Composite nonwoven fabric comprising adjacent microfine fibers in layers

Abstract

A composite nonwoven fabric for use in disposable surgical items such as surgical gowns, surgical drapes and the like. The fabric comprises at least two hydrophobic piles of microfine fibers of a fiber diameter of up to about 10 microns and at least one nonwoven cover ply. The nonwoven cover ply may be an apertured film, a spunbonded ply or an air laid, wet laid or carded ply of fibers preferably of staple length or longer. The cover ply may lend strength to the fabric and, of particular importance to surgical items, should be characterized by surface stability. When a single cover ply is employed, the exposed melt blown ply should be surface stabilized to improve its resistance to abrasion and pilling. When additional strength is required, the fabric may include a strength ply of hydrophobic spunbonded, air laid, wet laid or carded fibers. The composite nonwoven fabric demonstrates a unique relationship between air permeability and resistance to liquid and bacterial strikethrough, while maintaining cloth-like aesthetics substantially equivalent to those normally associated with woven fabrics.

Dependencies are inferred from the claim text.