CA1230810A - Extensible microfine fiber laminate - Google Patents

Extensible microfine fiber laminate

Info

Publication number
CA1230810A
CA1230810A CA000483611A CA483611A CA1230810A CA 1230810 A CA1230810 A CA 1230810A CA 000483611 A CA000483611 A CA 000483611A CA 483611 A CA483611 A CA 483611A CA 1230810 A CA1230810 A CA 1230810A
Authority
CA
Canada
Prior art keywords
fibers
ply
fiber structure
hydrophobic
conjugate fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000483611A
Other languages
French (fr)
Inventor
Charles J. Shimalla
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Chicopee Inc
Original Assignee
Chicopee Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Chicopee Inc filed Critical Chicopee Inc
Application granted granted Critical
Publication of CA1230810A publication Critical patent/CA1230810A/en
Expired legal-status Critical Current

Links

Classifications

    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/04Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a layer being specifically extensible by reason of its structure or arrangement, e.g. by reason of the chemical nature of the fibres or filaments
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/10Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer reinforced with filaments
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02Synthetic macromolecular fibres
    • B32B2262/0276Polyester fibres
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/04Cellulosic plastic fibres, e.g. rayon
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/726Permeability to liquids, absorption
    • B32B2307/7265Non-permeable
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/73Hydrophobic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2437/00Clothing
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00Stock material or miscellaneous articles
    • Y10S428/903Microfiber, less than 100 micron diameter
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00Stock material or miscellaneous articles
    • Y10S428/913Material designed to be responsive to temperature, light, moisture
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24446Wrinkled, creased, crinkled or creped
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913Rod, strand, filament or fiber
    • Y10T428/2929Bicomponent, conjugate, composite or collateral fibers or filaments [i.e., coextruded sheath-core or side-by-side type]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608Including strand or fiber material which is of specific structural definition
    • Y10T442/614Strand or fiber material specified as having microdimensions [i.e., microfiber]
    • Y10T442/621Including other strand or fiber material in a different layer not specified as having microdimensions

Abstract

EXTENSIBLE MICROFINE FIBER LAMINATE

ABSTRACT

An extensible water impervious laminated material having an improved hydrostatic head at higher extension is described. A preferred embodiment comprises an inner creped hydrophobic microfine fiber structure sandwiched between and bonded to two reinforcing layers of nonwoven fibers, said microfine fiber structure comprising at least one ply of microfine fibers having a fiber diameter of up to 10 microns. This material is especially useful as an operating room gown.

Description

~.Z30810 EXTENSIBLE MICROPHONE FIBER LAMINATE

This invention relates to extensible water impervious microphone fiber laminate materials having improved hydrostatic heats at higher extensions and, more particularly, to absorbent disposable operating room gowns which are impermeable to the passage of microorganisms and fluids.

Background of the Invention Composite fabrics for use in surgical gowns, surgical drapes and the like, are well known. The purpose of these fabrics is to place a bacteria barrier between the aseptic operative field and areas which are incapable of surgical cleansing. It it essential that such fabrics possess a high liquid strike through resistance (measured by the hydrostatic head test), high bacteria strikethrou~h no-distance, and adequate strength and tear resistance.
These fabrics should be sufficiently flexible and drape able. The operating room gown, in particular, must lung-lion, during the course of an operation, to prevent contamination of the patient, surgical instruments and other personnel through contact with the wearer and to prevent clothes of the wearer from becoming saturated with blood an other liquids. Previous operating room gowns composed of a melt flown layer or layers with one or two reinforcement layers of non woven fabric, generally have the deficiency that as the laminated composite is extended, as in the case of the surgeon bending his elbow, the melt blown fabric develop holes and loses its barrier properties. (These barrier properties can be measured by COOK

I

the hydrostatic head test described hereinafter.) The melt blown fabric has a lower elongation than that of the reinforcing layer or layers, so that during extension of the composite, the melt blown fabric will fail (rupture) before the reinforcing layers fail. Thus, it is of little use to provide a high tensile strength reinforcing layer if the barrier properties of the composite are lost by extension of the melt blown fabric.

lo In accordance with the present invention, a groped micro-fine fiber layer (preferably melt blown) is incorporate as the barrier layer. As a result thereof, the extension of the laminated fabric will not cause deterioration of the barrier properties until much higher levels of extension are reached. In addition, a much softer fabric laminate will also result due to the much greater extent sublet of the microphone fixer layer. Furthermore, the microphone fiber (melt blown layer) may be groped to a sufficient degree of compaction such that it will be virtually unaffected at the rupture elongation of the reinforcing layer or layers.

Although the microphone fibers utilized in the present invention are preferably produced by melt blowing, such microphone fibers can also be produced, for instance by a centrifugal spinning operation (see VinicXi's U.S. Patent No. 3,388,194) and by other methods.

Although the laminate of the present invention is portico-laxly useful in the case of operating room gowns which are subject to considerable extension at the elbows, never the-less such laminate is also suitable for use as an operate in room drape, a tray cover for surgical instruments, laparotomy packs, obstetric packs, backing layers for diapers or sanitary napkins and for any other application I 81~

wherein an impermeable material would be desirable. The material is also suitable for surgical face masks.

The Prior Art The Kit son et at. U.S. Patent No. 4,196,245 describes a composite non woven fabric which comprises at least two hydrophobic plies of microphone fibers and at least one non woven cover ply. There is no disclosure in Kit son concerning the use of groped plies of ~icrofine fibers.

Loden in U.S. Patent No. 3,837,995 describes a web con-twining one or more layers of melt blown fibers and one or more layers of larger diameter natural fibers. No groping of the melt blown layers of fibers is disclosed.

