CN1643202A - Nonwoven fabric with low ion content and method for its manufacture - Google Patents

Abstract

The invention relates to a nonwoven fabric with a relatively low content of ionic contaminants, which is realized by the following method: the fabric is washed with deionized water, preferably during the nonwoven production process, thereby eliminating or at least reducing the need for expensive and time consuming clean room washing. The fabric is primarily comprised of continuous filament fibers and can be made into end products such as cleaning wipes and protective clothing for use in surface coating operations in clean rooms and automotive paintrooms. The invention also includes a method of making a nonwoven fabric having a relatively low level of ionic contaminants.

Description

Nonwoven fabric with low ion content and method for its manufacture

technical field

The present invention relates to nonwovens having a relatively low content of ionic contaminants by washing the fabric with deionized water, preferably during the nonwoven production process, thereby eliminating or at least reducing the need for expensive And the need for time-consuming clean room washing. The fabric is mainly composed of continuous long fibers and can be made into end products such as cleaning wipes and protective clothing for cleanrooms and surface coating operations such as automotive paint booths. The invention also includes a method of making a nonwoven fabric having a relatively low content of ionic contaminants.

Background of the invention

Various fabrics have been manufactured in the past into wipes or wipes for many different cleaning purposes such as industrial clean rooms, preparing surfaces to be coated and general cleaning. Each of the different uses emphasizes that these types of wipes should meet certain standards. For example, wipes used in cleanrooms must meet stringent performance standards. These standards address sorption and contamination, including maximum allowable particulates, unspecified extractables, and individual ionic contaminants. The standards for the release of particulate pollutants are particularly stringent, and various methods have been devised to meet these standards. For example, US Patent No. 5,271,995 to Paley et al. describes wipes with fused edges that have sealed edges that reduce contamination from fibrils. US Patent No. 5,229,181 to Diaber et al. describes a tubular fabric in which only two edges must be cut and sealed, thereby reducing contamination from loose fibers on the edges. US Patent No. 5,271,995 to Paley et al. describes a wiper for use in a clean room environment that reduces inorganic contaminants through the use of a specific yarn, "nylon bright". US Patent No. 5,069,735 to Reynolds describes a method of cutting the fabric into pieces using a hot air jet at 600 to 800°F to melt the fibers, thereby forming an edge banding product with reduced loose fiber contamination.

In addition, finishes have been used to improve the absorption of wipes made of hydrophilic fibers such as polyester. For example, GB 2 142 225 A discloses a rag with a fabric substrate and a porous polymer coating, wherein the coating is a "sulfonated product of a cross-linked polymer containing sulfonated aromatic residues" made.

Ions such as Na, Li, _NH4 , K, Mg, Ca, Fl, Cl, _NO4 , _PO4 and _SO4 are generally inherent in fabrics. These ions can be harmful to cleanroom environments, especially in the semiconductor industry, because these ions: (a) migrate into silicon circuits; (b) corrode silicon circuits; (c) cause damage to silicon circuits short circuit in the It is known that deionized water can be used to reduce or remove these ions from fabrics so that they can be used, for example, in clean room applications. The deionized water acts as an attractant for the ions in the fabric, thereby drawing these ions off the fabric and into the water, which is then removed or filtered for reuse. Typically, fabrics, usually wipes, are washed using a clean laundry to reduce or remove ions, thereby reducing ion levels. However, this method is very expensive and time-consuming, and due to the environment the wipes are exposed to during the wash cycle, such as too vigorous agitation and rinsing and exposure to high temperature water and chemicals, the method can have negative effects on the physical properties of the fabric. negative effect.

