WO2019036538A1 - Composite porous media and method of making and using the same - Google Patents

Composite porous media and method of making and using the same Download PDF

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Publication number
WO2019036538A1
WO2019036538A1 PCT/US2018/046805 US2018046805W WO2019036538A1 WO 2019036538 A1 WO2019036538 A1 WO 2019036538A1 US 2018046805 W US2018046805 W US 2018046805W WO 2019036538 A1 WO2019036538 A1 WO 2019036538A1
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WO
WIPO (PCT)
Prior art keywords
media
porous
sintered
fiber
foam
Prior art date
Application number
PCT/US2018/046805
Other languages
French (fr)
Inventor
Timothy MEREDITH
Timothy Allen Martin
Alan Nicholas WALTON
Saman Mahdavi SHAHIDANI
Chandrasiri Jayakody
Jack Cam CHAN
Roy Andersen
Janie WIERZBICKI
Avi Melech Robbins
Guoqiang Mao
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Porex Corporation
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Publication date
Application filed by Porex Corporation filed Critical Porex Corporation
Publication of WO2019036538A1 publication Critical patent/WO2019036538A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1669—Cellular material
    • B01D39/1676—Cellular material of synthetic origin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/0216—Bicomponent or multicomponent fibres
    • B01D2239/0233—Island-in-sea
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0622—Melt-blown
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1216—Pore size

Definitions

  • the present disclosure provides composite porous media.
  • the composite porous media provides a sintered media that is combined or otherwise associated with either (i) a porous fiber media or (ii) a porous foam media.
  • the sintered media may be a sintered porous plastic media or a sintered porous elastomeric media.
  • the disclosed porous media have many applications, including but not limited to, a liquid transfer medium, an impact resistant medium, or a wound care medium.
  • Sintered porous polymeric media including sintered porous plastic and elastomeric materials
  • porous fibers and open cell foams are widely used in filtration, wicking, absorbing, venting and liquid delivery related applications.
  • sintered porous polymeric media, porous fibers and open cell foams are used independently and as separate pieces.
  • improved porous media for use in filtration, wicking, absorbing, venting, impact attenuation, sound absorption, acoustic management
  • composite media comprise combinations of different kinds of media. These composite media have improved physical properties and functions in filtration, wicking, absorbing, venting, impact attenuation, sound absorption, acoustic management,
  • sintered porous media includes media the incorporate sintered porous plastic media, sintered porous elastomeric media, or both. These materials may be collectively referred to as "sintered porous polymeric media.”
  • the composite porous media described herein comprises at least two different compositions that are associated with one another or otherwise integrally secured to form a single component. This association may be referred to herein as a "multilayer,” such as a bilayer, a trilayer, or any other combination of layers.
  • the sintered porous media is a sintered porous plastic media, a sintered porous elastomeric media, or a combination thereof.
  • a second component may be a porous fiber media, porous foam media, or a combination thereof.
  • the porous foam media can be open cell porous foam media or closed cell porous foam media.
  • the porous foam media used herein are porous foam media having both closed cells and open cells. Open cells may form the majority of the cells. In one embodiment, at least 80% of the cells are open cells.
  • One type of composite media comprises sintered porous polymeric media and porous fiber media.
  • Another type of composite media comprises sintered porous polymeric media and open cell foam media.
  • Yet another type of composite media comprises sintered porous polymeric media, porous fiber and open cell foam media.
  • porous media have many applications, including but not limited to, a liquid transfer medium, an impact resistant medium, or a wound care medium.
  • the composite materials of the present disclosure provide improved overall performance in liquid storage and transferring capability, structural strength and stability in dry and wet conditions.
  • the composite materials are lightweight, flexible, breathable, swell resistant, and resilient and are useful in some embodiments as impact attenuation media.
  • the composite materials of the present disclosure used in cosmetic applications provide a pleasant experience in applying the cosmetic material to the skin or hair as they are comfortable, soft and deliver an adequate amount of cosmetic material compared with individual sintered porous polymeric media, open cell porous media or porous fiber media.
  • Figure 1 Schematic representation of a bilayer composite material with porous fiber media and sintered porous polymeric media.
  • FIG. 1 Schematic representation of a bilayer composite material with porous foam media and sintered porous polymeric media.
  • FIG. 3 Schematic representation of a bilayer composite material with porous fiber media and sintered porous polytetrafluoroethylene (PTFE) media.
  • PTFE polytetrafluoroethylene
  • Figure 4 Schematic representation of a bilayer composite material with porous foam media and sintered porous PTFE media.
  • Figure 5 Schematic representation of a bilayer composite material with porous fiber media and expanded porous sintered PTFE media.
  • Figure 6 Schematic representation of a bilayer composite material with porous foam media and expanded porous sintered PTFE media.
  • Figure 7 Schematic representation of a trilayer composite material with porous fiber media, sintered porous polymeric media and porous fiber media with the sintered porous polymeric media in the middle layer.
  • Figure 8 Schematic representation of a trilayer composite material with porous foam media, sintered porous polymeric media and porous foam media with the sintered porous polymeric media in the middle layer.
  • Figure 9 Schematic representation of a trilayer composite material with porous fiber media, sintered porous polymeric media and porous foam media with the sintered porous polymeric media in the middle layer.
  • Figure 10 Schematic representation of a trilayer composite material with porous fiber media, sintered porous polymeric media and porous foam media with the porous foam media in the middle layer.
  • FIG. 11 Schematic representation of a trilayer composite material with porous fiber media, sintered porous polymeric media and porous foam media with the porous fiber media in the middle layer.
  • FIG. 12 Schematic representation of a trilayer composite material with one layer of porous fiber media and two layers of sintered porous polymeric media with the porous fiber media in the middle layer.
  • Figure 13 Schematic representation of a trilayer composite material with one layer of porous foam media and two layers of sintered porous polymeric media with the porous foam media in the middle layer.
  • FIG. 14 Schematic representations of a bilayer composite porous media and sintered porous polymeric media with porous foam media or with porous fiber media with the sintered porous polymeric media having a curved structure as a cushioned media for cosmetic applicators.
  • the porous foam media and porous fiber media function as reservoirs for the cosmetic material.
  • FIG 15. Schematic representations of a bilayer composite porous media and sintered porous polymeric media with porous foam media or with porous fiber media with the sintered porous polymeric media having a curved structure as a cushioned media for cosmetic applicators.
  • the porous foam media and porous fiber media function as reservoirs for the cosmetic material.
  • Figure 16. Schematic representations of a bilayer composite porous media and sintered porous polymeric media with porous foam media or with porous fiber media with the sintered porous polymeric media having a curved structure as a cushioned media for cosmetic applicators.
  • the porous foam media and porous fiber media function as reservoirs for the cosmetic material.
  • Figure 17 Schematic representation of a bilayer composite material with porous fiber media and sintered porous polymeric media with the majority of the fibers oriented parallel to the interface between the two media.
  • Figure 18 Schematic representation of a bilayer composite material with porous fiber media and sintered porous polymeric media with the majority of the fibers oriented orthogonal to the interface between the two media.
  • FIG. 19 Schematic representation of a trilayer composite material with one layer of porous fiber media and two layers of sintered porous polymeric media with the porous fiber media in the middle layer with the majority of the fibers oriented parallel to the interfaces between the two media.
  • Figure 20 Schematic representation of a trilayer composite material with one layer of porous fiber media and two layers of sintered porous polymeric media with the porous fiber media in the middle layer with the majority of the fibers oriented orthogonal to the interfaces between the two media.
  • FIG. 21 Graphic representation of the average weight (gm) of liquid lost per cycle (of 10 average). Each cycle is one finger touch within the 10 seconds the container is open. The composite material shows consistent delivery rate for 500 cycles.
  • Figure 22 Comparative chart of the percent of energy absorbed by different materials using the ASTM D2632-1 method.
  • Figure 23 Photograph of a trilayer composite porous material of two layers of sintered porous elastomeric material above and below a layer of viscoelastic polyurethane foam tested in Example 10.
  • the present disclosure provides novel composite media with surprising properties. These composite media comprise combinations of different kinds of media.
  • sintered porous polymeric media used herein includes sintered porous plastic media and sintered porous elastomeric media or combinations thereof. These composite porous media comprise at least two compositions selected from a first group of sintered porous plastic media, sintered porous elastomeric media, or any combination thereof and a second group of porous fiber media, porous foam media, or any combination thereof.
  • One type of composite media comprises sintered porous polymeric media and porous fiber media.
  • Another type of composite media comprises sintered porous polymeric media and open cell porous foam media.
  • Yet another type of composite media comprises sintered porous polymeric media, porous fiber and open cell porous foam media.
  • porous media have many applications, including but not limited to, a liquid transfer medium, an impact resistant medium, or a wound care medium.
  • the composite materials of the present disclosure provide improved overall performance in liquid storage and transferring capability, structural strength and stability in dry and wet conditions.
  • the composite materials are lightweight, flexible, breathable, shape resilient and swelling resistant and are useful in some embodiments as impact attenuation media.
  • the composite materials of the present disclosure used in cosmetic applications provide a pleasant experience in applying the cosmetic material to the skin or hair as they are comfortable, soft and deliver an adequate amount of cosmetic material compared with individual sintered porous polymeric media, open cell porous media or porous fiber media.
  • Sintered porous plastic media can be made with any polymer disclosed in US Patent No. 6,030,558, US Patent No. 7,795,346 and US Patent No. 8,141,717.
  • sintered porous plastic media are made from polyethylene, polypropylene, polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), or combinations thereof.
  • Polyethylene includes high density polyethylene (HDPE), ultrahigh molecular weight polyethylene (UHMWPE), low density polyethylene (LDPE), or linear low density polyethylene (LLDPE), or combinations thereof.
  • the sintered porous plastic media may have an average pore size from about 5 microns to about 300 microns.
  • the sintered porous plastic media may have a pore volume from about 20 % to about 60 %.
