EP1629144A1 - Etoffe barriere composite respirante non tissee - Google Patents

Etoffe barriere composite respirante non tissee

Info

Publication number
EP1629144A1
EP1629144A1 EP20040775784 EP04775784A EP1629144A1 EP 1629144 A1 EP1629144 A1 EP 1629144A1 EP 20040775784 EP20040775784 EP 20040775784 EP 04775784 A EP04775784 A EP 04775784A EP 1629144 A1 EP1629144 A1 EP 1629144A1
Authority
EP
European Patent Office
Prior art keywords
film
films
nonwoven
layer
bonding
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP20040775784
Other languages
German (de)
English (en)
Inventor
Jr. Uyles W. Bowen
Michael P. Mathis
John A. Rotella
Lisa A. Schild
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Original Assignee
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly Clark Worldwide Inc, Kimberly Clark Corp filed Critical Kimberly Clark Worldwide Inc
Publication of EP1629144A1 publication Critical patent/EP1629144A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B46/00—Surgical drapes
    • A61B46/40—Drape material, e.g. laminates; Manufacture thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/0076—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised in that the layers are not bonded on the totality of their surfaces
    • B32B37/0084—Point bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2535/00—Medical equipment, e.g. bandage, prostheses, catheter
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/2481—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including layer of mechanically interengaged strands, strand-portions or strand-like strips
    • 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.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2139—Coating or impregnation specified as porous or permeable to a specific substance [e.g., water vapor, air, etc.]
    • 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.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2418—Coating or impregnation increases electrical conductivity or anti-static quality
    • 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]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/66—Additional nonwoven fabric is a spun-bonded fabric
    • 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]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/668—Separate nonwoven fabric layers comprise chemically different strand or fiber material
    • 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]
    • Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet
    • 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]
    • Y10T442/674—Nonwoven fabric with a preformed polymeric film or sheet
    • Y10T442/678—Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]
    • 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 is directed to cloth-like, liquid-impervious, breathable composite barrier fabrics. More particularly, the present invention is directed to cloth-like, liquid- impervious, breathable fi rn-nonwoven composite fabrics having biological liquid barrier capabilities for use as, for example, sterilization wrap, surgical draping, surgical gowns, cover garments, such as over-suits, and the like.
  • surgical articles in order to function satisfactorily, must achieve a balance of properties, features and performance characteristics.
  • Such surgical articles have, as a principal matter, been designed to greatly reduce, if not prevent, the transmission through the surgical article of biological liquids and/ or airborne contaminates.
  • liquid sources include the gown wearer's perspiration, body fluids from the patient, such as blood, and life support liquids, such as plasma and saline.
  • airborne contaminates include, without limitation, biological contaminates, such as bacteria, viruses and fungal spores.
  • Such contaminates may also include particulate material such as, without limitation, lint, mineral fines, dust, skin scales and respiratory droplets.
  • particulate material such as, without limitation, lint, mineral fines, dust, skin scales and respiratory droplets.
  • Such surgical articles further should be comfortable during use, that is, while being worn.
  • the breathability of the surgical article that is, its rate of water vapor transmission, is an important measure of how comfortable a surgical article is to use.
  • Other characteristics of surgical articles that impact upon the comfort of the article during use include, without limitation, the drapeability, cloth-like feel and hand and cool, dry feel of the articles.
  • Surgical articles also require a minimum level of strength and durability in order to provide the necessary level of safety to the user of the article, particularly during surgical procedures.
  • surgical articles desirably are inexpensive to manufacture, utilizing lightweight materials that enhance the comfort of the wearer during use, but also reduce the cost of such articles.
  • liquid impervious, breathable multilayer barrier fabrics of various constructions are known.
  • Surgical articles formed from liquid repellent fabrics such as fabrics formed from nonwoven webs or layers, have provided acceptable levels of liquid imperviousness, breathability, cloth-like drapeability, strength and durability, and cost.
  • personal protective equipment applications include, without limitation, laboratory applications, clean room applications, such as semiconductor manufacturing, agriculture applications, mining applications, environmental applications, and the like.
  • personal care articles such as adult mcontinent products and infant or child care diapers or garments such as training pants may utilize components with these desirable properties.