Wipes can be made from knitted, woven or non-woven fabrics. The fabric is typically cut into 9 inch by 9 inch squares. If the wipe is to be used in a clean room environment, it is often necessary to launder the fabric or wipe in a clean laundry room prior to packaging to remove or minimize contamination of the wipe. Dust-free laundry can use specialized filters, surfactants, sequestrants, purified water, and more to remove oils, reduce particle counts, and extract undesirable ionic contaminants. As mentioned earlier, expensive and time-consuming washing processes are too aggressive and can adversely affect the physical properties of fabrics. For example, any finish applied to the surface of the fabric may be removed during laundering, and the edges of the fabric may become unraveled or frayed, thereby causing an undesirable increase in fiber particle contamination. Therefore, the washing equipment used must be carefully and continuously monitored to control agitation, the amount and duration of rinsing, and the speed and duration of extraction.

As interest in the industry has increased, manufacturers have endeavored to develop new yarns and fabrics that can easily and cost-effectively meet the demand for contaminant-free fabrics. Such advances have already been made in the field of spunbond nonwovens. Spunbond nonwoven production methods are well known in the field of fabric technology and are described in various patents, for example, U.S. Patent No. 4,692,618 to Dorschner et al; U.S. Patent No. 4,340,563 to Appel et al; U.S. Patent No. Patent No. 3,338,992; US Patent No. 3,341,394 to Kinney; and US Patent No. 3,502,538 to Levy. In the past, nonwoven webs made by these methods have been used in a variety of end uses, such as air filters, vehicle trunk linings, and roofing materials, with relatively low cost and little or no emphasis on Properties such as drapability, handle and moisture absorption capacity are of considerable importance for cleanroom wipes and protective clothing.

However, recent developments in the field of spunbond fiber production have made it possible to produce nonwovens with improved drape, hand and moisture absorption properties ("hand" generally describes a fabric's tactile properties such as softness, firmness, elasticity, etc.). For example, U.S. Patents 5,899,785 and 5,970,583, both assigned to Firma Cari Freudenberg, describe a spunbond nonwoven roll of very fine continuous filaments and a method of making such a nonwoven roll using conventional spunbond nonwoven manufacturing processes. These references disclose spunbond composite fibers or multicomponent fibers that can be longitudinally split into microdenier sized fibers by mechanical or chemical action as an important raw material. However, although this method of nonwoven production is less expensive and simpler than similar knitting or weaving methods, fabrics made from it may need to be processed in a clean laundry Requirements for wipers in paint rooms.

Therefore, there is a need for an efficient and cost-effective method of producing nonwovens with relatively low levels of particle contamination and sufficient handle, drape, and and hygroscopic properties.

Summary of the invention

According to the foregoing, it is an object of the present invention to obtain a non-woven fabric with a low ionic content which is suitable for use as a wipe or protective clothing in clean rooms or surface coating operations such as automotive paint booths. The fabric is typically composed of synthetic continuous filaments, and more specifically, multicomponent continuous filaments that can be cleaved along their length by chemical or mechanical action, which generally enhances the fabric's handle, drape and moisture absorption properties . The fabric is typically obtained by rinsing the nonwoven material with deionized water, preferably during the nonwoven production process. The deionized fabrics are then further processed into, for example, various sized wipes or protective clothing that meet or exceed cleanroom or surface coating operations without the need for a cleanroom laundering process, saving considerable time and effort. cost, and protects the finishing properties of the fabric.

Another object of the present invention is to obtain a method for the production of nonwovens with a low ion content suitable for use as wipes or protective clothing in clean rooms or in surface coating operations such as automotive paint booths. Typically, nonwovens are manufactured according to various nonwoven manufacturing methods known to those skilled in the art. The fabric is then rinsed with deionized water, dried and taken-up, preferably through an in-line production process. Thereafter, the fabric is further processed into cleaning wipes or protective clothing. The wipes and/or protective garments can then be used for cleanroom and surface coating applications without the need for a cleanroom laundering process, thereby saving considerable time and expense, and preserving the finishing properties of the fabric.

Other objects, advantages and features of the invention will occur to those skilled in the art. Therefore, while the invention will be described and disclosed in terms of certain preferred embodiments and procedures, these are not intended to limit the scope of the invention. On the contrary, all such alternative embodiments, procedures and modifications are considered to be included within the scope and spirit of the disclosed invention and are to be limited only by the appended claims and their equivalents.

