Nonwoven fibrous webs including randomly oriented discrete fibers defining a multiplicity of non-hollow projections extending from a major surface of the nonwoven fibrous web (as considered without the projections), and a plurality of substantially planar land areas formed between each adjoining projection in a plane defined by and substantially parallel with the major surface. In some exemplary embodiments, the randomly oriented discrete fibers include multi-component fibers having at least a first region having a first melting temperature and a second region having a second melting temperature, wherein the first melting temperature is less than the second melting temperature. At least a portion of the oriented discrete fibers are bonded together at a plurality of intersection points with the first region of the multi-component fibers. In certain embodiments, the patterned air-laid nonwoven fibrous webs include particulates. Methods of making and using such patterned air-laid nonwoven fibrous webs are also disclosed.

A carded nonwoven fibrous web and method of making is provided. The web comprises at least 50%, by weight of the fibrous web, of staple fibers and at least 10%, by weight of the fibrous web, of non-fibrous latex binder, wherein, the staple fibers are autogenously bonded to each other and are bonded to each other by the latex binder.

Nonwoven materials having discrete three-dimensional deformations therein forming protrusions that extend outward from the first surface of the nonwoven material and wide base openings adjacent to the second surface of the nonwoven material are disclosed. At least some of the three-dimensional deformations may have improved protrusion dimensions after compressive forces are applied on the nonwoven material. In some cases, at least some of the protrusions may have one or more holes therein or completely therethrough. Methods of making the same are also disclosed.

Process for the production of a multilayer fabric comprising the steps of: (a) feeding at least a first fabric (101) and a second fabric (102) to a constraining device (15), wherein the first fabric (101) is a non-woven fabric, comprising a plurality of filaments adapted to be crimped, preferably bicomponent filaments; (b) constraining said first and said second fabric (102) to each other, so that to define a plurality of constraining points or zones (P) between said first fabric (101) and said second fabric, and so that said first and second fabric (102) are superimposed; (c) heating said first and second fabric (102), so that the filaments of the first fabric (101) develop a crimp, thus increasing the thickness of the first fabric (101) and shrinking the length and the width of the first fabric (101), the shrinking of the first fabric (101) being greater than the shrinking of the second fabric (102).

Nonwoven fabrics suitable for a wide variety of applications (e.g., healthcare, filtration, industrial, packaging, etc.) are provided. In one aspect, the nonwoven fabric includes a plurality of segmented fibers. Each of the plurality of segmented fibers may comprise a fiber axis and a plurality of alternating larger diameter and smaller diameter segments along the fiber axis. The plurality of segmented fibers may be substantially aligned in a first direction.

Disclosed is a wearable article continuous in a longitudinal direction and a transverse direction comprising a body-facing surface and a garment-facing surface; wherein at least a portion of the garment-facing surface is a nonwoven substrate material made of fibers having a Roughness (standard deviation of the grayscale image) of at least about 16, preferably at least about 18, more preferably at least about 20; and a fiber diameter of no more than about 22 μm, preferably no more than about 17 μm, more preferably no more than about 15 μm, according to the measurements herein.

A method for producing a foam-formed multilayered substrate that includes producing an aqueous-based foam including at least 3% by weight non-straight synthetic binder fibers, wherein the non-straight synthetic binder fibers have an average length greater than 2 mm; forming together a wet sheet layer from the aqueous-based foam and a cellulosic fiber layer, wherein the cellulosic fiber layer includes at least 60 percent by weight cellulosic fibers; and drying the combined layers to obtain the foam-formed multilayer substrate. A multilayered substrate includes a first layer including at least 60 percent by weight non-straight synthetic binder fibers having an average length greater than 2 mm; and a second layer including at least 60 percent by weight cellulosic fiber, wherein the first layer is in a facing relationship with the second layer, and wherein the multilayered substrate has a wet/dry tensile ratio of at least 60%.

The present invention relates to an elastic nonwoven fabric comprising a nonwoven web that is made of a plurality of fibers, which fibers are bicomponent fibers which each comprise a first component and a second component, wherein the first component is present in an amount in the range of from 80-95% by weight and the second component is present in an amount in the range of from 5-20% by weight, both weights based on the total weight of each fiber; wherein the first component comprises an ethylene/α-olefin copolymer and the second component comprises a low density polyethylene having a density in the range of from 0.90-0.95 g/cm.sup.3 (as determined with ASTM D792); wherein the first component and the second component both have a melt flow rate in the range of from 10-40 g/10 min (as determined by ASTM D1238 (190° C., 2.16 kg)); and wherein the nonwoven web comprises a side which is provided with a pattern of individualized bonded areas, wherein the surface of the bonded areas is in the range of 8-25%, based on the total surface of the side. The present invention further relates to a process for preparing the nonwoven fabric, and an article comprising the nonwoven fabric.

Nonwoven materials having at least one layer comprising high core bicomponent fibers are provided. The nonwoven materials can have multiple layers and are suitable for use in a variety of applications, including in absorbent products. The nonwoven materials can have improved resiliency and strength and can retain their structure under wetted conditions and after tension and compression.

Nonwoven fabrics suitable for a wide variety of applications (e.g., healthcare, filtration, industrial, packaging, etc.) are provided. In one aspect, the nonwoven fabric includes a plurality of segmented fibers. Each of the plurality of segmented fibers may comprise a fiber axis and a plurality of alternating larger diameter and smaller diameter segments along the fiber axis. The plurality of segmented fibers may be substantially aligned in a first direction.