Method for producing a composite fiber web

Abstract

A method for manufacturing a composite fiber web (100), comprising the following steps: - melt-blowing a first thermoplastic material flow (F1) comprising a first thermoplastic material toward at least one collecting suction surface (3) moving in a feed direction (V); - distributing a particulate material flow (FP) comprising a particulate material (104) toward the collecting suction surface in such a manner that the first thermoplastic material flow (F1) is intercepted in an interception zone (Z); the first thermoplastic material flow (F1) and the particulate material flow (FP) intercept each other in the interception zone at an interception angle (α) between 1 and 90 sexagesimal degrees, preferably between 15 and 40 sexagesimal degrees.

Description

Technical Field

[0001] The present invention relates to a method for producing a composite web, in particular a composite web comprising melted and blown fibers and particulate material, such as absorbent or superabsorbent material, such as a nonwoven web made of a nonwoven fabric. Background Art

[0002] Methods are known in the art for making composite webs comprising melted and blown fibers, known as "meltblown" fibers, and spunbond fibers, in which particulate material, for example in the form of discrete particles, is entrapped.

[0003] The particulate material may be, for example, an absorbent or superabsorbent polymer material. Examples of composite fiber webs comprising meltblown fibers and discrete particles are described and illustrated in documents US6494974 and EP0156160.

[0004] Absorbent (or superabsorbent) material refers to a material that is capable of retaining any liquid or capable of filtering a fluid (liquid or gas) containing foreign matter (solid, liquid or gas).

[0005] Concerning the production of composite fiber webs comprising meltblown fibers having discrete particles of particulate material entrapped therein, there is felt the need to develop a process for manufacturing a fiber web (meltblown or spunbond) which, with the equipment being identical, allows the ability to retain particulate material in the mass of meltblown fibers to be adjusted; in this way, composite fiber webs having different abilities to retain particulate material can be manufactured, so that such composite fiber webs can be used to manufacture different products with different properties (for example: absorbent products for hygienic purposes, protective masks, filter elements for the medical field, cigarette filters, anti-particle filters for the automotive industry). Summary of the invention

[0006] Here, the intention is to propose a method for producing a composite fiber web that can meet the above-mentioned needs.

[0007] More specifically, it is an object of the present invention to provide a method for producing a composite fiber web which at least allows adjusting the ability to retain particulate material in the mass of meltblown fibers.

[0008] The above objects are achieved by a method for manufacturing a composite fiber web comprising the technical features described in one or more of the appended claims. The dependent claims correspond to different possible embodiments of the invention.

[0009] According to a first aspect, the present invention relates to a method for manufacturing a composite fiber web, the composite fiber web comprising at least a first layer, the first layer comprising a mass of meltblown fibers formed by a melted and blown first thermoplastic material and a particulate material dispersed in the fibers and at least partially adhered to the fibers.

[0010] The method comprises the steps of meltblowing a first thermoplastic material flow comprising a first thermoplastic material towards at least one collecting suction surface moving in a feed direction to obtain a first mass of meltblown fibers, and distributing a particulate material flow comprising a particulate material towards the collecting suction surface in such a way as to intercept the thermoplastic material flow in an interception area.

[0011] According to one aspect, the first thermoplastic material flow and the particulate material flow intercept each other in the interception zone at an interception angle (α) between 1 and 90 sexagesimal degrees, preferably between 15 and 40 sexagesimal degrees.

[0012] Advantageously, the interception angle helps define the intersection region between the two flows.

[0013] Generally speaking, increasing the interception angle reduces the intersection area and improves process stability and distribution of the particulate material.

[0014] Advantageously, reducing the interception angle results in a higher confinement factor for example of particulate material.

[0015] According to one aspect, the flow of thermoplastic material and the flow of particulate material intercept each other in an interception zone at an interception height greater than or equal to zero and less than 300 mm from the collecting suction surface.

[0016] Advantageously, by increasing the interception height, it is possible to retain all of the particulate material and stabilize the process without losing excess particulate material.

