Activated Protective Fabric

• US 20100300054A1
• Filed: 06/02/2009
• Published: 12/02/2010
• Est. Priority Date: 06/02/2009
• Status: Active Grant

• Current Assignee: Clemson University
• Original Assignee: Clemson University
• Inventors: Lickfield, Deborah K., Stevens, Kathryn, Cole, Christine W., Brown, Philip J.
• Granted Patent: US 8,501,644 B2
• Time in Patent Office: Days
• US Class Current: 55/524
• CPC Class Codes: A62D 5/00 Composition of materials for coverings or clothing affording protection against harmful chemical agents
• CPC Class Codes: B01D 2239/025 comprising nanofibres
• CPC Class Codes: B01D 2239/0407 comprising particulate additives, e.g. adsorbents
• CPC Class Codes: B01D 2239/065 More than one layer present in the filtering material
• CPC Class Codes: B01D 2239/0668 The layers being joined by heat or melt-bonding
• CPC Class Codes: B01D 2239/1233 Fibre diameter
• CPC Class Codes: B01D 39/1623 of synthetic origin
• CPC Class Codes: B01D 39/2041 the material being filamentary or fibrous
• CPC Class Codes: B01D 39/2082 the material being filamentary or fibrous
• CPC Class Codes: B32B 2250/20 All layers being fibrous or filamentary
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/023 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2262/0246 Acrylic resin fibres
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/0292 Polyurethane fibres
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/105 Ceramic fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2305/20 : in the form of a non-woven mat
• CPC Class Codes: B32B 2307/546 : Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/718 : Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2307/724 : Permeability to gases, adsorption
• CPC Class Codes: B32B 2437/00 : Clothing
• CPC Class Codes: B32B 2535/00 : Medical equipment, e.g. bandage, prostheses or catheter
• CPC Class Codes: B32B 2571/00 : Protective equipment
• CPC Class Codes: B32B 33/00 : Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
• CPC Class Codes: B32B 37/06 : characterised by the heating method
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 442/3106 : Hollow strand material
• CPC Class Codes: Y10T 442/3114 : Cross-sectional configuration of the strand material is other than circular
• CPC Class Codes: Y10T 442/608 : Including strand or fiber material which is of specific structural definition
• CPC Class Codes: Y10T 442/611 : Cross-sectional configuration of strand or fiber material is other than circular
• CPC Class Codes: Y10T 442/612 : Hollow strand or fiber material

Abstract

Disclosed are fibrous activated materials that can remove and/or deactivate potentially dangerous airborne agents from a gas or air stream. Disclosed materials are multi-layer materials that include a fibrous nonwoven interceptor layer and an active layer immediately adjacent the interceptor layer. The interceptor layer is a fibrous membrane of very low basis weight and defines a relatively low porosity, and the active layer describes geometries, chemistries, etc. that can entrap and/or decontaminate compounds contained in an airstream passing through the material. Disclosed materials can be utilized in forming protective garments, face masks, and the like.

Claims

1. A protective fibrous material comprising:

one or more interceptor layers including polymeric fibers in a fibrous web formation, each interceptor layer having a basis weight of less than about 50 grams per square meter; and

one or more active layers positioned adjacent to the one or more interceptor layers, each active layer comprising polymeric fibers and each active layer having a basis weight of between about 5 and about 100 grams per square meter;

wherein

the protective fibrous material has a Frazier Air Permeability of at least about 1 cubic foot per minute.

2. The protective fibrous material of claim 1, wherein the polymeric fibers of the one or more interceptor layers include polymeric fibers less than about 15 micrometers in average diameter.

3. The protective fibrous material of claim 1, wherein the polymeric fibers of the one or more interceptor layers include nanofibers.

4. The protective fibrous material of claim 1, wherein the polymeric fibers of the one or more active layers include fibers defining a non-circular cross section.

5. The protective fibrous material of claim 4, wherein the fibers defining a non-circular cross section are capillary channeled fibers.

6. The protective fibrous material of claim 5, further comprising particulate material in the channels of the capillary channeled fibers.

7. The protective fibrous material of claim 1, wherein the polymeric fibers of the one or more active layers include fibers comprising a functional chemistry to collect, adhere, or otherwise bond a threat agent onto the surface of the fiber.