The Thongs U.S. Patent No. 3,650,882 discloses a multi-ply paper towel which has an elastically extensible inner we of groped tissue paper and two outer webs which are bonded 20 to either side of the inner web. The structure of Thomas is resigned so as to achieve materially greater liquid absorbency. In accordance with the present invention, on the other hand, the purpose of the groped inner ply of microphone fibers is to promote the nonabsorbency of the laminated material, since said crepe inner layer will prevent liquid strike through even after considerable extension of the laminate (such as the bending of the surgeon's elbow The Chapman et at. U.S. Patent No. 4,075,382 discloses a disposable non woven surgical towel having five plies. The center-most ply consists of a low-density, melt blown non woven material, which is, however, not groped.

The Herman son et at. U.S. Patent No. 2,864,362 and the Thomas U.S. Patent No. 3,477,084 each disclose an lZ3(~810 absorbent wise or dressing having a plurality of layers, toe inner layers being constructed of groped material.
However, the inner groped layers are absorbent rather than fluid impervious as is the case in accordance with the present invention.

The Thomas et at. U.S. Patent No. 3,597,299 discloses a disposable washcloth which includes groped cellulose wadding layers. The Murphy et at. U.S. Patent No.
3,544,420 discloses a groped tissue product formed by at least two superimposed sheets of groped tissue. In both cases the groped material is useful to improve the absorbency rather than the water impermeability of the product. The Becker et at. U.S. Patent No. 4,208,459 discloses a method of groping a fibrous web an the Gentile et at. U.S. Patent No. 3,879,257 relates to absorbent unitary laminate-like fibrous webs.

The present invention provides a soft drawable composite which is impervious to water. In accordance with a preferred embodiment of the present invention, the outer reinforcing layers utilize conjugate fibers composed of higher and lower melting components. This preserves the integrity of the higher melting component in view of the fact that the fusion process it carried out below the melting temperature of the higher melting component. The preservation of the integrity of the fibers maintains the strength in the reinforcing layers. Furthermore in accordance with a further preferred embodiment of the present invention, the melt temperature of the outer layers of the hydrophobic microphone fiber structure is chosen so as to substantially match the melt temperature of the lower melting component of the conjugate fiber. In this manner a far stronger and more intimate bond is SCHICK

lZ3(~810 formed, especially in the instance wherein the save material is use for the outer ply of the hydrophobic microphone fiber structure as well as the lower melting component of the conjugate fiber. Furthermore the bonding of the hydrophobic microphone fiber structure to the conjugate fibers can take place without significantly changing the hand or moisture vapor transmission of the hydrophobic microphone fiber structure. These features are disclosed, per so, in issued U.S. Patent No. 4,508,113.

Summary of the Invention In accordance with the present invention, there is pro-vowed an extensible water impervious laminated material having an improved hydrostatic head at higher extension, comprising at least one reinforcing layer of non woven fibers bowled to at least one hydrophobic groped ply of microphone fibers having a fiber diameter of up to 10 microns.

The preferred embodiment of the present invention provides an extensible water impervious laminated material having an improved hydrostatic head at higher extension, comprise in an inner groped hydrophobic microphone fiber structure sandwiched between and bonded to two reinforcing layers of non woven fibers, said hydrophobic mlcrofine fiber structure comprising at least one ply of microphone fibers having an average fiber diameter of up to 10 microns. The reinforcing layers preferably consist of conjugate fibers, which may optionally be blended with from 5-40~ of non conjugate fibers such as rayon or polyester fibers which are useful for improving the doublet and softness of the laminated material. The groped hydrophobic microphone fiber structure may comprise two or Gore plies bonded together. These plies are preferably prepared by ICKY
. ", SKYE

melt blowing and may consist of polyethylene, polyamide, polyethylene terephthalate, polybutylene terephthalate or polypropylene, although virtually any thermoplastic polymer or polymer blend Jay be utilized.

The reinforcing layers of non woven fabric may consist of a spun bonded non woven material or a restraining belt bonder sigh density polyethylene/polyethylene terephthalate sheath/core bico~ponent fiber fabric, which in turn Jay be blended with from 5-40% rayon or polyester fibers.

The groped hydrophobic microphone fiber structure may be prepared by any suitable groping process, although the MICREX Microcreper compressive treatment process is especially suitable. In accordance with the present invention, the degree of compaction of the groped ply of microphone fibers in the machine direction is preferably at least 10%. The commercially available groped materials are usually compacted to a greater extent in the machine direction, and accordingly, when an operating room gown is manufactured with the material of the present invention the direction of greatest extensibility thereof should coincide with the lengthwise axis of the sleeves of the garment. In accordance with a further preferred embodiment of the present invention, there is provided a water impervious laminated material having an improved hydrostatic head at higher extension, comprising at least one reinforcing layer of conjugate fiber, said layer of conjugate fibers having a first face and an opposite face, said conjugate fibers hying composed of a lower melting component and a higher melting component, wherein a substantial proportion of the surfaces of said conjugate fiber comprises said lower melting component, said lower melting component of said conjugate fibers which lie on US said first face being fuse bonded to a first ply of a Chic 687 ~23(~8~0 groped hydrophobic structure comprising multiple plies of microphone fibers having a fiber diameter of up to 10 microns, which structure comprises said first ply and at least one additional ply, said first ply of said hydrophobic microphone fiber structure being thermoplastic and possessing a lower melt temperature than said add-tonal ply of said hydrophobic microphone fiber structure, said lower melting component of said conjugate fibers having been fuse bonded at a temperature below the melt temperature of said higher welting component of said conjugate fibers so that the latter component retains its initial fiber-like integrity.

