Abstract: An air laying forming station (ALFS) forms a nonwoven substrate from a first material and a second material having at least one physical characteristic substantially different from the first material. The ALFS includes a forming chamber and a forming screen, moving relative to the forming chamber, for receiving deposit of the first and second materials. A first distributor supplies the first material. A vacuum source provides an air flow which deposits the first material onto the forming screen. A second distributor delivers the second material, independently from the first material between the first distributor and the forming screen, by gravity along one or more baffle members.

Abstract: Capillary channel structures having one or more intrastructure capillary channels, said structures comprising a polymer composition, wherein: said structures have a capillary channel base, and at least two polymeric capillary channel walls extending from said base along the length of said base in the axial direction for at least about 0.2 cm, said walls having a base end and a distal end, wherein said base and walls form said capillary channels; and said structures have a Specific Capillary Volume of at least about 1.2 cc/g, a Specific Capillary Surface Area of at least about 500 cm.sup.2 /g, and a Compressive Strength (Dry) of at least about 13,800 dynes/cm.sup.2. The structures can be in the form of fibers or sheets. The fibers have a Specific Capillary Volume of at least about 2.0 cc/g and a Specific Capillary Surface Area of at least about 2000 cm.sup.2 /g.