Infection control or protective clothing articles

Abstract

Infection control or protective clothing articles, such as gowns, to be worn by healthcare workers in a medical environment, for example a hospital or assisted living facility are disclosed. The articles are formed of a hydrophobic, breathable, poly-olefin-based web with a controlled pore size less than or about equal to the size of most bacterial or viral particles. The articles can also be made from composites including the polyolefin-based web. Methods of manufacturing the articles are also disclosed.

1 . A disposable, protective article comprising a composite of a free-standing, hydrophobic, breathable, polyolefin-based web with a median pore size less than or equal to 0.25 um and a non-woven material joined to at least one major surface of the polyolefin-based web. 
     
     
         2 . The disposable, protective article of  claim 1 , in which the non-woven material comprises polyethylene terephthalate, polypropylene, cellulose, glass, or combinations thereof. 
     
     
         3 . The disposable, protective article of  claim 1 , in which the non-woven material is adhesively, thermally, pressure, or ultrasonically joined to the at least one major surface of the polyolefin-based web. 
     
     
         4 . The disposable, protective article of  claim 1 , wherein the polyolefin-based web has a tortuosity greater than 1.2. 
     
     
         5 . The disposable, protective article of  claim 1 , wherein the polyolefin-based web has a porosity of 30% to 70%. 
     
     
         6 . The disposable, protective article of  claim 1 , wherein the article comprises two-layers joined at the edges of the article. 
     
     
         7 . The disposable, protective article of  claim 1 , wherein an individual layer of the polyolefin-based web has a thickness of 10 microns to 30 microns. 
     
     
         8 . The disposable, protective article of  claim 1 , wherein the polyolefin-based web was made using a dry process. 
     
     
         9 . The disposable, protective article of  claim 1 , wherein the polyolefin-based web was made using a wet process. 
     
     
         10 . The disposable, protective article of  claim 1 , wherein the polyolefin-based web comprises low density (LDPE), medium density (MDPE), linear low density (LLDPE), high density (HDPE), ultrahigh molecular weight (UHMWPE) polyethylene, polypropylene (PP), polymethyl pentene (TPX), or a mixture thereof. 
     
     
         11 . The disposable, protective article of  claim 1 , wherein the article comprises a gown. 
     
     
         12 . The disposable, protective article of  claim 11 , wherein the gown comprises a heat-sealed seam on the back that forms a tear-away seam. 
     
     
         13 . The disposable, protective article of  claim 11 , wherein the gown comprises two sleeves and a thumb hole in each sleeve. 
     
     
         14 . The disposable, protective article of  claim 11 , wherein the gown comprises two integral ties, one on each side of the gown, configured for tying together and securing the back of the gown during use. 
     
     
         15 . The disposable, protective article of  claim 11 , wherein the gown comprises two sleeves comprising polyolefin-based web folded back on itself and joined at common edges. 
     
     
         16 . A method of making a disposable, protective gown, the method comprising:
 extruding a polyolefin-based web;   processing and stretching the polyolefin-based web to impart a median pore size of 0.25 micron or less; and   cutting a gown shape out of a sheet of the polyolefin-based web.   
     
     
         17 - 19 . (canceled) 
     
     
         20 . A disposable, protective article formed from a free-standing, hydrophobic, breathable, polyolefin-based web with a median pore size less than or equal to 0.25 um. 
     
     
         21 . The disposable, protective article of  claim 20 , wherein the article comprises two-layers of the polyolefin-based web joined at the edges of the article. 
     
     
         22 . The disposable, protective article of  claim 20 , wherein the polyolefin-based web is not laminated with any other material. 
     
     
         23 . The disposable, protective article of  claim 20 , wherein the article comprises an outer surface and an inner surface composed of only the polyolefin-based web.