[0017] According to one aspect, at the interception area, the entire cross-section of the granular material flow parallel to the feed direction of the collecting suction surface has entered the first thermoplastic material flow and / or the entire cross-section of the thermoplastic material flow parallel to the feed direction of the collecting suction surface has entered the first flow of granular material.

[0018] According to one aspect, the thermoplastic material stream is meltblown by at least one nozzle located at a distribution distance (also referred to as "core-to-collector distance DCD") greater than 100 mm and less than 1200 mm, preferably between 250 mm and 400 mm, measured along a perpendicular line to the collecting suction surface.

[0019] The distribution distance affects the temperature of the fibers in the interception zone and therefore affects the retention and distribution of the particulate material between the fibers.

[0020] According to one aspect, the flow of thermoplastic material has a distribution width measured in the feed direction of the collecting suction surface, between 1 mm and 200 mm, preferably between 5 mm and 100 mm.

[0021] According to one aspect, the flow of particulate material has a distribution width, measured in the feed direction of the collecting suction surface, comprised between 1 mm and 200 mm, preferably equal to 25 mm.

[0022] According to one aspect, the flow of thermoplastic material comprises a corresponding compressed air flow and the flow of particulate material comprises a corresponding compressed air flow having the same compressed air flow velocity as the compressed air flow velocity of the thermoplastic material, so that advantageously the process is balanced.

[0023] Furthermore, the sum of the air flows of the thermoplastic material flow and the particulate material flow is preferably less than or equal to the air flow sucked by the collecting suction surface to stabilize the process.

[0024] According to one aspect, the method includes the step of forming a second layer of the composite fiber web, again using meltblowing technology.

[0025] The second layer is preferably formed on the collecting suction surface before making the first layer, so that the first layer is formed on the second layer already present on the collecting suction surface.

[0026] The step of forming a second layer (on which the first layer will be deposited) comprises the steps of meltblowing at least one thermoplastic material stream comprising a second thermoplastic material (e.g., the same thermoplastic material as the first layer) onto a collecting suction surface to form a second mass of meltblown fibers on the collecting suction surface.

[0027] As described above, the step of meltblowing the stream of thermoplastic material of the first layer is preceded by the step of meltblowing the stream of thermoplastic material of the second layer onto the collecting suction surface.

[0028] According to one aspect, the method comprises the step of forming a layer of composite fiber web on top of a first layer comprising particulate material incorporated in thermoplastic fibers, again using meltblowing technology.

[0029] The layer is preferably formed on the first layer on the collecting suction surface after the first layer has been formed on the collecting suction surface.

[0030] The step of forming a layer of composite web on top of the first layer includes the step of meltblowing a stream of thermoplastic material including a second thermoplastic material (eg, the same thermoplastic material as the first layer) onto the first layer to form a second mass of meltblown fibers on the first layer.

[0031] According to one aspect of the invention, the total thermoplastic material flow used to make the first layer may consist of two thermoplastic material flows defining the total flow and intercepting each other and the granular material flow.

[0032] The two flows of thermoplastic material and the flow of particulate material at least partially intercept each other on the collecting suction surface.

[0033] According to one aspect of the invention, the total thermoplastic material flow for making the first layer may consist of two thermoplastic material flows defining the total flow and intercepting each other and the particulate material flow on two collecting suction surfaces.

[0034] The two collecting suction surfaces face each other and define a channel for the flow of thermoplastic material and the flow of particulate material.

[0035] Preferably, the flow of thermoplastic material and the flow of particulate material at least partially intercept each other upstream of the passage.

[0036] Advantageously, the suction of the collecting surface through which the above-mentioned flow passes allows spreading the fibers of the material in transit so as to obtain an open-pored fibrous material known as “high loft”.

[0037] The dimension of the channel between the collecting surfaces measured in a direction perpendicular to the first collecting suction surface and the second collecting suction surface is between 1 mm and 20 mm, and adjusting this distance along with adjusting other process parameters helps to define the ability of the fiber web to retain particulate material.

