of the present invention is of thermoplastic man-made fibers. It is therefore possible to bond the individual layers of fabric to one of the known thermal bonding methods, for example by stretching the superposed layers between a set of heated rolls. At least one of these rollers should have a surface formed by protrusions 30 (see FIG. 3) that form separate diamond-like bonding faces in FIG. 1, formed by a combination of pressure and heat exerted on the fabric as it passes between the rolls. It is also possible to use other thermal bonding methods such as ultrasonic welding and the like. Other techniques for bonding layers of the composite fabric of the present invention may be the physical fiber entanglement of multiple layers, e.g., hydroentanglement, needling, and the like. In any case, the optimal way of bonding the individual layers is to provide separate, relatively small bonding areas which extend substantially over the entire surface of the composite fabric and convert the individual layers into a unitary unitary structure without adversely affecting the desired properties of the fabric. When bonding, the bonding areas cover about 5 to 75% of the surface of the composite fabric. However, the optimum overall surface coverage of the composite fabric by the bonding pads is about 10 to 25%.

In one method of making the composite fabric of the present invention, each of the fabric layers is formed separately and the layers are laminated. The individual fabric layers are stacked and joined as described above. It will be appreciated, however, that it is possible to form several layers of the present fabric substantially simultaneously, such as in an inline manufacturing process where one of the layers is formed and then a second or another layer is formed on the first or previous layer. In this second example, the bonding process can also take place inline and from below to the base layer so that it is possible to form the entire layer on both sides of the final layer. These manufacturing processes are well known to those skilled in the textile industry. Fig. 3 shows schematically the process of laying the previously formed layers 15, 17 and 19 on top of a conveyor 21 moving forward and subsequently joining the layers into an integral structure 10 therewith.

In this embodiment, the upper roller 28 is provided with surface protrusions 30 that allow the formation of separate joints 16.

It can be seen from the figure that the composite fabric 10 is wound onto a roll 32 for storage and subsequent use. The layers 15 and 19 may be made of man-made fibers, for example, by spinning, melt blowing, or other processes that provide a solid self-supporting fabric.

Fig. 4 schematically illustrates the process of fabric manufacturing according to * 1

In the present invention, the first synthetic and thermoplastic fiber layer 40 is manufactured by the traditional blown or spinning method 44 and then deposited on a forward moving conveyor 42. The cellulose fiber layer 48, either pre-formed (offline) or simultaneously (inline) As shown in FIG. 5, it is placed on the first layer 40 disposed on the conveyor belt 42. The third layer 50 of thermoplastic man-made fibers is manufactured by the traditional blowing or spinning method 51 and laid on the cellulosic layer 48 to form a three-layer structure in a layer of cellulosic fibers 48 is disposed between the outer layers 40 and 50 of artificial thermoplastic fibers. In the illustrated process, the plurality of superposed layers extend through a gap between two heated pressure rollers 54 and 56, one of which has protrusions 58 on the outer surface to allow thermal interconnection of the plurality of layers into an integral structure 59. The composite fabric may be collected on the roll 60 for further use. As will become clearer below, one of the layers 40 and 50 (the first and second layers), or both, can be made by traditional blow molding, spinning, or the like, including thermal bonding of the artificial staple fiber structures.

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Fig. 5 illustrates another embodiment of a fabric manufacturing process in accordance with the present invention. In this embodiment, the first man-made fiber layer 64 is made by blowing or spinning by an inline machine 66, guided over a guide roller 65 and placed on top of a first conveyor 67. As shown in the figure, the process also includes a carding section 68 in which the cellulose fiber package 69 is introduced into an inline carding line 70 from which it is carded

The textile 71 is applied directly to the second conveyor 72. From the conveyor 72, the cellulosic layer is laid on the layer 64 on the conveyor 67. Further, a third synthetic fiber layer 74 is formed by another traditional inline blowing or spinning apparatus 75 which is fed over the guide pulley 76. and laid on the surface of the cellulosic layer 71 such that the cellulosic layer 71 is sandwiched between the synthetic fiber layers 64 and 74.

These layers are advanced in the forward direction by a gap 77 between the two heated rollers 78 and 79, of which the upper 78 is provided on the outer surface with protrusions 81 which achieve separate thermal joints between at least the upper layer 74 and the cellulose layer 71. in an integral structure. The tightly bonded composite fabric 83 is wound onto a roll 85 for storage and subsequent use. It is also possible to form an artificial staple fiber layer 87 using a conventional air former 89 and insert it into the composite structure 83 between the cellulose layer 71 and one or both of the synthetic fiber layers 64 and 74.

