Breathable film and fabric having liquid and viral barrier
View Patent ↗A breathable viral barrier film, viral barrier laminate and surgical articles including the film or laminate are provided. The film has viral barrier properties in the presence of low surface tension liquids, as well as in the presence of aqueous liquids. The film includes a core layer surrounded by two skin layers. The core layer includes a polymer matrix, filler particles, and at least 0.5% by weight of a selected fluorochemical. The film is bonded to one or more nonwoven webs to provide laminates useful in surgical articles.
1. A breathable thermoplastic film, comprising:
a core layer including a thermoplastic polymer matrix, filler particles, and at least 0.5% by weight of a telomerized fluorochemical; and
skin layers on both sides of the core layer, each skin layer including a thermoplastic polymer matrix and zero to less than 0.5% by weight of the telomerized fluorochemical;
wherein the film is oleophilic and passes the federal performance standards set forth in ASTM F1670 and ASTM F1671.
2. The breathable thermoplastic film of claim 1 , wherein the core layer comprises 0.5% to about 5.0% by weight of the telomerized fluorochemical.
3. The breathable thermoplastic film of claim 1 , wherein the core layer comprises about 1.0-4.0% by weight of the telomerized fluorochemical.
4. The breathable thermoplastic film of claim 1 , wherein the core layer comprises about 2.0-3.0% by weight of the telomerized fluorochemical.
5. The breathable thermoplastic film of claim 1 , wherein each skin layer comprises less than about 0.3% by weight of the telomerized fluorochemical.
6. The breathable thermoplastic film of claim 1 , wherein each skin layer comprises less than about 0.1% by weight of the telomerized fluorochemical.
7. The breathable thermoplastic film of claim 1 , wherein the thermoplastic polymer matrix in the core layer comprises a polymer selected from olefin polymers, polyurethanes, copolyether esters, polyamide polyether block copolymers, ethylene methyl acrylate, ethylene ethyl acrylate, ethylene vinyl acetate and combinations thereof.
8. The breathable thermoplastic film of claim 1 , wherein the thermoplastic polymer matrix in the core layer comprises an olefin polymer.
9. The breathable thermoplastic film of claim 1 , wherein the thermoplastic polymer matrix in the core layer comprises a linear low density polyethylene and a single-site catalyzed ethylene-alpha olefin copolymer plastomer.
10. The breathable thermoplastic film of claim 1 , wherein the core layer comprises about 25-80% by weight of the thermoplastic polymer matrix and about 20-75% by weight of the filler particles.
11. The breathable thermoplastic film of claim 1 , wherein the core layer comprises about 30-60% by weight of the thermoplastic polymer matrix and about 40-70% by weight of the filler particles.
12. The breathable thermoplastic film of claim 1 , wherein the core layer comprises about 40-50% by weight of the thermoplastic polymer matrix and about 50-60% by weight of the filler particles.
13. The breathable thermoplastic film of claim 1 , wherein the thermoplastic polymer matrix in the skin layers comprises a polymer selected from heterophasic propylene-ethylene copolymers, propylene-ethylene random copolymers, ethylene vinyl acetate, ethylene methyl acrylate, amorphous ethylene alpha-olefin copolymers, having densities of about 0.89 grams/cm 3 or less, APAO polymers, and combinations thereof.
14. The breathable thermoplastic film of claim 1 , wherein the thermoplastic polymer matrix in the skin layers comprises a heterophasic propylene-ethylene copolymer and a propylene-ethylene random copolymer.
15. The breathable thermoplastic film of claim 1 , wherein the skin layers further comprise filler particles.
16. The breathable thermoplastic film of claim 15 , wherein the skin layers comprise about 25-80% by weight of the thermoplastic polymer matrix and about 20-75% by weight of the filler particles.
17. The breathable thermoplastic film of claim 15 , wherein the skin layers comprise about 30-60% by weight of the thermoplastic polymer matrix and about 40-70% by weight of the filler particles.
18. The breathable thermoplastic film of claim 15 , wherein the skin layers comprise about 40-50% by weight of the thermoplastic polymer matrix and about 50-60% by weight of the filler particles.
19. A breathable thermoplastic film, comprising:
a core layer including a thermoplastic polymer matrix, filler particles and at least 0.5% by weight of a fluorochemical; and
skin layers on both sides of the core layer, each skin layer including a thermoplastic polymer matrix;
wherein the film is oleophilic and passes the federal performance standards set forth in ASTM F1670 and ASTM F1671.
20. The breathable thermoplastic film of claim 19 , wherein the core layer comprises 0.5% to about 5.0% by weight of the fluorochemical.
21. The breathable thermoplastic film of claim 19 , wherein the core layer comprises about 1.0-4.0% by weight of the fluorochemical.
