Articles including multi-component fibers and particles and methods of making and using the same

Abstract

An article including multi-component fibers and particles is disclosed. The multi-component fibers include at least a first polymeric composition and a second polymeric composition, are adhered together, and are non-fusing at a temperature of at least 110° C. At least a portion of the external surfaces of the multi-component fibers includes the first polymeric composition. Particles are adhered or directly attached to the first polymeric composition on the external surfaces of at least some of the multi-component fibers along their lengths. The particles include at least one of activated carbon, superabsorbent polymer particles, and abrasive particles. In some embodiments, the particles are distributed throughout the thickness of a web of the multi-component fibers. A method of making the articles is also disclosed.

1 . An article comprising:
 multi-component fibers having external surfaces and comprising at least a first polymeric composition and a second polymeric composition, wherein at least a portion of the external surfaces of the multi-component fibers comprises the first polymeric composition, and wherein the multi-component fibers are adhered together and are non-fusing at a temperature of at least 110° C.; and   particles adhered at least to the first polymeric composition on the external surfaces of at least some of the multi-component fibers along their lengths, wherein the particles comprise at least one of activated carbon or superabsorbent polymer particles.   
     
     
         2 . An article comprising:
 a web of multi-component fibers having external surfaces and comprising at least a first polymeric composition and second polymeric composition, wherein at least a portion of the external surfaces of the multi-component fibers comprises the first polymeric composition, and wherein the multi-component fibers are adhered together and are non-fusing at a temperature of at least 110° C.; and   particles directly attached to the first polymeric composition on the external surfaces of at least some of the multi-component fibers along their lengths, wherein the particles comprise at least one of activated carbon, superabsorbent polymer particles, or abrasive particles, and wherein the particles are distributed throughout the thickness of the web.   
     
     
         3 . The article of  claim 2 , wherein the article is an abrasive article, wherein the particles are abrasive particles, and wherein the abrasive article does not include a size coat. 
     
     
         4 . The article of  claim 2 , wherein the particles are abrasive particles comprising cerium oxide. 
     
     
         5 . The article of  claim 1 , wherein the article is a filter comprising activated carbon. 
     
     
         6 . The article of  claim 2 , wherein the first polymeric composition has a softening temperature of up to 150° C., wherein the second polymeric composition has a melting point of at least 130° C., and wherein the difference between the softening temperature of the first polymeric composition and the melting point of the second polymeric composition is at least 10° C. 
     
     
         7 . The article of  claim 2 , wherein the first polymeric composition has an elastic modulus of less than 3×10 5  N/m 2  at a temperature of at least 80° C. measured at a frequency of one hertz. 
     
     
         8 . The article of  claim 2 , wherein the multi-component fibers are in a range from 10 micrometers to 300 micrometers in diameter and in a range from 3 millimeters to 60 millimeters in length. 
     
     
         9 . The article of  claim 2 , wherein the multi-component fibers are non-fusing at a temperature of at least 150° C. 
     
     
         10 . The article of  claim 2 , further comprising other, different fibers. 
     
     
         11 . The article of  claim 2 , wherein the particles have an average size up to twenty-five micrometers. 
     
     
         12 . A method of making an article, the method comprising:
 providing a mixture of particles and multi-component fibers, the multi-component fibers comprising at least a first polymeric composition and a second polymeric composition, and the particles comprising at least one of activated carbon, superabsorbent polymer particles, or abrasive particles; and   heating the mixture to a temperature at which the multi-component fibers are non-fusing and at which the first polymeric composition has an elastic modulus of less than 3×10 5  N/m 2  when measured at a frequency of one hertz, wherein at least a portion of the mixture becomes adhered together to form a web, and wherein the particles are dispersed throughout the thickness of the web.   
     
     
         13 . The method of  claim 12 , wherein the temperature is at least 80° C. 
     
     
         14 . The method of  claim 12 , wherein the first polymeric composition has a softening temperature of up to 150° C., wherein the second polymeric composition has a melting point of at least 130° C., and wherein the difference between the softening temperature of the first polymeric composition and the melting point of the second polymeric composition is at least 10° C. 
     
     
         15 . The method of  claim 12 , wherein the article is a filter comprising activated carbon, or wherein the article is an abrasive article. 
     
     
         16 . The article of  claim 1 , wherein the article is a filter comprising activated carbon. 
     
     
         17 . The article of  claim 1 , wherein the first polymeric composition has a softening temperature of up to 150° C., wherein the second polymeric composition has a melting point of at least 130° C., and wherein the difference between the softening temperature of the first polymeric composition and the melting point of the second polymeric composition is at least 10° C. 
     
     
         18 . The article of  claim 1 , wherein the first polymeric composition has an elastic modulus of less than 3×10 5  N/m 2  at a temperature of at least 80° C. measured at a frequency of one hertz. 
     
     
         19 . The article of  claim 1 , wherein the multi-component fibers are in a range from 3 millimeters to 60 millimeters in length. 
     
     
         20 . The article of  claim 1 , further comprising other, different fibers.