  • the present invention is drawn to a breathable barrier material having a first nonwoven layer and a first microporous film bonded together to form a composite laminate. A second microporous film and a second nonwoven layer are bonded to the composite laminate to form the barrier material.
  • the present invention is drawn to a breathable barrier material where the first and second films are disposed between the nonwoven layers. Either or both of the nonwoven layers may be made of a spunbond web. Either or both films may be configured as a monolayer or multilayer film.
  • the multilayer film may be made of a core layer constituting about 85% of the total film thickness and a skin layer constituting about 15% of the total film thickness.
  • two skin layers may be provided, each disposed on opposite sides of the core layer.
  • the two skin layers may each constitute about 7.5% of the total film thickness.
  • Breathability may be imparted to the film by use of suitable fillers.
  • the film may be manufactured from about 30% to about 75% by weight polyolefin resin and from about 70% to about 25% by weight of filler.
  • the present invention may have a water vapor transmission rate of at least about 500 grams per square meter per 24 hours, or in some embodiments at least about 5000 grams per square meter per 24 hours.
  • the material itself may be created by bonding the prebonded composite laminate to the second film, and second nonwoven layer to create bond points in the material and void spaces between the first and second films.
  • the void spaces between films may enhance liquid and viral barrier properties in the barrier material by creating a boundary that rrunixnizes passage of liquids and/ or viral components through the barrier material. These voids may also serve to trap such liquids and/ or viral components between the films.
  • Such a material may be found useful in applications directed to surgical gowns, surgical drapes, sterilization peel pouches, industrial protective garments, personal care articles, and other applications wherein the use of a breathable barrier thermoplastic elastomeric polyolefin is desirable.
  • FIG. 1 is a cross-sectional view of an exemplary barrier material of the present invention.
  • FIG. 2 is a cross-sectional side view of a multilayer film for use in the FIG. 1 barrier material. The right side of the film has been separated to facilitate its description .
  • FIG. 3 is a schematic view of a process for making the FIG. 1 barrier material.
  • FIG.4 is a SEM Micrograph of the FIG. 1 barrier material at 50x magnification.
  • the present invention is directed to an improved cloth-like, liquid-impervious, breathable barrier material, which possess a unique balance of performance characteristics and features making the material suitable for use in forming surgical articles, as well as other garment and over-garment applications, such as personal protective equipment applications.
  • the barrier material 10 is a laminate comprising four layers—a top nonwoven layer 12 formed, for example, of spunbond filaments, a bottom nonwoven layer 18 formed, for example, of spunbond filaments, a first middle breathable firm 14 formed, for example, of a microporous film, and a second middle breathable film 16 formed, for example, of a microporous film.
  • the individual layers of barrier material 10 are laminated, bonded or attached together by known means, including thermal-mechanical bonding, ultrasonic bonding, adhesives, stitching and the like.
  • the terms “layer” or “web” when used in the singular can have the dual meaning of a single element or a plurality of elements.
  • laminate means a composite material made from two or more layers or webs of material which have been bonded or attached to one another.
  • nonwoven fabric or “nonwoven web” mean a web having a structure of individual fibers or filaments that are interlaid, but not in an identifiable, repeating manner as in a knitted or woven fabric.
  • thermoplastic polymeric materials can be advantageously employed in making the fibers or filaments from which top nonwoven layer 12 and bottom nonwoven layer 18 are formed.
  • polymer shall include, but is not limited to, homopolymers, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc., and blends and modifications thereof.
  • polymer shall include all possible geometric configurations of the material, including, without limitation, isotactic, syndiotactic, random and atactic symmetries.
  • thermoplastic polymer or “thermoplastic polymeric material” refer to a long-chain polymer that softens when exposed to heat and returns to the solid state when cooled to ambient temperature.
  • exemplary thermoplastic materials include, without limitation, polyvinyl chlorides, polyesters, polyamides, polyfluorocarbons, polyolefins, polyurethanes, polystyrenes, polyvinyl alcohols, caprolactams, and copolymers of the foregoing.
  • Nonwoven webs that may be employed as the nonwoven layers 12 and 18 of the present invention may be formed by a variety of known forming processes, including spunbonding, airlaying, meltblowing, or bonded carded web formation processes.
  • top layer 12 and bottom layer 18 are both spunbond nonwoven webs, which have been found advantageous in forming barrier material 10.
  • Spunbond nonwoven webs are made from melt-spun filaments.