In the present invention, the composite fabric consists of at least two layers. At least one layer must be made of cellulose fibers. For the purposes of this invention, the term cellulose is understood to be made of staple fibers containing from 25 to 100% cellulose. Cellulosic materials suitable for making fibers include cotton, ramie, hemp, jute, flax, kenaf, pressed sugarcane, eucalyptus, viscose rayon (regenerated cellulose) and combinations thereof, but not wood fibers. The selected cellulosic fiber is typically processed in a known manner so as to result in a clean, clear fiber that readily absorbs liquids. For example, the cotton is cleaned and bleached to remove grease or the like from the fibers, and to make the fiber compliant and absorbent while not containing any foreign matter and having a clear color (white is considered a color). However, for many applications, only partial cleaning and bleaching is not required, as the degree of absorbency and / or capillarity of the fibers is sufficient for the purpose. Cellulose fibers suitable for making the present invention have a length of from about 0.5 to 3 inches. The cotton fibers should be about 0.5 to 1.25 inches long, while the ramie or flax fibers may have a maximum length of 3 inches.

-9Long fibers can be broken or chopped to desired length as needed. The cellulose fibers used do not convert into yarns or threads. However, they can be processed, for example, by carding or the like, so as to be oriented in a certain direction or, conversely, randomly to form a self-supporting structure. The fibers can be used directly from the package from the manufacturing process and introduced into the composite fabric as a layer in which the fibers are carded more or less parallel to each other or randomly oriented. The fineness of the cotton fibers should be between about 3 and 5 Micronaire units to provide sufficient flexibility and desired hand feel quality, drapability, and other properties of the composite fabric of the present invention. Cotton fibers larger than about 5 Micronair are less elastic and the fabrics formed from them tend to be rough and uncomfortable.

Cotton fibers are the preferred type of cellulose fibers for the production of the composite fabric of the present invention. They do not have a smooth surface and, unlike polyolefins having a surface tension (energy) of 31 dynes / cm, the cotton fibers r exhibit a surface tension of 44 dynes / cm and thus tend to remain in place after being embedded in the composite fabric of the invention. In addition, the cotton fibers multiply the excellent properties of the composite fabric, such as its capability, absorbency and fluid retention / capacity, volume expansion, water repellency ¹ while permitting vapor and gas leakage, and possibly even strength, especially when the blown structures have a basis weight than 0.5 g / m @ 2 (17 g / m @ 2).

Regardless of which cellulose fiber is used to form the inner layer of the present multilayer composite fabric, this inner layer must be composed of staple fibers and not filaments. Only staple fibers that are relatively short in length and often are combined in different lengths, all of which are less than 3 inches and optimally more than 2 inches, guarantee the diversity of their ends. Since these fibers are not spun into yarn, but are present individually in the inner layer and have no more distinct orientation than being arranged in a structure that is sufficiently compact for automatic devices to lay on the conveyor or other textile structure on the conveyor, terminating these fibers

10 the tendency to stretch in the textile structure in all directions. Thus, many fiber ends generally extend longitudinally with respect to the plane of the fabric and even protrude from the planar surface of the fabric. This property of the staple fiber fabric is one of the most important reasons why it is not used in this form in medicine. In accordance with the present invention, this unacceptable fabric may be attached between two fabrics of artificial nonwoven fibers so that the artificial fibers retain the short cellulose fibers.

However, these artificial fiber textile layers must be carefully selected so as not to adversely affect the feel and other desirable properties of the resulting composite fabric. Artificial fiber fabrics are also preferred because they allow the cellulosic fibers of the inner layer to impart desirable feel, capillarity and retention to the composite fabric. This object is achieved in the present invention by using synthetic fiber fabrics produced by a technology that guarantees sufficient air volume and at the same time of fine fibers to serve as a barrier to bacteria and the like while avoiding the penetration of vapors or liquids into an inner layer of cellulose fibers where the liquid is rapidly retained and impermeable to the outside.

The ends of the short staple fibers of the inner layer of the composite fabric, which are oriented generally laterally with respect to the plane of the inner layer, serve to delimit areas of liquid transport into the inner layer. The outer layers of synthetic fibers are inherently hydrophobic and have a low surface tension. Their fibers are uniformly long and carry fluid poorly. In contrast, the staple fibers of the inner layer are hydrophilic.

and have a relatively high surface tension, are smooth, twisted over a length of ^1, and many are so capable of draining liquid) into the body of the inner layer. In addition, the plurality of staple fiber ends of the inner layer, which extend longitudinally with respect to the plane of the inner layer, serve as pathways for conveying the liquid into the inner layer, both because of its affinity for liquids and because of its large number, the geometry and orientation in the inner layer are created by a large number of capillaries that assist in the movement of liquids into the inner layer and the retention of liquids within the layer. Cotton fibers also swell when soaked, so that they

-11 Suitable for textiles that are designed to absorb liquids and serve as barriers.

