Operating room gown and drape fabric

A sterile low cost disposable fabric suitable for use in making repellant breathable drapes and gowns for use in a sterile environment, said fabric comprising rudimentary discontinuous and alternating rows of entangled cellulosic and polymeric fiber rows extending in the machine direction, and having a predominantly poylmeric surface and predominantly cellulosic surface and at least said cellulosic fibers being subject to a repellant treatment, yielding a breathable repellant soft fabric with enhanced drape and enhanced frictional properties.

BACKGROUND OF THE INVENTION 
The prior art contains many examples of fabrics developed for use in 
disposable hospital gowns, surgical drapes, and wraps for medical 
components. These fabrics, which must be fluid repellant and themselves 
sterilizable, are used to maintain sterility by providing a barrier to 
contamination. In the case of fabrics used for making gowns the fabric 
needs also to be breathable and possess sufficient drape for comfort. U.S. 
Pat. No. 4,041,203 discloses a fabric developed for use as a wrap, gown or 
surgical drape. The fabric is a laminar structure having a top layer 
comprising a mat of discontinuous thermoplastic microfibers and the bottom 
layer comprising a web of thermoplastic continuous fibers, which layers 
are then bonded in discrete intermittent regions using, for example, heat 
to laminate the two layers together. UK Patent Application No. 2,074,093 
discloses another laminar fabric suitable for use in hospital gowns or 
tents. The laminar structure comprises a flexible layer of hydrophobic 
material and a continuous hydrophilic layer. As described in the 
application, the layers may be fastened together by sewing or by an 
adhesive, or the hydrophilic layer may be cast directly onto the 
microporous hydrophobic layer, and sufficient hydraulic force applied to 
force the hydrophilic polymer to penetrate into the surface void spaces of 
the hydrophobic layer. 
The prior art also contains many disclosures of entangled fiber fabrics; 
nonwoven fabrics formed by hydraulic entangling. U.S. Pat. No. 3,493,462 
discloses a nonpatterned fabric of interentangled fibrous material 
selected from the group consisting of cellulosic and synthetic textile 
fibers. U.S. Pat. No. 3,214,819 discloses various methods of producing 
entangled fiber fabrics including nonpatterned fabrics, or fabrics with a 
core or fabrics with a backing. U.S. Pat. No. 4,146,663 discloses a 
composite fabric formed by entangling extremely fine individual fibers 
having a average diameter of 0.1 to 6.0 microns into a woven or knitted 
fabric, said fabric being disclosed as a substratum for artificial 
leather. 
U.S. Pat. No. 3,449,809 discloses an improved process for producing 
nonwovens with the entangling method by using a polymeric additive in the 
water. This patent discloses that the improved process may also be used to 
stitch an assemblage together by entangling fibers from a top layer into 
and through lower layers. Defensive publication 17060 discloses a 
two-sided laminar fabric formed by uniting a web of synthetic fibers with 
paper sheet by mechanical entangling, fluid entanglement and/or bonding. 
Applicants' fabric is a two-sided fabric, but comprises alternating 
entangled discontinuous rows of polymeric fibers and wood pulp fibers. The 
publication contains no disclosures of entangled rows of polymeric fibers 
and wood pulp fibers. A duPont fabric sold under the name Fabric 450.TM. 
comprises an entangled fabric of polymeric and wood pulp fibers containing 
alternating rows of wood pulp and polymeric fibers with a thin veneer of 
wood pulp on one surface thereof. 
SUMMARY OF THE INVENTION 
The present invention comprises a sterile low-cost disposable fabric 
suitable for making repellant breathable surgical drapes, wraps for 
medical components, and gowns with enhanced comfort for hospital use or 
use within a sterile environment. The fabric has enhanced softness and 
drape and enhanced frictional properties. The fabric consists of entangled 
cellulosic fibers and entangled polymeric fibers. The fabric has a 
predominantly cellulosic fiber face and a predominantly polymeric fiber 
face. The polymeric fibers and cellulosic fibers are each entangled into 
rudimentary discontinuous and alternating rows extending in the machine 
direction of the fabric. At least the cellulosic fibers are subject to a 
repellant treatment. The cellulosic fibers present at the surface of the 
predominantly polymeric fiber surface are present in an overall 
nonpatterned distribution. The fabric is breathable, repellant and soft. 
