Nonwoven fabric with high heat resistance and barrier properties

Abstract

The nonwoven fabric includes a first outermost spunbond layer, a second outermost spunbond layer, and at least a first meltblown and / or melt fibrillated layer disposed directly or indirectly between the first outermost spunbond layer and the second outermost spunbond layer. The first outermost spunbond layer includes a first plurality of continuous fibers that are hot-melted and pressed against each other and define a microporous membrane on the outermost surface of the nonwoven fabric. The first plurality of continuous fibers comprises a first polymer composition having a first melting point, and the first meltblown layer and / or melt fibrillated layer comprises a first plurality of meltblown fibers and / or melt fibrillated fibers, the first plurality of meltblown fibers and / or melt fibrillated fibers comprising a third polymer composition having a third melting point, wherein the first melting point is lower than the third melting point.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 U.S.C. § 119(e) to US Provisional Application No. 62 / 936,826, filed November 18, 2019, which is expressly incorporated herein by reference in its entirety. technical field

[0003] Embodiments of the presently disclosed invention generally relate to nonwoven fabrics generally having outer spunbond layers and one or more meltblown and / or melt fibrillated layers positioned between the outer spunbond layers layer in which the nonwoven fabric may be suitable for use as a breathable barrier material in sterilizable and / or sterilizable packaging. Background technique

[0004] Medical packaging materials currently include medical grade paper and nonwovens. One such nonwoven is It is a nonwoven formed from flash-spun high-density polyethylene (HDPE) fibers. The medical grade paper can be steam sterilized (eg, at a temperature of about 134°C for about 6 minutes). Steam sterilization...

Examples

Embodiment approach

[0062] In another aspect, the present invention provides a method of forming a nonwoven fabric. According to some embodiments of the present invention, the method may comprise:

[0063] A first outermost spunbond layer comprising a first plurality of continuous fibers is provided or formed, wherein the first plurality of continuous fibers comprises a first polymer composition having a first melting point. The method may also include depositing at least a first meltblown layer and / or melt fibrillated layer positioned directly or indirectly on the first outermost spunbond layer, the first meltblown layer and / or meltblown layer The fibrillated layer includes a first plurality of meltblown fibers and / or melt fibrillated fibers, wherein the first plurality of meltblown fibers and / or melt fibrillated fibers includes a third polymer composition, the first plurality of meltblown fibers and / or melt fibrillated fibers The tripolymer composition has a third melting point that is higher ...

Embodiment

[0077] The present disclosure is then further illustrated by the following examples, which should in no way be construed as limiting. That is, the specific features described in the following examples are illustrative only and not restrictive.

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority under 35 U.S.C. § 119(e) to US Provisional Application No. 62 / 936,826, filed November 18, 2019, which is expressly incorporated herein by reference in its entirety. technical field

[0003] Embodiments of the presently disclosed invention generally relate to nonwoven fabrics generally having outer spunbond layers and one or more meltblown and / or melt fibrillated layers positioned between the outer spunbond layers layer in which the nonwoven fabric may be suitable for use as a breathable barrier material in sterilizable and / or sterilizable packaging. Background technique

[0004] Medical packaging materials currently include medical grade paper and nonwovens. One such nonwoven is It is a nonwoven formed from flash-spun high-density polyethylene (HDPE) fibers. The medical grade paper can be steam sterilized (eg, at a temperature of about 134°C for about 6 minutes). Steam sterilization...

Examples

Embodiment approach

[0062] In another aspect, the present invention provides a method of forming a nonwoven fabric. According to some embodiments of the present invention, the method may comprise:

[0063] A first outermost spunbond layer comprising a first plurality of continuous fibers is provided or formed, wherein the first plurality of continuous fibers comprises a first polymer composition having a first melting point. The method may also include depositing at least a first meltblown layer and / or melt fibrillated layer positioned directly or indirectly on the first outermost spunbond layer, the first meltblown layer and / or meltblown layer The fibrillated layer includes a first plurality of meltblown fibers and / or melt fibrillated fibers, wherein the first plurality of meltblown fibers and / or melt fibrillated fibers includes a third polymer composition, the first plurality of meltblown fibers and / or melt fibrillated fibers The tripolymer composition has a third melting point that is higher ...

Embodiment

[0077] The present disclosure is then further illustrated by the following examples, which should in no way be construed as limiting. That is, the specific features described in the following examples are illustrative only and not restrictive.

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