  • meltspun filaments refers to small diameter fibers and/ or filaments that are formed by extruding a molten thermoplastic material as filaments from a plurality of fine, usually circular, capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced, for example, by non-eductive or educrive fluid drawing or other well known spunbonding mechanisms. Lastly, the melt-spun filaments are deposited in a substantially random manner onto a moving carrier belt or the like to form a web of substantially continuous and randomly arranged, melt-spun filaments. Spunbond filaments generally are not tacky when they are deposited onto the collecting surface. The production of spunbond nonwoven webs is described in U.S.
  • melt-spun filaments formed by the spunbond process are generally continuous and have average diameters larger than 7 microns based upon at least 5 measurements, and more particularly, between about 10 and 100 microns.
  • denier is defined as grams per 9000 meters of a fiber or filament.
  • Spunbond webs generally are stabilized or consolidated (pre-bonded) in some manner immediately as they are produced in order to give the web sufficient integrity and strength to withstand the rigors of further processing into a finished product.
  • This pre- bonding step may be accomplished through the use of an adhesive applied to the filaments as a liquid or powder which may be heat activated, or more commonly, by compaction rolls.
  • reaction rolls means a set of rollers above and below the nonwoven web used to compact the web as a way of treating a just produced, melt-spun filament, particularly spunbond, web, in order to give the web sufficient integrity for further processing, but not the relatively strong bonding of later applied, secondary bonding processes, such as through-air bonding, thermal bonding, ultrasonic bonding and the like.
  • Compaction rolls slightly squeeze the web in order to increase its self-adherence and thereby its integrity.
  • An exemplary secondary bonding process utilizes a patterned roller arrangement for thermally bonding the spunbond web.
  • the roller arrangement typically includes a patterned bonding roll and a smooth anvil roll which together define a thermal patterning bonding nip.
  • the anvil roll may also bear a bonding pattern on its outer surface.
  • the pattern roll is heated to a suitable bonding temperature by conventional heating means and is rotated by conventional drive means, so that when the spunbond web passes through the nip, a series of thermal pattern bonds is formed.
  • Nip pressure within the nip should be sufficient to achieve the desired degree of bonding of the web, given the line speed, bonding temperature and materials forming the web. Percent bond areas within the range of from about 10 percent to about 20 percent are typical for such spunbond webs.
  • Each nonwoven layer 12 and/ or 18 may itself comprise a single layer of meltspun fabric, for example a spunbond or meltblown layer, or each nonwoven layer 12 and/ or 18 may comprise a plurality of separate nonwoven layers comprising any of identical layers, similar layers, or different layers.
  • each of the nonwoven layers 12, 18 may comprise a spunbond layer and a meltblown layer, or a first spunbond layer, a meltblown layer, and a second spunbond layer. Additional layers and combinations are possible as well, depending on the intended use of the product.
  • any of the nonwoven layers may be treated with an antistatic agent, a surfactant to impart hydrophilicity, or any other useful surface modifying agents so long as such an agent does not interfere with the intent of the invention.
  • the middle breathable films 14 and 16 may be formed of any microporous film that can be suitably bonded or attached to the top and bottom layers 12, 18 to yield a barrier material 10 having the unique combination of performance characteristics and features described herein.
  • One suitable class of film materials includes at least two basic components: a thermoplastic polyolefin polymer and a filler. These (and other) components may be mixed together, heated and then extruded into a monolayer or multilayer fil using any one of a variety of film-producing processes known to those of ordinary skill in the film processing art. Such film-making processes include, for example, cast embossed, chill and flat cast, and blown film processes.
  • each film 14 and 16 will include from about 30 to about 75 weight percent of the thermoplastic polyolefin polymer, or blend thereof, and from about 25 to about 70 percent filler.
  • Suitable polymers for use in the films include polyethylene, blends of polyethylenes, polypropylene, blends of polypropylenes, blends of polyethylene and polypropylene, blend combinations of polyethylene or polypropylene with suitable amorphous polymers, copolymers made from ethylene and propylene monomers, and blends of such copolymers with polyethylenes or polypropylenes or suitable amorphous polymers, semi- crystalline/ amorphous polymers, "heterophasic' polymers, or combinations thereof.