8. The protective fibrous material of claim 1, wherein the polymeric fibers of the one or more active layers include fibers comprising a functional chemistry to decontaminate a threat agent.

9. The protective fibrous material of claim 8, wherein the functional chemistry is a characteristic of an enzyme bound to the fiber.

10. The protective fibrous material of claim 8, wherein the functional chemistry is at the surface of a particle held on the fiber.

11. The protective fibrous material of claim 1, wherein each of the one or more active layers is a nonwoven web.

12. The protective fibrous material of claim 1, further comprising a first active layer immediately adjacent to a first interceptor layer and a second active layer immediately adjacent to the first interceptor layer such that the first interceptor layer is sandwiched between the first and second active layers.

13. The protective fibrous material of claim 1, the one or more interceptor layers further comprising ceramic or metal fibers.

14. A composite protective structure comprising a panel of a protective fibrous material, the protective fibrous material comprising:

one or more interceptor layers including polymeric fibers in a nonwoven web, each interceptor layer having a basis weight of less than about 10 grams per square meter and a porosity providing a Frazier Air Permeability of at least about 1 cubic foot per minute; and

one or more active layers in proximity to the one or more interceptor layers, each active layer including a plurality of polymeric fibers that entrap or decontaminate a threat agent, each active layer having a basis weight of between about 5 and about 100 grams per square meter;

wherein

the Frazier Air Permeability of the protective fibrous material is at least about 0.1 cubic foot per minute.

15. The composite protective structure of claim 14, wherein the protective structure is a garment.

16. The composite protective structure of claim 14, wherein the protective structure is a tent.

17. The composite protective structure of claim 14, wherein the protective structure is a blanket or a sleeping bag.

18. The composite protective structure of claim 14, wherein the protective structure is a filter medium.

19. The composite protective structure of claim 14, wherein the panel of the protective fibrous material is flexible and is joined to a second flexible panel of the protective fibrous material.

20. The composite protective structure of claim 19, wherein the flexible panels are joined with a stitched seam.

21. The composite protective structure of claim 19, wherein the flexible panels are joined with a stitchless seam.

22. A method of forming a protective structure comprising:

locating one or more interceptor layers adjacent to one or more active layers, each interceptor layer including polymeric fibers in a nonwoven web formation, each interceptor layer having a basis weight of less than about 10 grams per square meter and a Frazier Air Permeability of at least about 1 cubic foot per minute, each active layer including a plurality of polymeric fibers that entrap or decontaminate a threat agent; and

laminating the one or more interceptor layers to the one or more active layers to form a multilayer protective material.

23. The method according to claim 22, wherein the one or more interceptor layers and the one or more active layers are laminated to one another by application of pressure.

24. The method according to claim 22, wherein the one or more interceptor layers and the one or more active layers are laminated to one another by application of heat at a temperature less than the lowest melting temperature of the polymeric fibers contained in the one or more active layers and the one or more interceptor layers.

25. The method according to claim 22, further comprising adding a functional chemistry to at least a portion of the polymeric fibers of the one or more active layers, the functional chemistry entrapping or decontaminating a threat agent.

26. The method according to claim 25, wherein at least a portion of the polymeric fibers are capillary channeled fibers, and the functional chemistry is located in the channels of the capillary channeled fibers.

27. The method according to claim 26 wherein the functional chemistry is at the surface of a particulate.

28. The method according to claim 25, further comprising adding multiple different functional chemistries to at least a portion of the polymeric fibers of the one or more active layers, the functional chemistries entrapping or decontaminating multiple different threat agents.

29. The method according to claim 22, further comprising locating a first active layer immediately adjacent a first interceptor layer and a second active layer immediately adjacent the first interceptor layer, such that the first interceptor layer is sandwiched between the first and second active layers.

30. A protective fibrous material comprising one or more interceptor layers including ceramic or metal fibers in a fibrous web formation, each interceptor layer having a basis weight of less than about 50 grams per square meter, the protective fibrous material further comprising one or more active layers positioned adjacent to said interceptor layer or layers, each active layer having a basis weight of between about 5 and about 100 grams per square meter, wherein the Frazier Air Permeability of the protective fibrous material is at least about 1 cubic foot per minute.