Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/28—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
  • D01F6/32—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from copolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds comprising halogenated hydrocarbons as the major constituent
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/44—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds
  • D01F6/48—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polymers of halogenated hydrocarbons
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4282—Addition polymers
  • D04H1/4318—Fluorine series
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
  • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/608—Including strand or fiber material which is of specific structural definition
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/68—Melt-blown nonwoven fabric

Definitions

• the present invention relates generally to non-woven materials (e.g., fabric structures).
• the present invention relates to breathable non-woven melt-blown materials having oleophobic and/or hydrophobic properties.
• such fabric structures are highly desirable to form surgical drapes and gowns, wound dressings/bandages, outer garments, and barrier vents.
• MVTR moisture vapor transmission rate
• Conventional water-proof and breathable outerwear garments provide significant improvements in wearer comfort over non-permeable materials that may be used (e.g., polyvinylchloride (PVC) films).
• PVC polyvinylchloride
• any moderate to strenuous activity causes a rapid increase in temperature beneath these garments thereby causing great discomfort.
• a garment that was made from fabric materials that are non-wettable by fluids having surface tensions of less than about 42 dynes/cm and having MVTR's of greater than 100,000 g/m 2 /24hrs would be a significant improvement in wearer comfort. Again, however, such garment fabrics have not been provided to date.
• the present invention is embodied in materials comprised of a mass of melt-blown non-woven fibers comprised of a terpolymer of tetrafluroethylene, hexafluoropropylene and vinylidene fluoride monomers.
• materials are in the form of fabric structures which can be processed to form a variety of products for numerous end-use applications, such as for garments, bandages, barrier vents, filter media and the like.
• the melt-blown non-woven fibers are comprised of a THV terpolymer formed of between about 30 to about 70 wt.% of tetrafluoroethylene monomer, between about 10 to about 20 wt.% of hexafluoroethylene monomer, and between about 20 to about 65 wt.% vinylidene fluoride monomer.
• Secondable or “breathability” mean that a fabric structure is capable of exhibiting a moisture vapor transmission rate (MVTR) of greater than about 100,000 g/m 2 /24hrs.
• MVTR moisture vapor transmission rate
• Non-Wettable or “non-wettability” means that a fabric structure is not wetted by a fluid having a surface tension of less than about 42 dyne/cm.
• non-wettable fabric structures in accordance with the present invention will have an oil rating according to AATCC Test Method 118-1997 of at least 1.
• “Bulk airflow” means that a fabric structure exhibits a porosity of less than about 600 Gurley-seconds, when employing a Gurley densiometer having a one square inch orifice, 100 cc of air and 5 ounce cylinder.
• the term “bulk airflow” means that a fabric structure exhibits an air permeability in excess of 0.045 ft 3 /ft 2 /min at a differential pressure of 2163 Pascals.
• the non-woven materials (e.g., fabric structures) of the preferred embodiments according to the present invention may be prepared from a terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (hereinafter referred to as "THV polymer").
• THV polymer vinylidene fluoride
• the terpolymer includes from about 20 or less to about 65 wt. % or more vinylidene fluoride, more preferably from about 25, 30, or 35 to about 40, 45, 50, 55, or 60 wt. % vinylidene fluoride, and most preferably about 36.5 wt. % vinylidene fluoride.
• the terpolymer includes from about 30 or less to about 70 wt. % or more tetrafluoroethylene, more preferably from about 35 or 40 to about 45, 50, 55, 60, or 65 wt. % tetrafluoroethylene, and most preferably about 44.6 wt. % tetrafluoroethylene.
• the terpolymer includes from about 0 or less to about 20 wt. % or more hexafluoropropylene, more preferably from about 11 , 12, 13, 14, 15, 16, 17, or 18 to about 19 wt. % hexafluoropropylene, and most preferably about 18.9 wt. % hexafluoropropylene.
• Suitable THV polymers that may be employed in the practice of the present invention include DyneonTM Fluorothermoplastics available from Dyneon LLC of Oakdale MN. Particularly preferred is Dyneon THV Grade E-15125 "O". This grade has a melting point of 164 C, a melt flow rate of >200 (265 C/5Kg), a specific gravity of 2.004 g/cm 3 , a tensile at break of
• DyneonTM fluorothermoplastic terpolymers include DyneonTM THV 220, DyneonTM THV 410, DyneonTM THV 500, and DyneonTM THV X 610.
