Abstract: A multi-layered web is disclosed that is resilient and/or elastic in the Z-direction. Thus, when the web is compressed, the web assumes a compacted state and then expands to an expanded state when the compressive forces are removed. In one embodiment, the multi-layered web includes a middle layer made from a resilient blend of fibers positioned inbetween two outer layers. The middle layer, for instance, can contain elastomeric fibers, three-dimensional fibers, and/or debonded fibers.

Abstract: A system comprising a pulper configured to (i) accept surfactant, a liquid and fiber stock and (ii) generate a foam that suspends the fiber stock, wherein the foam has a half-life; a headbox configured to receive the foam-suspended fiber stock from the pulper and displace the foam-suspended fiber stock onto a forming wire, wherein a time it takes the foam-suspended fiber stock to move from the pulper to the headbox is less than the half-life; and a foam return device that removes at least some of the foam from the forming wire and returns the at least some of the foam to the pulper.

Abstract: A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

Abstract: A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

Abstract: A process for forming multi-layer fibrous web with good absorbent capacity and absorbent rate is disclosed. The multi-layer fibrous web can be used as absorbent articles, including wiping products, such as industrial wipers, food service wipers, and the like. The multi-layer fibrous web includes a first layer and a second layer, as well as a crossover zone, that has a capillary pressure between the capillary pressure of the first layer and the capillary pressure of the second layer.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: Methods and apparatuses for producing a substrate are described. A method and apparatus for introducing a component into a fluid supply is also presented. A method can include providing a first fluid supply. The fluid supply can be configured as a foam in some embodiments. The method can also include providing a component feed system and a supply of the component. The method can include introducing the component to a fluid supply in an eductor in some aspects. A resultant slurry including a fluid supply and the component can be transferred through a headbox. The resultant slurry can be dewatered to provide a substrate including the component.

Abstract: A system comprising a pulper configured to (i) accept surfactant, a liquid and fiber stock and (ii) generate a foam that suspends the fiber stock, wherein the foam has a half-life; a headbox configured to receive the foam-suspended fiber stock from the pulper and displace the foam-suspended fiber stock onto a forming wire, wherein a time it takes the foam-suspended fiber stock to move from the pulper to the headbox is less than the half-life; and a foam return device that removes at least some of the foam from the forming wire and returns the at least some of the foam to the pulper.

Abstract: A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

Abstract: A method for producing a foam-formed multilayered substrate that includes producing an aqueous-based foam including at least 3% by weight non-straight synthetic binder fibers, wherein the non-straight synthetic binder fibers have an average length greater than 2 mm; forming together a wet sheet layer from the aqueous-based foam and a cellulosic fiber layer, wherein the cellulosic fiber layer includes at least 60 percent by weight cellulosic fibers; and drying the combined layers to obtain the foam-formed multilayer substrate. A multilayered substrate includes a first layer including at least 60 percent by weight non-straight synthetic binder fibers having an average length greater than 2 mm; and a second layer including at least 60 percent by weight cellulosic fiber, wherein the first layer is in a facing relationship with the second layer, and wherein the multilayered substrate has a wet/dry tensile ratio of at least 60%.

Abstract: A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

Abstract: A multi-layered web is disclosed that is resilient and/or elastic in the Z-direction. Thus, when the web is compressed, the web assumes a compacted state and then expands to an expanded state when the compressive forces are removed. In one embodiment, the multi-layered web includes a middle layer made from a resilient blend of fibers positioned inbetween two outer layers. The middle layer, for instance, can contain elastomeric fibers, three-dimensional fibers, and/or debonded fibers.

Abstract: A method for producing a foam-formed multilayered substrate that includes producing an aqueous-based foam including at least 3% by weight non-straight synthetic binder fibers, wherein the non-straight synthetic binder fibers have an average length greater than 2 mm; forming together a wet sheet layer from the aqueous-based foam and a cellulosic fiber layer, wherein the cellulosic fiber layer includes at least 60 percent by weight cellulosic fibers; and drying the combined layers to obtain the foam-formed multilayer substrate. A multilayered substrate includes a first layer including at least 60 percent by weight non-straight synthetic binder fibers having an average length greater than 2 mm; and a second layer including at least 60 percent by weight cellulosic fiber, wherein the first layer is in a facing relationship with the second layer, and wherein the multilayered substrate has a wet/dry tensile ratio of at least 60%.

