The invention relates to a method for manufacturing an absorption and distribution nonwoven fabric made of staple fibers and absorbent material made of regenerated cellulose for personal hygiene products. The nonwoven fabric is composed of thermoplastic, synthetic staple fibers as support fibers, wherein the support fibers are homo- or bi-component, thermoplastic regenerated cellulose for personal hygiene products. The nonwoven fabric is composed of thermoplastic, synthetic staple fibers as supporting fibers, wherein the supporting fibers are homo- or bi-component, thermoplastic polymer fibers comprising fusible constituents, staple fibers of thermoplastic and/or duroplastic polymers as distribution fibers and absorbent material of regenerated cellulose. The nonwoven fabric is mechanically bonded and then thermally bonded by means of subsequent hot-air bonding. The invention also relates to an absorption and distribution nonwoven fabric produced by the method according to the invention and to a device for carrying out the method according to the invention.

Provided is a fiber sheet having elasticity. The fiber sheet (10) includes at least: a first fiber layer (1) containing crimped fibers each having a coil shape, the first fiber layer (1) having repetitive elasticity in a longitudinal direction of the fiber sheet; and a second fiber layer (2) containing elastomeric fibers. The second fiber layer (2) is integrated with the first fiber layer (1) by fusion or adhesion in a specific thickness ratio therebetween.

Nonwoven fabrics are provided that include a mechanically entangled blend of fibers comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers, in which the one or more additional fibers are different than the PCR-staple fibers. The PCR-staple fibers are mechanically entangled with the one or more additional fibers to define the nonwoven fabric.

A method of manufacturing a synthetic bale, including the steps of heating a mixture of a first plurality of fibers with a second plurality of fibers to cause the first plurality of fibers and the second plurality of fibers to thermally bond with one another to create bonded fibers, directing the bonded fibers into a forming chamber, and outputting the bonded fibers into a sheath configured for use as a synthetic ground-based bale.

A electrically-conductive broad good having an electrically-conductive nonwoven veil comprising with a plurality of metal-coated fibers looped randomly throughout the nonwoven veil and a binder material binding the plurality of metal-coated fibers together into the nonwoven veil and a first metal coating covering the conductive nonwoven veil wherein the first metal coating increases the number of electrical interconnections between the plurality of metal-coated carbon fibers within the conductive nonwoven veil and increases the conductivity and ampacity of the plurality of metal-coated fibers.

Nonwoven materials are provided that comprise multicomponent and monocomponent fibers. The multicomponent fibers comprise first and second polymers and the monocomponent fibers comprise the second polymer or a third polymer. The second and/or third polymer has a higher melting temperature than the first polymer. The fibers are selected to provide increased loft to the materials and are suitable for a variety of different applications and products, such as filter media for air or liquid filters and absorbent pads for bandages, wound dressings, diapers, adult incontinence products, feminine hygiene products and the like. Absorbent pads are provided comprising high loft nonwoven material that increases the absorbency of the pad. Filter media is provided comprising high loft nonwoven material that increases the dust holding capacity of the media.

Nonwoven fabrics are provided that include a mechanically entangled blend of fibers comprising (a) post-consumer recycled polymer staple fibers (PCR-staple fibers) and (b) one or more additional fibers, in which the one or more additional fibers are different than the PCR-staple fibers. The PCR-staple fibers are mechanically entangled with the one or more additional fibers to define the nonwoven fabric.

A disposable absorbent article having a topsheet, a backsheet, an absorbent core disposed between the topsheet and the backsheet, and a fluid management layer disposed between the topsheet and the absorbent core is disclosed. The fluid management layer is an integrated, carded, nonwoven disposed between the topsheet and the absorbent core. The absorbent article exhibits an average stain size of less than about 2400 mm{circumflex over ()}2, when measured in accordance with the Stain Size test method.

Provided is batting that includes a bonded nonwoven web made from a fiber mixture containing: (a) 20 to 55 wt % of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm; (b) 10 to 45 wt % of hollow conjugate fibers having a spiral crimp, and having a denier of 1.5 to 10.0 and a length of 51 to 84 mm; (c) 10 to 45 wt % of a first population of binder fibers which are elastomeric co-polyester binder fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110 C. to 180 C.; and (d) 1 to 20 wt % of a second population of binder fibers, which have a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and a bonding temperature of 80 C. to 135 C.

A filter medium is provided comprising a carrier layer; a melt-blown layer; and a spunbond layer. The melt-blown layer is disposed between the carrier layer and the spunbond layer. The spunbond layer comprises bicomponent fibers. The spunbond layer may have a basis weight of from about 10 g/m2 to about 40 g/m2 and may have a thickness of at least about 250 m. Also described herein is a method of producing the filter medium and filters and apparatus comprising the filter medium. The inclusion of a low density bicomponent spunbond layer as a pre-filter layer in the filter medium provides a lower basis weight filter medium with a comparable or improved filtration efficiency to a filter medium comprising a carded nonwoven pre-filter layer, while reducing the amount of materials used.