Patent Application
20230041219
The present invention relates to the application and development of a combined waterproof, moisture-permeable non-woven fabric that blocks viruses and blood, and more particularly to a P3 grade (CNS (Chinese National Standards) 14798), bend resistant non-woven protective clothing that protects against blood and viruses, which is provided with the functionality to block viruses and bacteria, as well as prevent blood contamination and guard against infected saliva aerosol particles.
When an infectious disease epidemic breaks out, there is sudden increase in demand for medical care protective equipment within a short period, with the cost of medical care protective equipment accordingly rising. Moreover, nations worldwide begin to attach importance to problems of shortage in protective equipment, such as protective clothing, masks, etc., among which protective clothing must be provided with resilient film material with specifications including high barrier protection, moisture-penetrability, waterproofing, and lightness. And the European Union Standard EN 14126, United States AAMI (Association for the Advancement of Medical Instrumentation), and Taiwan CNS (China National Standards) have their standard specifications regarding protective clothing for use against viruses and bacterial epidemics. However, the breathability of traditional P3 grade (CNS 14798) medical protective clothing is inferior, and thus there is a need for further development.
Past single layer breathable films are unable to block viruses because of the short breathable paths of the holes in the films, and if the material thickness is increased to lengthen the breathable paths, it is still unable to achieve the requirement for high breathability. Because the prior art is unable to achieve maximized effectiveness, hence, the inferior wearer comfortability, protective clothing made from such materials cannot be worn for long periods of time. When an epidemic breaks out, the demand for protective clothing increases, and because medical personnel need to wear protective clothing for long periods of time, thus, a new generation of protective clothing that must maintain a definite protective effect and improve comfortability has become a subject of future development.
Prior Art using the application of breathable composite laminate materials include Taiwan Patent No. 089110815 that relates to an absorption member provided with a top piece, a rear piece, and an absorption core between the top piece and the rear piece. The rear piece contains a vapor permeable and an essentially liquid impermeable composite laminate material, which is composed of a spun-bonded non-woven fabric adhered to a vapor permeable, thermoplastic film. The non-woven fabric is mainly composed of a first layer fabricated from compatible fibers that can be used to bond a web and a second layer fabricated from some fiber additives and a thermoplastic film that are compatible with a bonding adhesive and some that are incompatible.
Another prior art that has carried out research on moisture-permeability films includes Taiwan Patent No. 102144782, which discloses a moisture-permeable film able to maintain breathability, moisture-permeability, mechanical strength, and practicability, as well as permeable tolerance. A breathable film of Taiwan Patent No. 102144782 contains a polyethylene resin component (A) having a melt wave crest temperature of 130˜150° C. and a polyethylene resin density of 0.940˜0.970 g/cm3, an inorganic filler material (B), and styrene-based elastomers (C). In addition, relative to the total 100 mass percent of the aforementioned polyethylene resin component (A) and the inorganic filler material (B), a resin component structure with the addition of 1˜20 mass percent of the aforementioned styrene-based elastomers (C) has an effusion area less than 5%.
As for the manufacturing method study of antimicrobial compound fabric in the prior Art, Taiwan Patent No. 105106057 discloses an antimicrobial compound fabric combined or adhered to a fabric material. The processed fabric material, which can serve as sterilization material or disinfection material, and also possesses wash durability and non-permeable characteristics. A staining solution used in the processing cycle is composed of one or a plurality of antimicrobial agents, and the processed fabric material undergoes a heat treatment step.
Furthermore, the prior art connected with blood and virus blocking composite fabric coating research includes Taiwan Patent No. 099118884, which discloses a composite fabric composed of a non-woven fabric, wherein a fully-calendered non-woven fabric of fusible fibers is preferred; and a single breathable polymer layer. At least one surface of the fabric has excellent breathability, good abrasion resistance, and provides protection against both blood and virus agents. The composite woven fabric is composed of a single coating layer on a fibrous base material fabric. The composite woven fabric is provided with a MVTR (Moisture Vapour Transmission Rate) of at least 1500 g/m2/day, and has also passed both the ASTM (American Society for Testing Materials) F1670 blood blockage test and the ASTM F1671 virus blockage test.