As practice shows, a cellulose fiber fabric in which the fibers are not bonded to each other is unsuitable for most disposable medical products. Firstly, it is not strong enough to be self-supporting, and secondly, the fibers tend to release from the fabric and thus constitute unacceptable potential sources of contamination. E.g. loose fibers from surgical gowns, which could get into an open wound or incision, could be a source of granulomas and therefore fabrics for these applications must have fibers adequately fastened. According to the present invention, cellulose fibers can be combined with thermoplastic man-made fibers.

As will be discussed below, the combination of the cellulosic fiber layer and the thermoplastic synthetic fiber layer, which are thermally bonded to each other by separate bonding pads, produces a coherent composite fabric that exhibits improved properties, in particular wicking, retention and strength. In particular, the synthetic fiber layer imparts strength and abrasion resistance to the composite fabric, and therefore the cellulosic fiber layer is sandwiched between the outer synthetic fiber layers.

Previously blown and spun fabrics of thermoplastic man-made fibers required special and additional treatment to be used to produce disposable medical and sanitary products. However, the present inventors have found that by using selected fabrics with cellulose-based layers it is possible to produce a firmly bonded composite fabric that does not require any special treatment of the synthetic fiber layer and that these fabrics can be directly incorporated into the composite structure. Because of this ability, the present invention has a substantial economic benefit.

According to the present invention, the man-made fiber fabrics are made by blowing or spinning technology. The diameter of the blown man-made fibers should be approximately 0.5 to 10 microns, while the diameters of the fibers in the spun fabrics are between 8 and 50 microns. Generally, the spun fibers are coarser, but stronger than the blown fibers, since they acquire a strong orientation upon cooling. In both cases, the fibers form a self-supporting structure. The optimum basis weight of the blown fabric suitable for use in the present invention is very low, in the range of from about 0.05 to 10 oz / ydd, and preferably from 0.25 to 2 oz / yd ^. The optimum basis weight of the spunbonded fabric suitable for use in the present invention is also very low, in the range of about 0.1 to 10 oz / ydd, and most preferably between 0.3 and 2 oz / yd ^. Fabrics with a basis weight less than about 0.05 oz / yd generally do not have a sufficiently high fiber density to maintain cellulosic fibers and exhibit sufficient strength and other qualities required for composite

textilii. Fabrics with a higher basis weight, i.e., above 10 oz / yd < 3 > make, in combination with the cellulose layer, a composite fabric too coarse. For a more specific description of the spinning and blowing methods and fabrics produced by these processes, see: Proceedings, Fiber Producer Conference 1983,

12.-14. April 1983, pp. 6-1 to 6-11, which is incorporated herein by reference.

As already mentioned, the optimum composite fabric of the present invention comprises an inner layer of cellulose fibers that is sandwiched between the outer layers of man-made fibers. The composite fabric can therefore consist of different combinations of layers.

For example, in addition to the desired cellulosic fiber layer, the composite fabric may have a first blown synthetic fiber layer that contacts one side of the cellulosic fiber layer and a third spun synthetic fiber layer that touches the other side of the cellulose fiber layer. Similarly, the first and third layers may be either blown or spun fibers.

Further, it is possible to form multiple layers of cellulose fibers, which may or may not be separated by further inner layers of artificial fibers, whether blown or spun. In any case, the cellulose fibers must be protected by at least one outer layer and more preferably by two outer layers of artificial fibers. It should be appreciated that the addition of additional layers to the composite fabric increases its cost and may impair its feel and other qualities.

Samples of composite fabrics according to the present invention

The inventions were made as shown in FIG. The cellulose-based fibers were fed into a agitator and mixer where the fibers from the bale were loosened and mixed uniformly. From this machine, the fibers were fed to a carder, where a card was formed by carding, which was taken directly (without winding) from the carder and then laid on a layer of thermoplastic man-made fibers on a conveyor. The staple used in the manufacture of these samples had an output unit for random fiber orientation attached at the exit, so that the fibers were randomly arranged with little or no machine direction orientation. Thereafter, the cellulose fiber layer was covered with a third thermoplastic synthetic fiber layer such that the cellulose layer was sandwiched between the two outer layers of thermoplastic synthetic fibers. The laminate was then pushed through a gap between a set of heated rollers, one of which had a smooth surface and the other covered with separate diamond-shaped cross-sections. Further details of the operating parameters used in the manufacture of these samples and the composition of the various samples are given. Tables I and II.