Detailed description of the invention

The present invention discloses nonwoven fabrics with reduced ion content, which can be incorporated into articles for clean room and surface coating operations, and methods of making such fabrics. The fabric is first produced according to standard nonwoven manufacturing methods known to those skilled in the art. These production methods include spunbonding, melt blowing, wet forming, dry forming, thermal bonding, instant spinning, SMS (which is a combination of spunbonding, melt blowing and spunbonding) ), SMMS (which is a combination of spunbond, melt blown, melt blown and spunbond), and combinations thereof.

The fabric may be composed of continuous filaments, which may be single monocomponent fibers, multicomponent fibers, or any combination thereof. Multicomponent fibers can be split along their length either mechanically or chemically. For example, U.S. Patents 5,899,785 and 5,970,583, both assigned to Firma Carl Freudenberg and both incorporated herein by reference, describe spunbond nonwoven rolls of very fine continuous filaments and the manufacture of such nonwovens using conventional spunbond nonwoven manufacturing processes. The cloth roll method. These references disclose as important raw materials spunbond composite fibers or multicomponent fibers which can be split longitudinally by mechanical or chemical action. An example of mechanical action includes treating spunbond nonwoven rolls or fabrics made of these materials with high pressure water jets (ie, hydroentanglement) to split multicomponent long fibers into individual fibers.

These fibers may be of various fiber sizes, but they are preferably characterized by a fiber size below 5 denier. Furthermore, when extruded as multicomponent fibers, these fibers are preferably characterized by an individual fiber size of less than 1 denier.

These fibers can include a variety of fiber types including polyesters such as polyethylene terephthalate, polytriphenylene terephthalate and polybutylene terephthalate; polyamide , such as nylon 6 and nylon 6,6; polyolefins, such as polypropylene, polyethylene, and the like; polyaramids, such as Kevlar(R); polyurethane; polylactic acid; and any combination thereof.

After the nonwoven is made, it is typically rinsed with deionized water to remove ions from the fabric. The rinsing treatment carried out during the nonwoven production process is preferred, however, it can also be carried out separately from the nonwoven production process. Deionized water rinsing can be accomplished by dipping, padding, spraying, or any other technique that can apply a controlled amount of liquid to the fabric. If, for example, a spray bar is used for the deionized water rinse, a vacuum nozzle can be used with the spray bar to remove excess water from the fabric. After rinsing with deionized water, the fabric was dried. Drying may be accomplished by heating the fabric, drying the fabric at room temperature, or any combination thereof. Heating can be accomplished by any technique typically used in fabric manufacturing, such as dry heat from a tenter frame, microwave energy, infrared heating, steam, superheated steam, autoclave treatment, etc., or any combination thereof. In choosing a drying method that involves the use of heat, it is preferred to dry the fabric at a temperature of 300°F or less, especially if the fabric is at least partially composed of polyester. Commonly assigned U.S. Patent No. 6,189,189 (incorporated herein by reference) discloses a method for eliminating or reducing low molecular weight polymers or oligomers (also known as A method for the formation of "trimeric particles" that proliferate to the fabric surface when exposed to high heat-setting temperatures) to produce low-soiling wipes with high absorption. When these trimer particles are released from the fabric surface, they can detrimentally increase particle contamination.

After drying, the fabric is usually rolled or exported and can be further processed into various end products, for example wipes of various sizes or protective clothing. Wipes, while ideal for use in cleanrooms or in areas where surface coatings are performed, can also be used in a variety of end uses where it is preferable to use fabrics with low particle contamination. In addition, protective clothing such as sterile shoes, gowns, aprons, masks, gloves that are required in clean room or surface coating environments can be used in other industries such as hospital operating rooms, dental offices, veterinary surgery, Or any other industry that requires low-staining fabrics. These end uses can include sterile drapes, drapes, blankets, dentist bibs, gauze, bandages, tape, and the like.

