Process for high performance, permeable fibrous structure
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United States of America Patent
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Jul 14, 1998
Grant Date -
N/A
app pub date -
Apr 22, 1996
filing date -
Apr 22, 1996
priority date (Note) -
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Abstract
A novel, high performance yet permeable, tough, fibrous structure, and a process for making the structure are disclosed. The fibrous structure includes a stabilized microstructure of improved uniformity of fiber and particulate distribution. Beneficially, the fibrous structure is of improved structural integrity and stiffness, as a result of being reduced in thickness. The process includes the steps of dry forming a fibrous web including crimped staple composite fibers, thereafter distributing and entrapping the functional particles in the web, and thereafter heating the fibrous web to form a microstructure-stabilized fibrous web. According to the process, the microstructure-stabilized fibrous web is thereafter by an additional heat treating step carried out without application of pressure to the web, heated to a thermoforming temperature, and thereafter the heated web is reduced in thickness and yet microstructural relative geometry is maintained. IR heat may be used. A nip gap is advantageously used to reduce the heated web in thickness.
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