  • Examples of useful polymers are EXXPOL®, EXCEED®, and EXACTTM polymers from Exxon Chemical Company of Baytown, Texas; ENGAGE®, ACHIEVE®, ATTAIN®, AFFINITY®, and ELITE® polymers from Dow Chemical Company of Midland, Michigan; CAT ALLOY® polymers from Basell USA Inc. of Wilxnington, Delaware.
  • ethylene vinyl acetate EVA
  • EAA ethylene ethyl acrylate
  • EMA ethylene methyl acrylate
  • EBA ethylene butyl acrylate
  • PET polyester
  • PA nylon
  • EVOH ethylene vinyl alcohol
  • PS polystyrene
  • PU polyurethane
  • olefinic thermoplastic elastomers which are multistep reactor products wherein an amorphous ethylene propylene random copolymer is molecularly dispersed in a predominately semicrystalline high polypropylene monomer/ low ethylene monomer continuous matrix.
  • additives and ingredients may be added to the films 14, 16 provided such additives do not significantly interfere with the ability of the film layer to function in accordance with the teachings of the present invention.
  • additives and ingredients can include, for example, antioxidants, stabilizers, and pigments.
  • the films 14 and 16 also include a filler.
  • a "filler” is meant to include particulates and other forms of materials that may be added to the film polymer extrusion blend, will not chemically interfere with the extruded film, but are able to be uniformly dispersed throughout the film.
  • the fillers will be in particulate form and may have a spherical or non-spherical shape with average particle sizes in the range of about 0. 1 to about 7 microns.
  • organic and inorganic fillers are contemplated to be within the scope of the present invention provided that they do not interfere with the film formation process, or the ability of the film to function in accordance with the teachings of the present invention.
  • suitable fillers include calcium carbonate (CaC0 3 ), various kinds of clay, silica (SiO 2 ), alumina, barium carbonate, sodium carbonate, magnesium carbonate, talc, barium sulfate, magnesium sulfate, aluminum sulfate, titanium, dioxide (TiO 2 ), zeolites, cellulose-type powders, kaolin, mica, carbon, calcium oxide, magnesium oxide, aluminum hydroxide, pulp powder, wood powder, cellulose derivatives, chitin and chitin derivatives.
  • a suitable coating such as, for example, stearic acid, may also be applied to the filler particles.
  • films 14 and 16 may be formed using any one of the conventional processes known to those familiar with film formation.
  • the polyolefin polymer and filler are mixed in appropriate proportions given the ranges outlined herein and then heated and extruded into a monolayer or multilayer film as required.
  • the filler should be uniformly dispersed throughout the polymer blend and, consequently, throughout each film layer itself.
  • a film is considered "breathable" if it has a water vapor transmission rate of at least 300 grams per square meter per 24 hours (g/m 2 /24 hours), as calculated using the test method described herein.
  • the film will have a weight per unit area of less than about 80 grams per square meter (gsm) and after stretching and thinning, its weight per unit area will be from about 10 gsm to about 25 gsm.
  • the films used in the example of the present invention described below are multilayer films, such as the ABA-type film described below. It should be understood that other types of films, such as monolayer films, are also considered to be within the scope of the present invention provided the forming technique is compatible with filled films.
  • the multilayer film 20 includes a core layer 22 made from the extrudable thermoplastic polymers described above.
  • the core layer 22 has a first exterior surface 24 and a second exterior surface 26.
  • the core layer also has a core thickness 28.
  • Attached to the first exterior surface 24 of the core layer 22 is a first skin layer 30 which has a first skin thickness 32.
  • Attached to the second exterior surface 26 of the core layer 22 is an optional second skin layer 34 which has a second skin thickness 36.
  • the multilayer film 10 has an overall thickness 38.
  • a multilayer film of the present invention provides the core layer 22 with a combination of from about 26% to about 30% by weight of a linear low density polyethylene (LLDPE) copolymer, from about 15% to about 18% by weight of a single-site (metallocene) catalyzed copolymer, and from about 53% to about 57% by weight particulate calcium carbonate.
  • Skin layers 30 and 34 may comprise, for example, a combination of about 26% CATALLOY®, from about 7% to about 10% polypropylene random copolymer (RCP), and from about 57% to about 70% by weight particulate calcium carbonate.
  • the core layer 22 constitutes about 85% of the total film thickness 38.