In a potentially preferred, non-limiting embodiment of the present invention, it is desirable to subject the nonwoven to a mechanical process that increases the thickness and water absorption properties of the fabric. Commonly assigned U.S. Patents 4,837,902, 4,918,785, 5,822,835, and 6,178,607, which are incorporated herein by reference, describe fabric conditioning methods that divert low-pressure, high-velocity gaseous fluid flow from Spray in all directions onto the fabric mesh. This gas impingement method typically produces zigzag corrugations with small bend radii that extend down into the fabric, thereby breaking or weakening some of the fiber-fiber connections in the mesh structure, thereby enhancing the fabric's hand, drapability , thickness and moisture absorption properties. This method can be added to the nonwoven production process before or after the deionized water rinse process. For example, in the manufacture of spunbond nonwovens, the gas impingement process is performed on the fabric while it is still wet after the hydroentangling step. The nonwoven was then rinsed with deionized water and dried as previously described.

Another potentially preferred embodiment involves hydroentanglement of the fibers of the nonwoven, preferably spunbond nonwoven, using deionized water, rather than tap water. The fabric may be hydroentangled with deionized water from high velocity water jets, and then subjected to one or more of the following treatments in any order: a) gas impingement, b) further rinsing with deionized water, and c) drying .

In another potentially preferred, non-limiting embodiment of the present invention, it is desirable to add chemical finishes to the surface of the fabric to enhance aesthetics and performance properties such as water absorption, water repellency, particle attraction, etc. The chemical finish can be applied at any time after the fabric is formed. The chemical finish is preferably added after the hydroentanglement process and, if desired, after the gas impingement process, but typically before the final deionized water rinse. The chemical agent may be applied to the fabric by dipping, padding, spraying, foam coating, or any other technique that can apply a controlled amount of a liquid suspension to an article. Using one or more of these techniques allows the chemical to be evenly applied to the fabric. An example of chemicals that may be used is disclosed in commonly assigned International Publication WO 01/80706. This publication discloses a particle attracting finish that can be applied to fabrics to attract and remove particulate contamination from the surface.

The following examples illustrate various specific embodiments of the invention and are not intended to limit the scope of the invention.

All examples used 100 g/m2 spunbond nonwovens composed of continuous multicomponent splittable fibers that had been hydroentangled with high pressure water as described in the two previously cited Freudenberg patents. Knotting is performed to at least partially split the multicomponent fibers along their length into individual polyester and nylon 6,6 fibers. A fabric known by its product name Evolon(R) was obtained from Firma Carl Freudenberg of Weinheim, Germany. The fabric is composed of approximately 65% polyester fibers and approximately 35% nylon 6,6 fibers. The fabric is typically available in at least two variants, standard and point-bonded. The standard variant has not been subjected to further bonding treatments such as end gluing. End bonding is the process of bonding thermoplastic fibers into a nonwoven by heat and pressure to form a discrete fiber bond.

The fabrics described in the examples were tested for ion content before and after rinsing with deionized water according to Test Method IEST-RP-CC-004 §6.1.2.

Example 1:

A standard 9 inch by 9 inch piece of Evolon(R) fabric was placed in a beaker of deionized water and stirred for approximately 10 seconds. Remove the fabric from the beaker and squeeze excess water from the fabric with gloved hands. The fabric is then tested for its ion content in a wet state. The results are measured in parts per billion (ppb) and are listed in Table 1 below.

Table 1

Ion content of standard Evolon® fabrics before and after rinsing in deionized (DI) water Ions Before DI Rinse (ppb) After DI Rinse (ppb) Na 149,200 <1Li <1 <1NH ₄ <1 <1K <1 <1Mg <1 <1Ca 19,833 3420Fl 1100 347Cl 76,396 120NO ₄ 34,367 <1PO ₄ <1 493SO ₄ 37,333 940

