Abstract: A high pulp content nonwoven composite fabric is disclosed. The composite fabric contains 1) from more than about 0 to less than about 30 percent, by weight, of a nonwoven layer of conjugate spun filaments, the filaments containing at least one low-softening point component and at least one high-softening point component and having at least some exterior surfaces of the filaments composed of at least one low-softening point component; 2) more than about 70 percent, by weight, of pulp fibers; and 3) regions in which the low-softening point component at the exterior surfaces of the filaments is fused to at least a portion of the fibrous component. This high pulp content composite nonwoven fabric may be used as a heavy duty wiper or as a fluid distribution material, cover material, and/or absorbent material in an absorbent personal care product. Also disclosed is a method of making the high pulp content nonwoven composite fabric.

Abstract: The present invention provides a method for creping a nonwoven web using a hot melt adhesive as the creping adhesive. As a second aspect of the present invention, an internal adhesive is added to the polymers used to produce the nonwoven web during the nonwoven web forming process and this internal adhesive adheres the nonwoven web to the creping roll. Using the processes of the present invention, more energy efficient methods are provided for creping nonwoven webs. The creped nonwoven webs of the present invention are useful in a wide variety of application including as wipes, liners, transfer or surge layers, outercovers, other fluid handling materials and looped attachment materials for hook and loop fasteners.

Abstract: A high pulp content nonwoven composite fabric is disclosed. The composite fabric contains 1) from more than about 0 to less than about 30 percent, by weight, of a nonwoven layer of conjugate spun filaments, the filaments containing at least one low-softening point component and at least one high-softening point component and having at least some exterior surfaces of the filaments composed of at least one low-softening point component; 2) more than about 70 percent, by weight, of pulp fibers; and 3) regions in which the low-softening point component at the exterior surfaces of the filaments is fused to at least a portion of the fibrous component. This high pulp content composite nonwoven fabric may be used as a heavy duty wiper or as a fluid distribution material, cover material, and/or absorbent material in an absorbent personal care product. Also disclosed is a method of making the high pulp content nonwoven composite fabric.

Abstract: Disclosed is a liquid transport material composed of a pulp fibers hydraulically needled into a nonwoven fibrous structure adapted to have a liquid transport value of at least 12 grams of liquid per gram of material over 30 minutes. The liquid transport material may contain up to about 50 percent, by weight, short staple length fibers as well as effective amounts of various particulates. The liquid transport material may be used as a liquid transport component of an absorbent structure which may be part of, for example, a personal care product. Also disclosed is a process of making a liquid transport material utilizing hydraulic needling techniques.