In accordance with yet a further embodiment of the present invention there is provided an extensible water impervious laminated material having an improved hydrostatic head at higher extension, comprising an inner groped hydrophobic microphone fiber structure sandwiched between two reinforce in layers of conjugate fibers, each of said layers of conjugate fibers having a first face and an opposite face, said conjugate fibers being composed of a lower melting component and a higher melting component wherein a substantial proportion of the surfaces of said fibers comprises said lower melting component, said hydrophobic microphone fiber structure comprising a three-ply structure having an inner ply sandwiched between and bonded to two outer plies, each ply comprising a web of microphone fibers having a fiber diameter of up to 10 microns, said inner ply of said hydrophobic microphone fiber structure having a melt temperature higher than the melt temperatures of each of said outer plies of sail hydrophobic microphone fiber structure, said lower melting components of both layers of said conjugate fibers which lie on said first face having been fuse bonded to the adjacent outer plies of said hydrophobic microphone fiber structure at a temperature lZ3(~10 below the next temperature of said higher melting component of said conjugate fibers, so that the latter component retains its initial fiber-like integrity.

The melt temperature of the lower melting component of the conjugate fibers is preferably no more than 35C higher or lower than the welt temperature of the first ply of the hydrophobic microphone fiber structure. In the instance wherein the groped hydrophobic microphone fiber structure is sandwiched between two reinforcing layers of conjugate fibers, the melt ter~erature of each of the outer layers of the hydrophobic microphone fixer structure is preferably no more than 35C higher or lower than the lower welting component of the conjugate fixers in each of the reinforcing layers.

In the instance wherein the groped hydrophobic microphone fiber structure comprises three plies, toe inner ply may couriers isotactic polypropylene and the two outer plies may comprise ethylene/vinyl acetate copolymer. Alterna-lively, the inner ply of the three layer hydrophobic microphone fiber structure may comprise isotactic polyp propylene and the two outer plies may comprise polyp ethylene. In the instance wherein the groped hydrophobic microphone fiber structure compare two plies, the first ply which is bonded to the reinforcing layer may comprise ethylene/vinyl acetate copolymer, polypropylene, polyethylene, chlorinated polyethylene or polyvinyl chloride; and the second ply of the hydrophobic microphone fiber structure may comprise isotactic polypropylene.

In accordance with a further e~hodi~ent of the present invention, at least one of the two reinforcing layers of conjugate fibers Jay be blended with from 5-40% by weight 123(~8~0 of non conjugate fibers. Preferably, rayon or polyester fibers may be use in this connection for doublet anal softness. Nevertheless, the specific nature and melt temperatures of the non conjugate portions of the blend are not critical since the conjugate-rich material in the face of the reinforcing layer which is fused to the hydrophobic ~icrofine fiber structure insures the good bonding features provided by the present invention. In the case of a groped hydrophobic microphone fiber structure which comprises three plies, the outer plies (which constitute the lower melting plies thereof) Jay consist of any suit-able relatively low melting thermoplastic polymer such as ethylene/propylene copolymer, polyester copolymer, low density polyethylene, ethylene/vinyl acetate copolymer, high density polyethylene, chlorinated polyethylene or polyvinyl chloride. Although a preferred higher melting inner ply of the three ply hydrophobic microphone fiber structure may comprise isotactic polypropylene, never the-less, a number of other higher melting thermoplastic mate-fiats, such as polyester or polyamide may alto be used.

Although continuous filaments of conjugate fibers may reemployed for the reinforcing layers in accordance with the present invention, nevertheless, the preferred conjugate fibers are textile length, that it they are fibers having lengths of from 1/4 inch and preferably from 1/2 inch up to about 3 inches or more in length. Such conjugate fibers can be bicomponent fibers such as the sheath/core or side-by-side bicomponent fiber wherein there it a lower melting component and a higher molting component with a significant proportion and preferably a major proportion of the surface of the fiber being the lower melting component. Preferably the lower melting component is a polyolefin, and most preferably polyethylene. In many cases the sheath/core bicomponent fibers are : ,, ~23(~81 0 preferred because they exhibit a better bonding efficiency than the side-by-side bicomponent fibers, and because in some cases the side-by-side biconponent fibers may exhibit an excessive tendency to curl, crimp, or shrink during the heat bonding step. Both concentric and eccentric sheath/core bicomponent fibers can be used.

The non woven conjugate fiber reinforcing layers which are preferably used in accordance with the present invention can have basis weights from about ~.25 to about 3.0 ounces per square yard.

In the thermal bonding step the lower melting component of the conjugate fiber is at least partially fused so that lo where the fused surface touches another conjugate fiber, welding or fusing together of the two fibers will occur.
It it important that the conjugate fibers retain fibers, i.e., that the higher melting component of the conjugate fiber not melt or shrink significantly and thereby become beads or the like.

The multiple ply groped hydrophobic microphone fiber structure used in the prevent invention may be prepared by laminating separate components together and thereafter said components may be heat bonded together. The present invention also includes a process for preparing an extensible water impervious laminated material having an improved hydrostatic head at higher extension, comprising at least one reinforcing layer of non woven fibers bonded to at least one hydrophobic groped ply of microphone fibers having a fiber diameter of up to 10 microns, ,....

2308~0 said process comprising forming an assembly of a pro-groped ply of said microphone fibers and at least one reinforcing layer of non woven fixers placed adjacent thereto, subjecting said assembly to a temperature sufficient to fuse said layers of non woven fibers to said groped ply of microphone fibers; and cooling the assembly.