The results in Table 1 show that the ionic content of Li, NH ₄ , K and Mg did not change, while that of PO ₄ increased. The increase in PO ₄ may have originated from the gloves worn by the person performing the fabric test. This can be reduced or eliminated by manipulating the fabric with nalgeen forceps or by having the person performing the test wear another type of glove. However, Table 1 also shows that the ion contents of Na, Ca, Fl, Cl, _NO4 , and _SO4 were all significantly reduced. These results demonstrate the effectiveness of washing nonwovens with deionized water to remove ions from the nonwovens, thereby eliminating or at least reducing the need for expensive and time-consuming washes in a clean laundry room. Specifically, fabrics of the present invention achieved low ion levels of less than about 10,000 ppb for each of the ions shown in Table 1 after rinsing with deionized water. More preferably, the fabrics of the present invention achieve an ion concentration of less than about 5,000 ppb for each of the ions shown in Table 1 after rinsing with deionized water.

Example 2:

Example 1 was repeated, but the fabric used was the Evolon(R) end-bonded type (instead of the standard type). The results are measured in parts per billion (ppb) and are listed in Table 2 below.

Table 2

Ion content of end-bonded Evolon® fabrics before and after rinsing with deionized (DI) water Ions Before DI Rinse (ppb) After DI Rinse (ppb) Na 150,700 2567Li <1 <1NH ₄ <1 <1K <1 <1Mg <1 <1Ca 21,333 4707Fl <1 273Cl 81,200 1347NO ₄ 21,933 <1PO ₄ <1 760SO ₄ 37,096 1407

The results in Table 2 show that the ion contents of Li, _NH4 , K and Mg did not change, while those of _PO4 and Fl increased. As mentioned above, the increase in PO ₄ may originate from the gloves worn by the person performing the fabric test. This can be reduced or eliminated by manipulating the fabric with nalgeen forceps or by having the person performing the test wear another type of glove. However, Table 2 shows that the ion contents of Na, Ca, Cl, _NO4 , and _SO4 were all significantly reduced. Likewise, these results also demonstrate the effectiveness of washing nonwovens with deionized water to remove ions from the nonwovens, thereby eliminating or at least reducing the need for costly and time-consuming washes in a dust-free laundry . Specifically, fabrics of the present invention achieved low ion levels of less than about 10,000 ppb for each of the ions shown in Table 2 after rinsing with deionized water. More preferably, the fabrics of the present invention achieve an ion concentration of less than about 5,000 ppb for each of the ions shown in Table 2 after rinsing with deionized water.

The method of rinsing fabrics in deionized water to reduce or remove ion content may also be applied to woven or knitted fabrics and is considered to be within the scope of this invention. The deionized water rinse may be performed in a separate process from the weaving or knitting machines, as the manufacturing schemes commonly used for these fabric manufacturing processes usually require a large number of machines arranged symmetrically together, and water is not usually a major part of these fabric production processes.

In addition, the fabrics of the present invention can be incorporated into composite materials such that the composite material consists of one or more layers of deionized fabric laminated together with one or more layers of polymeric film. Nonwoven, woven and knitted fabrics can also be part of composites. These composites also have end uses in products such as graphite composite laminates for space shuttles in the aerospace industry, where contamination is a major concern because contaminants in this environment can interact with liquid Oxygen reacts and catches fire or explodes.

The above description and examples disclose the nonwoven fabric of the present invention having a low ion content and the method for producing such a nonwoven fabric. After the nonwoven production process, preferably during the production process, the nonwoven is rinsed in deionized water, whereby a low ion content is obtained. Advantageously, this is achieved without the use of dust-free washing, which typically adds cost, complexity and time consumption to the production process. Additionally, the method can be used with other chemical or mechanical methods to produce nonwovens with improved aesthetics and/or performance characteristics. Thus, the present invention provides extended use for cleanrooms, surface coating operations and the medical, dental and veterinary industries, such that the fabrics of the present invention can be incorporated into wipes, protective clothing, sterile drapes, drapes, drapes, bandages and any other product that needs to be made into a final product with a low ionic content.

These and other modifications and variations of this invention may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the invention. Furthermore, those of ordinary skill in the art will understand that the foregoing description is by way of example only, and is not intended to limit the scope of the invention described in the appended claims.