[0038] The collecting suction surface is preferably in the form of suction drums having parallel axes, and the channels are the gaps between them.

[0039] According to one aspect, a portion of the first layer is formed on the first drum and a portion is formed on the second drum, the two portions being joined in the channel.

[0040] According to one aspect, the method comprises obtaining the fibers of the first layer using a thermoplastic elastomer such that the matrix is ​​elastic.

[0041] According to one aspect, the method comprises adding a hydrophilic additive to a first thermoplastic material so as to obtain a hydrophilic fiber matrix, which is particularly useful in case the particulate material is an absorbent or superabsorbent polymer material. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Other features and advantages of the present invention become clearer in the following exemplary (and therefore non-limiting) description of a preferred but non-exclusive embodiment of a method for producing a composite fiber web, wherein the composite fiber web comprises at least a first layer, which in turn comprises a first mass of meltblown fibers and a particulate material dispersed in the fibers and at least partially adhered to the fibers.

[0043] The description is set forth below with reference to the accompanying drawings, which are provided for illustration purposes only and do not limit the scope of the invention, and in which:

[0044] - Figure 1 Schematically illustrates a part of a possible embodiment of a device for implementing a method for manufacturing a composite fiber web according to the present disclosure, some parts of which are shown as boxes;

[0045] Figure 2 Schematically shows a part of a possible embodiment of an apparatus for implementing a method for producing a composite fiber web according to the present disclosure;

[0046] - Figure 3 Schematically shows a part of a possible embodiment of an apparatus for implementing a method for producing a composite fiber web according to the present disclosure;

[0047] - Figure 4 Schematically shows a part of a possible embodiment of an apparatus for implementing a method for producing a composite fiber web according to the present disclosure;

[0048] - Figure 5 Schematically shows a part of a possible embodiment of an apparatus for implementing a method for producing a composite fiber web according to the present disclosure;

[0049] - Figure 6 Schematically shows a part of a possible embodiment of an apparatus for implementing a method for producing a composite fiber web according to the present disclosure;

[0050] - Figures 7 to 9 is a schematic side view showing an example of a composite fiber web manufactured using a method according to one or more aspects of the present disclosure, the composite fiber web including meltblown fibers and particulate material dispersed therein. DETAILED DESCRIPTION

[0051] Reference Figures 1 to 6 , reference numeral 1 generally denotes a part of an apparatus for implementing a possible embodiment of the method for manufacturing a composite fiber web according to the present disclosure.

[0052] Reference Figures 7 to 9 , reference numeral 100 denotes a segmented portion of a composite fiber web obtainable using a method according to one or more aspects of the present disclosure.

[0053] The fiber web 100 comprises at least one layer 101 of the type known as meltblown or spunbond, ie obtained by extruding and blowing out thermoplastic material.

[0054] Layer 101 includes a mass 102 of meltblown fibers 103 .

[0055] The fibers 103 are obtained in particular by melting at least one thermoplastic material.

[0056] In a preferred embodiment, the diameter of the fibers 103 is between 0.1 microns and 30 microns, preferably between 0.5 microns and 10 microns.

[0057] In a preferred embodiment, the grammage of the fibers 103 is between 0.1 gsm and 300 gsm, preferably between 1 gsm and 20 gsm.

[0058] Fibers 103 include a first thermoplastic material that is meltblown—that is, a first thermoplastic material that is placed in an extruder to produce layer 101 .

[0059] In a preferred embodiment, the first thermoplastic material is preferably polymeric - for example polypropylene (PP) or polyethylene (PE) - and is present in the fibers 103 in a percentage between 0 and 99% by weight, preferably between 70 and 95% by weight.

[0060] Preferably, the melt flow rate of the first thermoplastic material is between 1 and 2000, preferably 1200.

