Fibrous polymeric material and its composites

Abstract

A three dimensional porous elastomeric polymeric material is described that has a morphology primarily of polymeric fibers fused randomly along portions of their length, with a cross-section of a network of irregular polymeric areas that are interconnected to define interconnected voids; where the bulk density of the material is at least 0.35 grams/cc. The material is useful in garment and other protective covering applications where it can be adhered to various substrates to provide improved abrasion resistance. Composites of the material are described also.

1 . A three dimensional porous material comprised of: 
 polymeric fibers fused together randomly along portions of their length such that the cross-section comprises a network of irregular shapes of polymer that are interconnected so as to define void space; said material 
 having a bulk density of at least 0.35 gm/cc,  
 being elastomeric, and  
 having an air permeability of at least 10 cm 3 /cm 2 /sec.  
   
     
     
         2 . A three dimensional porous material comprised of: 
 polymeric fibers fused together randomly along portions of their length such that the cross-section comprises a network of irregular shapes of polymer that are interconnected so as to define void space; said material 
 having a bulk density of at least 0.35 gm/cc,  
 being elastomeric;  
 having an air permeability of at least 10 cm 3 /cm 2 /sec;  
 having a basis weight between 30 and 300 g/m 2 ; and  
 having an abrasion resistance of at least 100 cycles.  
   
     
     
         3 . The material of    claim 2    wherein the abrasion resistance is at least 1000 cycles.  
     
     
         4 . The material of    claim 2    wherein the basis weight is between 30 and 80 g/m 2  and the abrasion resistance is at least 100 cycles.  
     
     
         5 . The material of    claim 2    wherein the basis weight is between 80 and 100 g/m 2  and the abrasion resistance is at least 150 cycles.  
     
     
         6 . The material of    claim 2    wherein the basis weight is between 100 and 150 g/m 2  and the abrasion resistance is at least 300 cycles.  
     
     
         7 . The material of    claim 2    wherein the basis weight is between 80 and 120 g/m 2  and the abrasion resistance is at least 750 cycles.  
     
     
         8 . The material of    claim 2    wherein the basis weight is between 150 and 300 g/m 2  and the abrasion resistance is at least 1000 cycles.  
     
     
         9 . The material of    claim 1    wherein the polymeric fibers are comprised of polyurethanes, polyetheresters, polyetheramides or polyolefins.  
     
     
         10 . The material of    claim 2    wherein the polymeric fibers are polyurethane.  
     
     
         11 . The material of    claim 2    in which the polymeric fibers contain an additive.  
     
     
         12 . The material of    claim 11   , wherein said additive comprises a UV stabilizer.  
     
     
         13 . The material of    claim 1   , wherein the polymeric fibers comprise a thermoplastic polyurethane comprising diphenylmethane diisocyanate, polycaprolactone diol and butane diol.  
     
     
         14 . The material of    claim 2   , wherein the polymeric fibers comprise a thermoplastic polyurethane comprising diphenylmethane diisocyanate, polycaprolactone diol and butane diol.  
     
     
         15 . The material of    claim 1   , wherein said polymeric fibers comprise a thermoplastic polyurethane of dicyclohexylmethane diisocyanate, polycaprolactone diol and butane diol.  
     
     
         16 . The material of    claim 2   , wherein said polymeric fibers comprise a thermoplastic polyurethane of dicyclohexylmethane diisocyanate, polycaprolactone diol and butane diol.  
     
     
         17 . A process of making the three-dimensional porous polymeric material of    claim 1    or    2    comprising melt blowing an elastomeric polymer onto a carrier surface having an air permeability of less than 100 cm 3 /cm 3 /sec, and removing the carrier surface.  
     
     
         18 . A garment comprising the material of    claim 1    or    claim 2    wherein the garment comprises seams formed by joining a first region of polymeric fibers of the porous material to a second region of polymeric fibers.  
     
     
         19 . A garment comprising the material of    claim 1    or    2    laminated to at least one second material comprising a water resistant, water vapor permeable component, wherein the garment comprises water resistant seams formed by joining polymeric fibers of the porous material to said at least one second material.