Fibers with absorbent particles adhered thereto, methods for their production and articles thereof

Abstract

Composites where nonwoven fabrics having multicomponent synthetic fibers with adhered particles thereon are disclosed. The multicomponent fibers have at least one polymer component with a melting point below that of the other components, and the average apparent particle diameter is less than the average apparent fiber diameter. Methods of making the disclosed composites are also disclosed.

What is claimed is: 
     
         1 . A composite, comprising: multicomponent synthetic fibers, wherein the fibers comprise at least one exposed polymer and particles adhered to the exposed polymer,
 wherein that exposed polymer has a lower melting point than other components of the multicomponent fibers and,   wherein at least about 66% of the adhered particles have an apparent diameter that is less than the average apparent diameter of the multi-component fibers.   
     
     
         2 . The composite of  claim 1 , wherein at least about 75% of the particles have adhered to the surface of only one of the multicomponent fibers. 
     
     
         3 . The composite of  claim 1 , wherein the adhered particles are at least about 10 wt. % of the composite weight. 
     
     
         4 . The composite of  claim 1 , wherein the adhered particles are at least about 20 wt. % of the composite. 
     
     
         5 . The composite of  claim 1 , wherein the exposed polymer has a melting point at least about 20° C. lower than other constituents of the multicomponent fibers. 
     
     
         6 . The composite of  claim 1 , where the particles are metal organic frameworks. 
     
     
         7 . The composite of  claim 1 , where the multicomponent fibers are sheath:core, or island-in-the-sea, side-by-side, segmented pie, or tipped trilobal type fibers. 
     
     
         8 . The composite of  claim 1 , wherein at least about 75% of the adhered particles have an apparent diameter that is less than the average apparent diameter of the multicomponent fibers. 
     
     
         9 . The composite of  claim 1 , wherein at least about 90% of the adhered particles have an apparent diameter that is less than the average apparent diameter of the fibers. 
     
     
         10 . The composite of  claim 1 , wherein the adhered particles have an average apparent diameter that is about 75% smaller than the average apparent diameter of the fibers. 
     
     
         11 . The composite of  claim 1 , wherein the adhered particles have an average apparent diameter that is about 50% smaller than the average apparent diameter of the fibers. 
     
     
         12 . The composite of  claim 1 , wherein the adhered particles have an average apparent diameter that is about 25% smaller than the average apparent diameter of the fibers. 
     
     
         13 . The composite of  claim 1 , wherein the multicomponent fibers are in a nonwoven fabric. 
     
     
         14 . The composite of  claim 13 , wherein the nonwoven fabric is a spunbond, carded web, airlaid web, or wetlaid web. 
     
     
         15 . The composite of  claim 14 , wherein the nonwoven fabric is bonded by thermal point bonding or thru-air thermal bonding, needled entangled, hydro-entangled. 
     
     
         16 . The composite of  claim 14 , wherein the nonwoven fabric has a web porosity above about 90%. 
     
     
         17 . A method of forming a composite, comprising:
 a. heating multicomponent synthetic fibers, wherein the fibers comprise at least one exposed polymer having a lower melting point that other components of the multicomponent fibers, to a temperature where the at least one exposed polymer is molten;   b. contacting the heated multicomponent synthetic fibers with particles, such that the particles adhere to the exposed, molten polymer; and   c. cooling or allowing to cool the fibers with particles adhered thereto.   
       wherein at least about 66% of the adhered particles have an apparent diameter that is less than the average apparent diameter of the multi-component fibers. 
     
     
         18 . An article of clothing comprising the composite of  claim 1 .