  • the sintered porous plastic media may have a density from about 0.3 g/cc to about 0.7 g/cc.
  • Sintered porous plastic media may have an omni-directional pore structure.
  • the sintered porous plastic media have a tensile strength from 20 PSI to 1000 PSI based on ASTM D638 and hardness from 20 of shore A to 80 of shore D based on ASTM D2240. These exemplary features may be provided in various range. They may all be present in a single material or only one or more features may be present in a material sample.
  • Sintered porous elastomeric materials include those disclosed in US Patent No. 8, 141,717.
  • sintered porous elastomeric materials include non- hydrogenated and hydrogenated styrenic-based thermoplastic elastomers.
  • Styrenic-based elastomers include styrene-ethylene-butadiene-styrene (SEBS), styrene-ethylene-pentadiene- styrene (SEPS), styrene-ethylene-pentadiene (SEP), styrene-butadiene-styrene (SBS), styrene-ethylene-ethylene pentadiene-styrene (SEEPS), a copolymer of ethylene and propylene, fluorinated elastomers, ethylene vinyl acetate (EVA), acrylonitrile-butadiene rubber (NBR) or thermoplastic urethane, or combinations thereof.
  • SEBS styrene-ethylene-butadiene-styrene
  • SEPS styrene-ethylene-pentadiene- styrene
  • SEP styrene-ethylene-pentadiene
  • the sintered porous elastomeric media have an average pore size from about 10 microns to about 500 microns.
  • the sintered porous elastomeric media may have a pore volume from about 20 % to about 60 %.
  • the sintered porous elastomeric media may have a density from about 0.3 g/cc to about 0.8 g/cc.
  • Sintered porous elastomeric media may have an omni-directional pore structure.
  • the sintered porous elastomeric media have a tensile strength from 20 PSI to 1000 PSI based on ASTM D638 and hardness from 20 of shore A to 80 of shore D based on ASTM D2240.
  • These exemplary features may be provided in various range. They may all be present in a single material or only one or more features may be present in a material sample.
  • porous fiber media can be made from any of the fibers listed in US Patent No. 6,814,911, US Patent No. 6,840,692, US Patent No. 7,888,275, US Patent No. 8,334,034 and US Patent No. 8,939,295.
  • porous fiber media are made from bicomponent fibers.
  • Bicomponent fibers that can be used in the present disclosure include polyethylene (PE)/polyethylene terephthalate (PET) fibers, polyethylene (PE)/polypropylene (PP) fibers, Co-polyamide (PET) fibers, CoPET/PET fibers, co-polyamide/PP fibers, or combinations thereof.
  • the bicomponent fibers can be continuous fibers or staple fibers.
  • the porous fiber media in some embodiments, can comprise both monocomponent fibers and bicomponent fibers. Porous fiber media, in a specific embodiment, may be made from a melt blowing process.
  • the porous fiber media have an average pore size from about 10 microns to about 500 microns.
  • the porous fiber media may have a pore volume from about 40% to about 95%.
  • the porous fiber media may have a density from about 0.05 g/cc to about 0.5 g/cc.
  • porous fiber media may be made from melt blowing bicomponent fibers.
  • the porous fiber media in this disclosure is POREX high release media (HRM).
  • HRM POREX high release media
  • the HRJVI media is described in US Patent No. 7,888,275, the contents of which are incorporated here by reference.
  • HRM media is a thermally bonded non- woven fiber matrix.
  • the porous fiber media have a tensile strength from about 100 PSI to about 50000 PSI based on ASTM D638 and a hardness from about 20 of Shore OOO to Shore D based on ASTM D2240.
  • These exemplary features may be provided in various range. They may all be present in a single material or only one or more features may be present in a material sample.
  • the porous foam media can be an open cell foam or a closed cell foam.
  • the foam media is an open cell foam media.
  • the open cell foam is a polyurethane based open cell foam.
  • Open cell foam media have an average pore size of about 5 microns to about 500 microns.
  • the porous foam media may have a pore volume from about 40% to about 95%.
  • the porous foam media may have a density from about 0.05 g/cc to about 0.5 g/cc.
  • Open cell foam media have a pore density from about 10 to about 500 pores per inch, or from about 50 to about 300 pores per inch (PPI).
  • Open cell foam media may have an omnidirectional pore structure.
  • the open cell foam is a hydrophilic polyurethane foam, such as POREX Medisponge® foams.
  • the open cell foam media in the present disclosure have a tensile strength from about 10 PSI to about 300 PSI based on ASTM D3574 and a hardness from about 10 Shore OOO to about 40 Shore A 40 based on ASTM D2240.
  • These exemplary features may be provided in various range. They may all be present in a single material or only one or more features may be present in a material sample.
  • Sintered porous plastic media, sintered porous elastomeric media, porous fiber media and/or foam media can be bound together through direct thermal bonding or through use of adhesives.
  • Adhesives can be in liquid form, gel form, powder form or preformed webs.
  • the adhesive can be a pressure sensitive adhesive, hot melt adhesive, reactive hot melt adhesive, or thermosetting adhesives. Such adhesives are known to one of ordinary skill in the art. Other adhesives are also possible and considered within the scope of this disclosure.
  • porous foam media and fiber media can be formed directly onto a sintered porous plastic media or sintered porous elastomeric media.
  • pores are connected between two different media.
  • the pores of two different porous media at the interface will be at least 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% connected.
  • the adhesive or other binding material will not block gas and liquid transfer between two media at the interface.
  • composite porous media of the present disclosure have a layered structure.
  • at least one layer of the composite porous media is sintered porous polymeric media.
  • the composite porous media can be two layers (bilayer), three layers (trilayer) or more than three layers.
  • composite porous media have a bilayer structure and one layer is sintered porous polymeric media and another layer is a porous fiber media.
  • composite porous media have a bilayer structure and one layer is sintered porous polymeric media and another layer is a porous foam media.
  • composite porous media have a trilayer structure and one layer is sintered porous polymeric media and the other two layers are porous fiber media.
  • sintered porous polymeric media is the middle layer of a trilayer structure between two layers of porous fiber media.
  • composite porous media have a trilayer structure and one layer is sintered porous polymeric media and the other two layers are porous foam media.
  • sintered porous polymeric media is the middle layer of a trilayer structure between two layers of porous foam media.
  • composite porous media have a trilayer structure and one layer is a porous fiber media and the other two layers are sintered porous polymeric media.
  • porous fiber media is the middle layer of a trilayer composite media between two layers of sintered porous polymeric media.
  • composite porous media have a trilayer structure and one layer is porous foam media and the other two layers are sintered porous polymeric media.
  • the porous foam media is the middle layer of a trilayer composite media between two layers of sintered porous polymeric media.
  • composite porous media have a trilayer structure, one layer is porous foam media, one layer is porous fiber media and another layer is a sintered porous polymeric media.
  • porous foam media is the middle layer of a trilayer composite media between a layer of porous fiber media and a layer of sintered porous polymeric media.
  • porous fiber media is the middle layer of a trilayer composite media between a layer of porous foam media and a layer of sintered porous polymeric media.
  • sintered porous polymeric media is the middle layer of a trilayer composite media between a layer of porous foam media and a layer of porous fiber media.
  • any combination of a sintered porous polymeric media (which may be either a plastic media, an elastomeric media, or any combination thereof) in combination with one or more layers of a porous foam media and/or a porous fiber media is considered within the scope of this disclosure.
  • composite porous media have multiple sections and at least one section is sintered porous polymeric media.
  • the different media within the composite porous media cannot be separated without affecting overall performance of the composite porous media.
  • Composite porous media can have different shapes, such as spherical, cylindrical, rod, cube, water drop, and elliptical shapes or other three dimensional shapes.
  • composite porous media can have a continuous and discontinuous arrangement.
  • sintered porous polymeric media is the continuous component and is a single piece, and the porous foam media sections are discontinuous or segregated such that the porous foam sections do not connect to each other.
  • the porous foam media is the continuous component and is a single piece, and sintered porous polymeric media sections are discontinuous or segregated and do not connect to each other.
  • the porous fiber media is the continuous component and is a single piece, and sintered porous polymeric media sections are discontinuous or segregated and do not connect to each other.
  • the sintered porous polymeric media is the continuous component and is a single piece and the porous fiber media sections are discontinuous or segregated and do not connect to each other.
  • the porous foam media is the continuous component and is a single piece, and the porous fiber media sections are discontinuous or segregated and do not connect to each other.
  • composite porous media in present disclosure can have a complicated three-dimensional structure and one side of the structure has a different porous media from another side.
  • one side is sintered porous polymeric media and another side is porous foam media, or one side is sintered porous polymeric media and another side is porous fiber media, or one side is porous foam media and another is porous fiber media.
  • These side by side structures can occur in different shapes such as a rod, sphere, block or any other shape.
  • the composite porous media of the present disclosure may be flocked in some embodiments.
  • the fibers for flocking may be nylon fibers, polyethylene fibers,
  • polypropylene fibers cotton fibers, rayon fibers, polyester fibers or polyacrylic fibers, or combinations thereof.
  • the fibers may be attached to the surface of composite porous media.
  • the adhesive can be common adhesives used in the flocking process, such vinyl,
  • the fibers may have a length from about 0.1 mm to about 5 mm.
  • the composite porous media to be flocked may be placed on a holder to expose the area to be flocked.
  • Adhesive may be sprayed on the media to be flocked.
  • Electrostatically charged fibers of flock are propelled at high velocity towards the composite porous media surface to be flocked.
  • the composite porous media may have omnidirectional, semi-omnidirectional or unidirectional physical properties based on the compositions in the composite porous media. These physical properties include compressibility, impact resistance, fluid transportation, gas permeability, sound and wave adsorption, and friction.
  • the composite porous media of the present disclosure can be used to store and release liquid.
  • the liquid can be a cosmetic treatment formula.
