PROCESS FOR MAKING A FIBROUS STRUCTURE CONTAINING IMMOBILIZED PARTICULATE MATTER

摘要

Fibrous structures containing immobilized particulate matter and processes for making them are disclosed. These structures may be used for filters and for fabrics including chemical defense garments and others. The fibrous structures have webs containing composite fibers having a lower melting component and a higher melting component. The particles are distributed into the interior of the web and fused to the low melting component of the individual fibers without substantially reducing the available surface area of the particle. A fibrous structure of a composite staple having a nylon sheath and a polyester core, with activated carbon particles bonded to the sheath is specifically disclosed. The processes for producing such a fibrous structure include carding a web of staple fibers and distributing particulate matter therein, air laying a web of staple fibers and distributing particulate matter therein, spin bonding a web of continuous filaments and distributing particulate matter therein, and wet forming a web of staple fibers and particulate from a suspension thereof between two wet formed layers of staple fibers. One or more additional layers of nonwoven, woven, or knit webs or fabrics may be bonded thereto.