Extensible microfine fiber laminate

Claim 2

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.

Claim 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 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.

Claim 4

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.

Claim 5

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.

Claim 6

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.

Claim 7

The material of Claim 2 wherein the layers of nonwoven fabric are blended with from 5 to 40% by weight of rayon or polyester fibers.

Claim 8

The material of Claim 3 wherein the creped ply of microfine fibers was initially prepared by melt blowing.

Claim 9

6 . 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 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 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.

Claim 10

6 . 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 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 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.

Claim 11

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.

Claim 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.

Claim 13

The material of Claim 7, wherein each ply of the hydrophobic microfine fiber structure was initially prepared by melt-blowing.

Claim 14

An operating room gown comprising the material of Clain 1.

Claim 15

An operating room gown comprising the material of Clain 1.

Claim 16

The material of Claim 2, wherein said material has been bonded by means of a heated embossing calender, or by ultrasound.

Claim 17

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.

Claim 18

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.

Claim 19

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.

Claim 20

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.

Claim 21

A process for preparing an extensible water impervious 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.

Claim 22

A process for preparing an extensible water impervious 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.

Claim 23

A process for preparing 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 conponent 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 forning 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.

Claim 24

A process for preparing 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 conponent 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 forning 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.