Barrier element fabrics, barrier elements, and protective articles incorporating such elements

• US 5,683,809 A
• Filed: 05/05/1994
• Issued: 11/04/1997
• Est. Priority Date: 08/23/1993
• Status: Expired due to Fees

• Current Assignee: Fiberco Incorporated
• Original Assignee: Hercules Incorporated (Ashland Global Holdings, Inc.)
• Inventors: Gupta, Rakesh K., Smith, Thomas L., Legare, Richard J., Freeman, Walter J., Williams, Adrienne W., Harrington, James H.
• Primary Examiner(s): DIXON, MERRICK L
• Application Number:
  US08/238,324
• Time in Patent Office: 1,279 Days
• Field of Search: 428/401, 428/284, 428/288, 428/286, 428/287, 428/298, 428/323, 428/219, 428/340, 428/360, 428/365, 428/308.2, 428/296, 428/357, 428/172, 428/247, 128/846, 604/369, 604/370, 604/371, 604/372, 604/373, 604/374
• US Class Current: 428/365
• CPC Class Codes: A61F 13/494 characterised by edge leakage prevention means
• CPC Class Codes: A61F 13/51401 characterised by the material
• CPC Class Codes: A61F 2013/51011 characterized by the count of the fibres, e.g. denier or tex
• CPC Class Codes: A61F 2013/51441 being a fibrous material
• CPC Class Codes: A61F 2013/51452 being nonwovens
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/27 Web or sheet containing structurally defined element or component, the element or component having a specified weight per unit area [e.g., gms/sq cm, lbs/sq ft, etc.]
• CPC Class Codes: Y10T 428/29 Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
• CPC Class Codes: Y10T 428/2915 including textile, cloth or fabric
• CPC Class Codes: Y10T 428/298 Physical dimension
• CPC Class Codes: Y10T 442/2418 Coating or impregnation increases electrical conductivity or anti-static quality

Abstract

Protective articles such as diapers, having filmless hydrophobic barrier elements such as cuffs and backing sheets. The barrier cuffs--which can be, for instance, leg cuffs and waistbands--and the backing sheets can be provided from fabrics having a fabric weight of at least 10 gsy; these fabrics are made of cardable, hydrophobic polyolefin fibers having a dpf value of not more than about 2.0.

Claims

1. A waste containment article comprising a filmless hydrophobic barrier element selected from the group consisting of barrier cuffs and fluid-impervious backing components, the filmless hydrophobic barrier element comprising a nonwoven fabric comprising carded and bonded hydrophobic polyolefin staple fibers, substantially all of the staple fibers having a dpf value of not more than about 2.0, and:

(1) having a water hydrostatic head value of at least about 60 mm; and

(2) having a fabric weight of at least about 10 gsy.

2. The article of claim 1 wherein substantially all of the staple fibers have a dpf value of not more than about 1.8.

3. The article of claim 1 wherein the nonwoven fabric has an average pore size of not more than about 52 microns.

4. The article of claim 1 wherein the staple fibers comprise a polyolefin having a hydrophobic antistatic finish.

5. The article of claim 4 wherein the polyolefin comprises polypropylene, and wherein substantially all of the staple fibers are about 1 to 3 inches in length.

6. The article of claim 1 wherein the polyolefin comprises polypropylene.

7. The article of claim 1 which is a diaper, wherein the filmless hydrophobic barrier element comprises at least one member selected from the group consisting of leg cuffs, waistbands, and fluid-impervious backing components.

8. The article of claim 1 which is selected from the group consisting of shirts, pants, jackets, coats, hospital and surgical caps, hospital and surgical gowns, hospital and surgical scrub apparel, sheets, surgical table covers, Mayo stand covers, industrial garments, catamenial devices, and incontinence pads.

9. A protective article comprising a filmless hydrophobic barrier element, wherein the filmless hydrophobic barrier element comprises a nonwoven fabric having a water hydrostatic head value of at least about 60 mm and comprising carded and bonded hydrophobic polyolefin staple fibers, at least about 10 percent by weight of the staple fibers having a dpf value of not more than about 2.0.

10. The article of claim 9 which is a waste containment article.

11. The article of claim 10 wherein the filmless hydrophobic barrier element comprises at least one member selected from the group consisting of barrier cuffs and fluid-impervious backing components.

12. The article of claim 11 wherein at least about 30 percent by weight of the staple fibers have a dpf value of not more than about 2.0.

13. The article of claim 12 wherein at least about 40 percent by weight of the staple fibers have a dpf value of not more than about 2.0.

14. The article of claim 13 wherein at least about 50 percent by weight of the staple fibers have a dpf value of not more than about 2.0.