Claims (59)

1. A method of providing a nonwoven fabric with a low ion content, wherein said ions are selected from the group consisting of Na, Li, NH ₄ , K, Mg, Ca, Fl, Cl, NO ₄ , PO ₄ and SO ₄ , and wherein When tested according to test method IEST-RP-CC-004 §6.1.2, the ion on the fabric is less than about 10,000 ppb. The method includes the following steps: (a) provide non-woven fabrics; (b) optionally, subjecting the nonwoven to a gas impingement surface treatment; (c) Optionally, a chemical agent is applied to the surface of the non-woven fabric; (d) rinsing the nonwoven fabric with deionized water; and (e) The nonwoven fabric is dried. 2. The method according to claim 1, wherein the nonwoven fabric is rinsed with deionized water during the production of the nonwoven fabric. 3. The method of claim 1, wherein the nonwoven fabric is comprised of fibers, and wherein the fibers are selected from the group consisting of single monocomponent fibers, multicomponent fibers, and combinations thereof. 4. The method of claim 3, wherein the nonwoven fabric is comprised of fibers, and wherein the fibers are characterized by a fiber size of less than 5 denier. 5. The method of claim 3, wherein the nonwoven fabric is made of fibers, and wherein the fibers are multicomponent fibers, and wherein the multicomponent fibers can be split along their length by mechanical or chemical action single component fibers. 6. The method of claim 5, wherein the multicomponent fibers can be split mechanically or chemically along their length into monocomponent fibers, and wherein the monocomponent fibers are characterized by a fiber size of less than 1 denier. 7. The method of claim 3, wherein the nonwoven fabric is composed of fibers selected from the group consisting of polyester, polyamide, polyolefin, polyaramid, polyurethane, polylactic acid, and combinations thereof. 8. The method of claim 7, wherein the non-woven fabric is made of fibers, wherein the fibers are polyester, and wherein the polyester is selected from the group consisting of polyethylene terephthalate, polybenzone terephthalate Phenanthrene esters, polybutylene terephthalate, and combinations thereof. 9. The method of claim 7, wherein the nonwoven fabric is composed of fibers, wherein the fibers are polyamides, and wherein the polyamides are selected from the group consisting of nylon 6 and nylon 6,6 and combinations thereof. 10. The method of claim 7, wherein the nonwoven fabric is comprised of fibers, wherein the fibers are polyolefins, and wherein the polyolefins are selected from the group consisting of polypropylene, polyethylene, and combinations thereof. 11. The product of the method of claim 1. 12. A method of providing a nonwoven fabric with low ion content, wherein said ions are selected from Na, Li, NH ₄ , K, Mg, Ca, Fl, Cl, NO ₄ , PO ₄ and SO ₄ , and wherein When tested according to test method IEST-RP-CC-004 §6.1.2, the ion on the fabric is less than about 5,000 ppb, which method includes the following steps: (a) provide non-woven fabrics; (b) optionally, subjecting the nonwoven to a gas impingement surface treatment; (c) Optionally, a chemical agent is applied to the surface of the non-woven fabric; (d) rinsing the nonwoven fabric with deionized water; and (e) The nonwoven fabric is dried. 13. The product of the method of claim 12. 14. A method of providing a spunbond nonwoven fabric having a low ion content and consisting of continuous multicomponent fibers, wherein the multicomponent fibers are at least partially split into single component fibers along their length, wherein the ion selected From Na, Li, NH ₄ , K, Mg, Ca, Fl, Cl, NO ₄ , PO ₄ and SO ₄ , and when tested according to the test method IEST-RP-CC-004 §6.1.2, the ions on the fabric Less than about 10,000 ppb, the method includes the following steps: (a) providing a spunbond nonwoven comprising continuous multicomponent fibers at least partially split along their length into single component fibers; (b) optionally subjecting the spunbond nonwoven to a gas impingement surface treatment; (c) Optionally, coating a chemical agent on the surface of the spunbond nonwoven fabric; (d) rinsing the spunbond nonwoven with deionized water; and (e) The spunbonded nonwoven fabric is dried. 