A method for producing a nonwoven element particularly for hygiene products, has at least the following steps: forming a fibrous web sheet with a width direction extending transverse to the production direction and a thickness direction perpendicular thereto by supplying staple fibers from at least a first group which are formed from a thermoplastic material, consolidating the fibrous web sheet to form a nonwoven web by heating exclusively a first side of the fibrous web sheet through contact with a heated surface such that the staple fibers of the first group are partially melted, and cooling the nonwoven web.

Methods and apparatuses for producing a zoned and/or layered substrate are described. A substrate can include a first layer including a first zone, a second zone, and an interface between zones. The first zone can include a plurality of fibers. The second zone can include a plurality of fibers and can be offset from the first zone in a cross-direction. The interface can include at least some of the plurality of fibers of the first zone and at least some of the plurality of fibers of the second zone to provide a purity gradient with a transition width less than 3.8 cm as defined by the Purity Gradient Test Method as described herein.

The invention relates to a water-repellent and lipophilic composite needle-punched nonwoven fabric and a preparation method thereof. The method comprises the following steps: blending a PET fiber and a polyolefin-based fiber in a mass ratio of 3:1-1:3, and performing needle punching to obtain a composite needle-punched nonwoven fabric; carrying out hot-drying treatment on the composite needle-punched nonwoven fabric at 110-160° C. for 40-90 min; and carrying out water-repellent finishing on the hot-dried fabric using 50-70 mL/L of an aqueous solution of a modified resin-based fluorine-free waterproofing agent, and drying to obtain the water-repellent and lipophilic composite needle-punched nonwoven fabric, wherein the water-repellent finishing is dip rolling, the air pressure is 1.8 kPa and the liquid carrying rate is 160-230%. The preparation method of the invention is simple, and the prepared composite needle-punched nonwoven fabric has significantly improved water repellency, lipophilicity and tensile strength compared with the fabric before treatment.

Provided are a stretchable non-woven fabric including crimped fibers, satisfying the following formula: (σ.sub.65−σ.sub.55)/(σ.sub.30−σ.sub.20)≥2.5, when a stress σ (N/50 mm) at a strain ε of 20%, 30%, 55% and 65% in a stress-strain curve by a tensile test for at least one direction in a plane direction, is referred to as σ.sub.20, σ.sub.30, σ.sub.55 and σ.sub.65, respectively, and a bandage including the non-woven fabric. The non-woven fabric and the bandage lead small deterioration in stretching performance when used repeatedly, and can be excellent in repetition durability.

The present invention provides a chargeable sheath/core-structured fiber that contains a polypropylene-based resin as a main resin, wherein the sheath part contains (a) a carboxylic anhydride-modified polyolefin and (b) at least one antioxidant selected from the group consisting of a combined antioxidant a phenolic antioxidant and a phosphorus-based antioxidant, and sulfur-based antioxidants; and (c) an oil containing a polyoxyalkylene alkyl ether represented by the general formula (I) as a finishing oil is deposited on the outer surface of the sheath part, and that can satisfy heat resistance and charge retainability. (In the formula, R.sup.1 represents a saturated or unsaturated aliphatic hydrocarbon group having 10 to 30 carbon atoms; R.sup.2 represents a hydrogen atom or a methyl group; and k is an integer of 1 to 4.)

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Provided is a composite sheet material having a first layer and an airlaid nonwoven layer overlying the first layer wherein the airlaid nonwoven layer includes a blend of bamboo derived staple fibers and non-cellulose staple fibers, and in which the airlaid nonwoven layer includes a first surface disposed towards, and thermally bonded, to a surface of the first layer, and a second surface defining an outer surface of the composite sheet material.

Covers comprising a nonwoven fabric including a plurality of recycled polyester fibers, such as a plurality of staple fibers, is provided. The plurality of recycled polyester fibers may be formed from a post-consumer polyester, a post-industrial waste polyester, or a combination thereof. The covers provide desirable vapor transmission while also providing an improved hydrostatic head. The covers may be provided in a variety of configurations. Methods of forming such covers are also provided.

Nonwoven fabrics are provided that include a plurality of crimped bicomponent fibers having a first component comprising a first polymeric material comprising a first polymer or a first polymeric blend and a second component comprising a second polymeric material, in which the second polymeric material comprises a second polymeric blend of (i) at least one polypropylene polymer, (ii) at least one polyethylene polymer, and (iii) at least one compatibilizer comprising or consisting of at least one polypropylene-polyethylene copolymer.

The provided articles and methods use a non-woven fibrous web containing 60-100 wt % of oxidized polyacrylonitrile fibers; and 0-40 wt % of reinforcing fibers having outer surfaces comprised of a polymer with a melting temperature of from 100° C. to 300° C. The non-woven fibrous web has an average bulk density of from 15 kg/m.sup.3 to 50 kg/m.sup.3, with the plurality of fibers substantially entangled along directions perpendicular to a major surface of the non-woven fibrous web. Optionally, the oxidized polyacrylonitrile fibers can have a crimped configuration. Advantageously, these articles can display a combination of low thermal conductivity, high tensile strength, and flame resistance.

The present invention is generally related to a high capacity, high efficiency nonwoven filtration media comprising a gradient pore structure. In particular, the filtration media can comprise thermoplastic synthetic microfibers, fibrillated fibers, staple fibers, and a binder. Furthermore, the filtration media may be produced without the use of glass fibers or microglass fibers. Consequently, the filtration media of the present invention does not cause the same issues as conventional filtration media that comprises glass fibers and/or microglass fibers. Moreover, the filtration media can be used to treat fuel, lubrication fluids, hydraulic fluids, and various other industrial gases.