In accordance with one embodiment of the present invention there is provided a process for preparing a water impel-virus laminated material having an improved hydrostatic head at higher extension, comprising at least one layer of conjugate fibers, said layer of conjugate fibers having a first face and an opposite face, said conjugate fibers being composed of a lower melting component and a higher melting component, wherein a substantial proportion of toe surfaces of said conjugate fibers comprises said lower melting component, said lower melting component of said conjugate fibers which lie on said first face being fuse bonded to a first ply of a groped hydrophobic structure comprising multiple plies of microphone fibers having a fiber diameter of up to 10 microns, which structure comprise said first ply and at least one additional ply, said first ply of said hydrophobic ~icrofine fiber structure being thermoplastic and possessing a lower melt temperature than said additional ply of said structure, said lower melting component of said conjugate fibers having been fuse bonded at a temperature below the melt temperature of said higher melting component of said , ~23(:~810 conjugate fibers so that the latter component retains its initial fiber-like integrity;

said process comprising forming an assembly of said hydra-phobic microphone fiber structure which has been pre-creped and at least one layer of said conjugate fibers placed adjacent to said first ply of said hydrophobic microphone fiber structure;

subjecting said assembly to a temperature sufficient to fuse said lower melting component of said conjugate fibers which lie on said first face as well as the first ply of the hydrophobic microphone fiber structure in contact with said conjugate fibers without fusing the higher melting component of said conjugate fibers nor the additional ply of the hydrophobic microphone fiber structure, while main-twining said assembly under minimal pressure:

an cooling said assembly to resolidify said lower melting component of the conjugate fibers as well as said first ply of said hydrophobic microphone fiber structure, whereby said conjugate fibers are firmly bonded to said hydropho-big microphone fiber structure without impairing the integrity of said higher melting component of said fibers.
In a further embodiment of the prevent invention there is provided a process for preparing a water impervious laminated material having an improved hydrostatic head at higher extension comprising an inner groped hydrophobic ~icrofine fiber structure sandwiched between two reinforcing layers of conjugate fibers, each of said layers of conjugate fibers having a first face and an opposite face, said conjugate fibers being composed of a lower melting component and a higher welting component, . . .

1~3(~810 wherein a substantial proportion of the surfaces of said fibers comprises said lower melting component, said hydrophobic microphone fiber structure comprising a three-ply structure having an inner ply sandwiched between and bonded to two outer plies, each ply comprising a web of microphone fibers having a fiber diameter of up to 10 microns, said inner ply of said hydrophobic microphone fiber structure having a melt temperature higher than the melt temperatures of each of said outer plies of said hydrophobic microphone fiber structure, said lower melting components of both layers of said conjugate fibers which lie on said first faces having been fuse bonded to the afljacent outer plies of said hydrophobic microphone fiber structure at a temperature below the melt temperature of sail higher netting component of said conjugate fibers, so that the latter component retains its initial fiber-like integrity;

said process co~prlsing forming an assembly of said hydrophobic microphone fiber structure which has been pro-groped, ~andwicheA between two layers of said conjugate fibers subjecting said assembly to a temperature sufficient to fuse said lower melting components of said conjugate fiber which lie on said first faces in both of said layers thereof as well as both of said outer plies of said hydrophobic microphone fiber structure without fusing the higher melting components of said conjugate fibers nor the inner ply of the hydrophobic microphone fiber structure, while maintaining the assembly under minimal pressure:

and cooling said assembly to resolidify said lower melting components of the fibers as well as said outer plies of said hydrophobic nicrofine fiber structure, whereby said fibers are firmly hounded to said hydrophobic microphone SHEA
, . . . .

lZ~0810 fiber structure without impairing the integrity of sail higher melting component of said fibers.

The above-mentioned fusion steps may be carried out by means of a heated embossing calender or by the application of ultrasound in accordance with methods well known in the art. Furthermore, the thermal bonding step may also he carried out by any other suitable means for applying localized heat such as by sonic means, lasers, infrared heating or other types of radiant heating.

Brief Description of the Drawings Figure 1 is a schematic side elevation of an apparatus suitable for carrying out the process of the invention;
and Figure 2 is a cross section of the laminated material of the present invention.
Referring first to Figure 1, one preferred arrangement of an apparatus for carrying out the process of the invention is disclosed. The apparatus shown in Figure 1 is suitable for making the laminated material of the invention comprising a core of a groped microphone fiber structure with facings of heat-fusible conjugate fibers on both faces of said core. The groped microphone fiber structure may consist of one or more plies. A web 10 of heat-fusible conjugate fibers is laid down a from a card 12 on an endless belt 14. A pre-creped hydrophobic microphone fiber structure 20, fed from let-off 22, is then laid on top of web 10. A laminated three-ply groped hydrophobic micron fiber structure is utilized (as illustrated in Figure 2). The plies of the microphone fiber structure 20 may have been independently groped prior to being laminated together; or alternatively said plies may have COOK

1~3(~10 been fused together, in the flat state, prior to the groping step which is carried out on the resultant laminated structure. Although a number of different methods are known for groping materials, nevertheless a preferred method utilized in accordance with the groped structure 20, used in the present invention, is the MICREX
Microcreper compressive treatment process which is a mechanical method for treating sheets or web structures in an air dry state. In accordance with the MICREX process, an untreated web, supported by a main roll is introduced into a converging passage, firmly gripped and conveyed into a main treatment cavity where the microcreping process takes place. By adjustment of controls, varying amounts of residual compaction and groped cross section can be attained, depending upon the desired result and the characteristics of the material being treated. The treated web passes through a secondary passage between rigid and flexible retarders which control the uniformity and degree of compaction. The fully microcreped web is then continuously discharged without conveyor belts or other support to a take-up reel, such as roller 22 in Figure 1 of the present drawings. The hydrophobic microphone fiber structure 20, after having been laid upon web 10 forms a double layer web 28.
Web 28 is then passed under another station wherein a second web of heat-fu~ible conjugate fibers 30 is laid on top as from a card 32. Although webs 10 and 30 are preferably prepared from cards, nevertheless, aureole webs may also be used although the latter procedure is not particularly -utile in the instance wherein the webs are light weight. Although webs 10 and 30 are preferably fuse bonded in a subsequent step, said webs 10 and 30 may have been initially fuse bonded, in a prior step, before ., -~Z31~B~O

they are laid on either side of toe laminated structure 20.