15. The method of claim 14, wherein the spunbond nonwoven is rinsed with deionized water during the production of the spunbond nonwoven. 16. The method of claim 14, wherein the ions on the fabric are less than about 5,000 ppb when tested according to Test Method IEST-RP-CC-004 §6.1.2. 17. The method of claim 14, wherein the continuous multicomponent fibers are characterized by a fiber size of less than 5 denier. 18. The method of claim 14, wherein the monocomponent fibers are characterized by a fiber size of less than 1 denier. 19. The method of claim 14, wherein the spunbond nonwoven fabric is made of fibers, and wherein the fibers are selected from the group consisting of polyester, polyamide, polyolefin, polyaramid, polyurethane, polylactic acid, and combinations thereof thing. 20. The method of claim 19, wherein the spunbond nonwoven is comprised of polyolefin, and wherein the polyolefin is selected from the group consisting of polypropylene, polyethylene, and combinations thereof. 21. The method as claimed in claim 19, wherein the spunbonded nonwoven fabric is made of polyester, and wherein the polyester is selected from the group consisting of polyethylene terephthalate, polytriphenylene terephthalate, Polybutylene terephthalate and combinations thereof. 22. The method of claim 19, wherein the spunbond nonwoven is comprised of polyamide, and wherein the polyamide is selected from the group consisting of nylon 6, nylon 6,6, and combinations thereof. 23. The method of claim 22, wherein the spunbond nonwoven fabric is composed of polyester and nylon 6,6. 24. The method of claim 23, wherein the spunbond nonwoven fabric is composed of polyester and nylon 6,6, wherein polyester accounts for about 65% of the spunbond nonwoven fabric, and nylon 6,6 accounts for about 65% of the spunbond nonwoven fabric. About 35% of the non-woven fabric is bonded. 25. The product of the method of claim 14. 26. A non-woven fabric with low ion content, wherein said ions are selected from Na, Li, NH ₄ , K, Mg, Ca, Fl, Cl, NO ₄ , PO ₄ and SO ₄ , and wherein according to the test method The fabric had less than about 10,000 ppb of ions when tested in IEST-RP-CC-004 §6.1.2. 27. The nonwoven fabric of claim 26, wherein the nonwoven fabric is composed of continuous long fibers, and wherein the fibers are selected from the group consisting of single monocomponent fibers, multicomponent fibers, and combinations thereof. 28. The nonwoven fabric of claim 27, wherein the fibers are characterized by a fiber size of less than 5 denier. 29. The nonwoven fabric of claim 27, wherein the fibers are multicomponent fibers, and wherein the multicomponent fibers can be mechanically or chemically split into single component fibers along their length. 30. The nonwoven fabric of claim 29, wherein the monocomponent fibers are characterized by a fiber size of less than 1 denier. 31. The nonwoven fabric of claim 27, wherein the nonwoven fabric is composed of fibers selected from the group consisting of polyester, polyamide, polyolefin, polyaramid, polyurethane, polylactic acid, and combinations thereof. 32. The nonwoven fabric as claimed in claim 31, wherein the fibers are polyester, and wherein the polyester is selected from the group consisting of polyethylene terephthalate, polytriphenylene terephthalate, polyethylene terephthalate Butanediol esters and combinations thereof. 33. The nonwoven fabric of claim 31, wherein the fibers are polyamides, and wherein the polyamides are selected from the group consisting of nylon 6, nylon 6,6, and combinations thereof. 34. The nonwoven fabric of claim 31, wherein the fibers are polyolefins, and wherein the polyolefins are selected from the group consisting of polypropylene, polyethylene, and combinations thereof. 35. The nonwoven fabric of claim 26, wherein the nonwoven fabric is incorporated into a composite material, wherein one or more layers of nonwoven fabric are laminated with one or more layers of polymer film. 36. The nonwoven fabric of claim 35, wherein the composite material further comprises one or more layers of woven or knitted fabric. 