Method of stabilizing composite media and media produced thereby

Abstract

There is provided composite media and a method of producing them. The composite media contain a coalesced composite mixture of particles of an active ingredient and binder particles. The binder particles preferably also fuse the composite structure to front and back substrates. The composite media also have stabilizing particles that fuse with both the particles of an active ingredient and the substrates, thereby forming a composite medium according to the present invention.

What is claimed is:  
     
         1 . A composite medium comprising: 
 a backing sheet;    a covering sheet; and    a layer disposed between said backing sheet and said covering sheet, said layer having particles of an active ingredient, binder particles and stabilizing particles, wherein said active particles are coalesced by said binder particles, and wherein each of said stabilizing particles forms a bond with both said backing sheet and said covering sheet.    
     
     
         2 . The composite medium of  claim 1 , wherein said backing sheet is an impermeable material.  
     
     
         3 . The composite medium of  claim 1 , wherein said backing sheet is a permeable material.  
     
     
         4 . The composite medium of  claim 1 , wherein said covering sheet is a permeable material.  
     
     
         5 . The composite medium of  claim 1 , wherein said composite layer has an average thickness of about 0.2 mm to 5 mm.  
     
     
         6 . The composite medium of  claim 1 , wherein said particles of an active ingredient are formed from at least one component selected from the group consisting one of: adsorbent particles, absorbent particles, particles that release liquid or gases held therein, and mixtures thereof.  
     
     
         7 . The composite medium of  claim 1 , wherein said particles of an active ingredient are formed from at least one component selected from the group consisting one of: iodinated resin, activated carbon, activated alumina, alumina-silicates, ion-exchange resins, manganese oxides, iron oxides, zeolites, hydrophilic polymeric materials, and mixtures thereof.  
     
     
         8 . The composite medium of  claim 1 , wherein said particles of an active ingredient have an average particle size of between about 5 microns to 5000 microns.  
     
     
         9 . The composite medium of  claim 1 , wherein said binder particles are formed from at least one component selected from the group consisting one of thermoplastic materials, thermoset materials, and combinations thereof.  
     
     
         10 . The composite medium of  claim 1 , wherein said binder particles are formed from at least one component selected from the group consisting of: polypropylene, linear low-density polyethylene, low density polyethylene, ethylene-vinyl acetate copolymer, polyolefin, phenol-formaldehyde resin, melamine resin, and mixtures thereof.  
     
     
         11 . The composite medium of  claim 1 , wherein said binder particles have an average particle size of between about 5 microns to 50 microns.  
     
     
         12 . The composite medium of  claim 1 , wherein said stabilizing particles are formed from at least one component selected from the group consisting of thermoplastic materials, thermoset materials, and combinations thereof.  
     
     
         13 . The composite medium of  claim 1 , wherein said stabilizing particles are formed from at least one component selected from the group consisting of polypropylene, linear low-density polyethylene, low density polyethylene, ethylene-vinyl acetate copolymer, polyolefin, phenol-formaldehyde resin, melamine resin, and mixtures thereof.