High moisture permeability is a necessary requirement for non-woven protective clothing against blood and viruses in addition to being provided with the function to prevent blood and virus penetration. In other words, the surface of a waterproof moisture-permeable combination non-woven cloth for blocking blood and viruses must be completely impervious but must also allow for air dissipation. Accordingly, the present invention provides a non-woven protective clothing against blood and viruses that comprises: a non-woven fabric layer, which has two surfaces and a basic weight ≤70 g/m2; a high waterproof moisture-permeable layer, which is a porous film with a basic weight between 5˜30 g/m2. The percentage by weight of a powder in the high waterproof moisture-permeable layer is 40˜70%, and the draw ratio thereof is ≤400%. Moreover, the average grain diameters in the powder in the high waterproof moisture-permeable layer are 0.5˜3 μm, and calcium carbonate (CaCO3) is used as the powder. The high waterproof moisture-permeable layer is laminated to one of the surfaces of the non-woven fabric layer. The present invention further comprises an elastic pore filling layer, which is a hydrophilic polyurethane that is composed at least a hydrophilic waterborne polyurethane and a hydrophilic solventborne polyurethane. The elastic pore filling layer is coated or printed onto the surface of the high waterproof moisture-permeable layer, and the thickness of the elastic pore filling layer is thinner than that of the high waterproof moisture-permeable layer. The present invention is characterized in that the synthetic blood permeability of the non-woven protective clothing against blood and viruses can resist pressure of 2.0 psi for 1 minute, and the Phi-X174 bacteriophage penetrability thereof can resist pressure of 2.0 psi for 1 minute. Further, after dispersing the powder, the high waterproof moisture-permeable layer is a drawn porous polyethylene or polypropylene film. The material for the non-woven fabric layer is a selected composition of a hydro-acupuncture non-woven fabric, a needle-punched non-woven fabric, a spun-bonded non-woven fabric, or a melt-blown non-woven fabric. The fiber diameters in the non-woven fabric layer are 0.5˜40 μm, and fiber material therein is at least a polyethylene, polypropylene, polyester, polyvinyl alcohol, rayon, cotton, polyurethane, or a styrene-ethylene)/butylene-styrene copolymer.
The high waterproof moisture-permeable layer is a three layer extruded film with a layer ratio of 1:1:1, 1:2:1, 1:3:1, 1:4:1, or 1:5:1, and the thickness ratio of the high waterproof moisture-permeable layer to the elastic pore filling layer is 16:1.5 to 16:3. The high waterproof moisture-permeable layer laminated to the non-woven fabric layer has a moisture permeability between 1500˜7500 g/m2·24 hr, and has a basic weight of 40˜100 g/m2. The non-woven fabric layer has a moisture permeability that reaches ≥1500 g/m2·24 hr, and the percentage by weight of the powder in the high waterproof moisture-permeable layer is 40˜60%. The high waterproof moisture-permeable layer has a moisture permeability that reaches ≥1500 g/m2·24 hr, and the average grain diameters in the powder therein are 2 μm; moreover, the high waterproof moisture-permeable layer has a moisture permeability that reaches ≥1500 g/m2·24 hr. The non-woven protective clothing against blood and viruses has a moisture permeability that reaches ≥1500 g/m2·24 hr. The high waterproof moisture-permeable layer of the present invention comprises the non-woven fabric layer, the surface of which is provided with at least a three layer extruded film of the high waterproof moisture-permeable layer, as well as the elastic pore filling layer coated or printed onto the surface of the high waterproof moisture-permeable layer, thereby achieving the function to block blood and viruses by providing high water pressure resistance and high air permeability.