  • it may be liquid foundation, liquid blush, inks, astringent or a toner, water, facial masks, antiseptic, a blemish treatment, fungus or antibacterial treatment, nail polish remover, cosmetic gels, biologies, or any other type of liquid cosmetic or treatment formula.
  • the liquid is stored in the composite porous media and is released from the composite porous media onto a target surface by compressing at least one section of the composite porous media.
  • the composite porous media can also be used to control the release of the liquid by varying the liquid retention capability of sintered porous polymeric media, fiber media and open cell foam media
  • one of the porous media (foam or fiber) with high pore volume is for holding liquid and another porous media (sintered porous polymeric media) with relatively low pore volume is for controlled release of the liquid from the media to the target.
  • Porous composite materials may have different fluid delivery properties based on fiber orientation within the porous composite materials.
  • liquid holding media has a large pore size and the release media has a smaller pore size.
  • the liquid holding media is a softer material and the release media is a rigid material.
  • the liquid holding media is deformable during application of liquid and the release media is not deformable during the application of liquid.
  • the liquid holding media is an open cell foam and the liquid release media is a sintered porous polymeric media.
  • the open cell foam can be a polyurethane foam.
  • the liquid holding media is a porous fiber media and the liquid release media is a sintered porous polymeric media.
  • Porous fiber media can be woven fiber, non-woven fiber or melt blown fiber.
  • the fiber can be a continuous fiber or staple fiber, monocomponent fiber or bicomponent fiber, or a combination of monocomponent and bicomponent fibers.
  • Porous composite materials may have different fluid delivery properties based on fiber orientation within the porous composite materials. Liquid is released easily from the surface of the sintered porous polymer media.
  • sintered porous polymeric liquid release media has an average pore size between about 10 microns to about 200 microns and with an average pore volume less than about 60%.
  • porous fiber media has an average pore size between about 30 microns to about 500 microns and with a pore volume of at least 80%.
  • Open cell polyurethane in this specific application has 10 to 500 pores per inch (PPI) and with pore volume of at least 80%.
  • the overall compressibility of the material is about 30% to 60% under 5 pounds per square inch (PSI).
  • the liquids in present disclosure include biological fluids, water, cosmetic liquids, inks and cosmetic gels.
  • the liquids can have a viscosity from about 1 to about 100,000 centipoise (CPS).
  • the composite porous media in could be used in any cushion type cosmetic devices or in a facial mask for skin treatment.
  • the composite porous media of the present disclosure can be used to reduce the force of impact and function as protective cushions in sports gear, military gear, personal protection gear, or healthcare devices, such as helmets, shoulder pads, chest pads, thigh pads, shin pads, glove pads, knee pads, insoles for shoes, etc.
  • the composite porous media products have the unexpected advantages of dissipating energy, they are easy to form and are comfortable.
  • the composite porous media may be used in any type of sport gloves.
  • Nonlimiting examples include hockey gloves, soccer gloves, cricket gloves, golf gloves, weightlifting gloves, or catchers' baseball gloves.
  • the composite porous media can be used in a thigh cushion pad for people to prevent bone fracture of the femur caused by a fall.
  • the composite porous media can be used as a cushion after or during surgery to protect the knee, hip, foot, skull, sacrum, ankle, or any other body part.
  • the material may help prevent bed sores from a patient lying in a stationary position for an extended period of time.
  • the composite porous media provide overall benefits in flexible, comfort, and security.
  • the impact resistant device has a layered structure wherein one layer is sintered porous polymeric media.
  • Sintered porous polymeric media disperse the force of an impact to the open cell foam layer or porous fiber layer in a composite porous media.
  • the impact resistance media has a trilayer structure with sintered porous elastomeric material in the middle layer between two open cell foam layers, or between one open cell foam layer and one porous fiber layer.
  • sintered porous polymeric material is sintered porous elastomeric material. Self-venting wound care
  • the composite porous media can be used in wound care.
  • the composite porous media for wound care media has a bilayer structure, one layer is a hydrophilic open cell polyurethane foam layer containing a therapeutic agent and the other layer is a hydrophobic porous layer that is breathable and helps wound repair by acting as a bacterial barrier and maintaining proper moisture balance in the wound area.
  • the hydrophobic layer can be a sintered polyethylene layer, a sintered
  • the hydrophobic layer can contain an antimicrobial agent and prevent liquid penetration during accidental contact with water, or prevent fluid leaking from the wound.
  • the sintered porous polymeric media in this application may function as an aerosol and bacterial barrier.
  • Bilayer composite material with a fiber layer and a sintered porous plastic layer
  • Method 1 A composite porous media comprising a porous fiber layer and a sintered porous plastic layer is made by applying a die cut, 3M chemical resistant adhesive transfer tape 96105 CR to a sintered porous FIDPE sheet.
  • the sintered porous FIDPE sheet was 1/16 inch thick, and had an average pore size of 70 microns and pore volume of about 40 %.
  • the adhesive tape was pre-die cut with 1/4 inch holes to make tape with about 60 open spaces.
  • the fiber layer was a POREX FIRM fiber sheet with 1/4 inch in thickness, and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers.
  • the fibers in FIRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer.
  • the fiber sheet was laminated onto the sintered porous HDPE sheet through the die cut adhesive tape by applying 2 psi pressure for 30 seconds.
  • Method 2 A composite porous media comprising a fiber layer and a sintered porous plastic layer was made by spraying 3M super 77 spray adhesive on a sintered porous HDPE sheet.
  • the sintered porous HDPE sheet is 1/16 inch thick, and has an average pore size of 70 microns and pore volume of about 40 %.
  • the fiber layer was a POREX HRM fiber sheet with 1/4 inch in thickness, and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers.
  • the fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer.
  • the fiber sheet was laminated on the top of the sintered porous HDPE sheet after adhesive is sprayed and the laminated sheet was kept under 2 psi pressure for 30 seconds.
  • Method 3 A composite porous media comprising a porous fiber layer and a sintered porous plastic layer was made by placing a Spunfab® polyolefin based adhesive web between the sintered porous HDPE sheet and porous fiber sheet.
  • the sintered porous HDPE sheet was 1/16 inch thick, and had an average pore size of 70 microns and pore volume of about 40 %.
  • the fiber sheet was a POREX HRM fiber sheet with 1/4 inch in thickness and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers.
  • the fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer.
  • the composite porous sheet is put in a 90 °C oven and compressed at 10 psi for 30 minutes.
  • Method 4 A composite porous media comprising a porous fiber layer and a sintered porous plastic layer was made by sintering polyethylene powder on the POREX HRM fiber disk.
  • a 1/16 thick layer of UHMWPE powders with average particle size of about 120 microns in the bottom of a mold an 1 ⁇ 4 inch thick POREX HRM fiber disk with a density of about 0.2 g/cc and an average fiber diameter of 3 deniers was put on the top of UHMWPE powder.
  • the mold was heated to about 350°F at 10 psi pressure for about 15 minutes and then cooled to the room temperature.
  • the resulted composite porous media having sintered porous plastic layer directly bonded to the POREX HRM.
  • the fibers in HRM had a general orientation either parallel or vertical to the interface between sintered porous plastic layer and porous fiber layer depending on the fiber orientation in the POREX HRM.
  • Bilayer composite material with a porous fiber layer and a sintered porous elastomeric layer.
  • Method 1 A composite porous media comprising a porous fiber layer and a sintered porous elastomeric layer was made by spaying 3M super 77 spray adhesive on a sintered porous SEPS sheet.
  • the sintered porous SEPS sheet was 1/16 inch thick, and had an average pore size of 120 microns and pore volume of about 40 %.
  • the porous fiber layer was a POREX HRM fiber sheet with 1/4 inch in thickness and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers.
  • the fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer.
  • the porous fiber sheet was laminated onto the sintered porous SEPS sheet by applying 2 psi pressure for about 30 seconds.
  • Method 2 A composite porous media comprising a porous fiber layer and a sintered porous elastomeric layer was made by applying a die cut 3M chemical resistant adhesive transfer tape 96105 CR to a sintered porous SEPS sheet.
  • the sintered porous SEPS sheet is 1/16 inch thick, and had an average pore size of 120 microns and pore volume of about 40 %.
  • the porous fiber layer was a POREX HRM fiber sheet with 1/4 inch in thickness and has a density of about 0.2 g/cc and an average fiber diameter of 3 deniers.
  • the fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer.
  • the porous fiber sheet was laminated onto the sintered porous SEPS sheet by applying 2 psi pressure for 30 seconds.
  • Method 3 A composite porous media comprising a porous fiber layer and a sintered porous elastomeric layer was made by placing a Spunfab® polyolefin based adhesive web between the sintered porous SEPS sheet and the porous fiber sheet.
  • the sintered porous SEPS sheet is 1/16 inch thick, and had an average pore size of 120 microns and pore volume of about 40 %.
  • the porous fiber layer was a POREX HRM fiber sheet with 1/4 inch in thickness and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers.
  • the fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer.
  • the composite porous sheet was put in a 90 °C oven and compressed at 10 psi for 30 minutes.
  • Method 1 A composite porous media comprising an open cell polyurethane foam layer and a sintered porous plastic layer is made by applying a die cut Avery Dennison FT 8302 pressure sensitive adhesive film to a sintered porous HDPE sheet.
  • the sintered porous HDPE sheet is 1/16 inch thick, and has an average pore size of 70 microns and pore volume of about 40 %.
  • the FT 8302 adhesive tape is pre-die cut with 1/4 inch holes to make tape with about 60 open spaces.
  • the hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL
  • the open cell polyurethane sheet is laminated onto sintered porous HDPE sheet by applying 2 psi pressure for 30 seconds.
  • Method 2 A composite porous media comprising an open cell polyurethane foam layer and a sintered porous plastic layer is made by spaying a 3M supper 90 adhesive on the sintered porous HDPE sheet.
  • the sintered porous HDPE sheet is 1/16 inch thick and has an average pore size of 70 microns and pore volume of about 40 %.