The enhanced drape of the fabric makes it easier to handle and fold as a 
wrap for medical components. When used as a surgical drape, the fabric 
more easily conforms to uneven surface and more easily falls away from the 
upper surface of, for instance, a table or mayo stand effectively getting 
the fabric out of the way of the operating room personnel. The enhanced 
frictional properties of the fabric lend to its characteristics as a wrap 
for medical components in that the wrap is not easily dislodged and does 
not easily come unwrapped. When used as a surgical drape, the enhanced 
frictional properties provide a drape which will more easily stay where it 
is initially placed and may provide a nonslip, gripping surface for 
surgical instruments and the like disposed on the drape. The enhanced 
softness and drape of the fabric provide a gown or other wearing apparel 
with improved comfort to the wearer.

DETAILED DESCRIPTION OF THE DRAWINGS 
FIGS. 1 and 2 show a prior art fabric, Fabric 450.TM. and the fabric 
according to the present invention. Both fabrics are made with polyester 
and wood pulp. Both fabrics have a predominantly wood pulp fiber surface 
which is not shown. Applicants' fabric is a two-sided fabric with a wood 
pulp surface and a polymeric fiber surface. The polymeric fiber surface of 
Applicants' fabric is shown in FIG. 2. FIG. 1 shows the other surface of 
the prior art fabric which is designated "polymeric fiber surface" for 
easy comparison with Applicants' polymeric fiber surface. The wood pulp 
has been stained and appears dark in the figures. As may be seen in FIG. 1 
the prior art fabric comprises alternating rows of polyester fibers and 
wood pulp fibers and hence does not have a predominantly polymeric fiber 
face but a regular array of rows of polyester fibers 10 and wood pulp 
fibers 12. FIG. 2 discloses only rudimentary or discontinuous rows of 
polyester fibers 20 and wood pulp fibers 22. As may be seen, the wood pulp 
fibers are additionally scattered over the predominantly polyester 
surface. When viewed by the naked eye, the stained fabrics shown in FIGS. 
1 and 2 have a different appearance with FIG. 1 displaying a striped 
configuration while FIG. 2 shows an overall mottled color. 
In both FIGS. 3 and 4, the polymeric fibers have been dissolved out of the 
fabric leaving only the wood pulp fibers. FIG. 3 shows the polymeric fiber 
surface of the prior art fabric. The wood pulp fibers in FIG. 3 occur in 
entangled rows 30. Recesses 32 and 34 occur where the polymeric fibers 
have been dissolved away. In Applicants' fabric as shown in FIG. 4, the 
remaining wood pulp fibers occur in rudimentary, discontinuous entangled 
rows 40. The rudimentary or discontinuous rows of the polymeric fibers may 
be noted by the voids 42 where the polymeric fibers have been dissolved 
away. Regions 44 of the fabric show discontinuity of the wood pulp rows 
and the polymeric voids or rows and a general entangling of the wood pulp 
fibers. 
In FIGS. 5 and 6, the wood pulp fibers have been dissolved away leaving 
only the polymeric fibers. FIG. 5 shows the "polymeric fiber side" of the 
prior art fabric. As may be seen in FIG. 5 the polymeric fibers 50 are 
present in parallel rows of relatively unentangled fiber bundles 50 
separated by voids 52 left by the dissolved wood pulp fibers. In 
Applicants' fabric shown in FIG. 6, the polymeric fibers show less 
bundling and more overall entanglement, however, rudimentary rows 60 of 
polymeric fibers may be seen. Voids 62 left by the wood pulp fibers occur 
between the rudimentary rows of the polymeric fibers and across the face 
of the fabric. 