After web 30 is laid on top of the double layer web I the resulting triple layer web 34 is then passed through a fusion unit 36 Jo fuse the lower melting component of the conjugate fibers in webs 10 and 30 while maintaining the integrity of the higher melting component of these fibers as fibers, and to fuse or soften the outer surfaces of the laminated groped hydrophobic microphone fiber structure 20 50 as to securely bond webs 10 and 30 on either side of structure 20. When the multiple layer web emerges from the fusion unit 36, it cools to thereby form the material 38 of the invention. When the material 38 cools, the fused lower melting component of the conjugate fixers, solidifies, and bonds then form where their surfaces touch other fibers. The material I is then collected on a conventional wind-up 40. Any suitable means of fusion bonding may be used in fusion unit 36, suck as by means of a conventional heated embossing calender, or by subjecting the assembly to ultrasonic radiation.

Figure 2 illustrates a cross sectional view of the laminated material of the present invention. Thus, toe laminated groped microphone fiber structure 20, comprising low melting outer plies 13 and 15 and higher melting inner ply 14, are shown sandwiched between layers 10 and 30 of conjugate others. The temperature of the fusion unit 36 is maintained below that of the welt temperature of the higher melting components of the conjugate fibers as well as below the melt temperature of inner ply 14 of the laminated groped microphone fiber structure 20. In the instance wherein structure 20 consists of a polypropylene core 14 and low melting ethylene vinyl acetate coupler plies 13 and 15, sandwiched between two layers of , 123~81C~

conjugate fibers 10 an 30 comprising a polyethylene/
polyethylene terephthalate seat core bico~ponent fiber, the temperature maintained in the fusion unit is preferably in toe range of 120C to 130C.

The exact temperatures employed in the fusion unit 36 will depend upon the nature of the conjugate fiber used and toe dwell time employed in the fusion unit. For instance when the lower melting component of the conjugate fiber is polyethylene, the bonding temperature is usually from about 110C to about 150C, and when the lower melting component is polypropylene, the bonding temperature is usually from about 150C to about 170C. Specific conditions under which the thermal bonding is achieved are illustratefl in the examples below. The temperatures referred to are the temperatures to which the fibers are heated in order to achieve bonding. In order to achieve high speed operations, much higher temperatures with short exposures tires can be used.
The examples below illustrate various aspects of the invention.

Example 1 A laminate material is made ho a procedure analogous to that illustrated in Figure 1 using a trico~ponent groped hydrophobic microflne fiber structure counseling of a core of polypropylene microphone fibers ~andwlched between two plies of low melting ethylene/vinyl acetate microphone fibers. The thickness of the tricomponent groped struck lure is 29 mill The polypropylene core has a softening range of 110-120C and a melting point of about 165C.

COOK

:
. . . , 1~3~

The ethylene/vinyl acetate copolymer has a softening range of 90-100C and a melting point of about 110C.

Webs of through-air bonded conjugated fibers (0.5 ounces 5 per square yard) prepared by carding are placed on either side of the tricomponent microphone fiber structure. The conjugate fibers consist of high density polyethylene/polyethylene terephthalate sheath/core bicomponent fibers, toe core hying concentric. The high 10 density polyethylene in the conjugate fibers has a softening range of 110-125C and a melting point of about 132C. The polyethylene terephthalate core of the conjugate fibers has a softening range of 240-260C and a melting point of about 265C. The polyethylene comprises 15 50% of the conjugate fiber.

The conjugate fiber woks are laminated to the groped microphone fiber structure using an embossing calender at about 126C. The resulting material is a soft droopily 20 fabric col~lposite which is impervious to water and in which the groped microphone fiber core does not rupture at the rupture elongation of the conjugate fiber webs.

Certain properties of the material obtained in accordance 25 with Example 1 are as follows:

Thickness of each conjugate fiber facing: 10 mix Weight of composite material: 2 ounces/yard2 The material produced in accordance with Example 1 is suitable for use as an operating room gown which Casey not 1;~3(:~810 lose its barrier properties even after having been stretched 7% of its length. Furthermore, the material produced in accordance with Example 1 possesses improved integrity, durability and strength.
s Example 2 Example 1 is repeated with the following modifications:

Only a two component groped microphone fiber structure is used, the lower melting component inanely the ethylene/
vinyl acetate copolymer) is placed facing upwardly with the next ply of polypropylene facing downwardly. There-after only one layer of the high density polyethylene/

polyethylene terephthalate conjugate fibers is placed on top of the microphone fiber structure, with the lower layer of conjugate fixers being omitted. Otherwise, the bonding procedure is the save a that carried out in connection with Example 1. The resultant composite material is a soft drawable fabric, which upon extension, retains the hydrostatic head possessed by the unstretched fabric.

Example PA

A laminated material it jade by a procedure analogous to that illustrated in Figure 1 using a single hydrophobic groped ply of microphone fibers consisting of a 100~
polypropylene welt blown web weighing 0.85 ounces per square yard. This polypropylene core has a softening range of 110-120C and a welting point of about 165-C. A
random web of 100~ high density polyethylene/polyethylene terephthalate sheath/core bicomponent fibers weighing 0.8 ounces per square yard is place on one side of the polypropylene core. This web is through-air bonder.

. .

~LZ~(~810 The high density polyethylene in the conjugate fibers has a softening range of 110-125C and a welting point of about 132C. The polyethylene terephthalate core of the conjugate fibers has a softening range of 240-260C an a melting point of about 265C. The polyethylene comprises 50~ of the conjugate fiber. Thereafter, on the opposite side of toe polypropylene core is placed a random web layer of 0.5 ounce per square yard and restraining belt bonder web made of 90~ bicomponent fiber/10% rayon. Sail bico~ponent fibers are also conjugate fibers consisting of high density polyethylene/polyethylene terephthalate sheath/core hi component fibers, the core hying concentric.