  • the hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL
  • the open cell polyurethane sheet is laminated onto sintered porous HDPE sheet by applying 2 psi pressure for 30 seconds.
  • Method 3 A composite porous media comprising an open cell polyurethane foam layer and a sintered porous plastic layer is made by placing a Vilmed® co-polyamide based adhesive web between the sintered porous HDPE sheet and the hydrophilic open cell polyurethane sheet.
  • the sintered porous HDPE sheet is 1/16 inch thick and has an average pore size of 70 microns and pore volume of about 40 %.
  • the hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL
  • the composite porous sheet is put in a 90 °C oven and compressed at 10 psi for 30 minutes.
  • Method 4 A composite porous media comprising an open cell polyurethane foam and a sintered porous plastic layer was made by sintering polyethylene powder on the POREX Medisponge foam.
  • an aluminum mold cavity placing a 1/16 thick layer of UHMWPE powders with average particle size of about 120 microns in the bottom of a mold, an 1 ⁇ 4 inch thick POREX Medisponge foam disk with a density of about 0.1 g/cc was put on the top of UHMWPE powder.
  • the mold was heated to about 350°F at 10 psi pressure for about 15 minutes and then cooled to the room temperature.
  • the resulted composite porous media having sintered porous plastic layer directly bonded to the POREX Medisponge foam.
  • Bilayer composite material with an open cell polyurethane foam layer and a sintered porous elastomeric layer
  • Method 1 A composite porous media comprising an open cell polyurethane foam layer and a sintered porous elastomeric layer is made by applying a die cut Avery Dennison FT 8302 pressure sensitive adhesive film to a sintered porous SEPS sheet.
  • the sintered porous SEPS sheet is 1/16 inch thick and has an average pore size of 120 microns and pore volume of about 40 %.
  • the FT 8302 adhesive tape is pre-die cut with 1/4 inch holes to make tape with about 60 open spaces.
  • the hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL
  • the open cell polyurethane sheet is laminated onto the sintered porous SEPS sheet by applying 2 psi pressure for 30 seconds.
  • Method 2 A composite porous media comprising an open cell polyurethane foam layer and a sintered porous elastomeric layer is made by spaying a 3M supper 90 adhesive on the sintered porous SEPS sheet.
  • the sintered porous SEPS sheet is 1/16 inch thick and has an average pore size of 120 microns and pore volume of about 40 %.
  • the hydrophilic open cell polyurethane sheet is 1/2 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL
  • the open cell polyurethane sheet is laminated onto the sintered porous SEPS sheet by applying 2 psi pressure for 30 seconds.
  • Method 3 A composite porous media comprising an open cell polyurethane foam layer and a sintered porous elastomer layer is made by placing a Vilmed® co-polyamide based adhesive web between the sintered porous SEPS sheet and the hydrophilic open cell polyurethane sheet.
  • the sintered porous SEPS sheet is 1/16 inch thick and has an average pore size of 120 microns and pore volume of about 40 %.
  • the hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL
  • the composite porous sheet is put in a 90 °C oven and compressed at 10 psi for 30 minutes.
  • a trilayer structure can be made by repeating the process of making the two layer structure as disclosed in Example 1 in order to add the third layer.
  • Tri layer composite material with bonded non-woven and sintered porous elastomers Tri layer composite material with bonded non-woven and sintered porous elastomers.
  • a trilayer structure can be made by repeating the process of making the two layer structure as disclosed in Example 2 in order to add the third layer.
  • a trilayer structure can be made by repeating the process of making the two layer structure as disclosed in Example 3 in order to add the third layer.
  • a trilayer structure can be made by repeating the process of making the two layer structure as disclosed in Example 4 in order to add the third layer.
  • the tested media is a composite porous media disk with 2 inches in diameter with an overall thickness of 0.525 inch.
  • the bottom part of the disk is a high release porous fiber material with a thickness of 0.4 inch and a void volume of 85%.
  • the top part of the disk is a sintered porous plastic with a thickness of 0.125 inch and average pore size of 70 and pore volume of 40%.
  • An Avery Dennison transfer pressure sensitive adhesive 0.05 mm thick was applied 1/4 inch around the perimeter of the disk.
  • the disk was loaded and saturated with about 17 ml of ethanol based perfume solution and the disk was kept in a closed container before each test. The total weight of the disk and container were recorded.
  • Figure 21 shows the average weight (gm) lost per cycle (of 10 average). Each cycle is one finger touch within the 10 seconds the container is open.
  • the composite material shows a consistent delivery rate for 500 cycles
  • the tested composite porous media was two layers with 1/8 inch sintered porous material and 1/2 inch polyurethane foam. This product is labeled 2 layer in Figure 22.
  • the sintered porous material is sintered porous elastomeric material made from pelletized Septon (Kuraray, Houston, TX) particles with an average pore size of 120 microns and pore volume of 40%.
  • the polyurethane foam is a viscoelastic foam with a density of 7.25 lb/ft 3 (0.12g/cc) (SRF-EP5 foam from POREX).
  • the two layers were bound together by a rubber based transfer pressure sensitive adhesive tape from Avery Dennison.
  • the tested composite porous media with three layers in this example has a configuration as in Figure 23.
  • This product is labeled as 3 layer improved NUBIFORM® (Porex Corporation, Fairburn, GA) in Figure 22.
  • the top layer is 1/8 inch sintered porous elastomeric material made from pelletized Septon (Kuraray, Houston TX) particles with an average pore size of 120 microns and pore volume of 40%;
  • the middle layer is 3/8 inch polyurethane viscoelastic foam with a density of 7.25 lb/ft 3 (0.12g/cc) (SRF-EP5 foam from POREX),
  • the bottom layer is 1/8 inch sintered porous elastomeric material made from pelletized Septon (Kuraray, Houston TX) particles with 120 microns and pore volume of 40%.
  • the different layers were bound together by a rubber based transfer pressure sensitive adhesive tape from Avery Dennison.
  • Composite self-venting wound care media comprising a sintered porous PTFE layer and porous foam media
  • Method 1 A composite porous media comprising an open cell polyurethane foam layer and a sintered porous plastic layer is made by placing a Vilmed® co-polyamide based adhesive web between the sintered porous PTFE liner material and the hydrophilic open cell polyurethane sheet.
  • the sintered porous PTFE sheet is 0.5 mm thick and has an average pore size of 1 micron and pore volume of about 40 %.
  • the hydrophilic open cell polyurethane sheet is about 5 mm in thickness and has a density of about 0.1 g/cc and an average pore density in the range of 100- 250 PPL
  • the composite porous sheet is laminated at 90 °C
  • Method 2 A composite porous media comprising an open cell polyurethane foam layer and a sintered porous PTFE layer is made by casting an open cell hydrophilic polyurethane foam layer onto the sintered porous PTFE liner material and heat curing the composite structure.
  • the sintered porous PTFE sheet is 0.1 mm thick and has an average pore size of 1 micron and pore volume of about 40 %.
  • polyurethane foam layer is about 5 mm in thickness and has a density of about 0.1 g/cc and an average pore density in the range of 100-250 PPL

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Abstract

The present disclosure provides composite porous media. In one example, the composite porous media provides a sintered media that is combined or otherwise associated with either (i) a porous fiber media or (ii) a porous foam media. The sintered media may be a sintered porous plastic media or a sintered porous elastomeric media. The disclosed porous media have many applications, including but not limited to, a liquid transfer medium, an impact resistant medium, or a wound care medium.

Description

COMPOSITE POROUS MEDIA AND METHOD OF MAKING AND USING THE
SAME
FIELD OF THE INVENTION
[0001] The present disclosure provides composite porous media. In one example, the composite porous media provides a sintered media that is combined or otherwise associated with either (i) a porous fiber media or (ii) a porous foam media. The sintered media may be a sintered porous plastic media or a sintered porous elastomeric media. The disclosed porous media have many applications, including but not limited to, a liquid transfer medium, an impact resistant medium, or a wound care medium.
BACKGROUND
[0002] Sintered porous polymeric media (including sintered porous plastic and elastomeric materials), porous fibers and open cell foams are widely used in filtration, wicking, absorbing, venting and liquid delivery related applications. Currently sintered porous polymeric media, porous fibers and open cell foams are used independently and as separate pieces. There is a need for improved porous media for use in filtration, wicking, absorbing, venting, impact attenuation, sound absorption, acoustic management,
contamination control, evaporation, controlled liquid and powder release, and liquid or powder delivery related applications.
SUMMARY OF THE INVENTION
[0003] The present disclosure addresses this unmet need and provides novel composite media. These composite media comprise combinations of different kinds of media. These composite media have improved physical properties and functions in filtration, wicking, absorbing, venting, impact attenuation, sound absorption, acoustic management,
contamination control, evaporation, controlled liquid and powder release, and liquid or powder delivery related applications.
[0004] The term "sintered porous media" used herein includes media the incorporate sintered porous plastic media, sintered porous elastomeric media, or both. These materials may be collectively referred to as "sintered porous polymeric media." The composite porous media described herein comprises at least two different compositions that are associated with one another or otherwise integrally secured to form a single component. This association may be referred to herein as a "multilayer," such as a bilayer, a trilayer, or any other combination of layers. In one example, the sintered porous media is a sintered porous plastic media, a sintered porous elastomeric media, or a combination thereof. A second component may be a porous fiber media, porous foam media, or a combination thereof. The porous foam media can be open cell porous foam media or closed cell porous foam media. In one embodiment, the porous foam media used herein are porous foam media having both closed cells and open cells. Open cells may form the majority of the cells. In one embodiment, at least 80% of the cells are open cells.
[0005] One type of composite media comprises sintered porous polymeric media and porous fiber media. Another type of composite media comprises sintered porous polymeric media and open cell foam media. Yet another type of composite media comprises sintered porous polymeric media, porous fiber and open cell foam media.