  • Such multilayer films 20 may be formed by a wide variety of processes well known to those of ordinary skill in the film forming industry. Two particularly advantageous processes are cast film, coextrusion processes and blown film coextrusion processes. In such processes, the two or three layers are formed simultaneously and exit the extruder in a multilayer form. Due to the extremely ihin nature of the multilayer films according to the present invention such processes will most likely prove to be the most advantageous though it also may be possible to form multilayer films using separate extrusion processes.
  • each film as initially formed generally is thicker and noisier than desired, as it tends to make a "rattling" sound when shaken. Moreover, each film does not have a sufficient degree of breathability as measured by its water vapor transmission rate. Consequently, each film is heated to a temperature equal to or less than about 5° C. below the melting point of the polyolefin polymer and then stretched using an in-line machine direction orientation (MDO) unit to at least about two times (2x) its original length to thin the film and render it porous. Further stretching of the films 14, 16, to about three times (3x), four times (4x) or more, their original length is expressly contemplated in connection with forming films 14 and/ or 16 of the present invention.
  • MDO machine direction orientation
  • the films 14 and 16 after being stietch-thinned should have an "effective" film gauge or thickness of from about 0.2 mil to about 1.2 mil in some embodiments. In other embodiments, it is contemplated that the effective gauge be from about 0.2 mil to about 0.6 mil.
  • the effective gauge is used to take into consideration the voids or air spaces in breathable film, layers. For normal, non-filled, non-breathable films, the actual gauge and effective gauge of the film typically will be the same. However, for filled films that have been stietch-thinned, as described herein, the thickness of the film will also include air spaces. In order to disregard this added volume, the effective thickness is calculated according to the test method set forth herein.
  • One of the films, for example fihn 14 is formed using any type of conventional film forming equipment 40, such as cast or blown film equipment.
  • the film 14 having a formulation as described herein then is passed through a filmsitetching apparatus 42 to stretch and thin the film, to an effective gauge of 0.6 mil or less.
  • a filmsitetching apparatus is a Machine Direction Orienter unit, Model No. 7200, available from the Marshall & Williams Company, having offices in Buffalo, R.I.
  • a nonwoven layer for example spunbond nonwoven layer 12 is formed.
  • a conventional spunbond nonwoven web manufacturing process as described herein, can be used to form the nonwoven layer 12.
  • the spunbond web 12 is formed of substantially continuous and randomly arranged, melt- spun filaments, that are deposited onto a moving continuous forming wire 44 from extruders 46.
  • the webs of randomly arranged, melt-spun filaments then can be pre- bonded by passing the web through a pair of compaction rolls (not shown) to give the web sufficient integrity and strength for further processing.
  • One or both of the compaction rolls may be heated to aid in bonding the web 12.
  • one of the compaction rolls also has a patterned outer surface that imparts a discrete bond pattern with a prescribed bond area to web 12.
  • the opposing compaction roll usually is a smooth anvil roll, although this roll also may have a patterned outer surface if desired.
  • the film layer 14 and web 12 are brought together and laminated to one another using a pair of laminating or bonding rolls 48, 50, as shown in FIG. 3, or other conventional bonding means, in order to produce a composite laminate 52 of the present invention.
  • bonding roll 48 is a pattern roll
  • second bonding roll 50 is a smooth roll. Both rolls are driven by conventional means, such as, for example, electric motors (not shown).
  • Pattern roll 48 is a right circular cylinder that may be formed of any suitable, durable material, such as, for example, steel, to reduce wear on the rolls during use. Pattern roll 48 has on its outermost surface a pattern of raised bonding area. An intermittent pattern of discrete, regularly repeating bonding points can be suitably employed, for example, as is conventional in the art.
  • the bonding areas on pattern roll 48 form a nip with the smooth or flat outer surface of opposed positioned anvil roll 50.
  • Anvil roll 50 also is a right circular cylinder that can be formed of any suitable, durable material, such as, for example, steel, hardened rubber, resin-treated cotton or polyurethane.
  • the pattern of raised bonding areas on the pattern roll 48 is selected such that the area of at least one surface of the resulting composite laminate 52 occupied by bonds after passage through the nip formed between pattern rolls 48, 50 ranges from about 10 percent to about 30 percent of the surface area of the barrier material.
