Particle-containing meltblown webs

Abstract

A meltblown web having meltblown fibers and particles is provided. The particles are embedded in and retained by one or more meltblown fibers as a result of surface penetration of the particles into one or more meltblown fibers. The surface penetration of any particle into one or more meltblown fibers is generally slight thus leaving a substantial amount of the surface area of any particle available for interaction with any medium to which the web is exposed.

We claim:  
     
         1 . A substantially nondusting meltblown web, comprising: 
 (a) at least one air-formed nonparticle-containing layer comprising meltblown fibers and staple fibers, the staple fibers engaging at least some of the meltblown fibers to space the meltblown fibers apart from each other, and the staple fibers being retained within the nonparticle-containing layer by entanglement with the meltblown fibers; and    (b) at least one air-formed particle-containing layer comprising meltblown fibers, particles and staple fibers, the particles being retained in the particle-containing layer by surface penetration into the meltblown fibers, the staple fibers engaging at least some of the meltblown fibers to space the meltblown fibers apart from each other, and the staple fibers being retained within the particle-containing layer by entanglement with the meltblown fibers.    
     
     
         2 . The web of  claim 1 , wherein the particle-containing layer comprises about 0.1 to about 80%, by weight, particles.  
     
     
         3 . The web of  claim 1 , wherein the particles are heat-stable particles.  
     
     
         4 . The web of  claim 1 , wherein the staple fibers are wood fibers.  
     
     
         5 . The web of  claim 1  being die-cuttable.  
     
     
         6 . The web of  claim 1 , further comprising at least one particle-containing layer between at least two nonparticle-containing layers.  
     
     
         7 . The web of  claim 6 , wherein the particles are heat-stable particles.  
     
     
         8 . The web of  claim 6 , wherein the staple fibers are wood fibers.  
     
     
         9 . The web of  claim 6  being die-cuttable.  
     
     
         10 . A substantially nondusting meltblown web, comprising at least one air-formed layer comprising meltblown fibers and particles, the particles being retained within the layer by surface penetration into the meltblown fibers.  
     
     
         11 . The web of  claim 10 , wherein the particles are heat-stable particles.  
     
     
         12 . The web of  claim 10  being die-cuttable.  
     
     
         13 . A substantially nondusting meltblown web, comprising at least one layer comprising meltblown fibers, particles and staple fibers, the particles being retained within the layer by surface penetration into the meltblown fibers, the staple fibers engaging at least some of the meltblown fibers to space the meltblown fibers apart from each other, and the staple fibers being retained within the layer by entanglement with the meltblown fibers.  
     
     
         14 . The web of  claim 13 , wherein the particle containing layer comprises about 0.1 to about 80%, by weight, particles.  
     
     
         15 . The web of  claim 13 , wherein the particles are heat-stable particles.  
     
     
         16 . The web of  claim 13 , where the staple fibers are wood fibers.  
     
     
         17 . The web of  claim 13  being die-cuttable.