[0006] These porous media have many applications, including but not limited to, a liquid transfer medium, an impact resistant medium, or a wound care medium. The composite materials of the present disclosure provide improved overall performance in liquid storage and transferring capability, structural strength and stability in dry and wet conditions. The composite materials are lightweight, flexible, breathable, swell resistant, and resilient and are useful in some embodiments as impact attenuation media. The composite materials of the present disclosure used in cosmetic applications provide a pleasant experience in applying the cosmetic material to the skin or hair as they are comfortable, soft and deliver an adequate amount of cosmetic material compared with individual sintered porous polymeric media, open cell porous media or porous fiber media.
BRIEF DESCRIPTION OF THE FIGURES
[0007] Figure 1. Schematic representation of a bilayer composite material with porous fiber media and sintered porous polymeric media.
[0008] Figure 2. Schematic representation of a bilayer composite material with porous foam media and sintered porous polymeric media.
[0009] Figure 3. Schematic representation of a bilayer composite material with porous fiber media and sintered porous polytetrafluoroethylene (PTFE) media.
[0010] Figure 4. Schematic representation of a bilayer composite material with porous foam media and sintered porous PTFE media.
[0011] Figure 5. Schematic representation of a bilayer composite material with porous fiber media and expanded porous sintered PTFE media. [0012] Figure 6. Schematic representation of a bilayer composite material with porous foam media and expanded porous sintered PTFE media.
[0013] Figure 7. Schematic representation of a trilayer composite material with porous fiber media, sintered porous polymeric media and porous fiber media with the sintered porous polymeric media in the middle layer.
[0014] Figure 8. Schematic representation of a trilayer composite material with porous foam media, sintered porous polymeric media and porous foam media with the sintered porous polymeric media in the middle layer.
[0015] Figure 9. Schematic representation of a trilayer composite material with porous fiber media, sintered porous polymeric media and porous foam media with the sintered porous polymeric media in the middle layer.
[0016] Figure 10. Schematic representation of a trilayer composite material with porous fiber media, sintered porous polymeric media and porous foam media with the porous foam media in the middle layer.
[0017] Figure 11. Schematic representation of a trilayer composite material with porous fiber media, sintered porous polymeric media and porous foam media with the porous fiber media in the middle layer.
[0018] Figure 12. Schematic representation of a trilayer composite material with one layer of porous fiber media and two layers of sintered porous polymeric media with the porous fiber media in the middle layer.
[0019] Figure 13. Schematic representation of a trilayer composite material with one layer of porous foam media and two layers of sintered porous polymeric media with the porous foam media in the middle layer.
[0020] Figure 14. Schematic representations of a bilayer composite porous media and sintered porous polymeric media with porous foam media or with porous fiber media with the sintered porous polymeric media having a curved structure as a cushioned media for cosmetic applicators. The porous foam media and porous fiber media function as reservoirs for the cosmetic material.
[0021] Figure 15. Schematic representations of a bilayer composite porous media and sintered porous polymeric media with porous foam media or with porous fiber media with the sintered porous polymeric media having a curved structure as a cushioned media for cosmetic applicators. The porous foam media and porous fiber media function as reservoirs for the cosmetic material. [0022] Figure 16. Schematic representations of a bilayer composite porous media and sintered porous polymeric media with porous foam media or with porous fiber media with the sintered porous polymeric media having a curved structure as a cushioned media for cosmetic applicators. The porous foam media and porous fiber media function as reservoirs for the cosmetic material.
[0023] Figure 17. Schematic representation of a bilayer composite material with porous fiber media and sintered porous polymeric media with the majority of the fibers oriented parallel to the interface between the two media.
[0024] Figure 18. Schematic representation of a bilayer composite material with porous fiber media and sintered porous polymeric media with the majority of the fibers oriented orthogonal to the interface between the two media.
[0025] Figure 19. Schematic representation of a trilayer composite material with one layer of porous fiber media and two layers of sintered porous polymeric media with the porous fiber media in the middle layer with the majority of the fibers oriented parallel to the interfaces between the two media.
[0026] Figure 20. Schematic representation of a trilayer composite material with one layer of porous fiber media and two layers of sintered porous polymeric media with the porous fiber media in the middle layer with the majority of the fibers oriented orthogonal to the interfaces between the two media.
[0027] Figure 21. Graphic representation of the average weight (gm) of liquid lost per cycle (of 10 average). Each cycle is one finger touch within the 10 seconds the container is open. The composite material shows consistent delivery rate for 500 cycles.
[0028] Figure 22. Comparative chart of the percent of energy absorbed by different materials using the ASTM D2632-1 method.
[0029] Figure 23. Photograph of a trilayer composite porous material of two layers of sintered porous elastomeric material above and below a layer of viscoelastic polyurethane foam tested in Example 10.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The present disclosure provides novel composite media with surprising properties. These composite media comprise combinations of different kinds of media. The term sintered porous polymeric media used herein includes sintered porous plastic media and sintered porous elastomeric media or combinations thereof. These composite porous media comprise at least two compositions selected from a first group of sintered porous plastic media, sintered porous elastomeric media, or any combination thereof and a second group of porous fiber media, porous foam media, or any combination thereof. One type of composite media comprises sintered porous polymeric media and porous fiber media. Another type of composite media comprises sintered porous polymeric media and open cell porous foam media. Yet another type of composite media comprises sintered porous polymeric media, porous fiber and open cell porous foam media.
[0031] These porous media have many applications, including but not limited to, a liquid transfer medium, an impact resistant medium, or a wound care medium. The composite materials of the present disclosure provide improved overall performance in liquid storage and transferring capability, structural strength and stability in dry and wet conditions. The composite materials are lightweight, flexible, breathable, shape resilient and swelling resistant and are useful in some embodiments as impact attenuation media. The composite materials of the present disclosure used in cosmetic applications provide a pleasant experience in applying the cosmetic material to the skin or hair as they are comfortable, soft and deliver an adequate amount of cosmetic material compared with individual sintered porous polymeric media, open cell porous media or porous fiber media.
Sintered Porous Plastic Media
[0032] Sintered porous plastic media can be made with any polymer disclosed in US Patent No. 6,030,558, US Patent No. 7,795,346 and US Patent No. 8,141,717. In one embodiment, sintered porous plastic media are made from polyethylene, polypropylene, polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), or combinations thereof. Polyethylene includes high density polyethylene (HDPE), ultrahigh molecular weight polyethylene (UHMWPE), low density polyethylene (LDPE), or linear low density polyethylene (LLDPE), or combinations thereof.
[0033] The sintered porous plastic media may have an average pore size from about 5 microns to about 300 microns. The sintered porous plastic media may have a pore volume from about 20 % to about 60 %. The sintered porous plastic media may have a density from about 0.3 g/cc to about 0.7 g/cc. Sintered porous plastic media may have an omni-directional pore structure.
[0034] The sintered porous plastic media have a tensile strength from 20 PSI to 1000 PSI based on ASTM D638 and hardness from 20 of shore A to 80 of shore D based on ASTM D2240. These exemplary features may be provided in various range. They may all be present in a single material or only one or more features may be present in a material sample. Sintered Porous Elastomeric Media
[0035] Sintered porous elastomeric materials include those disclosed in US Patent No. 8, 141,717. In some embodiments, sintered porous elastomeric materials include non- hydrogenated and hydrogenated styrenic-based thermoplastic elastomers. Styrenic-based elastomers include styrene-ethylene-butadiene-styrene (SEBS), styrene-ethylene-pentadiene- styrene (SEPS), styrene-ethylene-pentadiene (SEP), styrene-butadiene-styrene (SBS), styrene-ethylene-ethylene pentadiene-styrene (SEEPS), a copolymer of ethylene and propylene, fluorinated elastomers, ethylene vinyl acetate (EVA), acrylonitrile-butadiene rubber (NBR) or thermoplastic urethane, or combinations thereof.
[0036] The sintered porous elastomeric media have an average pore size from about 10 microns to about 500 microns. The sintered porous elastomeric media may have a pore volume from about 20 % to about 60 %. The sintered porous elastomeric media may have a density from about 0.3 g/cc to about 0.8 g/cc. Sintered porous elastomeric media may have an omni-directional pore structure.
[0037] The sintered porous elastomeric media have a tensile strength from 20 PSI to 1000 PSI based on ASTM D638 and hardness from 20 of shore A to 80 of shore D based on ASTM D2240. These exemplary features may be provided in various range. They may all be present in a single material or only one or more features may be present in a material sample.
Porous Fiber Media
[0038] The porous fiber media can be made from any of the fibers listed in US Patent No. 6,814,911, US Patent No. 6,840,692, US Patent No. 7,888,275, US Patent No. 8,334,034 and US Patent No. 8,939,295. In some embodiments, porous fiber media are made from bicomponent fibers. Bicomponent fibers that can be used in the present disclosure include polyethylene (PE)/polyethylene terephthalate (PET) fibers, polyethylene (PE)/polypropylene (PP) fibers, Co-polyamide (PET) fibers, CoPET/PET fibers, co-polyamide/PP fibers, or combinations thereof. The bicomponent fibers can be continuous fibers or staple fibers. The porous fiber media, in some embodiments, can comprise both monocomponent fibers and bicomponent fibers. Porous fiber media, in a specific embodiment, may be made from a melt blowing process.
[0039] The porous fiber media have an average pore size from about 10 microns to about 500 microns. The porous fiber media may have a pore volume from about 40% to about 95%. The porous fiber media may have a density from about 0.05 g/cc to about 0.5 g/cc. [0040] In another embodiment, porous fiber media may be made from melt blowing bicomponent fibers.
[0041] In a specific embodiment, the porous fiber media in this disclosure is POREX high release media (HRM). The HRJVI media is described in US Patent No. 7,888,275, the contents of which are incorporated here by reference. HRM media is a thermally bonded non- woven fiber matrix.
[0042] The porous fiber media have a tensile strength from about 100 PSI to about 50000 PSI based on ASTM D638 and a hardness from about 20 of Shore OOO to Shore D based on ASTM D2240. These exemplary features may be provided in various range. They may all be present in a single material or only one or more features may be present in a material sample.
