Process for making chemical protective wipes and such wipes
A process for making chemical protective wipes is disclosed. A top layer is fully needlepunched ( 102 ). A bottom layer is fully needlepunched ( 104 ). Then, an adsorption layer is sandwiched between the top layer and the bottom layer ( 106 ). Then, the sandwich is fully needlepunched ( 108 ).
1. A process for making chemical protective wipes, the process comprising:
fully needlepunching a top layer to form a needle punched coherent top layer to greater than 100 punches/cm 2 ;
fully needlepunching a bottom layer to form a needle punched coherent bottom layer to greater than 100 punches/cm 2 ; then,
sandwiching an adsorption layer between the coherent top layer and the coherent bottom layer to form a composite; and then,
fully needlepunching the composite to form a multilayer composite interlocked only at the interfaces between the layers.
2. The process of claim 1 , wherein the step of fully needlepunching the top layer comprises: fully needlepunching a top stack of two or more top layers to greater than 100 punches/cm 2 ; whereby the sandwiching step comprises: sandwiching an adsorption layer between the top stack and the coherent bottom layer.
3. The process of claim 2 , wherein the step of fully needlepunching the bottom layer comprises: fully needlepunching a bottom stack of two or more bottom layers to greater than 100 punches/cm 2 ; whereby the sandwiching step comprises: sandwiching an adsorption layer between the top stack and the bottom stack.
4. The process of claim 3 , wherein the step of fully needlepunching the top stack of two or more top layers comprises: separately fully needlepunching each of the top layers of the top stack wherein the step of fully needlepunching the bottom stack of two or more bottom layers comprises: separately fully needlepunching each of the bottom layers of the bottom stack.
5. The process of claim 3 , wherein the step of fully needlepunching the top stack of two or more top layers comprises:
stacking the two or more top layers into the top stack; and then,
fully needlepunching the top stack to greater than 100 punches/cm 2 ;
wherein the step of fully needlepunching the bottom stack of two or more bottom layers comprises: stacking the two or more bottom layers into the bottom stack; and then,
fully needlepunching the bottom stack to greater than 100 punches/cm 2 .
6. The process of claim 3 , wherein the step of fully needlepunching the top stack of two or more top layers comprises: fully needlepunching the top stack of two or more top layers from above and from below; and wherein the step of fully needlepunching the bottom stack of two or more bottom layers comprises: fully needlepunching the bottom stack of two or more bottom layers from above and from below.
7. The process of claim 6 , wherein the step of fully needlepunching the sandwich comprises: fully needlepunching the sandwich from above and from below.
8. The process of claim 7 , wherein the sandwiching step comprises: sandwiching a plurality of adsorption layers between the top stack and the bottom stack.
9. The process of claim 8 , wherein the top and bottom layers comprise fibers having denier within the range of about 1-3.
10. The process of claim 8 , wherein the top and bottom layers comprise fibers having denier equal to about 1.5.
11. The process of claim 8 , wherein the top and bottom layers comprise fibers having lengths within the range of about 1-3 inches.
12. The process of claim 8 , wherein the top and bottom layers comprise fibers having lengths equal to about 1.5 inch.
13. The process of claim 8 , wherein at least a portion of the needlepunching comprises oblique needlepunching.
14. The process of claim 8 , wherein at least a portion of the needlepunching comprises straight needlepunching.
15. The process of claim 3 , wherein the step of fully needlepunching the top stack of two or more top layers comprise the step of fully needlepunching from above and from below at about 50-1500 strokes per minute; and wherein the step of fully needlepunching the bottom stack of two or more bottom layers comprise the step of fully needlepunching from above and from below at about 50-1500 strokes per minute.
16. The process of claim 3 , wherein the step of fully needlepunching the top stack of two or more top layers comprise the step of fully needlepunching from above and from below at about 500-750 strokes per minute; and wherein the step of fully needlepunching the bottom stack of two or more bottom layers comprise the step of fully needlepunching from above and from below at about 500-750 strokes per minute.
17. The process of claim 1 , wherein each of the top and bottom layers weighs about 10-500 grams per square meter.
18. The process of claim 1 , wherein each of the top and bottom layers weighs about 43.8 grams per square meter.