Disposable nonwoven surgical towel

Claim 1

WHAT WE CLAIM IS:- 1 A disposable, sterilizable, surgical towel having a five-ply construction comprising a nonwoven central ply of wettable microfibrous melt-blown fibers having a 125 basis weight of from 20 to 60 grams per square meter and two identical primary laminates, one on each side of the centre ply and each comprising an intermediate nonwoven ply of wettable thermoplastic 13 G 1 574498 fibers having a basis weight of from 10 to grams per square meter adhesively secured to an outer nonwoven fibrous ply having a basis weight of from 10 to 30 grams per square meter, the outer plies comprising the outermost plies of the towel and the centre ply and the primary laminates being bonded together about the periphery of the towel. 2 A disposable towel according to claim 1 wherein each of said outer plies is a wet strength paper tissue. 3 A disposable towel according to claim 1 or claim 2, wherein the intermediate plies each have a basis weight of about 15 grams per square meter. 4 A disposable towel according to any one of the preceding claims wherein the centre ply has a basis weight of about 30 grams per square meter. A disposable towel according to any one of the preceding claims wherein the centre ply and the primary laminates are additionally joined by a plurality of individual spot bonds so arranged as to reduce relative shifting of the centre ply and the primary laminates when the towel is used with a wiping action, the spot bonds having no significant effect on the overall softness and absorptive capacity of the towel. 6 A disposable towel according to claim wherein the bond about the periphery of the towel and the spot bonds are heat bonds. 7 A disposable towel according to any one of the preceding claims wherein the primary laminates are cold embossed. 8 A disposable towel according to any one of claims 1 to 6 wherein the primary laminates are hot embossed. 9 A disposable towel according to any one of the preceding claims wherein the outer plies are wet strength resin treated plies. A disposable towel according to any one of the preceding claims wherein the fibers of the intermediate and centre plies are wetting-agent-treated, melt-blown polypropylene fibers. 11 A process for making a disposable, sterilizable, surgical towel having a five-ply construction comprising the steps of making fibrous primary laminate webs by adhesively bonding a first thermoplastic nonwoven fabric web having a basis weight of from 10 to 30 grams per square meter to a second nonwoven fibrous web having a basis weight of from 10 to 30 grams per square meter, locating one of the primary laminate webs to either side of a third melt-blown microfibrous nonwoven web having a basis weight of from 20 to 60 grams per square meter, with the thermoplastic side of the primary laminate webs 65 adjacent the third microfibrous web, the first, second and third webs being wettable, joining the third microfibrous web and the primary laminates by bonding to form a continuous five-ply web of towels with each 70 towel bonded about its periphery and severing the towels from the five-ply web thefeof. 12 A process according to claim 11 wherein each first web is hydrophobic and 75 is treated with a wetting agent prior to being adhesively bonded to the second nonwoven fibrous web. 13 A process according to claim 11 wherein each first web is hydrophobic and 80 is treated with a wetting agent subsequent to being adhesively bonded to the second nonwoven fibrous web. 14 A process according to any of claims 11 to 13 wherein the third web is hydro 85 phobic and is treated with a wetting agent prior to its assembly with the primary laminates. A process according to any one of claims 11 to 14 wherein the last bonding 90 step is a heat bonding step. 16 A process according to any one of claims 11 to 15 including the step of cold embossing the primary laminates prior to their joinder to the third web 95 17 A process according to any one of claims 11 to 15 including the step, of hot embossing the primary laminates prior to their joinder to the third web. 18 A process according to any one of 100 claims 11 to 17 wherein each second nonwoven fibrous ply is a wet strength paper tissue having a basis weight of about 15 g/m 2 and including the step of surface treating the tissue side of the primary lami 105 nates with a wet-strength resin. 19 A process according to any one of claims 11 to 18 including the step of additionally joining the primary laminates and the third web with a plurality of spot bonds 110 A process according to claim 19 wherein the spot bonds are heat bonds. 21 A process according to any one of claims 11 to 20 wherein each first web has a basis weight of about 15 grams per square 115 meter. 22 A process according to any one of claims 11 to 21 wherein the third web has a basis weight of about 30 grams per square meter 120 1 574498 23 A process according to any one of claims 11 to 22 including the steps of hot embossing the primary laminates and treating the tissue sides thereof with a wetstrength resin prior to the joinder of the primary laminates to the second web. 24 A disposable towel substantially as described herein and as illustrated in the accompanying drawings. A process of making a disposable 10 towel substantially as described herein and illustrated in the accompanying drawings. For the Applicants:GILL JENNINGS & EVERY, Chartered Patent Agents, 53/64 Chancery Lane, London WC 2 A 1 HN. Printed for Her Majesty's Stationery Office by The Tweeddale Press Ltd, Berwick-upon-Tweed, 1980. Published at the Patent Office, 25 Southampton Buildings, London, WC 2 A l AY, from which copies may be obtained