[0061] The fibers 103 include an elastomer, ie a substance capable of reducing the elasticity of the fibers 103 in the sense of reducing the resistance of the fibers 103 to deformation under mechanical stress.

[0062] The elastomer can be melted and ejected alone (thus constituting all of the thermoplastic materials), melted and ejected together with the first thermoplastic material, or melted and ejected together with the first thermoplastic material and the second thermoplastic material (i.e., the elastomer is placed in an extruder to produce a meltblown type fiber web 100).

[0063] In general, the first thermoplastic material and the second thermoplastic material are thermoplastic materials suitable for being melted and sprayed. Preferably, the first thermoplastic material and the second thermoplastic material can be selected from the group of the following materials by way of non-exhaustive examples: polypropylene and derivatives, polyethylene and derivatives, polylactic acid and derivatives, polyhydroxyalkanoates and derivatives, cellulose and derivatives, cellulose acetate and derivatives, starch and derivatives, polyesters (e.g., polyethylene terephthalate), polyurethanes, polyamides, polycarbonates, general thermoplastic biopolymers, polyoxymethylene and derivatives, polysulfones and derivatives, acrylates / methacrylates and derivatives.

[0064] Preferably, the particulate material may comprise one or more compounds which may be selected by way of non-exhaustive example from the group of the following materials: absorbent or superabsorbent materials (polymeric or non-polymeric), graphene, odour eaters (e.g. activated carbon, zeolites, carbonates, silicates), chitosan, antibacterial or virucidal materials (e.g. titanium dioxide, zinc oxide, copper oxide, colloidal silver, polyethylene glycol).

[0065] When extruded together with at least the first thermoplastic material, ie when it itself constitutes the thermoplastic material, the elastomer serves in particular to reduce the elasticity of the fibers 103, ie to make them softer and more flexible.

[0066] In a preferred embodiment, the percentage of elastomer present in the fibers is between 0% and 99% by weight, preferably between 5% and 30% by weight.

[0067] Indeed, in a preferred embodiment, as described above, the fibers 103 may be made entirely of an elastomeric thermoplastic material—such as Vistamaxx. TM Made so as to be particularly elastic.

[0068] In other words, in a preferred embodiment, the elastomer itself constitutes the first thermoplastic material, that is, the mass body 102 may be substantially completely made of the elastomer.

[0069] In a preferred embodiment, the fibers 103 include a hydrophilic additive that is added to the extruder to render the fibers 103 hydrophilic.

[0070] If the hydrophilic additive is added in the extruder, the hydrophilic additive may be water-based or non-aqueous-based.

[0071] The percentage of hydrophilic additive present in the fibers 103 is between 1% and 10% by weight, preferably between 3% and 6% by weight.

[0072] The grammage of the layer 101 as a whole is preferably between 50 and 1500 gsm.

[0073] The layer 101 further comprises a particulate material 104 dispersed in the fibers 103 and at least partially adhered to the fibers.

[0074] The gram weight of the particulate material present in the composite web 1 is between 8 and 990 gsm, preferably between 50 and 700 gsm.

[0075] In a preferred embodiment, the particulate material 104 comprises an absorbent or superabsorbent material, such as SAP, for example Saviva B3.

[0076] Advantageously, if an elastomer is present in the fibers 103 or the elastomer itself constitutes the fibers 103, the fibers 103 are particularly sticky, particularly during a meltblowing process.

[0077] In this way, the particulate material 104 is better adhered to and retained by the fibers.

[0078] Without loss of generality, reference is made hereinafter to a preferred embodiment in which the particulate material is a superabsorbent material (SAP) and the resulting fiber web is an absorbent fiber web.

[0079] The method for manufacturing a composite fiber web comprising a layer 101 comprises the steps of meltblowing a first flow F1 of thermoplastic material comprising a first thermoplastic material, eg by means of an extruder 2 towards at least one collecting suction surface 3 moving in a feeding direction V, to obtain a mass 102 of meltblown fibers.

