Abstract: Provided is a nonwoven material, including a spunbound layer including fibers having an average diameter between 12 and 25 microns, a meltblown layer adjacent to the spunbound layer and including fibers having an average diameter between 2 and 5 microns, and an electrospun layer adjacent to the meltblown layer and including nanofibers having an average diameter between 100 and 400 nanometers. Also provided is an electrospun layer having a basis weight of at least 0.2 gsm, the total basis weight of the meltblown layer is at least twice that of the electrospun layer, and the total basis weight of all of the meltblown layers in the material constitutes at least 3% of the basis weight of the material. Further provided is a spunbound layer that may have an average pore size between 70 and 120 microns, the meltblown layer may have an average pore size between 15 and 25 microns, and the electrospun layer may have an average pore size between 500 nanometers and 2 microns.

Abstract: A non-woven material is provided, comprising an external non-elastic base layer and an auxiliary layer comprising an elastic material, the base layer and auxiliary layer being mechanically bonded to one another.

Abstract: A nonwoven web material made up of a composite of at least two layers is described. The at least two layers include a spunbond continuous fiber layer and a meltblown fiber layer. The composite is subjected to thermal calender bonding and water jet treatment. The water jet treatment serves to break meltblown fibers and cause ends thereof to extend through the spunbond layer. The ends sticking out provide a velvet-like surface to the exterior of the web material and, thus, softness to the web material. The water jet treatment does not destroy the thermal calender bonds. The web material has a mean flow pore size of between about 10 and about 100 microns. The mean flow pore size defines primary absorbent characteristics in the web material, e.g., absorptive capacity, absorption rate and wicking ability.

Abstract: A nonwoven web material made up of a composite of at least two layers is described. The at least two layers include a spunlaid continuous fiber layer and a meltblown fiber layer. The composite, in absence of any prebonding, is subjected to water jet treatment to break meltblown fibers and cause ends thereof to extend through the spunlaid layer. The ends sticking out provide a velvet-like surface to the exterior of the web material and, thus, softness to the web material. The web material has a mean flow pore size of between about 10 and about 100 microns. The mean flow pore size defines primary absorbent characteristics in the web material, e.g., absorptive capacity, absorption rate and wicking ability.

Abstract: A process for producing a windable spunlaid material, and a product produced by the process, wherein minimal web compaction occurs and thermal, mechanical and chemical prebonding is not necessary. Filaments are produced and laid on a moving support to provide a web having a machine direction tensile strength of less than 5 N per 5 cm at a basis weight of 50 gsm. The web is then passed through a compacting calender. The filaments of the spunlaid web are not subjected to a temperature exceeding the melting point of the filaments. Preferably, the calender through which the web passes has a surface temperature of less than 130° C. at a calender nip pressure of 30 N/mm. The resulting web is windable under low tension, i.e., a tension of less than 40 N/m. The wound spunlaid material can then be stored and/or transport, to provide a nonwoven material.

Abstract: A lightweight nonwoven material is described. The nonwoven material includes at least three layers wherein a first layer is spunlaid, a second layer is meltblown, and a third layer is spunlaid, the first and third layers being external layers. The basis weight of the nonwoven material is 15.0 gsm or less and the weight of the second meltblown layer is about 5% or less of the total basis weight. The preferred polymer for the nonwoven material is polypropylene, in particular for the meltblown fibers is a resin having a molecular weight distribution Mw/Mn in a range of about 1.8-3.2. Hydrophilicity can be imparted to the nonwoven material by inclusion of a surfactant additive in an extrusion melt during formation of fibers, or by topical treatment following formation of the layers of the nonwoven material. The method of making the nonwoven material involves formation of the layers thereof as continuous fibers and forming the layers in a continuous sequential manner, i.e.

Abstract: A nonwoven material composed of hydrophobic material rendered hydrophilic through the inclusion of an internal additive is described. The nonwoven material includes at least one layer of which can be continuous filament spunmelt or meltblown. The layer can be provided alone or as one of a composite material. Hydrophilicity is imparted to the nonwoven material by inclusion of a surfactant additive in an extrusion melt during formation of fibers which will form a layer of nonwoven material. By controlling the internal additive utilized and modifying the type of fibers formed, e.g., continuous, non-continuous (staple), denier size, etc., the absorbency and barrier properties of a nonwoven material can be predetermined in view of the use to which the nonwoven material is to be applied.

Abstract: A process for making a single layer or multi-layer nonwoven material having improved cross-directional strength and feel, and the nonwoven material made thereby, is described. The process provides a nonwoven material including at least one layer formed of polymeric continuous filaments. The layer(s) are formed in a continuous sequential manner, i.e., a subsequent layer being formed on top of a preceding layer or layers. Thereafter, in the absence of any prebonding, the layer(s) are subjected to hydroentanglement. The basis weight of the nonwoven material is from about 17 to 150 gsm. The nonwoven material has improved properties based on treating the layer(s) by hydroentanglement. Varying the number of water jets and the pressure of the water allows variance in the properties obtained in the final product.

Abstract: A method of making spunmelt/film composite materials, as well as the product of the method, is described. The method is a continuous in-line process including in-line production of a continuous filament spunmelt web, placement of a film on the spunmelt web, optional placement of at least one nonwoven fabric on the film, joining or bonding of the formed layered structure by subjecting the layered structure to calendering using heated rolls. The basis weight of the continuous filament spunmelt web is from about 13.5 gsm to about 100 gsm and of the polyolefin film from about 10 gsm to about 40 gsm. The total composite basis weight tolerance ranges from about 25 gsm to about 150 gsm. No adhesive or secondary thermal bonding is utilized in the process.

Abstract: A lightweight nonwoven material having hydrophilic characteristics is described. The nonwoven material includes at least three layers wherein a first layer is spunlaid, a second layer is meltblown, and a third layer is spunlaid, the first and third layers being external layers. The basis weight of the nonwoven material is 13.5 gsm or less and the basis weight of the second meltblown layer is 3.5 gsm or less, preferably less than 3.0 gsm, and more preferably less than 2.5 gsm. Hydrophilicity is imparted to the nonwoven material by inclusion of a surfactant additive in an extrusion melt during formation of fibers, or by topical treatment following formation of the layers of the nonwoven material. The method of making the nonwoven material involves formation of the layers thereof as continuous fibers and forming the layers in a continuous sequential manner, i.e., a subsequent layer being formed on top of a preceding layer or layers.