• the DyneonTM fluorothermoplastic terpolymers with higher melt flow rates are preferred due to the ease with which satisfactory melt blown webs may be prepared.
• the melt-blown fibers may include a single THV polymer or combinations or blends of a THV polymer and one or more additional polymers.
• discrete fibers formed of such other polymers may be melt-blown concurrently with or subsequently to the THV polymer so as to form a non-woven fibrous blend of THV and such other polymers or fibrous layers formed predominantly of the THV and such other polymers, respectively.
• the additional polymers that may be employed in the practice of the present invention include another fluorothermoplastic terpolymer, or any other suitable polymer.
• Suitable polymers may include any suitable homopolymer, copolymer, or terpolymer, including but not limited to polysulfone, polyethersulfone (PES), polyarylsulfone, fluorinated polymers such as polyvinylidene fluoride (PVDF), polyolefins including polyethylene and polypropylene, polytetrafluoroethylene (PTFE or TeflonTM), poly(tetrafluoroethylene-co-ethylene) (ECTFE or HalarTM), acrylic copolymers, polyamides or nylons, polyesters, polyurethanes, polycarbonates, polystyrenes, polyethylene-polyvinyl chloride, polyacrylonitrile, cellulose, and mixtures or combinations thereof.
• PVDF polyvinylidene fluoride
• PVDF polyolefins including poly
• the fluorothermoplastic terpolymer may be subjected to a pretreatment, for example grafting or crosslinking, prior to melt blowing, or may be subjected to a post-treatment, for example grafting or crosslinking, after a melt blown web is made.
• a pretreatment for example grafting or crosslinking
• a post-treatment for example grafting or crosslinking
• a melt blown web is made.
• THV polymer there is no particular molecular weight range limitation for the THV polymer.
• the weight ratio of the tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride monomers in the THV polymer there is no particular limitation on the weight ratio of the tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride monomers in the THV polymer.
• Various molecular weights and/or different monomer ratios may be preferred for melt
• the materials of the present invention are melt-blown non-woven structures.
• the preferred THV polymers may be melt-blown using virtually any conventional melt-blowing technique to make sheets, tubes, cylinders and like structural forms for a variety of end use applications.
• the materials of the present invention are most preferably a mass of melt-blown non-woven fibers, which fibers as noted above are most preferably formed of a THV polymer.
• Non-woven materials of the present invention may be made using conventional melt- blowing techniques described more fully in U.S. Patents Nos. 3,776,796; 3,825,379; 3,904,798; 4,021 ,281 ; and 5,591 , 335 . (the entire content of each such cited patent being incorporated expressly hereinto by reference).
• the diameters of the melt-blown THV fibers forming the non-woven materials of the present invention are not critical. Thus, average fiber diameters of less than 500 ⁇ m, and preferably less than 100 ⁇ m, and typically less than 50 ⁇ m may be melt-blown if desired. Most preferably, the fibers have an average diameter which is greater than about 1 ⁇ m, and more preferably greater than about 5 ⁇ m.
• the non-woven fabrics may be fashioned into a variety of products, for example, garments (e.g., surgical or other similar medical gowns, drapes and the like), bandages, and bulk airflow barrier vents.
• garments e.g., surgical or other similar medical gowns, drapes and the like
• bandages e.g., surgical or other similar medical gowns, drapes and the like
• bulk airflow barrier vents e.g., the fabrics of this invention may be mated (e.g., by sewing, gluing and the like) to one or more other woven, non-woven or knit fabric structures to suit virtually any end use application where the non-wettable and breathable properties of the fabric structures of this invention are needed.
• a THV polymer obtained commercially from Dyneon, LLC and having the following properties was employed in the Examples:

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Nonwoven Fabrics (AREA)
• Materials For Medical Uses (AREA)
• Professional, Industrial, Or Sporting Protective Garments (AREA)
• Artificial Filaments (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)

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• 2003
  • 2003-01-02 EP EP03700027A patent/EP1483024A2/de not_active Withdrawn
  • 2003-01-02 JP JP2003558249A patent/JP2005514494A/ja active Pending
  • 2003-01-02 WO PCT/US2003/000101 patent/WO2003057961A2/en not_active Ceased
  • 2003-01-02 US US10/500,644 patent/US20050118917A1/en not_active Abandoned
  • 2003-01-02 AU AU2003200840A patent/AU2003200840A1/en not_active Abandoned
  • 2003-01-02 CA CA002472516A patent/CA2472516A1/en not_active Abandoned

Non-Patent Citations (1)

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