Porous Foam Media
[0043] The porous foam media can be an open cell foam or a closed cell foam. In one embodiment, the foam media is an open cell foam media. In another embodiment, the open cell foam is a polyurethane based open cell foam. Open cell foam media have an average pore size of about 5 microns to about 500 microns. The porous foam media may have a pore volume from about 40% to about 95%. The porous foam media may have a density from about 0.05 g/cc to about 0.5 g/cc. Open cell foam media have a pore density from about 10 to about 500 pores per inch, or from about 50 to about 300 pores per inch (PPI). Open cell foam media may have an omnidirectional pore structure. One embodiment of present disclosure, the open cell foam is a hydrophilic polyurethane foam, such as POREX Medisponge® foams.
[0044] The open cell foam media in the present disclosure have a tensile strength from about 10 PSI to about 300 PSI based on ASTM D3574 and a hardness from about 10 Shore OOO to about 40 Shore A 40 based on ASTM D2240. These exemplary features may be provided in various range. They may all be present in a single material or only one or more features may be present in a material sample.
Structure of composite porous media
[0045] Sintered porous plastic media, sintered porous elastomeric media, porous fiber media and/or foam media can be bound together through direct thermal bonding or through use of adhesives. Adhesives can be in liquid form, gel form, powder form or preformed webs. In different embodiments, the adhesive can be a pressure sensitive adhesive, hot melt adhesive, reactive hot melt adhesive, or thermosetting adhesives. Such adhesives are known to one of ordinary skill in the art. Other adhesives are also possible and considered within the scope of this disclosure.
[0046] In one embodiment, porous foam media and fiber media can be formed directly onto a sintered porous plastic media or sintered porous elastomeric media.
[0047] At the interfaces between sintered porous polymeric media, porous fiber media and open cell foam media, the pores are connected between two different media.
[0048] Even with binding adhesives, the pores of two different porous media at the interface will be at least 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% connected. The adhesive or other binding material will not block gas and liquid transfer between two media at the interface.
[0049] In one embodiment, composite porous media of the present disclosure have a layered structure. In one embodiment, at least one layer of the composite porous media is sintered porous polymeric media. The composite porous media can be two layers (bilayer), three layers (trilayer) or more than three layers.
[0050] In one embodiment, composite porous media have a bilayer structure and one layer is sintered porous polymeric media and another layer is a porous fiber media.
[0051] In another embodiment, composite porous media have a bilayer structure and one layer is sintered porous polymeric media and another layer is a porous foam media.
[0052] In still another embodiment, composite porous media have a trilayer structure and one layer is sintered porous polymeric media and the other two layers are porous fiber media.
[0053] In a specific embodiment, sintered porous polymeric media is the middle layer of a trilayer structure between two layers of porous fiber media.
[0054] In another embodiment, composite porous media have a trilayer structure and one layer is sintered porous polymeric media and the other two layers are porous foam media.
[0055] In a specific embodiment, sintered porous polymeric media is the middle layer of a trilayer structure between two layers of porous foam media.
[0056] In another embodiment, composite porous media have a trilayer structure and one layer is a porous fiber media and the other two layers are sintered porous polymeric media.
[0057] In one embodiment, porous fiber media is the middle layer of a trilayer composite media between two layers of sintered porous polymeric media.
[0058] In another embodiment, composite porous media have a trilayer structure and one layer is porous foam media and the other two layers are sintered porous polymeric media.
[0059] In one embodiment, the porous foam media is the middle layer of a trilayer composite media between two layers of sintered porous polymeric media. [0060] In another embodiment, composite porous media have a trilayer structure, one layer is porous foam media, one layer is porous fiber media and another layer is a sintered porous polymeric media.
[0061] In a specific embodiment, porous foam media is the middle layer of a trilayer composite media between a layer of porous fiber media and a layer of sintered porous polymeric media.
[0062] In another specific embodiment, porous fiber media is the middle layer of a trilayer composite media between a layer of porous foam media and a layer of sintered porous polymeric media.
[0063] In yet another embodiment, sintered porous polymeric media is the middle layer of a trilayer composite media between a layer of porous foam media and a layer of porous fiber media.
[0064] It should be understood that any combination of a sintered porous polymeric media (which may be either a plastic media, an elastomeric media, or any combination thereof) in combination with one or more layers of a porous foam media and/or a porous fiber media is considered within the scope of this disclosure.
[0065] In another embodiment, composite porous media have multiple sections and at least one section is sintered porous polymeric media. The different media within the composite porous media cannot be separated without affecting overall performance of the composite porous media.
[0066] Composite porous media can have different shapes, such as spherical, cylindrical, rod, cube, water drop, and elliptical shapes or other three dimensional shapes.
[0067] For example, composite porous media can have a continuous and discontinuous arrangement. In one embodiment, sintered porous polymeric media is the continuous component and is a single piece, and the porous foam media sections are discontinuous or segregated such that the porous foam sections do not connect to each other. In another embodiment, the porous foam media is the continuous component and is a single piece, and sintered porous polymeric media sections are discontinuous or segregated and do not connect to each other. In another embodiment, the porous fiber media is the continuous component and is a single piece, and sintered porous polymeric media sections are discontinuous or segregated and do not connect to each other. In still another embodiment, the sintered porous polymeric media is the continuous component and is a single piece and the porous fiber media sections are discontinuous or segregated and do not connect to each other. In yet another embodiment, the porous foam media is the continuous component and is a single piece, and the porous fiber media sections are discontinuous or segregated and do not connect to each other.
[0068] Side by side structure: composite porous media in present disclosure can have a complicated three-dimensional structure and one side of the structure has a different porous media from another side. For example, one side is sintered porous polymeric media and another side is porous foam media, or one side is sintered porous polymeric media and another side is porous fiber media, or one side is porous foam media and another is porous fiber media. These side by side structures can occur in different shapes such as a rod, sphere, block or any other shape.
[0069] The composite porous media of the present disclosure may be flocked in some embodiments. The fibers for flocking may be nylon fibers, polyethylene fibers,
polypropylene fibers, cotton fibers, rayon fibers, polyester fibers or polyacrylic fibers, or combinations thereof. The fibers may be attached to the surface of composite porous media. The adhesive can be common adhesives used in the flocking process, such vinyl,
polyurethane, EVA and epoxy based adhesives. The fibers may have a length from about 0.1 mm to about 5 mm.
[0070] The composite porous media to be flocked may be placed on a holder to expose the area to be flocked. Adhesive may be sprayed on the media to be flocked.
Electrostatically charged fibers of flock are propelled at high velocity towards the composite porous media surface to be flocked.
[0071] The composite porous media may have omnidirectional, semi-omnidirectional or unidirectional physical properties based on the compositions in the composite porous media. These physical properties include compressibility, impact resistance, fluid transportation, gas permeability, sound and wave adsorption, and friction.
Applications of composite porous media
Liquid Transfer
[0072] The composite porous media of the present disclosure can be used to store and release liquid. In one embodiment, the liquid can be a cosmetic treatment formula. For example, it may be liquid foundation, liquid blush, inks, astringent or a toner, water, facial masks, antiseptic, a blemish treatment, fungus or antibacterial treatment, nail polish remover, cosmetic gels, biologies, or any other type of liquid cosmetic or treatment formula. The liquid is stored in the composite porous media and is released from the composite porous media onto a target surface by compressing at least one section of the composite porous media.
[0073] The composite porous media can also be used to control the release of the liquid by varying the liquid retention capability of sintered porous polymeric media, fiber media and open cell foam media
[0074] In one embodiment, one of the porous media (foam or fiber) with high pore volume is for holding liquid and another porous media (sintered porous polymeric media) with relatively low pore volume is for controlled release of the liquid from the media to the target.
[0075] Porous composite materials may have different fluid delivery properties based on fiber orientation within the porous composite materials.
[0076] In another embodiment the liquid holding media has a large pore size and the release media has a smaller pore size.
[0077] In another embodiment, the liquid holding media is a softer material and the release media is a rigid material.
[0078] In one embodiment, the liquid holding media is deformable during application of liquid and the release media is not deformable during the application of liquid.
[0079] In a specific embodiment, the liquid holding media is an open cell foam and the liquid release media is a sintered porous polymeric media. In this embodiment, the open cell foam can be a polyurethane foam.
[0080] In a specific embodiment, the liquid holding media is a porous fiber media and the liquid release media is a sintered porous polymeric media. Porous fiber media can be woven fiber, non-woven fiber or melt blown fiber. The fiber can be a continuous fiber or staple fiber, monocomponent fiber or bicomponent fiber, or a combination of monocomponent and bicomponent fibers. Porous composite materials may have different fluid delivery properties based on fiber orientation within the porous composite materials. Liquid is released easily from the surface of the sintered porous polymer media.
[0081] In one embodiment, sintered porous polymeric liquid release media has an average pore size between about 10 microns to about 200 microns and with an average pore volume less than about 60%. In another embodiment, porous fiber media has an average pore size between about 30 microns to about 500 microns and with a pore volume of at least 80%. Open cell polyurethane in this specific application has 10 to 500 pores per inch (PPI) and with pore volume of at least 80%. The overall compressibility of the material is about 30% to 60% under 5 pounds per square inch (PSI). [0082] The liquids in present disclosure include biological fluids, water, cosmetic liquids, inks and cosmetic gels. The liquids can have a viscosity from about 1 to about 100,000 centipoise (CPS).
[0083] The composite porous media in could be used in any cushion type cosmetic devices or in a facial mask for skin treatment.
Impact resistance
[0084] The composite porous media of the present disclosure can be used to reduce the force of impact and function as protective cushions in sports gear, military gear, personal protection gear, or healthcare devices, such as helmets, shoulder pads, chest pads, thigh pads, shin pads, glove pads, knee pads, insoles for shoes, etc. The composite porous media products have the unexpected advantages of dissipating energy, they are easy to form and are comfortable.
