Abstract: The present invention discloses a nonwoven web and methods for manufacturing the nonwoven web. One aspect of the invention includes a plurality of outwardly facing nozzles that are positioned at various angles with respect to the axis of a pipe the nozzles are located on. Another aspect of the invention pertains to perturbing at least a portion of a fiber matrix prior to the fiber matrix collecting on a forming surface. The perturbed fiber matrix provides for an increase in cross-machine direction fiber strength of the nonwoven web.

Abstract: A coform material is provided including a nonwoven web containing a mixture of staple fibers and an absorbent material including pulp fibers. The staple fibers are present in an amount of from about 5 wt. % to about 50 wt. % and the pulp fibers are present in an amount of from about 50 wt. % to about 95 wt. %. The staple fibers have an average length of from about 5 mm to about 50 mm. The staple fibers and pulp fibers are thermally bonded or hydraulically entangled to form the nonwoven web. Methods and systems for producing coform materials are also provided.

Abstract: A fiber forming device is disclosed that is well suited to producing nonwoven webs having excellent barrier properties. In one aspect, the fiber forming device can be used to produce meltblown webs or coform webs. The fiber forming device includes a die head containing multiple rows of polymer nozzles for forming fibers. Air flow paths are positioned on either side of the rows of polymer nozzles. In addition, an air flow path is positioned in between the rows of polymer nozzles. The air flow paths produce an attenuating gas stream that attenuates fibers being produced by the polymer nozzles and directs the fibers onto a forming surface for forming nonwoven webs.

Abstract: Systems, methods and apparatus for a meltblown die comprising a die body; a die tip mounted to the die body and having one or more capillaries, wherein the die tip is configured to direct polymer out through the one or more capillaries into a forming zone, a plurality of passages having an interior region and configured to direct attenuating fluid through the interior region and out into the forming zone; and an air management device having a plurality of air shaping devices, wherein the air management device is at least partially within at least one of the plurality of passages, and the plurality of air shaping devices are configured to re-arrange air flow in the at least one of the plurality of passages to reduce turbulence of the attenuating fluid in at least one of the interior region and the forming zone.

Abstract: The present invention discloses a nonwoven web and methods for manufacturing the nonwoven web. The present invention specifically discloses a nonwoven web that includes a co-forming process wherein a first gas stream includes meltblown fibers that are extruded from a first die head, a second gas stream that includes spunblown fibers that are extruded from a second die head and a third die head that includes pulp fibers that are extruded from a pulp nozzle. By sandwiching spunblown fibers between meltblown fibers during the co-forming processes, a nonwoven web having improved cross-machine direction tensile strength is formed.

Abstract: A system and method for providing a plurality of fibers from a spinneret; subjecting the fibers to quench air; attenuating the fibers through a closed stretching unit; reducing a velocity of the plurality of fibers in a diffuser that is spaced apart from an exit of the closed stretching unit in a direction of travel of the fibers, the diffuser having opposed diverging sidewalls; and subjecting the fibers to an applied electrostatic charge before the fibers enter the diffuser, wherein the electrostatic charge is applied by one or more electrostatic charging units.

Abstract: A barrier mask, or face mask is provided that includes a mask body that includes a filter portion, an upper elastic portion, and a lower elastic portion, where the mask body includes at least one meltblown layer. The face mask also includes one or more elastic straps. A method of forming a face mask is also provided, where the method includes electrostatically treating the meltblown layer during the face mask formation process.

Abstract: The present invention discloses a nonwoven web and methods for manufacturing the nonwoven web. One aspect of the invention includes a plurality of outwardly facing nozzles that are positioned at various angles with respect to the axis of a pipe the nozzles are located on. Another aspect of the invention pertains to perturbing at least a portion of a fiber matrix prior to the fiber matrix collecting on a forming surface. The perturbed fiber matrix provides for an increase in cross-machine direction fiber strength of the nonwoven web.

Abstract: An elastomeric composition, including at least one skin layer and a core layer, with non-blocking properties such that the elastomeric composition can be wound is provided. The core layer includes an elastomer, and the skin layer includes an elastomer, which may be the same or different from the core layer, and a non-elastic polyolefin. Further, the skin layer can be present as a small portion of the total elastomeric composition, and may maintain the elastic efficiency of the composition.

Abstract: A method of making nonwoven webs comprising providing a spinneret including a pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer into a region adjacent the first side of the spinneret, directing only a second stream of molten propylene polymer into a region distal to the first side of the spinneret, extruding only the first stream propylene polymer through the exit openings in a first zone where the exit opening comprises exit ports in the first zone having a first density; extruding only the second stream propylene polymer through the exit openings of a second zone where the exit opening comprises exit ports in the second zone having a second density less than the first density; and the second zone is distal to the first side with the first zone being between the second zone and the first side.

