Process for making fibrous structures
Processes for making fibrous structures and more particularly processes for making fibrous structures comprising filaments are provided.
1. A process for making a fibrous structure, the process comprising the steps of:
a. meltblowing a plurality of first filaments comprising a first polymer from a die comprising filament-forming holes such that the first filaments comprise single filaments each produced from a single filament-forming hole, wherein the first filaments are externally attenuated;
b. combining the plurality of first filaments with solid additives to form a mixture;
c. collecting the mixture of the first filaments and solid additives on a collection device to produce a formed fibrous structure; and
d. adding a layer of second filaments to at least one surface of the formed fibrous structure.
2. The process according to claim 1 wherein the process further comprises the step of:
e. supplying at least the first polymer to the die.
3. The process according to claim 1 wherein the die comprises one or more filament-forming holes, wherein one or more fluid-releasing holes are associated with one filament-forming hole such that a fluid exiting the fluid-releasing hole contacts an exterior surface of a filament exiting the filament-forming hole.
4. The process according to claim 1 wherein at least one row of filament-forming holes comprises two or more filament-forming holes.
5. The process according to claim 3 wherein more than one fluid-releasing hole is associated with a filament-forming hole.
6. The process according to claim 3 wherein one fluid-releasing hole is concentrically positioned around one filament-forming hole.
7. The process according to claim 1 wherein the first polymer comprises a synthetic polymer.
8. The process according to claim 7 wherein the synthetic polymer is selected from the group consisting of: polyvinyl alcohol, polyvinyl alcohol derivatives, polyesters, nylons, polyolefins, polylactic acids, polyhydroxyalkanoates, polycaprolactones and mixtures thereof.
9. The process according to claim 7 wherein the synthetic polymer comprises a polyolefin.
10. The process according to claim 9 wherein the polyolefin comprises polypropylene.
11. The process according to claim 1 wherein the first polymer comprises a natural polymer.
12. The process according to claim 11 wherein the natural polymer is selected from the group consisting of: starch, starch derivatives, cellulose, cellulose derivatives, hemicellulose, hemicellulose derivatives and mixtures thereof.
13. The process according to claim 1 wherein the first polymer comprises a compostable polymer.
14. The process according to claim 13 wherein the compostable polymer is selected from the group consisting of: polylactic acids, polyhydroxyalkanoates, polycaprolactones and mixtures thereof.
15. The process according to claim 1 wherein the solid additives comprise fibers.
16. The process according to claim 15 wherein the fibers comprise wood pulp fibers.
17. The process according to claim 1 wherein the second filaments comprise a second polymer.
18. The process according to claim 17 wherein the second polymer is the same as the first polymer.