[0080] The step of meltblowing the flow F1 is performed along a main trajectory T1 , wherein “trajectory” refers to the bisector of the angle formed by the distribution through each nozzle 5 of the extruder 2 .

[0081] The flow F1 is preferably supported by or comprises a corresponding air flow A1 .

[0082] The flow F1 of thermoplastic material is meltblown by at least one nozzle 5 located at a dispensing distance h1 measured along a perpendicular to the surface 3 of greater than 100 mm and less than 1200 mm, preferably between 250 mm and 400 mm.

[0083] The flow F1 has a distribution width d1 , measured in the feed direction of the surface 3 , of between 1 mm and 200 mm, preferably between 5 mm and 100 mm.

[0084] The method comprises the step of distributing a particulate material flow FP comprising particulate material 104 , for example by means of a distributor 4 .

[0085] The step of distributing the flow of particulate material is performed along a main trajectory TP, wherein “trajectory” is understood to be the bisector of the angle formed by the distribution by the distributor 4 .

[0086] The flow FP is preferably supported by or comprises a corresponding air flow AP.

[0087] Preferably, flow A1 and flow AP are equal in velocity so that neither one exceeds the other and both contribute to creating a balanced process.

[0088] Furthermore, the sum of the air flows A1 and AP is preferably less than or equal to the air flow sucked by the collecting surface 3 in order to stabilize the process.

[0089] The flow FP has a distribution width d2 , measured in the feed direction of the surface 3 , comprised between 1 mm and 200 mm, preferably equal to 25 mm.

[0090] Advantageously, adjusting d2 changes the distribution of the particulate material; in the case of SAP, the so-called "free expansion" can be controlled, as the fibers capture the SAP, preventing its agglomeration.

[0091] In one embodiment, the SAP is also extruded through its own extruder and helps form fibers that are themselves absorbent.

[0092] The flow FP is distributed towards the collecting suction surface 3 in such a way that the flow F1 of thermoplastic material is intercepted in the interception zone Z.

[0093] Especially referring to Figure 3 , it can be observed that, in zone Z, the entire cross section of flow FP preferably enters flow F1 .

[0094] More specifically, at the interception zone Z, the entire cross section of the particulate material flow FP parallel to the feeding direction of the collecting suction surface 3 has entered the thermoplastic material flow F1.

[0095] In other words, at the interception zone Z, the entire cross section of the thermoplastic material flow F1 parallel to the feeding direction of the collecting suction surface 3 has entered the particulate material flow FP.

[0096] The height h1 affects the temperature of the fibers in the zone Z and the type of motion of the flow F1; increasing h1 reduces the temperature of the fibers in the zone Z and reduces the bonding between the fibers and the granular material. In the case of SAP, a lower confinement factor is closely associated with a poorer wet-dry integrity.

[0097] As in Figure 3 As schematically shown in , the flow F1 and the flow of particulate material intercept each other in the zone Z at an interception angle α.

[0098] Preferably, the angle is between 1 and 90 sexagesimal degrees, more preferably between 15 and 40 sexagesimal degrees.

[0099] The interception angle α determines the intersection area 6 of flows F1 and FP; when setting other process parameters—for example, the height of the flow intersection, ie the height of the area Z relative to the collecting surface—the smaller the value of α, the larger the area 6.

[0100] Increasing the intersection time and space advantageously allows for increased bonding between the fibers and the particulate material, thereby constraining the particulate material to a greater extent.

[0101] In the case of superabsorbent materials, if α decreases below a certain value, the SAP is over-constrained, thereby reducing the free expansion of the absorbent web and thus reducing its absorbent capacity.

[0102] If α increases above a certain value, the process may become turbulent, resulting in an uneven distribution of the particulate material.

[0103] To simplify the process setup, we may refer to trajectories T1 and TP and consider that these trajectories intersect at an angle α.

