Allergen barrier fabrics

Abstract

Fabrics having enhanced allergen barrier capabilities are described. The fabrics are woven and calendered, and desirably face finished to provide lightweight, thin fabrics having good aesthetic properties. The fabrics also have good moisture vapor transport characteristics and superior allergen barrier capabilities, and in particular, superior barrier capabilities for cat dander allergen (representing smaller allergen particle size), as well as dust mite allergen. Protective coverings made from the fabrics and methods for their production are also described.

We claim:  
     
         1 . An allergen barrier fabric comprising a substantially all-polyester, woven material having a warp yarn set and a fill yarn set, said material allowing the flow through of less than about 1 nanogram of Fel d1 cat dander allergen when subjected to a Fel d1 airflow test.  
     
     
         2 . An allergen barrier fabric according to  claim 1 , wherein said material allows flow through of less than about 0.5 nanograms of Fel d1 cat dander allergen.  
     
     
         3 . An allergen barrier fabric according to  claim 1 , wherein said material allows flow through of less than about 0.31 nanograms, so as to provide an effective barrier to the transfer of cat dander allergen.  
     
     
         4 . An allergen barrier fabric according to  claim 1 , wherein said woven material is calendered.  
     
     
         5 . An allergen barrier fabric according to  claim 1 , wherein at least one of said warp and fill yarn sets comprises microdenier yarns.  
     
     
         6 . An allergen barrier fabric according to  claim 1 , wherein said material has a moisture vapor transmission rate of at least about 400 g/sq m/24 hrs.  
     
     
         7 . An allergen barrier fabric according to  claim 1 , wherein said fabric has a moisture vapor transmission rate of at least about 430 g/sq m/24 hrs.  
     
     
         8 . An allergen barrier fabric according to  claim 1 , wherein said fabric has a weight of about 3 ounces or less per square yard.  
     
     
         9 . An allergen barrier fabric according to  claim 1 , wherein said fabric has a thickness of about 8 mils or less.  
     
     
         10 . An allergen barrier fabric according to  claim 1 , wherein said fabric has a thickness of about 7 mils or less.  
     
     
         11 . An allergen barrier fabric according to  claim 1 , wherein at least one of said warp and fill yarn sets comprises microdenier yarns, said material has a moisture vapor transmission rate of at least about 425 g/sq m/24 hrs, a weight of about 3 oz/sq yd or less, and allows a flow through of about 0.31 nanograms or less of Fel d1 cat dander when subjected to a Fel d1 airflow test, so as to be an effective barrier against cat dander allergen.  
     
     
         12 . An allergen barrier fabric comprising a polyester/cotton calendered woven material having a weight of about 4 oz/sq yd or less, wherein said material allows for the flow through of less than about 10 nanograms of Fel d1 cat dander when subjected to a Fel d1 airflow test.  
     
     
         13 . An allergen barrier fabric according to  claim 12 , wherein said material allows for the flow through of less than about 8 nanograms of Fel d1 cat dander when subjected to a Fel d1 airflow test.  
     
     
         14 . An allergen barrier fabric according to  claim 12 , wherein said material has a moisture vapor transmission rate of at least about 400 g/sq m124 hrs.  
     
     
         15 . An allergen barrier fabric according to  claim 12 , wherein said material has a thickness of about 10 mils or less.  
     
     
         16 . An allergen barrier fabric according to  claim 12 , wherein said material is calendered.  
     
     
         17 . A protective covering comprising the fabric of  claim 1 .  
     
     
         18 . A protective covering comprising a calendered woven substantially all-polyester fabric having a moisture vapor transmission rate of at least about 400 g/sq m/24 hrs, and allowing a flow through of less than about 1 nanogram of Fel d1 cat dander allergen when subjected to a Fel d1 airflow test.  
     
     
         19 . A protective covering according to  claim 16 , wherein said material allows flow through of less than about 0.5 nanograms of Fel d1 cat dander allergen.  
     
     
         20 . A protective covering according to  claim 16 , wherein said material allows flow through of less than about 0.31 nanograms, so as to provide an effective barrier to the transfer of cat dander allergen.