15. The article of claim 11 wherein the nonwoven fabric has a basis weight of about 10-50 gsy.

16. The article of claim 11 wherein the staple fibers comprise a hydrophobic antistatic finish.

17. The article of claim 16 wherein the polyolefin comprises polypropylene, and wherein substantially all of the staple fibers are about 1 to 3 inches in length.

18. The article of claim 11 wherein the polyolefin comprises polypropylene.

19. The article of claim 11 wherein the staple fibers comprise fibers of at least two different dpf values.

20. The article of claim 19 wherein about 10 to 90 percent by weight of the staple fibers have a dpf value of about 0.5 to 2.0, and about 10 to 90 percent by weight of the staple fibers have a dpf value of about 2.2 to 4.0 dpf.

21. The article of claim 19 wherein about 10 to 90 percent by weight of the staple fibers have a dpf value of about 1.0 to 1.8, and about 10 to 90 percent by weight of the staple fibers have a dpf value of about 2.2 to 4.0 dpf.

22. The article of claim 19 wherein the nonwoven fabric comprises a layer comprising the fibers of at least two different dpf values.

23. The article of claim 19 wherein the nonwoven fabric comprises at least two layers, a first layer of the at least two layers comprising fibers having a first dpf value and a second layer of the at least two layers comprising fibers having a second dpf value, the first dpf value being different from the second dpf value.

24. The article of claim 23 wherein the nonwoven fabric is a two layer fabric consisting essentially of the first layer and the second layer.

25. The article of claim 23 wherein the first dpf value is about 0.5 to 2.0 and the second dpf value is about 2.2 to 4.0, about 10 to 90 percent by weight of the staple fibers having the first dpf value and about 10 to 90 percent by weight of the staple fibers have the second dpf value.

26. The article of claim 25 wherein the polyolefin comprises polypropylene, and wherein substantially all of the staple fibers are about 1 to 3 inches in length.

27. The article of claim 25 wherein the staple fibers comprise a hydrophobic antistatic finish.

28. The article of claim 27 wherein the polyolefin comprises polypropylene, and wherein substantially all of the staple fibers are about 1 to 3 inches in length.

29. The article of claim 23 wherein the first dpf value is about 1.0 to 1.8 and the second dpf value is about 2.2 to 4.0, about 10 to 90 percent by weight of the staple fibers having the first dpf value and about 10 to 90 percent by weight of the staple fibers have the second dpf value.

30. The article of claim 22 wherein about 10 to 90 percent by weight of the staple fibers have a dpf value of about 0.5 to 2.0, and about 10 to 90 percent by weight of the staple fibers have a dpf value of about 2.2 to 4.0 dpf.

31. The article of claim 30 wherein the staple fibers comprise a polyolefin having a hydrophobic antistatic finish.

32. The article of claim 31 wherein the polyolefin comprises polypropylene, and wherein substantially all of the staple fibers are about 1 to 3 inches in length.

33. The article of claim 30 wherein the polyolefin comprises polypropylene, and wherein substantially all of the staple fibers are about 1 to 3 inches in length.

34. The article of claim 22 wherein about 10 to 90 percent by weight of the staple fibers have a dpf value of about 1.0 to 1.8, and about 10 to 90 percent by weight of the staple fibers have a dpf value of about 2.2 to 4.0 dpf.

35. The article of claim 19 which is a diaper, wherein the filmless hydrophobic barrier element comprises at least one member selected from the group consisting of leg cuffs, waistbands, and fluid-impervious backing components.

36. The article of claim 19 which is selected from the group consisting of shirts, pants, jackets, coats, hospital and surgical caps, hospital and surgical gowns, hospital and surgical scrub apparel, sheets, surgical table covers, Mayo stand covers, industrial garments, catamenial devices, and incontinence pads.

37. A waste containment article comprising:

(a) a fluid-impervious backing component, comprising a filmless hydrophobic barrier element;

(b) a body-contacting surface; and

(c) a fluid-adsorbing component situated between the fluid-impervious backing component and body-contacting surface;

wherein the filmless hydrophobic barrier element comprises a nonwoven fabric;

having a water hydrostatic head value of at least about 60 mm; and

comprising carded and bonded hydrophobic polyolefin staple fibers, at least about 10 percent by weight of the staple fibers having a dpf value of not more than about 2.0;

wherein the staple fibers comprise fibers of at least two different dpf values;

wherein the nonwoven fabric comprises at least two layers;

a first layer of the at least two layers comprising fibers having a first dpf value; and

a second layer of the at least two layers being situated between the first layer and the fluid-adsorbing component, and comprising fibers having a second dpf value, the first dpf value being different from the second dpf value; and

wherein the first dpf value is about 2.2 to 4.0 and the second dpf value is about 0.5 to 2.0, about 10 to 90 percent by weight of the staple fibers having the first dpf value and about 10 to 90 percent by weight of the staple fibers have the second dpf value.