  • the bonding area of the composite laminate 52 may be varied to achieve the above-mentioned percent bond area, as is known in the art.
  • bonding may be accomplished using a Ramisch bond pattern.
  • the Ramisch bond pattern has a bond area of about 8% to about 14%, a pin density of about 52 pins/in 2 , and a pin depth at 8% bond area of about 0.052 inch.
  • the Ramisch bond pattern is a relatively deep, open pattern suitable for use in stretch applications.
  • any suitable conventional thermal bonding means may be used for thermally bonding the layers including, but not Umited to, standard heat rolls, ultrasound and through-air-bonding.
  • the temperature of the outer surface of the pattern roll 48 may be varied by heating or cooling relative to the smooth roll 50. Heating and/ or cooling can affect, for example, the degree of lamination of the individual layers forming the laminate 52.
  • Heating and/ or cooling of pattern roll 48 and/ or smooth roll 50 may be effected by conventional means (not shown) well known in the art.
  • the specific ranges of temperatures to be employed in forming the laminate 52 are dependent on a number of factors, including the types of polymeric materials employed in forming the individual layers of the laminate 52, the dwell time of the individual layers within the nip and the nip pressure between the pattern roll 48 and anvil roll 50.
  • the laminate 52 may be wound onto roll 54 for subsequent processing.
  • the second film 16 and nonwoven layer 18 may be formed from similar materials and in a manner similar to that of the first film 14 and nonwoven layer 12 respectively as depicted in FIG. 3.
  • the film 16, nonwoven layer 18, and laminate 52 are brought together and laminated to one another using a pair of laminating or bonding rolls as shown in FIG.3, or other conventional bonding means.
  • FIG. 4 depicts the resulting barrier material 10 depicting voids between the films 14 and 16, that is, each film 14 and 16 is separate between the bonded regions. It is believed that these voids enhance liquid and viral barrier properties in the barrier material 10 by creating a boundary that minimizes passage of liquids and/ or viral components through the barrier material 10 and may serve to trap such liquids and/ or viral components between the films 14 and 16.
  • the barrier material 10 may continue in-line for further processing and converting.
  • different apparatus may be used for stietch-thinning the films 14, 16.
  • Other known means for bonding and laminating the films 14, 16 to nonwoven layers 12, 18 may be used, provided the resulting barrier material 10 has the required properties described herein.
  • formation of the films 14, 16 and/ or nonwoven layers 12, 18 may take place at a remote location, with rolls of the individual layers unwound and fed to the nip formed between pattern roll 48 and smooth roll 50.
  • a two component material that can be formed as above described by omitting one of the spunbond webs, for example.
  • Typical spunbond weights for such applications are between about 0.6 osy to about 1.5 osy, commonly between about 0.9 osy to about 1.3 osy.
  • These materials may also be thermally or adhesively laminated to the stretch-thinned film to form the composite. In whatever manner bonding is accomplished, the existence of the voids between films should be maintained.
  • a suitable technique for determining the WVTR (water vapor transmission rate) value of a material is the test procedure standardized by INDA (Association of the Nonwoven Fabrics Industry), number IST-70.4-99, entitled "STANDARD TEST METHOD FOR WATER VAPOR TRANSMISSION RATE THROUGH NONWOVEN AND PLASTIC FILM USING A GUARD FILM AND VAPOR PRESSURE SENSOR” which is incorporated by reference herein.
  • the INDA procedure provides for the determination of WVTR, the permeance of the film to water vapor and, for homogeneous materials, water vapor permeability coefficient.
  • the INDA test method is well known and will not be set forth in detail herein. However, the test procedure is summarized as follows.
  • a dry chamber is separated from a wet chamber of known temperature and humidity by a permanent guard film and the sample material to be tested.
  • the purpose of the guard film is to define a definite air gap and to quiet or still the air in the air gap while the air gap is characterized.
  • the dry chamber, guard film, and the wet chamber make up a diffusion cell in which the test fil is sealed.
  • the sample holder is known as the Permatran-W model 100K manufactured by Mocon/Modern Controls, Inc, Minneapolis, Minn.
  • a first test is made of the WVTR of the guard film and air gap between an evaporator assembly that generates 100 percent relative humidity.
  • Water vapor diffuses through the air gap and the guard film and then mixes with a dry gas flow which is proportional to water vapor concentration.