[0104] As in Figure 1 and Figure 2 As schematically shown in , the flow F1 and the flow FP intercept each other, as explained above, at an interception height h measured perpendicularly to the collecting surface 3 and greater than or equal to zero.

[0105] In simpler terms, the entire cross section of the particulate material flow FP, preferably parallel to the feeding direction of the collecting suction surface 3, enters the thermoplastic material flow F1 at a height h greater than or equal to zero.

[0106] In a preferred embodiment, the particulate material flow FP is at right angles to the collecting suction surface 3 .

[0107] Reference Figure 8 and Fig. 9 It should be noted that, in a preferred embodiment of the present invention, the composite fiber web 100 includes at least a second layer 105, which is also meltblown or spunbonded and is located below the first layer 101 as shown in the drawings.

[0108] Layer 105 includes a mass 106 of, for example, meltblown fibers 107 .

[0109] In a preferred embodiment of the method, layer 105 is produced “in process”, that is to say directly on the collecting suction surface 3 before forming layer 101 .

[0110] Figure 8 The fiber web is for example made of Figure 4The device shown is made and the associated method comprises a step of meltblowing a flow F2 of thermoplastic material onto a collecting suction surface 3 , for example by means of a corresponding extruder 7 .

[0111] A mass 106 is formed on the surface 3 by the flow F2 , thus forming a layer 105 , on which the first layer 101 of the composite fiber web 100 is placed.

[0112] The step of meltblown flow F2 is carried out before the step of meltblown flow F1 , that is to say the extruder 7 is located upstream of the extruder 2 and the distributor 4 in the feed direction V of the surface 3 .

[0113] Thus, the first layer 101 overlies the second layer 105, thereby helping to retain the particulate material, particularly SAP, without constraining it.

[0114] like Fig. 9 As shown, the composite fiber web 100 may include another layer 108 (e.g., Fig. 9 shown).

[0115] The layer 108 comprises a mass 109 of, for example, meltblown fibers, which is obtained by a step (not shown) of meltblowing a stream of thermoplastic material comprising a thermoplastic material onto the first layer 101 to form the mass 109 of meltblown fibers on the layer 101 .

[0116] exist Figure 5 In the embodiment shown, the method comprises the step of meltblowing a flow F3 of thermoplastic material, for example dispensed by respective nozzles 8 and preferably comprising a first thermoplastic material, towards a collecting suction surface 3 to facilitate forming a mass 102 of fibers 103 .

[0117] Flow F3 intercepts flow F1 in an interception region preferably positioned as described above, thereby forming a total thermoplastic material flow, and intercepting the particulate material flow FP.

[0118] like Figure 6 As shown, flows F1, F3 and FP move towards two collecting suction surfaces 9, 10, which are positioned relative to each other to define a channel 11 for the total thermoplastic material flow and the particulate material flow; preferably, flows F1, F3 and FP at least partially intercept each other upstream of the channel 11.

[0119] The dimension d of the channel 11 measured in a direction perpendicular to the surfaces 9 and 10 is between 1 and 20 mm.

[0120] Generally speaking, forming mass 102 from a pair of thermoplastic material streams improves the balance of the air streams and facilitates more efficient capture of particulate material.

[0121] In the preferred embodiment shown, the surface 9 is in the form of a collecting suction drum having an axis of rotation R9 and the surface 10 is in the form of a collecting suction drum having an axis of rotation R10 parallel to the axis R9.

[0122] A channel 11 is defined between the outer cylindrical collecting surface of drum 9 and the outer cylindrical collecting surface of drum 10 .

[0123] Advantageously, by adjusting the distance d and the suction of the drum, or in general, by adjusting the distance d and the suction of the collecting surface, the passing material can be spread out to obtain a more open fiber mass.

[0124] The method described allows optimizing the use of particulate material (reducing the amount of particulate material lost during production) and reducing its constraint factor; if the particulate material is an absorbent or superabsorbent polymer material, the method allows obtaining absorbent products characterized by a higher absorption capacity (for the same amount of absorbent material used).