Abstract: Disclosed herein are improvements to processes and equipment for the manufacture of composite nonwoven webs comprising a mixture of two or more different fibers and formed from at least two streams of air-entrained fibers. Adjacent the perimeter of an exit port of one of the fiber streams are located a series of spaced tabs and apertures. As a first stream of air-entrained fibers pass the series of tabs and apertures, vortices are formed therein. When mixed with a second stream of air-entrained fibers, the vortices within the first stream of fibers causes increased mixing of the fibers, helping to drive the first fibers deeper into the second stream of air-entrained fibers.

Abstract: Absorbent nonwoven wipes having improved strength and hand feel comprising a non-homogeneous mixture of small diameter polymeric meltblown fibers and absorbent staple fibers with meltblown fiber rich outer surfaces and staple fiber rich inner regions and wherein a minor amount of staple fibers also protrude through the meltblown fiber rich regions. Wet wipes and dispensers for housing the same are also provided.

Abstract: Disclosed herein are improvements to processes and equipment for the manufacture of composite nonwoven webs comprising a mixture of two or more different fibers and formed from at least two streams of air-entrained fibers. Adjacent the perimeter of an exit port of one of the fiber streams are located a series of spaced tabs and apertures. As a first stream of air-entrained fibers pass the series of tabs and apertures, vortices are formed therein. When mixed with a second stream of air-entrained fibers, the vortices within the first stream of fibers causes increased mixing of the fibers, helping to drive the first fibers deeper into the second stream of air-entrained fibers.

Abstract: An elastic nonwoven laminate that contains an elastic film laminated to one or more nonwoven facings is provided. The nonwoven facing contains a conventional polyolefin and can also contain a polyolefin-based plastomer. The laminate is activated by grooving to decouple the nonwoven facing from the elastic film. To reduce fiber-pull out that can result due to activation by grooving, the laminate can be post-bonded at room or elevated temperatures and a specific range of pressures to compact the fibers of the facing and minimize fiber pull-out/fuzziness while not sacrificing the softness, elasticity, and feel of the laminate.

Abstract: An elastic nonwoven laminate that contains an elastic film laminated to one or more nonwoven facings is provided. The nonwoven facing contains a conventional polyolefin and can also contain a polyolefin-based plastomer. The laminate is activated by grooving to decouple the nonwoven facing from the elastic film. To reduce fiber-pull out that can result due to activation by grooving, the laminate can be post-bonded at room or elevated temperatures and a specific range of pressures to compact the fibers of the facing and minimize fiber pull-out/fuzziness while not sacrificing the softness, elasticity, and feel of the laminate.

Abstract: An elastic nonwoven laminate that contains an elastic film laminated to one or more nonwoven facings is provided. The nonwoven facing contains a conventional polyolefin and can also contain a polyolefin-based plastomer. The laminate is activated by grooving to decouple the nonwoven facing from the elastic film. To reduce fiber-pull out that can result due to activation by grooving, the laminate can be post-bonded at room or elevated temperatures and a specific range of pressures to compact the fibers of the facing and minimize fiber pull-out/fuzziness while not sacrificing the softness, elasticity, and feel of the laminate.

Abstract: A polyolefin material that comprises a thermoplastic composition is provided. The composition contains a continuous phase that includes a polyolefin matrix polymer and a nanoinclusion additive dispersed within the continuous phase in the form of discrete domains. The composition further includes a butene polymer. A porous network is defined within the thermoplastic composition that includes a plurality of nanopores.

Abstract: An elastic nonwoven laminate that contains an elastic film laminated to one or more nonwoven facings is provided. The nonwoven facing contains a conventional polyolefin and can also contain a polyolefin-based plastomer. The laminate is activated by grooving to decouple the nonwoven facing from the elastic film. To reduce fiber-pull out that can result due to activation by grooving, the laminate can be post-bonded at room or elevated temperatures and a specific range of pressures to compact the fibers of the facing and minimize fiber pull-out/fuzziness while not sacrificing the softness, elasticity, and feel of the laminate.

Abstract: Fibers that are formed from a thermoplastic composition that contains a polymer and high surface area nanostructures are provided. The fibers have a voided structure and low density while maintaining good strength characteristics. To achieve such a structure, a blowing agent in the thermoplastic composition is activated during extrusion to form bubbles in the fibers. The high surface area nanostructures in the formed fibers can be formed of or carry the blowing agent and can enhance the strength of the fibers and compensate for the non-load bearing voids of the fibers.

Abstract: An elastic composite formed from a lightweight nonwoven facing that has a low degree of strength in the cross-machine direction (“CD”) is provided. Through selective control over certain parameters of the materials employed in the composite and the formation process, the present inventors have discovered that such low strength and lightweight facings may be readily laminated to an elastic film without significantly damaging their integrity. For example, in one embodiment, the elastic film may possess a multi-layered construction that includes an elastomeric elastic layer positioned adjacent to a strength-enhancing thermoplastic layer. The polymer content and thickness of the thermoplastic layer are generally selected to impart additional strength and integrity to the film. Likewise, the polymer content of the elastic layer may also be selected so that the film possesses a sufficient tack for adhering to the facing.