FIGS. 7 and 8 disclose the prior art fabric and Applicants' fabric 
respectively in cross-section. As may be seen in FIG. 7, the prior art 
fabric has a veneer of wood pulp on the surface 70 with the remainder of 
the fabric and the face 76 comprising alternating rows of polymeric fibers 
72 and wood pulp fibers 74. Applicants' fabric shown in FIG. 8, has a 
predominantly wood pulp surface 80 and a predominantly polymeric fiber 
surface 82 with a very discontinuous pattern of groupings of wood pulp and 
polymeric fibers along the length of the fiber samples shown. 
The fabric of the present invention displays enhanced machine direction, 
softness and drape as compared to the prior art fabric, as well as 
enhanced frictional properties. It may be surmised that the softness in 
the machine direction is achieved by the discontinuity of the rows of wood 
pulp and polymeric fibers. In addition it may be surmised that the 
slightly enhanced cross-directional strength of the fabric and the 
enhanced frictional properties of the fabric are due to the more overall 
entangled nature of the fabric of the present invention. The enhanced 
frictional properties of the fabric of the present invention are shown in 
Table 1. 
TABLE 1 
______________________________________ 
Static Static 
Frictional Coefficient 
Force (gms) of Friction 
Direction 
Direction 
Direction 
Direction 
Sample "A" "B" "A" "B" 
______________________________________ 
Applicants' Roll 
201 231 1.04 1.20 
#E92721-B-EF Fabric 
Prior Art 112 173 0.57 0.90 
Fabric 450 .TM. 
______________________________________ 
As may be noted, Applicants' fabric in the "B" direction shows a 33 percent 
increase in both frictional force and coefficient of friction; while in 
the "A" direction discloses a 79 percent increase in static frictional 
force and a 82 percent increase in static coefficient of friction. The 
static frictional force and the static coefficient of friction were 
measured according to the standard ASTM Method D-1894-78, wherein "A" and 
"B" are arbitrarily assigned to the machine direction, and its reverse. 
As may be seen in Table 2 below, samples 1, 2, 3, and 4 of the fabric of 
the present invention (made of entangled wood pulp and polyester fibers) 
show a decreased machine direction stiffness over the prior art Fabric 
450.TM. with an average decrease in the machine direction of 20 percent, 
and with a slightly enhanced cross-directional stiffness. The stiffness as 
set forth in Table 2 was measured according to the standard TAPPI T498 
Handleometer test. 
TABLE 2 
______________________________________ 
Machine Cross- 
Stiffness (gms.) direction 
direction 
______________________________________ 
Sample 1 28.9 6.5 
2 29.2 6.9 
3 28.5 6.6 
4 29.7 6.9 
Avg. 29.1 6.7 
Fabric 450 .TM. 36.6 5.3 
______________________________________ 
The fabrics of the present invention are low cost disposable fabrics 
suitable for use in making repellant breathable drapes, wraps for medical 
components, or gowns for use in a sterile environment. The material is 
easily sterilizable and at least the cellulosic fibers may be subject to a 
repellant treatment. The polymeric fibers of the fabric of the present 
invention may comprise polyester, nylon, or polyolefin fibers having a 
length of from about one-half inch to about one and one-half inch, of 1 to 
2 denier. The cellulosic fibers may comprise wood pulp or other cellulosic 
pulp fibers which may be repellant treated. The fabric is made utilizing 
the fluid entangling process similar to that set forth in the Evans U.S. 
Pat. No. 3,485,706. In making the fabric of the present invention, the 
polymeric fibers are laid down in a batt and partially entangled. The 
cellulosic fibers are then disposed atop the polymeric fibers and 
entangled into and through the polymeric fibers. In a preferred method, 
the cellulosic fibers are supplied and utilized in a repulpable, low wet 
strength tissue. 
The foregoing description and drawings are illustrative but are not to be 
taken as limiting. Other variations and modifications are possible without 
departing from the spirit and scope of the present invention.