The two conjugate fiber webs are laminate to the crepe microphone fiber web using an embossing calender at about 122C (both the embossed roll and the sooth roll were at 122C). The embosses roll was a cross-hatch pattern. The pressure on hot sizes of the laminated material was 150 pounds per lineal inch and the line speed was 30 feet per minute. A fixed gap of 0.0005 inch was use.

Example 3B

A control sample was prepared, in an identical manner to the laminated material prepared in accordance with Example PA, but the polypropylene core web was not groped.

TEST PROCEDURES
A number of comparative tests were conducted in order to compare the extensible melt blown laminate of Example PA
with the substantially identical laminate of Example 3B
in which the polypropylene core was not groped. For the purpose of the following tests, the laminate of Example PA

lZ3~810 is designated as the groped material and the laminate of Example 3B is designated as the control uncropped material.

Bursting Strength Test (Mullen Burst) Both the control uncropped material and the groped material were subjected to the Mullen Burst test in accordance with ASTM D-3786-79. The results are set forth in Tale 1. In this test a specimen of toe fabric is clasped over an expandable diaphragm. The diaphragm is expanded by fluid pressure to the point of specimen rupture. The difference between the total pressure required to rupture the specie Men an the pressure required to inflate toe diaphragm is reported as the bursting strength.

MULLEN BURST TEST
Run No. Control UncrepedCreped (Unstretched) 1 26.8 34.0
2 28.4 34.4
3 27.8 35.8 Average 27.7 lobs. Average 34.7 lobs.

From the above Table 1 it will be seen that the groping of the melt blown inner layer increases the burst strength by 25%, under standard testing condition, a compared to that of the uncropped control.

Strip Tensile Strength Test The control uncropped material and the groped material were subjected to a standard strip tensile test in accordance with ASTM D-1682-64. This test indicates both toe COOK
..

.

: :
:.

lZ3(~ 0 breaking load and elongation of textile fabrics. The breaking load (machine direction and the elongation at break are indicated in the following Tables 2 and 3 respectively, both for the uncropped control material and the groped material.

STRIP TENSILE TEST MACHINE DIRECTION

Control UncrepedCreped Run No Peak Load Peak Load 17.9 lobs. 6.8 lobs.
27.5 lobs. 7.5 lobs.
37.5 lobs. 7.0 lobs.
47.0 lobs. 7.3 lobs.
57.2 ohs. 6.5 lobs.
Average 7.4 lbs.Average 7.0 lobs.

% ELONGATION AT BREAM MACHINE DIRECTION) Control UncrepeaCreped Run No Peak Strain Peak Strain -1 26.5~ 22.2%
2 18.8% 22.3%
3 26.5% 23.6%
4 21.3% 38.7%
21.4g 19.7%
Average average 25.3%

- ~23(~810 From Table 3, it will be seen that the average elongation at break of the groped material is approximately 10 higher than the average elongation at break of the uncropped control material.

Hydrostatic Head Test In order to determine the water repellency of the fabric, samples from both the uncropped control material and the groped material were subjected to a modification of the basic hydrostatic pressure test ATTICS TM~127-1977, both in the unstretched condition (Table 4! and stretched at 7 (Table I In this test, a specimen is subjected to increasing water pressure while the surface is observed for leakage. The hydrostatic pressure test which was actually carried out differed in a minor manner from toe standard hydrostatic pressure test ATTICS TM#127-1977 in that the water reservoir was raised manually rather than automatically as in the standard test. Normally, the hydrostatic head test is carried out on fabric which is in a relaxed, i.e., an unstretched condition. on order to demonstrate the advantages of the present invention, the fabrics were stressed to a 7% elongation level (Table S);
they were then held in the extended position with a jig and the hydr~statlc head test was carried out on the fabrics while they were in the extended condition. These are the samples referred to in the tables a "stretched at 7%". With respect to the data shown in Table S, samples were cut 3 1/2 inches wide and 10 inches long in the machine direction. A stretching jig was set up so that holder were 7 inches apart. Samples were placed in the stretcher and stretched to 7 1/2 inches (7% stretch). A
clamp was used to Keep the fabric in a stretches state.
Manual hydrostatic head testing was performed in accordance with the basic hydrostatic pressure test ATTICS
TM~127-1977 on the stretched fabric.

....

.. ..

I

HYDROSTATIC HEAD TEST (UNSTRETCHED)
5 Run No. Control Uncropped cam Crepe (cm) 1 34.5 53.0 2 51.4 53.0 3 53.0 53.0 4 53.0 53.0 53.0
6 45.8 Average 48.4+7.4 cmAverage 53.0 cm HYDROSTATIC HEAD _ STY (STRETCHED AT 7%) Control Uncropped (cm)Creped (cm) 20 Run No Stretched at starched at 7%

1 22.2 41.1 2 28.1 48.3 3 26.3 36.0 4 31.2 53.0 31.7 49.0 6 30.6 53.0 Average 28.3~3.7 cmAverage 46.7~6.8 cm As will be seen from Tables 4 and 5 the head on the uncropped control material dropped from 48.4~7.4 cm in the unstretched condition, to only 28.3~3.7 cm when stretched at 7%, i.e., a decrease of 41.53%.

Conversely the groped material only dropped from 53 cm in the unstretched condition, to 46.7~6.8 cm when stretched ..:., 1~3(~810 at 7%. Thus there was very little loss of hydrostatic head of the groped material upon stretching. Furthermore, upon examining Tables 4 and 5, it will be seen that the hydrostatic head of the groped material, even after being stretched at 7%, was substantially as high as the hydrostatic head of the uncropped control material even before any stretching had occurred in the latter. These results clearly indicate that if an operating root gown is manufactured in accordance with the present invention, the bending of the elbow, resulting in a stretch of 7%, would not adversely affect the barrier properties thereof.

