Abstract: The present invention provides a nonwoven web or laminate having at least one surface with abrasion resistance and a low degree of free fibers on the surface. Also provided is a lofty nonwoven web laminate from multicomponent fibers having at least one surface with improved abrasion resistance and reduced fuzziness over other multicomponent fiber nonwoven webs. This nonwoven webs and laminate can be used where nonwoven webs and laminates are currently used, but are particularly suitable as a filter media. Also described is a method for producing a nonwoven web having at least one abrasion resistant surface. The process includes using a liner material between the forming surface and the forming nonwoven web, wherein the liner is removed after the nonwoven web is bonded. Removing the liner exposes the abrasion resistant surface of the nonwoven web or laminate.

Abstract: A nonwoven web useful as a filter medium includes a plurality of bicomponent multilobal fibers including a higher melting polymer component, a lower melting polymer component, and an interface between the polymer components. The fibers are bonded together at points of contact including the lower melting polymer components, to provide a coherent filter medium. The multilobal fibers include raised lobal regions and depressed regions between the lobes which catch, trap or ensnare particulate matter that is being filtered from a gaseous or liquid medium. The multilobal fibers may be electrecized to provide electrostatic attraction between the fibers and the particles.

Abstract: An improved nonwoven web composite is formed by combining splittable bicomponent thermoplastic filaments with a component selected from other fibers and particles. The bicomponent filaments include distinct regions of first and second incompatible polymers extending the length of the filaments. After the bicomponent filaments are combined with the other fibers and/or particles, the bicomponent filaments are caused to split lengthwise along boundaries between the regions of different polymers, resulting in a web or matrix of finer filaments which entrap, ensnare and contain the other fibers and/or particles within the web or matrix. The nonwoven web composite is particularly useful for making absorbent articles, which require durability and optimum levels of absorbent fibers and/or particles.

Abstract: An integrated nonwoven laminate material suitable for use as a filter medium having a microfiber layer integrated with a low loft multicomponent spunbond layer and a high loft multicomponent spunbond layer and a method of producing the integrated nonwoven laminate material. In one embodiment of this invention, a laminate material is through-air bonded to form an integrated nonwoven laminate material which is then electret treated to enhance attraction between particles being filtered and the fibers of the integrated nonwoven laminate material. In one embodiment of this invention, the integrated nonwoven laminate material is used as a filter having an ASHRAE Standard 52.1-1992 Dust Spot Efficiency of about 40% to about 95% and an ASHRAE Standard 52.2-1999 MERV (Minimum Efficiency Reporting Value) of 12 to 16.

Abstract: Nonwoven webs of continuous filaments are provided having a mixture or blend of first and second continuous filaments wherein the first and second continuous filaments are different from the first continuous filaments in one or more respects such as size, cross-sectional shape, polymer composition, crimp level, wettability, liquid repellency, and charge retention. The second continuous filaments can be substantially surrounded by the first continuous filaments wherein the ratio of first continuous filaments to second continuous filaments exceeds about 2:1.

Abstract: The present invention provides a cleaning sheet that has an enhanced dirt, dust and/or debris pick-up and retention characteristics, which can be used in dry applications and/or wet applications. The cleaning sheet is prepared from a nonwoven web containing plurality of multicomponent multilobal filaments, wherein the multicomponent multilobal filaments have a plurality of raised lobal regions separated by depressed regions. The cleaning sheet also has voids between the plurality of multicomponent multilobal filaments which allow for enhanced dirt, dust and/or debris pick-up and retention. The nonwoven web can be a single layer or a layer of a multilayer laminate. The nonwoven web is optionally electret treated. Also disclosed is a cleaning implement and cleaning kit containing the cleaning sheet.

Abstract: The present invention relates to a composite structure which is capable of use as a filter medium and a method for producing the same. The composite structure contains at least a first nonwoven layer, said first layer having a first surface and a second surface, as well as a rigidifying or stiffening component. The rigidifying component is applied in semi-molten state to the one surface of the nonwoven layer and provides sufficient stiffness and/or resilience to the composite such that the composite is self-pleatable yet retains flexibility. The rigidifying or stiffening component may be filaments of a polymer or polymer blend or alternatively the rigidifying or stiffening component may also be a wax or wax blend.

Abstract: There is provided a process which comprises the step of subjecting a just produced spunbond web to a high flow rate, heated stream of air across substantially the width of the web to very lightly bond the fibers of the web together. Such bonding should be the minimum necessary in order to satisfy the needs of further processing yet not detrimentally affect the web. The fibers of the web may be monocomponent or biconstituent and the web should be substantially free of adhesives and not subjected to compaction rolls.