Nonwoven fibrous webs and methods of making and using thereof

Abstract

Disclosed herein are nonwoven fibrous web comprising a population of fibers, wherein the fibers are formed from a composite that comprises: (i) a thermoplastic elastomeric polymer (TPE) component; (ii) a soft elastomeric polymer component that at ambient temperatures is above its glass transition temperature; and (iii) optionally a filler. Also described are methods of making these nonwoven fibrous webs as well as articles made therefrom.

1 . A nonwoven fibrous web comprising a population of fibers, wherein the fibers are formed from a composite that comprises:
 (i) a thermoplastic elastomeric polymer (TPE) component;   (ii) a soft elastomeric polymer component that at ambient temperatures is above its glass transition temperature; and   (iii) optionally a filler.   
     
     
         2 . The web of  claim 1 , wherein the TPE component comprises a polyisobutylene-based TPE. 
     
     
         3 . The web of  claim 1 , wherein the TPE component comprises triblock copolymer having at least one elastomeric polyisobutylene block. 
     
     
         4 . The web of  claim 1 , wherein the TPE component comprises polystyrene-polyisobutylene-polystyrene (SIBS). 
     
     
         5 . The web of  claim 1 , wherein the TPE component comprises poly(alloocimene-b-isobutylene-b-alloocimene). 
     
     
         6 . The web of  claim 1 , wherein the TPE component has a structure selected from the group consisting of linear, star, arborescent, comb, brush, centipede, hyperbranched, and dendritic. 
     
     
         7 . The web of  claim 1 , wherein the soft elastomeric polymer component is selected from the group consisting of polyisobutylene, polyisobutylene-isoprene copolymers, polyisobutylene-styrene copolymers, polyisobutylene-alkyl styrene copolymers, halogenated polyisobutylene-alkyl styrene terpolymers, and combinations thereof. 
     
     
         8 . (canceled) 
     
     
         9 . The web of  claim 1 , wherein the soft elastomeric polymer component has a structure selected from the group consisting of linear, star, arborescent, comb, brush, centipede, hyperbranched, and dendritic. 
     
     
         10 . The web of  claim 1 , wherein the TPE is present in an amount from about 10% to about 90% by weight of the composite, and wherein the soft elastomeric polymer component is present in an amount from about 90 to about 10% by weight of the composite, based on the total weight of the composite. 
     
     
         11 . (canceled) 
     
     
         12 . The web of  claim 1 , wherein the filler is present in an amount from about 2% to about 40% by weight of the composite, such as from about 5% to about 30% by weight, based on the total weight of the composite. 
     
     
         13 . The web of  claim 1 , wherein the filler comprises an antimicrobial filler. 
     
     
         14 . The web of  claim 1 , wherein the antimicrobial filler is an inorganic material that comprises one more antimicrobial metals chosen from silver, copper, zinc, and combinations thereof. 
     
     
         15 . (canceled) 
     
     
         16 . The web of  claim 1 , wherein the population of fibers comprises population of fine fibers, a population of microfibers, a population of ultrafine microfibers, a population of sub-micrometer fibers, or any combination thereof. 
     
     
         17 . The web of  claim 1 , wherein the nonwoven fibrous web is formed as a single layer. 
     
     
         18 . The web of  claim 1 , wherein the nonwoven web is self-supporting. 
     
     
         19 . The web of  claim 1 , wherein the nonwoven fibrous web exhibits a water contact angle of at least 120°, as determined by goineometry. 
     
     
         20 . The web of  claim 1 , wherein the nonwoven web has a basis weight of at least 80 g/m 2 , such as a basis weight of at least 100 g/m 2 , at least 150 g/m 2 , or at least 200 g/m 2 . 
     
     
         21 . The web of  claim 1 , wherein the nonwoven web exhibits an average filtration efficiency relative to 20 nm to 450 nm NaCl particles of at least 60%, measured using the U.S. NIOSH (National Institute for Occupational Safety and Health) N95 Filtering Facepiece Respirator (FFR) certification method. 
     
     
         22 . (canceled) 
     
     
         23 . An article comprising a nonwoven fibrous web defined by  claim 1 , selected from the group consisting of a gas filtration article, a liquid filtration article, a sound absorption article, a surface cleaning article, a cellular growth support article, a drug delivery article, a personal hygiene article, and a wound dressing article. 
     
     
         24 . (canceled) 
     
     
         25 . A method of making a fibrous nonwoven web, the method comprising:
 forming a plurality of fibers from a composite comprising:
 (i) a thermoplastic elastomeric polymer (TPE) component; 
 (ii) a soft elastomeric polymer component that at ambient temperatures is above its glass transition temperature; and 
 (iii) optionally a filler; and 
   collecting at least a portion of the fibers to form a nonwoven web.   
     
     
         26 - 46 . (canceled)