In general, the material of the present invention, when subjected to the hydrostatic head test at 7% elongation, retains at least about 70% of the hydrostatic head which is achieved at zero elongation.

SHAKER

. . . .

Claims (31)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. An extensible water impervious laminated material having an improved hydrostatic head at higher extension comprising at least one reinforcing layer of nonwoven fibers bonded to at least one hydrophobic creped ply of microfine fibers having a fiber diameter of up to 10 microns.
2. An extensible water impervious laminated material having an improved hydrostatic head at higher extension, comprising an inner creped hydrophobic microfine fiber structure, sandwiched between and bonded to two reinforcing layers of nonwoven fibers, said hydrophobic microfine fiber structure comprising at least one ply of microfine fibers having a fiber diameter of up to 10 microns.
3. An extensible water impervious laminated material having an improved hydrostatic head at higher extension, comprising an inner creped hydrophobic microfine fiber structure sandwiched between and fuse bonded to two reinforcing layers of nonwoven conjugate fibers, said hydrophobic microfine fiber structure comprising at least one ply of microfine fibers having a fiber diameter of up to 10 microns.
4. The material of Claim 3 in which the creped hydrophobic microfine fiber structure comprises at least two plies of microfine fibers having a fiber diameter of up to 10 microns.
5. The material of Claim 2 wherein the hydrophobic microfine fiber structure comprises polyethylene, polyethylene terephthalate, polypropylene, polybutylene terephthalate or polyamide.
6. The material of Claim 2 wherein the layers of nonwoven fabric comprise high density polyethylene/polyethylene terephthalate sheath/core bicomponent fibers.
7. The material of Claim 6 wherein the layers of nonwoven fabric are blended with from 5 to 40% by weight of rayon or polyester fibers.
8. The material of Claim 2, in which the material has been prepared by a continuous process and wherein the degree of compaction of the creped ply of microfine fibers in the machine direction is at least 10%.
9. The material of Claim 3 wherein the creped ply of microfine fibers was initially prepared by melt blowing.
10. An extensible water impervious laminated material having an improved hydrostatic head at higher extensions comprising at least one reinforcing layer of conjugate fibers, said layer of conjugate fibers having a first face and an opposite face, said conjugate fibers being composed of a lower melting component and a higher melting compo-nent, wherein a substantial proportion of the surfaces of said conjugate fibers comprises said lower melting component, said lower melting component of said conjugate fibers which lie on said first face being fuse bonded to a first ply of a creped hydrophobic structure comprising multiple plies of microfine fibers having a fiber diameter of up to 10 microns, which structure comprises said first ply and at least one additional ply, said first ply of said hydrophobic microfine fiber structure being thermo-plastic and possessing a lower melt temperature than said additional ply of said hydrophobic microfine fiber structure, said lower melting component of said conjugate fibers having been fuse bonded at a temperature below the melt temperature of said higher melting component of said conjugate fibers so that the latter component retains its initial fiber-like integrity.
11. The material of Claim 10, in which the melt tempera-ture of the lower melting component of the conjugate fibers is no more than 35°C higher or lower than the melt temperature of the first ply of the hydrophobic microfine fiber structure.
12. An extensible water impervious laminated material having an improved hydrostatic head at higher extensions comprising an inner creped hydrophobic microfine fiber structure sandwiched between two reinforcing layers of conjugate fibers, each of said layers of conjugate fibers having a first face and an opposite face, said conjugate fibers being composed of a lower melting component and a higher melting component, wherein a substantial proportion of the surfaces of said fibers comprises said lower melting component, said hydrophobic microfine fiber structure comprising a three-ply structure having an inner ply sandwiched between and bonded to two outer plies, each ply comprising a web of microfine fibers having a fiber diameter of up to 10 microns, said inner ply of said hydrophobic microfine fiber structure having a melt temperature higher than the melt temperatures of each of said outer plies of said hydrophobic microfine fiber structure, said lower melting components of both layers of said conjugate fibers which lie on said first face having been fuse bonded to the adjacent outer plies of said hydrophobic microfine fiber structure at a temperature below the melt temperature of said higher melting component of said conjugate fibers, so that the latter component retains its initial fiber-like integrity.
13. The material of Claim 12, in which the melt tempera-ture of each of the outer layers of the hydrophobic micro-fine fiber structure is no more than 35°C higher or lower than the lower melting component of said conjugate fibers.
14. The material of Claim 12, in which the inner ply of said hydrophobic microfine fiber structure comprises iso-tactic polypropylene and the two outer plies comprise ethylene/vinyl acetate copolymer.
15. The material of Claim 10, wherein the conjugate fiber is a high density polyethylene/polyester sheath/core bi-component fiber.
16. The material of Claim 12, wherein the conjugate fiber is a high density polyethylene/polyester sheath/core bi-component fiber.
17. The material of Claim 10, in which the first ply of the creped hydrophobic microfine fiber structure is selected from the group consisting of ethylene/vinyl acetate copolymer, polyethylene, chlorinated polyethylene and polyvinyl chloride and the additional ply of the hydrophobic microfine fiber structure comprises isotactic polypropylene.
18. The material of Claim 16, wherein the inner ply of the hydrophobic microfine fiber structure comprises isotactic polypropylene and the two outer plies comprise polyethylene.
19. The material of Claim 12, wherein the outer plies of the hydrophobic microfine fiber structure are selected from the group consisting of ethylene/vinyl acetate copolymer, polyethylene, chlorinated polyethylene and polyvinyl chloride and may be the same or different.
20. The material of Claim 19, wherein the inner ply of the hydrophobic microfine fiber structure comprises isotactic polypropylene.
21. The material of Claim 12, wherein each ply of the hydrophobic microfine fiber structure was initially prepared by melt-blowing.
22. An operating room gown comprising the material of Claim 1.
23. The material of Claim 2, wherein said material has been bonded by means of a heated embossing calender, or by ultrasound.
24. The material of Claim 3, wherein said conjugate fibers are eccentric core sheath/core bi-component fibers.
25. The material of Claim 3 in which said layers of conjugate fibers are blended with from 5 to 40% by weight of non-conjugate fibers.
26. The material of Claim 2 which when subjected to the hydrostatic head test at 7% elongation, retains at least about 70% of the hydrostatic head which is achieved at zero elongation.
27. A process for preparing an extensible water impervious laminated material having an improved hydrostatic head at higher extension comprising at least one reinforcing layer of nonwoven fibers bonded to at least one hydrophobic creped ply of microfine fibers having a fiber diameter of up to 10 microns, said process comprising forming an assembly of a precreped ply of said microfine fibers and at least one reinforcing layer of nonwoven fibers placed adjacent thereto; subjecting said assembly to a temperature sufficient to fuse said layers of nonwoven fibers to said creped ply of microfine fibers;
and cooling the assembly.
28. A process for preparing an extensible water imper-vious laminated material having an improved hydrostatic head at higher extensions, comprising at least one layer of conjugate fibers, said layer of conjugate fibers having a first face and an opposite face, said conjugate fibers being composed of a lower melting component and a higher melting component, wherein a substantial proportion of the surfaces of said conjugate fibers comprises said lower melting component, said lower melting component of said conjugate fibers which lie on said first face being fuse bonded to a first ply of a creped hydrophobic structure comprising multiple plies of microfine fibers having a fiber diameter of up to 10 microns, which structure comprises said first ply and at least one additional ply, said first ply of said hydrophobic microfine fiber structure being thermoplastic and possessing a lower melt temperature than said additional ply of said structure, said lower melting component of said conjugate fibers having been fuse bonded at a temperature below the melt temperature of said higher melting component of said conjugate fibers so that the latter component retains its initial fiber-like integrity;