The structural characteristics of the present invention thus distinguishes and differentiates it from the prior art; moreover, it's originality, advancement, and practical effectiveness are unmistakable. Regarding the technical problems the present invention intends to adopt and objectives thereof, it is believed an in-depth understanding of the aforementioned objects, structure, and characteristics of present invention will be gained after reading the detailed description of the preferred embodiment modes of the present invention in conjunction with the diagrams.
To enable a further understanding of said objectives, structures, characteristics, and effects, as well as the technology and methods used in the present invention and effects achieved, a brief description of the drawings is provided below followed by a detailed description of the preferred embodiments.
The following description uses specific concrete examples to describe the embodiment modes of the present invention. Persons skilled in the related art can easily deduce other advantages and effects of the present invention from the content disclosed in the specification. The present invention can also use other different concrete embodiments to clarify its performance and applications. Each detail described in the specification can also be based on a different perspective and application, enabling various types of modifications and alterations to be carried out without deviating from the spirit of the present invention.
Referring first to
Referring to
In another embodiment mode of the present invention, the non-woven protective clothing against blood and viruses comprises: the non-woven fabric layer 101, which has two surfaces and a basic weight of 70 g/m2; and the high waterproof moisture-permeable layer 201, which is a three layer extruded film with a basic weight of 5 g/m2, wherein the percentage by weight of the powder 20111 in the high waterproof moisture-permeable layer 201 is 40%, and the draw ratio thereof is 300%. The average grain diameters in the powder 20111 in the high waterproof moisture-permeable layer 201 are 1 μm, and calcium carbonate (CaCO3) is used as the powder 20111; moreover, the high waterproof moisture-permeable layer 201 is laminated to one of the surfaces of the non-woven fabric layer 101, and has a moisture permeability that reaches 7500 g/m2·24 hr (CNS 12222). In addition, the present embodiment further comprises the elastic pore filling layer 301, which is a hydrophilic polyurethane that is selected from at least a hydrophilic waterborne polyurethane or a hydrophilic solventborne polyurethane. The elastic pore filling layer 301 is coated or printed onto the surface of the high waterproof moisture-permeable layer 201. The present embodiment mode is characterized in that the synthetic blood permeability of the non-woven fabric protective clothing against blood and viruses can resist a pressure of 2.0 psi for one minute (CNS 14799); and the Phi-X174 bacteriophage penetrability thereof can resist a pressure of 2.0 psi for one minute (CNS 14800). The material for the non-woven fabric layer 101 is a selected composition of a hydro-acupuncture non-woven fabric, a needle-punched non-woven fabric, a spun-bonded non-woven fabric, or a melt-blown non-woven fabric, wherein the fiber diameters in the non-woven fabric layer 101 is 0.5 μm, and the fiber material therein is selected from polyethylene, polypropylene, polyester, polyvinyl alcohol, rayon, cotton, polyurethane, polyester/rayon mixed fibers, polyethylene/rayon mixed fibers, or a styrene-ethylene/butylene-styrene copolymer. In the present embodiment mode, the high waterproof moisture-permeable layer 201 is a three layer extruded film with a layer ratio of 1:1:1, 1:2:1, 1:3:1, 1:4:1, or 1:5:1. The thickness ratio of the high waterproof moisture-permeable layer 201 to the elastic pore filling layer 301 is 16:1.5 to 16:3. The average moisture permeability of the non-woven protective clothing against blood and viruses is 3600 g/m2·24 hr (CNS 12222). In the present embodiment mode, test results for the synthetic blood penetrability of the non-woven protective clothing against blood and viruses using pressure >13.8 kPa showed no penetration (CNS 14799), and test results for virus penetrability using pressure >13.8 kPa showed no penetration (CNS 14800). In other words, the present invention has passed CNS 14798 National Standard P3 grade tests.