22. The breathable thermoplastic film of claim 19 , wherein the core layer comprises about 2.0-3.0% by weight of the fluorochemical.
23. The breathable thermoplastic film of claim 19 , wherein each skin layer comprises less than about 0.3% by weight of the fluorochemical.
24. The breathable thermoplastic film of claim 19 , wherein each skin layer comprises less than about 0.1% by weight of the fluorochemical.
25. The breathable thermoplastic film of claim 19 , wherein the thermoplastic polymer matrix in the core layer comprises a polymer selected from olefin polymers, polyurethanes, copolyether esters, polyamide polyether block copolymers, ethylene methyl acrylate, ethylene ethyl acrylate, ethylene vinyl acetate and combinations thereof.
26. The breathable thermoplastic film of claim 19 , wherein the thermoplastic polymer matrix in the core layer comprises an olefin polymer.
27. The breathable thermoplastic film of claim 19 , wherein the thermoplastic polymer matrix in the core layer comprises a linear low density polyethylene and a single-site catalyzed ethylene-alpha olefin copolymer plastomer.
28. The breathable thermoplastic film of claim 19 , wherein the core layer comprises about 25-80% by weight of the thermoplastic polymer matrix and about 20-75% by weight of the filler particles.
29. The breathable thermoplastic film of claim 19 , wherein the core layer comprises about 30-60% by weight of the thermoplastic polymer matrix and about 40-70% by weight of the filler particles.
30. The breathable thermoplastic film of claim 19 , wherein the core layer comprises about 40-50% by weight of the thermoplastic polymer matrix and about 50-60% by weight of the filler particles.
31. The breathable thermoplastic film of claim 19 , wherein the thermoplastic polymer matrix in the skin layers comprises a polymer selected from heterophasic propylene-ethylene copolymers, propylene-ethylene random copolymers, ethylene vinyl acetate, ethylene methyl acrylate, amorphous ethylene alpha-olefin copolymers having densities of about 0.89 grams/cm 3 or less, APAO polymers, and combinations thereof.
32. The breathable thermoplastic film of claim 19 , wherein the thermoplastic polymer matrix in the skin layers comprises a heterophasic propylene-ethylene copolymer and a propylene-ethylene random copolymer.
33. The breathable thermoplastic film of claim 19 , wherein the skin layers further comprise filler particles.
34. The breathable thermoplastic film of claim 33 , wherein the skin layers comprise about 25-80% by weight of the thermoplastic polymer matrix and about 20-75% by weight of the filler particles.
35. The breathable thermoplastic film of claim 33 , wherein the skin layers comprise about 30-60% by weight of the thermoplastic polymer matrix and about 40-70% by weight of the filler particles.
36. The breathable thermoplastic film of claim 33 , wherein the skin layers comprise about 40-50% by weight of the thermoplastic polymer matrix and about 50-60% by weight of the filler particles.
37. A breathable, laminate, comprising:
a breathable thermoplastic film including a core layer and skin layers on both sides of the core layer;
a first nonwoven layer joined to one of the skin layers; and
a second nonwoven layer joined to the other of the skin layers;
the core layer including a thermoplastic polymer matrix, filler particles and at least about 0.5% by weight of a fluorochemical;
each skin layer including a thermoplastic polymer matrix;
wherein the film is oleophilic and the laminate passes the federal performance standards set forth in ASTM F1670 and ASTM F1671.
38. The breathable, viral barrier laminate of claim 37 , wherein each nonwoven layer comprises a material selected from a spunbond web, a meltblown web, a bonded carded web, an air laid web, and a laminate or composite including one or more nonwoven webs.
39. The breathable, viral barrier laminate of claim 37 , wherein each nonwoven layer comprises a spunbond web.
40. The breathable, viral barrier laminate of claim 37 , wherein the first nonwoven layer comprises a spunbond web and the second nonwoven layer comprises a spunbond-meltblown-spunbond laminate.
41. A surgical article comprising the breathable, viral barrier laminate of claim 37 .
42. A surgical gown comprising the breathable, viral barrier laminate of claim 37 .
43. A surgical drape comprising the breathable, viral barrier laminate of claim 37 .
44. A surgical face mask comprising the breathable, viral barrier laminate of claim 37 .
45. A surgical scrub comprising the breathable, viral barrier laminate of claim 37 .
46. A sterile wrap comprising the breathable, viral barrier laminate of claim 37 .
47. A sterilization peel pouch comprising the breathable, viral barrier laminate of claim 37 .
48. A personal protective article comprising the breathable, viral barrier laminate of claim 37 .
49. A fenestration material comprising the breathable, viral barrier laminate of claim 37 .