  • the electrical signal is routed to a computer for processing.
  • the computer calculates the transmission rate of the air gap and guard film and stores the value for further use.
  • the transmission rate of the guard film and air gap is stored in the computer as CalC.
  • the sample material is then sealed in the test cell. Again, water vapor diffuses through the air gap to the guard film and the test material and then mixes with a dry gas flow that sweeps the test material. Also, again, this mixture is carried to the vapor sensor.
  • the computer then calculates the transmission rate of the combination of the air gap, the guard film, and the test material. This information is then used to calculate the transmission rate at which moisture is transmitted through the test material according to the equation:
  • TR "1 test material TR ⁇ l test material, guardfilm, airgap- TR ' guardfilm, airgap
  • WVTR Fp sat (T)RH/A Psat (T)(1-RH)) where:
  • a barrier material according to the present invention was made.
  • the film formulation was cast into a multilayer film having a core layer that contained on a total weight percent basis based upon the weight of the film, 26-30% by weight of a Ziegler-Natta catalyzed linear low density polyethylene (LLDPE) copolymer, about 15% to about 18% by weight of a single-site (metallocene) catalyzed copolymer, and from about 53% to about 57% by weight particulate calcium carbonate.
  • the skin layers each contained, a combination of about 34% CATALLOY®, from about 7% to about 10% polypropylene random copolymer (RCP), and about 57% by weight particulate calcium carbonate.
  • the core layer constituted about 85% of the total film thickness.
  • the CaCO 3 in the core and skin layers was coated with from about 0.5 to 3.0% behenic acid based upon the weight of the CaCO 3 , having a 0.9 to 1.3 micron average particle size and a top cut of 8 microns.
  • the spunbond facing layers were both 0.60 ounces per square yard nonwoven webs formed from extrudable thermoplastic resins of homopolymer polypropylene from BP/ Amoco 2% titanium dioxide (white), 0.09% anti-static compound and 0.91 SCC 11111 blue color concentrate.
  • the spunbond filaments were essentially continuous in nature and had an average fiber size of 2.0 dpf.
  • One of the films and nonwoven layers were laminated together to form an 18.5 g/m 2 composite laminate having a MOCON value of 7466 g/m 2 /24hr using Ramisch pattern thermal bonding rolls, as described herein.
  • the pattern roll had a bonding temperature of about 185° F. and the smooth anvil roll had a temperature of about 145° F.
  • the nip pressure formed between the rolls was about 440 psig.
  • the second film alone had a basis weight of 18.75 g/m 2 and together with the second nonwoven layer in an unbonded configuration had a MOCON value of 6293 g/m 2 /24hr.
  • the second film and nonwoven layer were thermally bonded to the composite laminate using a C-star pattern.
  • a second sample of barrier material was created with increased calcium carbonate level in the skin (57 to 65%) having the same properties as the first; however, in this sample the second film and nonwoven layer were thermally bonded to the composite laminate using the Ramisch bond pattern.
  • the MOCON of this barrier material was in the range of 4500- 6500 g/m 2 /24hr, and the bacteriophage results were 31 out of 32 samples passing the test.

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Abstract

L'invention a trait à une matière barrière respirante, qui comporte une première couche non tissée et un premier film microporeux, qui sont liés ensemble pour que soit formé un stratifié composite. Un second film microporeux et une seconde couche non tissée sont liés au stratifié composite afin que soit formée la matière barrière, de façon que les films soit disposés entre les couches non tissées. Le stratifié composite est lié au second film et à la seconde couche non tissée, ce qui crée des points de liaison dans la matière et des espaces vides entre les premier et second films. Les espaces vides entre les films peuvent améliorer les propriétés de protection contre les liquides et les virus de la matière barrière, en créant une frontière qui réduit au minimum le passage de liquides et/ou de constituants viraux à travers la matière barrière.
EP20040775784 2003-05-09 2004-02-20 Etoffe barriere composite respirante non tissee Withdrawn EP1629144A1 (fr)

Applications Claiming Priority (2)

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US10/434,552 US20040224596A1 (en) 2003-05-09 2003-05-09 Nonwoven breathable composite barrier fabric
PCT/US2004/005032 WO2005017248A1 (fr) 2003-05-09 2004-02-20 Etoffe barriere composite respirante non tissee

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