[0125] Still another object of the present invention is a method for manufacturing an article, preferably for hygiene, biomedical or anti-particle applications, comprising divided portions of a composite fiber web 100 manufactured according to the method described herein.

[0126] Preferably, the biomedical article is a protective mask for the face, preferably having a virucidal and / or bactericidal effect.

[0127] In one embodiment, the article is a smoking article and / or semi-finished product for the tobacco industry, preferably a cigarette filter.

Claims

1. A method for manufacturing a composite fiber web (100), the composite fiber web (100) comprising at least a first layer (101), the first layer (101) further comprising: - a first mass (102) of meltblown fibers (103), the meltblown fibers (103) comprising at least a first thermoplastic material that has been melted and blown; - a particulate material (104) which is dispersed in the fibers (103) and at least partially adhered to the fibers (103), The method comprises the following steps for making the first layer (101): - melt-blowing a first flow (F1) of thermoplastic material comprising said first thermoplastic material towards at least one collecting suction surface (3) moving in a feeding direction (V) to obtain said first mass (102) of melt-blown fibers; - distributing the flow (FP) of particulate material comprising said particulate material (104) towards said collecting suction surface (3) in such a way as to intercept said first flow (F1) of thermoplastic material in an interception zone (Z); The method is characterized in that the first thermoplastic material flow (F1) and the particulate material flow (FP) intercept one another in the interception region at an interception angle (α) between 1 and 90 sexagesimal degrees, The flow (FP) of particulate material (104) has a distribution width (d2) measured along the feeding direction of said collecting suction surface (3) between 1 mm and 200 mm.

2. The method according to claim 1, characterized in that The first thermoplastic material flow (F1) and the particulate material flow (FP) intercept each other in the interception zone (Z) at an interception height (h) greater than or equal to zero and less than 300 mm relative to the collecting suction surface (3).

3. The method according to claim 1 or 2, characterized in that: The particulate material flow (FP) is at right angles to the collecting suction surface (3).

4. The method according to claim 1 or 2, characterized in that: At the interception zone (Z), the entire cross section of the particulate material flow (FP) parallel to the feeding direction of the collecting suction surface (3) has entered the first thermoplastic material flow (F1).

5. The method according to claim 1 or 2, characterized in that: At said interception zone (Z), the entire cross section of said first thermoplastic material flow (F1) parallel to the feeding direction of said collecting suction surface (3) has entered the first flow of particulate material (104).

6. The method according to claim 1 or 2, characterized in that: The first thermoplastic material flow (F1) is meltblown by at least one nozzle (5), the at least one nozzle (5) being located at a dispensing distance (h1) greater than 100 mm and less than 1200 mm measured along a perpendicular line to the collecting suction surface (3).

7. The method according to claim 1 or 2, characterized in that: The first flow (F1) of thermoplastic material has a distribution width (d1) measured according to the feeding direction of the collecting suction surface (3) between 1 mm and 200 mm.

8. The method according to claim 1 or 2, characterized in that: The distribution width (d2) is equal to 25 mm.

9. The method according to claim 1 or 2, characterized in that: The first thermoplastic material flow (F1) comprises a first air flow (A1) and the particulate material flow (FP) comprises a second air flow (AP), the first air flow (A1) and the second air flow (AP) having equal velocities.

10. The method according to claim 1 or 2, comprising a second step of meltblowing at least a second thermoplastic material flow (F2) comprising a second thermoplastic material on the collecting suction surface (3) to form at least a second mass body (106) of meltblown fibers on the collecting suction surface (3), the second mass body (106) of meltblown fibers defining a second layer (105) of the composite fiber web (100), the first layer (101) of the composite fiber web (100) being positioned on the second layer (105), the second step of meltblowing the second thermoplastic material flow (F2) on the collecting suction surface (3) occurring before the step of meltblowing the first thermoplastic material flow (F1).