[0085] In different embodiments, the composite porous media may be used in any type of sport gloves. Nonlimiting examples include hockey gloves, soccer gloves, cricket gloves, golf gloves, weightlifting gloves, or catchers' baseball gloves.
[0086] In one embodiment for healthcare, the composite porous media can be used in a thigh cushion pad for people to prevent bone fracture of the femur caused by a fall.
[0087] In other embodiments for healthcare, the composite porous media can be used as a cushion after or during surgery to protect the knee, hip, foot, skull, sacrum, ankle, or any other body part. For example, the material may help prevent bed sores from a patient lying in a stationary position for an extended period of time. The composite porous media provide overall benefits in flexible, comfort, and security.
[0088] In one embodiment, the impact resistant device has a layered structure wherein one layer is sintered porous polymeric media. Sintered porous polymeric media disperse the force of an impact to the open cell foam layer or porous fiber layer in a composite porous media.
[0089] In a specific embodiment, the impact resistance media has a trilayer structure with sintered porous elastomeric material in the middle layer between two open cell foam layers, or between one open cell foam layer and one porous fiber layer.
[0090] In one specific embodiment, sintered porous polymeric material is sintered porous elastomeric material. Self-venting wound care
[0091] The composite porous media can be used in wound care. For example, in one embodiment the composite porous media for wound care media has a bilayer structure, one layer is a hydrophilic open cell polyurethane foam layer containing a therapeutic agent and the other layer is a hydrophobic porous layer that is breathable and helps wound repair by acting as a bacterial barrier and maintaining proper moisture balance in the wound area.
[0092] The hydrophobic layer can be a sintered polyethylene layer, a sintered
polytetrafluoroethylene (PTFE) layer or an expanded-PTFE layer, or combinations thereof. The hydrophobic layer can contain an antimicrobial agent and prevent liquid penetration during accidental contact with water, or prevent fluid leaking from the wound. The sintered porous polymeric media in this application may function as an aerosol and bacterial barrier.
[0093] The following examples will serve to further illustrate the present disclosure without, at the same time, however, constituting any limitation thereof. On the contrary, it is to be clearly understood that resort may be had to various embodiments, modifications and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the disclosure.
EXAMPLE 1
Bilayer composite material with a fiber layer and a sintered porous plastic layer
[0094] Method 1 : A composite porous media comprising a porous fiber layer and a sintered porous plastic layer is made by applying a die cut, 3M chemical resistant adhesive transfer tape 96105 CR to a sintered porous FIDPE sheet. The sintered porous FIDPE sheet was 1/16 inch thick, and had an average pore size of 70 microns and pore volume of about 40 %. The adhesive tape was pre-die cut with 1/4 inch holes to make tape with about 60 open spaces.
[0095] The fiber layer was a POREX FIRM fiber sheet with 1/4 inch in thickness, and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers. The fibers in FIRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer. The fiber sheet was laminated onto the sintered porous HDPE sheet through the die cut adhesive tape by applying 2 psi pressure for 30 seconds.
[0096] Method 2: A composite porous media comprising a fiber layer and a sintered porous plastic layer was made by spraying 3M super 77 spray adhesive on a sintered porous HDPE sheet. The sintered porous HDPE sheet is 1/16 inch thick, and has an average pore size of 70 microns and pore volume of about 40 %. The fiber layer was a POREX HRM fiber sheet with 1/4 inch in thickness, and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers. The fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer. The fiber sheet was laminated on the top of the sintered porous HDPE sheet after adhesive is sprayed and the laminated sheet was kept under 2 psi pressure for 30 seconds.
[0097] Method 3 : A composite porous media comprising a porous fiber layer and a sintered porous plastic layer was made by placing a Spunfab® polyolefin based adhesive web between the sintered porous HDPE sheet and porous fiber sheet. The sintered porous HDPE sheet was 1/16 inch thick, and had an average pore size of 70 microns and pore volume of about 40 %. The fiber sheet was a POREX HRM fiber sheet with 1/4 inch in thickness and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers. The fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer. The composite porous sheet is put in a 90 °C oven and compressed at 10 psi for 30 minutes.
Method 4: A composite porous media comprising a porous fiber layer and a sintered porous plastic layer was made by sintering polyethylene powder on the POREX HRM fiber disk. In an aluminum mold cavity, placing a 1/16 thick layer of UHMWPE powders with average particle size of about 120 microns in the bottom of a mold, an ¼ inch thick POREX HRM fiber disk with a density of about 0.2 g/cc and an average fiber diameter of 3 deniers was put on the top of UHMWPE powder. The mold was heated to about 350°F at 10 psi pressure for about 15 minutes and then cooled to the room temperature. The resulted composite porous media having sintered porous plastic layer directly bonded to the POREX HRM. The fibers in HRM had a general orientation either parallel or vertical to the interface between sintered porous plastic layer and porous fiber layer depending on the fiber orientation in the POREX HRM.
EXAMPLE 2
Bilayer composite material with a porous fiber layer and a sintered porous elastomeric layer.
[0098] Method 1 : A composite porous media comprising a porous fiber layer and a sintered porous elastomeric layer was made by spaying 3M super 77 spray adhesive on a sintered porous SEPS sheet. The sintered porous SEPS sheet was 1/16 inch thick, and had an average pore size of 120 microns and pore volume of about 40 %. The porous fiber layer was a POREX HRM fiber sheet with 1/4 inch in thickness and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers. The fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer. The porous fiber sheet was laminated onto the sintered porous SEPS sheet by applying 2 psi pressure for about 30 seconds.
[0099] Method 2: A composite porous media comprising a porous fiber layer and a sintered porous elastomeric layer was made by applying a die cut 3M chemical resistant adhesive transfer tape 96105 CR to a sintered porous SEPS sheet. The sintered porous SEPS sheet is 1/16 inch thick, and had an average pore size of 120 microns and pore volume of about 40 %. The porous fiber layer was a POREX HRM fiber sheet with 1/4 inch in thickness and has a density of about 0.2 g/cc and an average fiber diameter of 3 deniers. The fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer. The porous fiber sheet was laminated onto the sintered porous SEPS sheet by applying 2 psi pressure for 30 seconds.
[00100] Method 3 : A composite porous media comprising a porous fiber layer and a sintered porous elastomeric layer was made by placing a Spunfab® polyolefin based adhesive web between the sintered porous SEPS sheet and the porous fiber sheet. The sintered porous SEPS sheet is 1/16 inch thick, and had an average pore size of 120 microns and pore volume of about 40 %. The porous fiber layer was a POREX HRM fiber sheet with 1/4 inch in thickness and had a density of about 0.2 g/cc and an average fiber diameter of 3 deniers. The fibers in HRM had a general orientation parallel to the interface between sintered porous plastic layer and porous fiber layer. The composite porous sheet was put in a 90 °C oven and compressed at 10 psi for 30 minutes.
EXAMPLE 3
Bilayer composite material with an open cell foam layer and a sintered porous plastic layer [00101] Method 1 : A composite porous media comprising an open cell polyurethane foam layer and a sintered porous plastic layer is made by applying a die cut Avery Dennison FT 8302 pressure sensitive adhesive film to a sintered porous HDPE sheet. The sintered porous HDPE sheet is 1/16 inch thick, and has an average pore size of 70 microns and pore volume of about 40 %. The FT 8302 adhesive tape is pre-die cut with 1/4 inch holes to make tape with about 60 open spaces. The hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL The open cell polyurethane sheet is laminated onto sintered porous HDPE sheet by applying 2 psi pressure for 30 seconds.
[0100] Method 2: A composite porous media comprising an open cell polyurethane foam layer and a sintered porous plastic layer is made by spaying a 3M supper 90 adhesive on the sintered porous HDPE sheet. The sintered porous HDPE sheet is 1/16 inch thick and has an average pore size of 70 microns and pore volume of about 40 %. The hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL The open cell polyurethane sheet is laminated onto sintered porous HDPE sheet by applying 2 psi pressure for 30 seconds.
[0101] Method 3 : A composite porous media comprising an open cell polyurethane foam layer and a sintered porous plastic layer is made by placing a Vilmed® co-polyamide based adhesive web between the sintered porous HDPE sheet and the hydrophilic open cell polyurethane sheet. The sintered porous HDPE sheet is 1/16 inch thick and has an average pore size of 70 microns and pore volume of about 40 %. The hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL The composite porous sheet is put in a 90 °C oven and compressed at 10 psi for 30 minutes.
[0102] Method 4: A composite porous media comprising an open cell polyurethane foam and a sintered porous plastic layer was made by sintering polyethylene powder on the POREX Medisponge foam. In an aluminum mold cavity, placing a 1/16 thick layer of UHMWPE powders with average particle size of about 120 microns in the bottom of a mold, an ¼ inch thick POREX Medisponge foam disk with a density of about 0.1 g/cc was put on the top of UHMWPE powder. The mold was heated to about 350°F at 10 psi pressure for about 15 minutes and then cooled to the room temperature. The resulted composite porous media having sintered porous plastic layer directly bonded to the POREX Medisponge foam. EXAMPLE 4
Bilayer composite material with an open cell polyurethane foam layer and a sintered porous elastomeric layer
[0103] Method 1 : A composite porous media comprising an open cell polyurethane foam layer and a sintered porous elastomeric layer is made by applying a die cut Avery Dennison FT 8302 pressure sensitive adhesive film to a sintered porous SEPS sheet. The sintered porous SEPS sheet is 1/16 inch thick and has an average pore size of 120 microns and pore volume of about 40 %. The FT 8302 adhesive tape is pre-die cut with 1/4 inch holes to make tape with about 60 open spaces. The hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL The open cell polyurethane sheet is laminated onto the sintered porous SEPS sheet by applying 2 psi pressure for 30 seconds.