Abstract: A high topography nonwoven substrate includes synthetic binder fibers; a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein each projection element has a height, a diameter or width, a cross-section, a sidewall, a proximal end where the projection element meets the base layer, and a distal end opposite the proximal end, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

Abstract: A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

Abstract: An absorbent article having a fluid-handling system includes a fluid permeable bodyside liner; a fluid impermeable outer cover; an absorbent core disposed between the liner and the outer cover, wherein the absorbent core includes superabsorbent material and optionally fluff pulp; and a core wrap at least partially encircling the absorbent core, wherein the core wrap includes a three-dimensionally patterned, wetlaid, cellulosic tissue nonwoven material. Fibers of the nonwoven material are entirely cellulose fibers, and the core wrap includes opposing core wrap surfaces each having a textured surface. Each surface includes an average material plane, a plurality of ridges extending in a z-direction from the average material plane, and a plurality of grooves alternating with the plurality of ridges, wherein the grooves depth extend in the opposite z-direction from the average material plane.

Abstract: An absorbent article having a fluid-handling system includes a fluid permeable bodyside liner; a fluid impermeable outer cover; an absorbent core disposed between the liner and the outer cover, wherein the absorbent core includes superabsorbent material and optionally fluff pulp; a tissue core wrap encircling the absorbent core; and a distribution sub-layer disposed between the absorbent core and the outer cover and within the core wrap, wherein the distribution sub-layer includes a three-dimensionally patterned, wetlaid, cellulosic tissue nonwoven material. The distribution sub-layer includes opposing distribution sub-layer surfaces each having a textured surface, wherein each surface includes an average material plane, a plurality of ridges extending in a z-direction from the average material plane, and a plurality of grooves alternating with the plurality of ridges, wherein the grooves depth extend in the opposite z-direction from the average material plane.

Abstract: A method for producing a foam-formed multilayered substrate that includes producing an aqueous-based foam including at least 3% by weight non-straight synthetic binder fibers, wherein the non-straight synthetic binder fibers have an average length greater than 2 mm; forming together a wet sheet layer from the aqueous-based foam and a cellulosic fiber layer, wherein the cellulosic fiber layer includes at least 60 percent by weight cellulosic fibers; and drying the combined layers to obtain the foam-formed multilayer substrate. A multilayered substrate includes a first layer including at least 60 percent by weight non-straight synthetic binder fibers having an average length greater than 2 mm; and a second layer including at least 60 percent by weight cellulosic fiber, wherein the first layer is in a facing relationship with the second layer, and wherein the multilayered substrate has a wet/dry tensile ratio of at least 60%.

Abstract: An absorbent article having a fluid-handling system includes a fluid permeable body side liner; a fluid impermeable outer cover; an absorbent core disposed between the liner and the outer cover, wherein the absorbent core includes superabsorbent material and optionally fluff pulp; a synthetic nonwoven surge layer disposed adjacent the liner between the absorbent core and the liner; and a dispersion layer disposed between the surge layer and the absorbent core, wherein the dispersion layer includes a three-dimensionally patterned, wetlaid, cellulosic tissue nonwoven material. The dispersion layer also includes opposing dispersion layer surfaces each having a textured surface, wherein each surface includes an average material plane, a plurality of ridges extending in a z-direction from the average material plane, and a plurality of grooves alternating with the plurality of ridges, wherein the grooves depth extend in the opposite z-direction from the average material plane.

Abstract: A method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 1% by weight crimped synthetic fibers and at least 1% by weight binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate. A substrate includes an aqueous-based polymer foam including at least 1% by weight crimped synthetic fiber and at least 1% by weight binder fiber, wherein the substrate is free of superabsorbent material. A method for producing a high-bulk, foam-formed substrate includes producing an aqueous-based foam including at least 2% by weight crimped binder fibers; forming a wet sheet from the aqueous-based foam; and drying the wet sheet to obtain the foam-formed substrate, wherein the foam-formed substrate is free of superabsorbent material, and wherein the substrate has a dry density between 0.02 g/cc and 0.1 g/cc.