Patent ID: 6319342
Filing Date: 2001-11-20
Classification: A61F,D04H

Abstract:
A method of forming a meltblown web, the method comprising:(a) forming at least one layer by the steps of:(i) forming a first primary stream containing meltblown fibers;(ii) forming a first secondary stream comprising staple fibers;(iii) merging the first primary stream and the first secondary stream so that the first primary stream comprises the staple fibers entangled with the meltblown fibers; and(iv) thereafter directing the first primary stream comprising the staple fibers entangled with the meltblown fibers onto a moving forming surface to form a first layer comprising the staple fibers entangled with the meltblown fibers;(b) forming at least one particle-containing layer by the steps of:(i) forming a second primary stream containing meltblown fibers;(ii) forming a first tertiary stream comprising heated particles;(iii) merging the second primary stream and the first tertiary stream so that the second primary stream comprises particle-containing meltblown fibers;(iv) forming a second secondary stream comprising staple fibers;(v) merging the second primary stream comprising particle-containing meltblown fibers and the second secondary stream so that the second primary stream comprises the staple fibers entangled with the particle-containing meltblown fibers; and(vi) thereafter directing the second primary stream comprising the staple fibers entangled with the particle-containing meltblown fibers onto the first layer on the moving forming surface to form a second layer comprising the staple fibers entangled with the particle-containing meltblown fibers.