11. The method according to claim 1 or 2 comprises a third step of meltblowing at least a third thermoplastic material flow comprising a third thermoplastic material on the first layer (101) of the composite fiber web (100) to form at least a third mass body (109) of meltblown fibers on the first layer (101) of the composite fiber web, the third mass body (109) of meltblown fibers defining a third layer (108) of the composite fiber web (100) positioned on the first layer (101) of the composite fiber web (100), the third step of meltblowing the third thermoplastic material flow occurring after the step of meltblowing the first thermoplastic material flow (F1).

12. The method according to claim 1, comprising the steps of: A fourth thermoplastic material flow (F3) comprising the first thermoplastic material is melt-blown toward the collecting suction surface (3) in a manner that intercepts the first thermoplastic material flow (F1) and the particulate material flow (FP), wherein the first thermoplastic material flow (F1) and the fourth thermoplastic material flow (F3) define the total thermoplastic material flow to obtain the first mass body (102) of melt-blown fibers.

13. The method according to claim 12, characterized in that The steps of meltblowing a first thermoplastic material flow (F1), distributing a particulate material flow (FP) and meltblowing a fourth thermoplastic material flow (F3) occur towards a first collecting suction surface (9) and a second collecting suction surface (10), the first collecting suction surface (9) and the second collecting suction surface (10) being relatively positioned to define a channel (11) for the total thermoplastic material flow and the particulate material flow (FP), the first thermoplastic material flow (F1), the fourth thermoplastic material flow (F3) and the particulate material flow (FP) at least partially intercepting each other upstream of the channel (11).

14. The method according to claim 13, characterized in that The channel (11) has a dimension (d) between 1 mm and 20 mm measured in a direction perpendicular to the first collecting suction surface (9) and the second collecting suction surface (10).

15. The method according to claim 13 or 14, characterized in that The first collecting suction surface (9) is in the form of a first collecting suction drum, the second collecting suction surface (10) is in the form of a second collecting suction drum, the first collecting suction drum and the second collecting suction drum have corresponding rotation axes (R9, R10) parallel to each other, and the channel (11) is defined between a first outer cylindrical collecting surface of the first collecting suction drum and a second outer cylindrical collecting surface of the second collecting suction drum.

16. The method according to claim 1 or 2, characterized in that: The first thermoplastic material is a thermoplastic elastomer.

17. The method according to claim 1 or 2, characterized in that: At least the first thermoplastic material flow (F1) comprises a molten hydrophilic additive ejected together with the first thermoplastic material.

18. The method according to claim 1 or 2, characterized in that: The particulate material (104) comprises one or more compounds selected from the group consisting of: absorbent or superabsorbent materials; graphene; odor capturing materials; chitosan; antibacterial or virucidal materials.

19. The method according to claim 1 or 2, characterized in that: The particulate material (104) comprises an absorbent or superabsorbent polymer material.

20. The method according to claim 1 or 2, characterized in that: The interception angle (α) is between 15 and 40 sexagesimal degrees.

21. The method according to claim 6, characterized in that The dispensing distance (h1) is between 250 mm and 400 mm.

22. The method according to claim 7, characterized in that The distribution width (d1) of the first thermoplastic material flow (F1) is between 5 mm and 100 mm.

23. The method according to claim 18, characterized in that The odor capturing material is activated carbon, zeolite, carbonate, silicate, and the antibacterial or antiviral material is titanium dioxide, zinc oxide, copper oxide, colloidal silver, polyethylene glycol.

24. A method for manufacturing an article for hygiene, biomedical or anti-particle use, the article comprising a block of a composite fiber web (100), wherein the block is made using a method according to any one of the preceding claims.

25. The method according to claim 24, characterized in that The article is a protective cover for the face.

26. The method according to claim 25, characterized in that The protective cover has a virucidal and / or bactericidal effect.

27. The method according to claim 24, characterized in that The articles are smoking articles and / or semi-finished products for the tobacco industry.

28. The method according to claim 27, characterized in that The product is a cigarette filter.

Images