TABLE I

Parameters and their levels

Parameter Number of levels Values

Blown textiles

1. Resin

2. Area weight text.

Staple fiber fabrics

1. Plos. mass

2. Contained fibers

3. Fiber denier

- cotton denier

- PP denier

Himont Val tec 442

Exxon PD 3495G

0.7 oz / yd ²

0.5 oz / yd ²

1.0 oz / yd ² cotton (C), polypropylene (PP)

1.75 (Veratec 'Easy Street')

2.2 (Hercules T-185) 3.0 (BASF bico 'Merge 1080')

-144. Length of fiber

- cotton fiber - PP fiber 1 1 1 inch 1.5 inches Thermal bonding 1. Shape of engraved surface 1 diamond. 2. Elevated area sample 1 16,6% * 3. Gap pressure 1 250 PLI (lbs / linear inch) 4. Temperature - upper cylinder 4 128 ° C, 133 ° C, 134 ° C, 135 ° C - lower cylinder 4 127 ° C, 129 ° C, 131 ° C, 132 ° C 5. Surface speed of calender rolls and 29 ft / min * Kusterova connecting surface calender used in production

of the samples in Table II.

TABLE II

Technological conditions for the production of blown / cotton / blown laminate samples

Sample No. Surface Mass ² Composition Injection (oz / yd ² )

Upper / Middle / Lower Upper Middle Lower 'Ί 1 0.7 / 1.0 / 0.7 UT-1-24 ³ 100% cotton UT-1-24 "in 2 0.7 / 1.0 / 0.7 UT-1-24 100% cotton UT-1-24 3 0.7 / 1.0 / 0.5 UT-1-24 100% cotton UT-1-17 ⁴ 4 0.7 / 1.0 / 0.7 UT-1-24 100% pp ⁵ UT-1-24 5 0.7 / 1.0 / 0.5 UT-1-24 100% pp ⁵ UT-1-17 6 0.7 / 1.0 / 0.5 UT-1-24 100% .BF pp ⁶ UT-1-17 7 0.7 / 1.0 / 0.7 UT-1-24 100% BF pp. ⁶ UT-1-24

-15 cry. TAB II

C. Coupling temperature Cylinder (° C) Composition composite textile Cotton (%) PP (%) Upper Lower 1 128 129 41.8 58.2 2 ¹³⁴ 129 41.8 58.2 3 134 129 45.4 54.6 4 135 132 0 100 5 135 132 0 100 6 135 132 0 100 7 135 132 0 100

production of 40 inch outer layer composed of blown polypropylene (PP) fibers of different lengths and middle staple layer blown polypropylene from Himont resin (0.7 oz / yd ^) blown polypropylene from Hercules resin (0.5 oz / yd ^) )

Polypropylene Hercules Grade T-185 BASF two-component fiber.

The following characteristics of the samples produced according to the data in Tables I and II were tested as follows:

Barrier - A barrier means the ability of a substance to withstand the ingress of fluid and microorganisms. Creating a barrier protects the operating room staff and patients from infection.

Test The test procedure used

Hydrostatic pressure test method AATCC

127-1985

Grease Replication Rate 118-1983 AATCC Test Method

-16Intersection when water strikes 42-1985

Water Spray Penetration Rate 22-1985 AATCC Test Method AATCC Test Method

Strength - Non-woven fabrics used in medical applications must also be strong enough to prevent them from tearing or puncturing all the time from production to use of the finished product.

Test

Test procedure

Strength at Strength v Strength at Elongation Elongation (Mull) Elongation at Tension

IST ¹ 110,0 - - 70 (82) IST 100,0 - - 70 (R82) IST 30,0 - - 70 (R82) IST 110,0 - - 70 (82)

Standard INDA test (Association of the Nonwovens Fabrics Industry)

Drapiness and comfort - the drapeability of a nonwoven fabric means its ability to adapt to the shape of the object it covers. These objects include patients, operating tables and equipment. Convenience means airiness, proper material selection and product design.

Test_Test procedure

Breathability (Frázier) IST 70.1 - 70 (R82)

Length for bending when suspended on beam ASTM D 1388 - 64

The results of these tests are shown in Tables IIIA and IIIB.

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Results of testing laminate textiles without

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The data in Table III show that the lightweight laminates of the present invention exhibit strength values that fully entitle them to replace previously made synthetic fiber materials, i.e., prior art textiles that have been popularly used in the medical field. In addition, the present laminates have good feel (bending length) and barrier properties as opposed to laminates not coated with cellulose fibers.

As will be seen later, the laminates of the present invention have excellent liquid absorption, retention and absorption properties, making them more suitable for medical applications.

Repellent coating

The laminate samples were provided with a surface fluorochemical layer to improve their repellency against water, oils, blood, alcohol and other water-containing liquids and their ability to form a barrier.

