Abstract: The present invention is directed toward a method of making a composite structure including receiving a substantially planar nonwoven spunbond layer including a plurality of multicomponent fibers, thermally bonding the nonwoven spunbond layer at a first bond temperature, laying down a meltblown layer on top of the thermally bonded nonwoven spunbond layer to form an intermediate structure, and thermally bonding the intermediate structure at a second bond temperature to form a final composite structure. Composite structures including a spunbond layer and a meltblown layer, wherein the composite structure has a tensile strength of at least about 130 N/2.54 cm in both machine and cross directions, a tear strength of at least 3.0 N/2.54 cm, and an LRV of about 2.0 or higher are also provided herein.

Abstract: A non-shedding hybrid nonwoven web comprised of 99% by mass of functional material(s) co-mingled with the filaments. High level of particle retention within the fabric is provided without the aid of adhesives, binders, adhesive polymers, or post processes. This composite web has a multi-layered structure with a uniform distribution of sorptive particles and desired opposed color contrast on each side. The process includes providing two converging streams of blown polymeric filaments, passive feed of functional material(s) in between the filament streams, and collecting the hybrid webs.

Abstract: Composites where nonwoven fabrics having multicomponent synthetic fibers with adhered particles thereon are disclosed. The multicomponent fibers have at least one polymer component with a melting point below that of the other components, and the average apparent particle diameter is less than the average apparent fiber diameter. Methods of making the disclosed composites are also disclosed.

Abstract: The present invention is directed toward a method of making a composite structure including receiving a substantially planar nonwoven spunbond layer including a plurality of multicomponent fibers, thermally bonding the nonwoven spunbond layer at a first bond temperature, laying down a meltblown layer on top of the thermally bonded nonwoven spunbond layer to form an intermediate structure, and thermally bonding the intermediate structure at a second bond temperature to form a final composite structure. Composite structures including a spunbond layer and a meltblown layer, wherein the composite structure has a tensile strength of at least about 130 N/2.54 cm in both machine and cross directions, a tear strength of at least 3.0 N/2.54 cm, and an LRV of about 2.0 or higher are also provided herein.

Abstract: Methods and apparatuses for printing a three-dimensional fibrous structure are disclosed. A fibrous layer is printed onto a printing surface by forcing fibers through at least one extrusion die and onto the printing surface. The extrusion die and/or printing surface are moved in the X, Y, and/or Z direction while printing the fibers.