In another embodiment mode of the present invention, the non-woven protective clothing against blood and viruses comprises: the non-woven fabric layer 101, which has two surfaces and a basic weight of 40 g/m2; and the high waterproof moisture-permeable layer 201, which is a three layer extruded film with a basic weight of 30 g/m2, wherein the percentage by weight of the powder 20111 in the high waterproof moisture-permeable layer 201 is 70%, and the draw ratio thereof is 400%. The average grain diameters in the powder 20111 in the high waterproof moisture-permeable layer 201 are 3 μm, and calcium carbonate (CaCO3) is used as the powder 20111; moreover, the high to waterproof moisture-permeable layer 201 is laminated to one of the surfaces of the non-woven fabric layer 101, and has a moisture permeability that reaches 1500 g/m2·24 hr (CNS 12222). In addition, the present embodiment further comprises the elastic pore filling layer 301, which is a hydrophilic polyurethane that is selected from at least a is hydrophilic waterborne polyurethane or a hydrophilic solventborne polyurethane. The elastic pore filling layer 301 is coated or printed onto the surface of the high waterproof moisture-permeable layer 201. The present embodiment mode is characterized in that the synthetic blood permeability of the non-woven fabric protective clothing against blood and viruses can resist a pressure of 2.0 psi for one minute (CNS 14799); and the Phi-X174 bacteriophage penetrability thereof can resist a pressure of 2.0 psi for one minute (CNS 14800). The material for the non-woven fabric layer 101 is a selected composition of a hydro-acupuncture non-woven fabric, a needle-punched non-woven fabric, a spun-bonded non-woven fabric, or a melt-blown non-woven fabric, wherein the fiber diameters in the non-woven fabric layer 101 is 40 μm, and the fiber material therein is selected from polyethylene, polypropylene, polyester, polyvinyl alcohol, rayon, cotton, polyurethane, or a styrene-ethylene/butylene-styrene copolymer. In the present embodiment mode, the high waterproof moisture-permeable layer 201 is a three layer extruded film with a layer ratio of 1:1:1, 1:2:1, 1:3:1, 1:4:1, or 1:5:1. The thickness ratio of the high waterproof moisture-permeable layer 201 to the elastic pore filling layer 301 is 16:1.5 to 16:3. The average moisture permeability of the non-woven protective clothing against blood and viruses is 3600 g/m2·24 hr (CNS 12222). In the present embodiment mode, test results for the synthetic blood penetrability of the non-woven protective clothing against blood and viruses using pressure >13.8 kPa showed no penetration (CNS 14799), and test results for virus penetrability using pressure >13.8 kPa showed no penetration (CNS 14800). In other words, the present invention has passed CNS 14798 National Standard P3 grade tests.
The present invention provides a non-woven protective clothing against blood and viruses with distinguishing features that include providing a three layer extruded film of the high waterproof moisture-permeable layer 201 on the surface of the non-woven fabric layer 101, and coating or printing the elastic pore filling layer 301 onto the surface of the high waterproof moisture-permeable layer 201, which are able to improve the bend resistance characteristics of the non-woven protective clothing against blood and viruses. The present invention was bent through 180 degrees at least 5000 times, and the bent areas showed no visual signs of cracking. The present invention is distinct and differentiates itself from the prior art; its originality, advancement, and practical effectiveness are unmistakable, and enable effective improvements on the shortcomings of prior art, and, therefore, has considerable practicability in use.
In conclusion, the concrete structures of the embodiments disclosed above enable the non-woven protective clothing against blood and viruses of the present invention to perform the functions of bend resistance, high water pressure resistance, and high air permeability. The overall structure of the present invention has not been seen in like products, moreover, the contents of this specification have not been publicly disclosed prior to this application, clearly complying with the essential elements as required for a new patent, Accordingly, a patent application is proposed herein.
It is of course to be understood that the embodiments described herein are merely illustrative of the principles of the invention and that a wide variety of modifications thereto may be effected by persons skilled in the art without departing from the spirit and scope of the invention as set forth in the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 110128614 | Aug 2021 | TW | national |