[0104] Method 2: A composite porous media comprising an open cell polyurethane foam layer and a sintered porous elastomeric layer is made by spaying a 3M supper 90 adhesive on the sintered porous SEPS sheet. The sintered porous SEPS sheet is 1/16 inch thick and has an average pore size of 120 microns and pore volume of about 40 %. The hydrophilic open cell polyurethane sheet is 1/2 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL The open cell polyurethane sheet is laminated onto the sintered porous SEPS sheet by applying 2 psi pressure for 30 seconds.
[0105] Method 3 : A composite porous media comprising an open cell polyurethane foam layer and a sintered porous elastomer layer is made by placing a Vilmed® co-polyamide based adhesive web between the sintered porous SEPS sheet and the hydrophilic open cell polyurethane sheet. The sintered porous SEPS sheet is 1/16 inch thick and has an average pore size of 120 microns and pore volume of about 40 %. The hydrophilic open cell polyurethane sheet is 1/4 inch in thickness and has a density of about 0.1 g/cc and an average pore density of about 100 PPL The composite porous sheet is put in a 90 °C oven and compressed at 10 psi for 30 minutes.
EXAMPLE 5
Tri layer composite material with bonded non-woven and sintered porous plastics
[0106] A trilayer structure can be made by repeating the process of making the two layer structure as disclosed in Example 1 in order to add the third layer. EXAMPLE 6
Tri layer composite material with bonded non-woven and sintered porous elastomers.
[0107] A trilayer structure can be made by repeating the process of making the two layer structure as disclosed in Example 2 in order to add the third layer.
EXAMPLE 7
Trilayer composite material with open cell foam and sintered porous plastics
[0108] A trilayer structure can be made by repeating the process of making the two layer structure as disclosed in Example 3 in order to add the third layer.
EXAMPLE 8
Trilayer composite material with open cell foam and sintered porous elastomers
[0109] A trilayer structure can be made by repeating the process of making the two layer structure as disclosed in Example 4 in order to add the third layer.
EXAMPLE 9
Perfume delivery for composite porous media with sintered porous plastic and porous fiber media
[0110] The tested media is a composite porous media disk with 2 inches in diameter with an overall thickness of 0.525 inch. The bottom part of the disk is a high release porous fiber material with a thickness of 0.4 inch and a void volume of 85%. The top part of the disk is a sintered porous plastic with a thickness of 0.125 inch and average pore size of 70 and pore volume of 40%. An Avery Dennison transfer pressure sensitive adhesive 0.05 mm thick was applied 1/4 inch around the perimeter of the disk.
[0111] The disk was loaded and saturated with about 17 ml of ethanol based perfume solution and the disk was kept in a closed container before each test. The total weight of the disk and container were recorded.
[0112] The data were collected by measuring the total weight of the disk and container after a robotic finger with a closed cell foam tip contacted the top disk surface for 0.5 seconds. For each test, the container was open for 10 seconds. The difference before and after the robotic touching is the amount of perfume transferred from the disk onto the finger and evaporated to atmosphere. The touching contact surface between the finger and the disk is about 1.9 cm2 and the touch time is 0.5 seconds. [0113] Table 1 show perfume holding capacity and release capability for sintered porous plastic, sintered porous plastic with two pore sizes, sintered porous plastic and elastomer and composite material with sintered porous plastic and porous fiber. The composite material with sintered porous plastic and porous fiber showed much higher perfume holding capacity and release capability than sintered polymeric materials
[0114] Table 1 Perfume holding capacity and release capability for different material.
Figure imgf000020_0001
[0115] Figure 21 shows the average weight (gm) lost per cycle (of 10 average). Each cycle is one finger touch within the 10 seconds the container is open. The composite material shows a consistent delivery rate for 500 cycles
EXAMPLE 10
Energy absorption for composite porous media with sintered porous elastomer and polyurethane foam
[0116] The tested composite porous media was two layers with 1/8 inch sintered porous material and 1/2 inch polyurethane foam. This product is labeled 2 layer in Figure 22. The sintered porous material is sintered porous elastomeric material made from pelletized Septon (Kuraray, Houston, TX) particles with an average pore size of 120 microns and pore volume of 40%. The polyurethane foam is a viscoelastic foam with a density of 7.25 lb/ft3 (0.12g/cc) (SRF-EP5 foam from POREX). The two layers were bound together by a rubber based transfer pressure sensitive adhesive tape from Avery Dennison.
[0117] The tested composite porous media with three layers in this example has a configuration as in Figure 23. This product is labeled as 3 layer improved NUBIFORM® (Porex Corporation, Fairburn, GA) in Figure 22. The top layer is 1/8 inch sintered porous elastomeric material made from pelletized Septon (Kuraray, Houston TX) particles with an average pore size of 120 microns and pore volume of 40%; the middle layer is 3/8 inch polyurethane viscoelastic foam with a density of 7.25 lb/ft3 (0.12g/cc) (SRF-EP5 foam from POREX), the bottom layer is 1/8 inch sintered porous elastomeric material made from pelletized Septon (Kuraray, Houston TX) particles with 120 microns and pore volume of 40%. The different layers were bound together by a rubber based transfer pressure sensitive adhesive tape from Avery Dennison.
[0118] Energy absorption was measured using an ElasTek™ (Shore™ Style) Vertical Rebound Resiliometer according to ASTM D2632-1. An ASTM D2632 master resiliometer reference spring apparatus was used to calibrate the resiliometer. For each trial, the mass (approximately 28g) at the top of the resiliometer was released, fell and impacted the sample. For two layer material, the sintered elastomeric side faced up to receive the impact.
[0119] The energy absorption for the three layered structure and the two layered structure were 76% and 73%, respectively. These composite structures had better energy absorption than the currently available commercial products shown in Figure 22.
EXAMPLE 11
Composite self-venting wound care media comprising a sintered porous PTFE layer and porous foam media
[0120] Method 1 : A composite porous media comprising an open cell polyurethane foam layer and a sintered porous plastic layer is made by placing a Vilmed® co-polyamide based adhesive web between the sintered porous PTFE liner material and the hydrophilic open cell polyurethane sheet. The sintered porous PTFE sheet is 0.5 mm thick and has an average pore size of 1 micron and pore volume of about 40 %. The hydrophilic open cell polyurethane sheet is about 5 mm in thickness and has a density of about 0.1 g/cc and an average pore density in the range of 100- 250 PPL The composite porous sheet is laminated at 90 °C
[0121] Method 2: A composite porous media comprising an open cell polyurethane foam layer and a sintered porous PTFE layer is made by casting an open cell hydrophilic polyurethane foam layer onto the sintered porous PTFE liner material and heat curing the composite structure. The sintered porous PTFE sheet is 0.1 mm thick and has an average pore size of 1 micron and pore volume of about 40 %. The hydrophilic open cell
polyurethane foam layer is about 5 mm in thickness and has a density of about 0.1 g/cc and an average pore density in the range of 100-250 PPL
[0122] All patents, publications and abstracts cited above are incorporated herein by reference in their entirety. It should be understood that the foregoing relates only to preferred embodiments of the present disclosure and that numerous modifications or alterations may be made therein without departing from the spirit and the scope of the present disclosure as defined in the following claims.

Claims

CLAIMS What is claimed is:
1. A porous composite media comprising at least two components bonded to one another, a first component comprising a sintered porous polymeric media, and a second component comprising a porous fiber media, a porous foam media, or any combination thereof.
2. The porous composite media of claim 1, wherein the sintered porous polymeric media comprises a sintered porous plastic media, a sintered porous elastomeric media, or any combination thereof.
3. The porous composite media, of claim 1 wherein the at least two components are provided in individual layers that are bound together.
4. The porous composite media of claim 3, wherein the individual layers are bound together through a thermal bond, an adhesive bond, or a combination thereof.
5. The porous composite media of claim 2, wherein the sintered porous plastic media is polyethylene or polypropylene.
6. The porous composite media of claim 2, wherein the sintered porous plastic media has an average pore size from about 5 microns to about 300 microns, a pore volume from about 20 % to about 60 % and a density from about 0.3 g/cc to about 0.7 g/cc
7. The porous composite media of claim 2, wherein the sintered porous elastomeric media comprises non-hydrogenated or hydrogenated styrenic-based thermoplastic elastomers.
8. The porous composite media of claim 7, wherein the thermoplastic elastomers are selected from the group consisting of styrene-ethylene-butadiene-styrene (SEBS), styrene-ethylene- pentadiene-styrene (SEPS), styrene-ethylene-pentadiene (SEP), styrene-butadiene-styrene (SBS), styrene-ethylene-ethylene pentadiene-styrene (SEEPS), a copolymer of ethylene and propylene, fluorinated elastomers, ethylene vinyl acetate (EVA), acrylonitrile-butadiene rubber ( BR) and thermoplastic urethane, or any combination thereof.
9. The porous composite media of claim 2, wherein the sintered porous elastomeric media has an average pore size from about 10 microns to about 500 microns, a pore volume from about 20 % to about 60 % and a density from about 0.3 g/cc to about 0.8 g/cc.
10. The porous composite media of claim 1, wherein the porous fiber media has an average pore size from about 10 microns to about 500 microns, a pore volume from about 40% to about 95%, and a density from about 0.05 g/cc to about 0.5 g/cc.
11. The porous composite media of claim 1, wherein the porous foam media is open cell foam media or closed cell foam media.
12. The porous composite media of claim 11, wherein the open cell foam has an average pore size of about 5 microns to about 500 microns, a pore volume from about 40% to about 95% and a density from about 0.05 g/cc to about 0.5 g/cc.
13. The porous composite media of claim 11, wherein the open cell foam media is a polyurethane based open cell foam.
14. The porous composite media of claim 1, wherein the porous foam media or porous fiber media is preformed, and wherein the sintered porous polymeric media is formed on the top of preformed porous foam or fiber media by sintering polymer particles or elastomeric particles together.
15. Use of the porous composite media of any of the preceding claims as a liquid transfer medium, an impact resistant medium, or a wound care medium.
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