Surface fluorochemical treatment was performed by traditional method of surface treatment - so-called klocování. This impregnation is performed by immersing the sample in a chemical mixture and then passing through a gap between a set of rollers that squeeze excess chemicals from the impregnated laminate by pressure. The gap pressure can be controlled to achieve the desired degree of crease (Wet Piek Up Percentage, WPU%). The degree of squeezing is the amount of surface solution absorbed by the laminate sample. Untreated samples were weighed after cutting. Samples drawn through the foil for fluorochemical impregnation were weighed after finishing. The degree of squeezing was determined using the following formula:

WPU% = Impregnation Weight. sample - weight neimpreg. sample * 100

Weight of impregnated sample

Table 4 shows the degree of crease for the different laminate samples.

TABLE IV Degree of squeezing of laminate samples MSM Sample no. Squeezing degree f%) 1 152.10 2 145.50 3 149.43 4 157.96 5 157.90 6 140.91 7 140.11

Fluorochemical impregnation of the laminate samples was performed on an 18 inch wide flar. The fluorine chemical used was 5% Zonyl PPR from Dupont. A crease rate of 140% was planned. The specimens were fluorochemically impregnated with a two-well fissure and two gaps under 30 psi pressure. The impregnated samples were then treated in a convection oven on a spiked frame at 250 degrees Fahrenheit for 3.5 minutes. The following chemical mixture was used for impregnation:

Klocování (planned degree of creasing 140%)

Ingredients Weight ratio (%)

Zonyl PPR 3.6

Water 96.4

Total 100.0

Fluorochemically coated samples were tested by the above test procedures to determine their barrier-forming ability, strength, drapability, and comfort. The test results of the impregnated laminate samples are shown in Table V.

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TABLE V

Test results of impregnated laminate fabrics u

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The value of hydrostatic pressure required to force the liquid through the samples was very high in the untreated samples, indicating a good ability of the blown fabric to form a barrier. However, the impregnated samples 1, 2 and 3 having only cotton staple fibers in the middle layer showed much higher hydrostatic pressure values than the corresponding unimpregnated samples and generally higher values than the impregnated samples containing only polypropylene fibers in the middle layer. On the other hand, the hydrostatic pressure of most samples containing only PP in the core was significantly reduced by performing a repellent coating. It was found that the water penetration rate of most impregnated samples increased due to fluorochemical impregnation. The greatest advantage of the fluorochemical coating was, according to the results obtained, an increase in the grease repelling rate from 0.0 (for unimpregnated samples) to an excellent 6.0 to 8.0 (for fluorochemically impregnated samples). Summing up the results, we find that the greatest value of grease repelling 8 has fluorochemically impregnated samples that only contain cotton at their core.

Another series of samples, designated 8-15 in the following Tables, was prepared for comparison. Except for Sontara, which contained wood pulp, none of the samples contained a layer of cellulose fibers but one or more layers of artificial fibers. Table VI shows the composition and method of manufacture of each sample.

The hydrostatic pressure required to push the liquid through the samples was very high for the untreated samples, indicating good barrier blowing capability. However, the impregnated samples 1, 2 and 3 having only cotton staple fibers in the middle layer showed much higher hydrostatic pressure values than the corresponding unimpregnated samples and generally higher values than the impregnated samples containing only polypropylene fibers in the middle layer. On the other hand, the hydrostatic pressure of most samples containing only PP in the core was significantly reduced by performing a repellent coating. It was found that the water penetration rate of most impregnated samples increased due to fluorochemical impregnation. The greatest advantage of the fluorochemical coating was, according to the results obtained, an increase in the grease repelling rate from 0.0 (for unimpregnated samples) to an excellent 6.0 to 8.0 (for fluorochemically impregnated samples). Summing up the results, we find that the greatest value of grease repelling 8 has fluorochemically impregnated samples that only contain cotton at their core.

Another series of samples, designated 8-15 in the following Tables, was prepared for comparison. Except for Sontara, which contained wood pulp, none of the samples contained a layer of cellulose fibers but one or more layers of artificial fibers. Table VI shows the composition and the manufacturing method of each sample.

-CJTABLE VI

Structure and type of surface treatment of nonwovens

C. Type of fabric Obsaž .fibers Structure Surface .adjustment 8 Tyvek 1422A 100% PE ¹ spun none 9 Tyvek 1422R 100% PE spun léčJ Coronou 10 Sontara 50% polyester paved none 50% dř.buni čina and spinning 11 Sontara 50% polyester paved DuPont RF ⁴ 50% dř.buni Or on and spinning 12 SMS (1.8 oz / yd ² ) 100% PP ² Lam-SMS ³ none 13 SMS (1.8 oz / yd ² ) 100% PP Lam-SMS KC RF ⁵ •her 14 SMS (2.3 oz / yd ² ) 100% PP Lam-SMS none '1 15 Dec SMS (2.3 oz / yd ² ) 100% PP Lam-SMS KC RF

IpE - Polyethylene ² PP - Polypropylene

O

Lam-SMS - thermally bonded laminate of spun / blown / spun nonwoven ⁴ DuPont RF - repellent product from DuPont ³ KC RF - repellent product from Kimberly-Clark.