37. The nonwoven fabric of claim 26, wherein the nonwoven fabric is incorporated into an article for clean room applications. 38. The nonwoven fabric of claim 26, wherein the nonwoven fabric is incorporated into an article for surface coating service applications. 39. The nonwoven fabric of claim 26, wherein the nonwoven fabric is incorporated into an article for hospital operating room applications. 40. The nonwoven fabric of claim 26, wherein the nonwoven fabric is incorporated into an article for use in a dental office. 41. The nonwoven fabric of claim 26, wherein the nonwoven fabric is incorporated into an article for veterinary operating room applications. 42. A non-woven fabric with low ion content, wherein said ions are selected from Na, Li, NH ₄ , K, Mg, Ca, Fl, Cl, NO ₄ , PO ₄ and SO ₄ , and wherein according to the test method The fabric had less than about 5,000 ppb of ions when tested in IEST-RP-CC-004 §6.1.2. 43. A spunbond nonwoven having a low ion content and consisting of continuous multicomponent fibers at least partially split along their length into single component fibers, wherein said ions are selected from the group consisting of Na, Li, NH ₄ , K, Mg, Ca, Fl, Cl, NO ₄ , PO ₄ and SO ₄ , and wherein the ions on the fabric are less than about 10,000ppb. 44. The spunbond nonwoven fabric of claim 43, wherein the ions on the fabric are less than about 5,000 ppb when tested according to Test Method IEST-RP-CC-004 §6.1.2. 45. The spunbond nonwoven of claim 43, wherein the multicomponent fibers are characterized by a fiber size of less than 5 denier. 46. The spunbond nonwoven of claim 43, wherein the monocomponent fibers are characterized by a fiber size of less than 1 denier. 47. The spunbonded nonwoven fabric as claimed in claim 43, wherein the spunbonded nonwoven fabric is made of fibers selected from polyester, polyamide, polyolefin, polyaramid, polyurethane, polylactic acid and their combinations of. 48. The spunbond nonwoven of claim 47, wherein the fibers are polyolefins, and wherein the polyolefins are selected from the group consisting of polypropylene, polyethylene, and combinations thereof. 49. The spunbonded nonwoven fabric of claim 47, wherein the fibers are polyester, and wherein the polyester is selected from the group consisting of polyethylene terephthalate, polytriphenylene terephthalate, polyethylene terephthalate Butylene glycol dicarboxylates and combinations thereof. 50. The spunbond nonwoven of claim 47, wherein the fibers are polyamides, and wherein the polyamides are selected from the group consisting of nylon 6, nylon 6,6, and combinations thereof. 51. The spunbond nonwoven fabric of claim 50, wherein the spunbond nonwoven fabric is composed of polyester and nylon 6,6. 52. The spunbond nonwoven fabric of claim 51, wherein the spunbond nonwoven fabric is made of polyester and nylon 6,6, wherein polyester accounts for about 65% of the spunbond nonwoven fabric, wherein nylon 6 , 6 accounts for about 35% of spunbond nonwovens. 53. The spunbond nonwoven of claim 43, wherein the spunbond nonwoven is incorporated into a composite wherein one or more layers of the spunbond nonwoven are laminated with one or more polymer films together. 54. The spunbonded nonwoven fabric of claim 53, wherein the composite material further comprises one or more layers of woven or knitted fabric. 55. The spunbond nonwoven of claim 43, wherein the spunbond nonwoven is incorporated into an article for clean room applications. 56. The spunbond nonwoven of claim 43, wherein the spunbond nonwoven is incorporated into an article for surface coating service applications. 57. The spunbond nonwoven of claim 43, wherein the spunbond nonwoven is incorporated into an article for hospital operating room applications. 58. The spunbond nonwoven of claim 43, wherein the spunbond nonwoven is incorporated into an article for dental office applications. 59. The spunbond nonwoven of claim 43, wherein the spunbond nonwoven is incorporated into an article for veterinary operating room applications.