said process comprising forming an assembly of said hydrophobic microfine fiber structure which has been precreped and at least one layer of said conjugate fiber placed adjacent to said first ply of said hydrophobic microfine fiber structure;

subjecting said assembly to a temperature sufficient to fuse said lower melting component of said conjugate fibers which lie on said first face as well as the first ply of the hydrophobic microfine fiber structure in contact with said conjugate fibers without fusing the higher melting component of said conjugate fibers nor the additional ply of the hydrophobic microfine fiber structure, while maintaining said assembly under minimal pressure;

and cooling said assembly to resolidify said lower melting component of the conjugate fibers as well as said first ply of said hydrophobic microfine fiber structure, whereby said conjugate fibers are firmly bonded to said hydrophobic microfine fiber structure without impairing the integrity of said higher melting component of said fibers.
29. A process for preparing an extensible water imper-vious laminated material having an improved hydrostatic head at higher extensions comprising an inner creped hydrophobic microfine fiber structure sandwiched between two reinforcing layers of conjugate fibers, each of said layers of conjugate fibers having a first face and an opposite face, said conjugate fibers being composed of a lower melting component and a higher melting component, wherein a substantial proportion of the surfaces of said fibers comprises said lower melting component, said hydrophobic microfine fiber structure comprising a three-ply structure having an inner ply sandwiched between and bonded to two outer plies, each ply comprising a web of microfine fibers having a fiber diameter of up to 10 microns, said inner ply of said hydrophobic microfine fiber structure having a melt temperature higher than the melt temperatures of each of said outer plies of said hydrophobic microfine fiber structure, said lower melting components of both layers of said conjugate fibers which lie on said first faces having been fuse bonded to the adjacent outer plies of said hydrophobic microfine fiber structure at a temperature below the melt temperature of said higher melting component of said conjugate fibers, so that the latter component retains its initial fiber-like integrity;

said process comprising forming an assembly of said hydrophobic microfine fiber structure which has been precreped, sandwiched between two layers of said conjugate fibers;

subjecting said assembly to a temperature sufficient to fuse said lower melting components of said conjugate fibers which lie on said first faces in both of said layers thereof as well as both of said outer plies of said hydrophobic microfine fiber structure without fusing the higher melting components of said conjugate fibers nor the inner ply of the hydrophobic microfine fiber structure, while maintaining the assembly under minimal pressure;

and cooling said assembly to resolidify said lower melting components of the fibers as well as said outer plies of said hydrophobic microfine fiber structure, whereby said fibers are firmly bonded to said hydrophobic microfine fiber structure without impairing the integrity of said higher melting component of said fibers.
30. The process of Claim 28, wherein said fusing step is carried out by means of a heated embossing calender, or by application of ultrasound.
31. The process of Claim 29, wherein said fusing step is carried out by means of a heated embossing calender, or by application of ultrasound.
CA000483611A 1984-06-13 1985-06-11 Extensible microfine fiber laminate Expired CA1230810A (en)

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US5405682A (en) 1992-08-26 1995-04-11 Kimberly Clark Corporation Nonwoven fabric made with multicomponent polymeric strands including a blend of polyolefin and elastomeric thermoplastic material
US5643662A (en) 1992-11-12 1997-07-01 Kimberly-Clark Corporation Hydrophilic, multicomponent polymeric strands and nonwoven fabrics made therewith
US6500538B1 (en) 1992-12-28 2002-12-31 Kimberly-Clark Worldwide, Inc. Polymeric strands including a propylene polymer composition and nonwoven fabric and articles made therewith

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BR8502812A (en) 1986-02-18
DE3584792D1 (en) 1992-01-16
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JPS613740A (en) 1986-01-09
AU4361785A (en) 1985-12-19
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AU578100B2 (en) 1988-10-13
JP2563872B2 (en) 1996-12-18

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