These properties were tested for various properties that were of importance to the use of laminates as fabric substitutes. The results of these tests are shown in Table VII.

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-25 (1) Each value is an average of 35 samples (2) Due to the large number of samples needed for this test, only one set of five pieces was tested at a time

As can be seen from Table VIII, several different woven fabrics differing in the type of fibers contained, basis weight and surface finish were obtained from commercial sources for further comparison purposes. 100% cotton denim is used to make trousers. Ash is used for trousers and shirts. Denim had a nominal basis weight of 10, 12 and 14.5 oz / yd 4. Indigo denims were made of unbleached and uncoloured greige (unglued), de-glued and partially cleaned material, and de-glued, partially cleaned and fluorochemically impregnated material. The white denim and ash were stripped, cleaned and bleached. Part of the white denim was also fluorochemically impregnated. The ash was evaluated after desizing, cleaning and bleaching, durability and surface treatment and fluorochemical impregnation. All surface treatments and impregnations were carried out using commercial equipment at the factory. See Table IX for more details on these substances.

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TABLE VIII

Number and structure of yarn and denim threads and poplin

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-27 (1) Bl means indigo denim (2) W 2 means white denim (stripped, cleaned and bleached) (3) indigo events we have been partially stripped and cleaned (4) stripped, cleaned and bleached (5) left tached, cleaned, bleached and durable surface treated (6) stripped, cleaned, bleached, durable surface treated and impregnated with fluorocarbon

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TABLE IX

The basis weight, thickness and permeability of denim and ash

Norainál.pl. Actual Full Weight Thickness Breathability nj

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-29 ¹ values per sample are the average of the values measured twice for 50 samples the values per sample are the average of the values measured for 50 samples

Bl stands for indigo denim

W denotes white denim (despatched, cleaned and bleached) ⁵ indigo denim have been partially despatched and cleaned ⁶ despatched, cleaned and bleached despatched, cleaned, bleached and durable surface treated

O stripped, cleaned, bleached, durable surface treated and impregnated with fluorocarbon

The contacting and drape values of the composite fabrics of the present invention were close to those of fabrics that have been used to date for the manufacture of surgical gowns and similar medical equipment. Even the breathability values of these composite fabrics, i.e. about 25 to 37 ft ³ / min / ft ² (feet ³ / mi n / ft ² ), are comparable, for example, to the values of shirt fabrics and their ability to form a barrier and their airiness are the same as woven materials. Due to the presence of the fibrous layer in the present composite fabric, the filtration efficiency of the fabric is higher than that of previously produced monolayer woven fabrics, thereby increasing the suitability of the present composite fabric for applications where barrier-forming capability is required.

The absorbency and retention properties of some of the prior art fabrics, cotton mats and laminates made in accordance with the present invention were investigated. Absorption capacity was determined by a procedure developed by the Swedish Institute for Textile Research (TEFO) and evaluated in the TAPPI Journal in July 1987 (Shishoo). Fig. 6 shows a test apparatus consisting of a large funnel 80 with a glass frit 82 and a graduated measuring cylinder with a scale of 84. A 100 cm ² round sample 86 was placed overnight at 21 ° C and 65% relative humidity. It was then placed face up on a glass frit. A hundred milliliters of liquid cast at a speed of 7 mm / s and a height of 2.54 cm were used to saturate it. Then the saturated sample was quickly loaded with a circular load 88 of 100 cm area and weight of 100 g and allowed to rest for 10 minutes. The amount of liquid trapped in the cylinder was then measured and the absorbency (C) of the sample was calculated as follows:

C = a-b where a = total amount of liquid delivered (100 ml) b = liquid (ml) not absorbed under pressure 100

Bye

The test was repeated seven times with each sample and the results

-31 rounded to milliliters. After determining the absorbency, the retention capacity was determined. After determining the amount of liquid not absorbed within 10 minutes in the absorbency test, the sample was still loaded with 2.9 kilograms to apply a pressure of 3 kPa (100 Pa was already developed for the absorbency test) and the sample was left under pressure for 5 minutes. After this time, the amount of liquid in the cylinder was recorded and the sample was loaded with an additional 2 kilograms, resulting in a pressure of 5 kPa. The wet sample was subjected to this pressure for an additional 5 minutes and the amount of liquid collected in the cylinder was again recorded. The amount of liquid (Crm and Crm) remaining in the sample under two different pressure values was calculated as follows: r

Crm = C - c where C = absorption capacity c = liquid not absorbed under 3 kPa

Crm = C - c 'where C = absorption capacity c' = liquid not absorbed at 5 kPa

The test was repeated seven times with each sample and the results were rounded to milliliters. The results are shown in Table XI. A further comparison was to the absorption and retention capacity of 100% carded cotton fabrics under different loads and is shown in Table XII. Samples Nos 37 to 40 in Table XI do not contain a layer of cellulose fibers. Their absorption and retention capacities are negligible. From these data and the data in the preceding tables, it can be seen that the laminates of the present invention are in many physical respects superior to the prior art nonwoven fabrics used primarily in health care and the like. The present fabrics are also very lightweight and it is known that fabrics having less (by weight) blown material have a better ability to absorb and retain liquids and hence greater economic benefits. Moreover, although it has been found that with increasing weight 100% cotton fabrics lose part of their retention capacity, when these cotton fabrics have been incorporated into the laminate structure of the present invention, the resulting laminate has surprisingly high retention capability even with a higher weight of the inner cotton layer.

-32P

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-55 ¹ Laminated and thermally bonded on a Kuster calender with 14.7% diamond bonded area. Samples 20 and 21 were combined under 150 PLI pressure using a top patterned cylinder at 41 ° C and a bottom smooth cylinder at 41 ° C and at a fabric movement speed of 10 yards / min (9.1 m / min). Samples 25A and 25B were joined using a top roller at 88 ° C and a bottom roller at 90 ° C under a pressure of 250 PLI and a fabric speed of yards / min (9.1 m / min). Samples 26A and 26B were joined using a top roller at 105 ° C and a bottom roller at 100 ° C under a pressure of 250 PLI and at a fabric movement speed of 10 yards / min (9.1 m / min). Samples 22,23,24,27,28A, 28B, 28C, 29A, 29B, 29C,

30A, 30B, 30C, 31A, 31B, 32A, and 32B were joined using a 134 ° C top roller and a 129 ° C bottom roller under 250 PLI at a fabric speed of 10 yards / min (9.1 m / min) min).

The remaining samples, unless otherwise indicated, were laminated under the same conditions except for the upper and lower roll temperatures (125 and 122 ° C, respectively).

Veratec Easy Street - stripped, cleaned and bleached cotton carded on a carding machine (40 inches, Hollingsworth - On Wheels) with a combination of flat and semi-grain fabrics. The fabrics were wound on a roll of 18 cm width and a circumference of 1.5 m.

O ^J non-calendered thermally bonded nonwoven staple fibers from Veratec

Note:

(a) Samples 31C and 31D, and 32C and 32D were bonded using a Ramisch Kleinewefers calender at an area of 21.6% under a pressure of 250 PLI, at a top roller temperature of 134 ° C and a bottom roller 129 ° C at a fabric movement speed of 10 yards. min (9.1 m / min).

(b) Samples 26D, 26E and 26F, 28D, 28E and 28F, 29D, 29E and 29F, and 30D,

30E and 30F were bonded using a Ramisch Kleinewefers calender at an area of 21.6% under a pressure of 250 PLI, at a top roller temperature of 134 ° C and a bottom roller temperature of 129 ° C and at a fabric movement speed of 10 yards / min. ).

-36TABLE XI

Absorption and retention capacity

Sample no. Absorption capacity (100 Pa) ¹ English Translation: capacity capacity (3 kPa) ² (5 kPa) ³ Tyvek 1422A 5 5 5 Tyvek 1422R ^; 6 5.5 5 Sontara (not impregnated) 8 7 7 SMS (not impregnated) 8 8 8 (1.8 oz / yd ² ) SMS (non-imp.) (2.3 oz / yd ² ) 5 5 5 20 * 12 10 9.5 21 * 9.5 9 8.5 22 * 14 12 12 25A, 25B • 7.0 6.0 6.0 26A, 26B 8.5 8.0 8.0 27 * 8.5 8.0 8.0 28 * 11 9.5 9.0 29 * 14.5 12 11.5 30 * 17 14.5 14 31A, 31B 8 7 6.5 32A, 32B 7.5 6.5 6.0 33 * 18 15 Dec 14 34 * 7 6.5 6.0 35 * 12 11 11 36 * 17 14 13 37 * 4 4 4 38 * 7 7 7 39 * 8 7.5 7.5 40 * 7 7 7 41 16 14 13.5 42 9 7.5 7 43 14 11 10.5 44 10 9 8 45 12 11 11 46 8.5 7 7 47 28 18 17

* Sample description see Tables VI and X (sample numbers correspond to the numbers in Tables VI and X) ¹ calculated by subtracting the quantity of liquid discharged into the measuring cylinder after 10 minutes from the original 100 ml batch calculated by subtracting the amount of liquid not absorbed by the sample at 3 kPa calculated by subtracting the amount of liquid not sampled at 5 kPa from the absorption capacity

-58TABLE 12

Sample no. Absorbent Retention Retention drip ta drip ta kapaci ta (100 Pa) ¹ (3kPa) ² (5 kPa) ³

1.0 oz / yd ² 24 20.5 19.5 2,0 9 oz / yd 33 20.0 19.0 3.0 oz / yd ² 34 18.5 16.5 4.0 oz / yd ² 46 23 21.0

^{1 is} calculated by subtracting the amount of liquid discharged into the measuring cylinder after 10 minutes from the original 100 ml batch

AND..

² 'calculated by subtracting the amount of liquid not absorbed by the sample at 3 kPa from the absorption capacity ³ calculated by subtracting the amount of liquid not absorbed by the sample at 5 kPa from the absorption capacity

The capillarity of the samples was tested using the device shown in Fig. 7. It consists of a scale 90 with printer 92 attached, a laboratory jack 94, a test liquid water reservoir 95, a funnel 98 with a coarse (40-60 micron) glass frit 100, a rubber hose 102 for connecting the funnel 98 to the water reservoir 94. 100g round weights 106 (area 100 cm ² ) and stopwatches (not shown). The funnel 98 is vertically adjustable on a circular stand 110. Even each fabric tested that was stored at 20 ° C and 65% relative humidity overnight,

7 randomly cut seven circular specimens of 100 cm area. During the test, the water tank was lifted until the glass surface was glass

-39frits damp (but no water on it). Then a 100 gram sample was placed on the frit. The stopwatch started at the time the sample was placed on the sample, and every 10 seconds for 3 minutes the weight of the test liquid was read and transferred from the water tank to the sample. liquid on time. This test was repeated a total of seven times for one fabric tested.

Data for each sample can be found in Table X. Graphs of the amount of liquid versus time observed during the tests are shown in Figures 8 to 34.

Giant. 8 to 34 clearly show that the wicking values of prior art fiber-containing laminates are very low.

However, when these fabrics are combined with a layer of natural cellulose fibers, the resulting laminates exhibit excellent capillary action, making them suitable for use in healthcare and other areas.

Although the present invention has been demonstrated in particular. ¹ , but those skilled in the art will recognize that it can be modified in various ways. E.g. other than the diamond bonding patterns described above may be used. Further, various fluorochemical impregnation methods which are well known in the market and can be used. They can be found, for example, in Handbook of Fiber Science and Technology, Volume II; Chemical Processing of Fibers and Fabrics, Functional Finishes, Part B, published by Menachem Lewin and Stephen B.

See and listed in the literature list of this report on pages 172-183.

Claims (6)

PATENT CLAIMS Multilayer nonwoven composite fabric, in particular suitable for replacing woven fabrics, characterized in that, from a first layer of fibrous material selected from the group consisting of thermoplastic blown artificial fibers, thermoplastic spun fibers, thermoplastic man-made staple fibers and combinations thereof, from about 0.05 to about 10 oz / yd ^2, and preferably from about 0.25 to about 2 oz / yd ² , and from a second cellulose staple fiber layer having a basis weight in the range of about 0, 1 to about 10 oz / yd and preferably from about 1 to 4 oz / yd ² and whose fibers have a length in the range of about 0.5 to about 3 inches and a weight in the range of about 2 and 5 micronair, and the two layers are thermally bonded to form a coherent structure with a breathability of from about 25 to about 37 ft ³ / min / ft ² , with a bond area between layers of from about 5 to about 75% of one of the faces of the composite fabric and, optimally, between about 10 and 30% of the area of the composite fabric. 2. The composite fabric of claim 1 comprising a third layer of fibrous material selected from the group consisting of thermoplastic blown man-made fibers, thermoplastic spun man-made fibers, thermoplastic man-made staple fibers, and combinations thereof, having a basis weight in the range of about 0.05 to about 10 oz / yd ² and the optimum interval is about 0.10 to 2.0 oz / yd ² and which is disposed on the side of said second layer facing away from said first layer and thermally bonded to at least said second layer so that that said second layer is sandwiched between said first and said third layer. Composite fabric according to claim 1 or 2, characterized in that said layers are joined to each other at separate points after The entire flat surface of said fabric such that the joint surfaces form a substantially uniform pattern. The composite fabric of claim 1 or 2, wherein the first and third layers have an air volume of over about 85%. The composite fabric of claim 1 or 2, which has a water-wicking rate in the range of about 0.01 g / s to about 0.05 g / s and a water retention value at 3 kPa of about 7 to about 15. 6. A composite fabric according to claim 1 or 2, characterized in that it has an extrusion strength of from about 40 to about 225 kPa.