Abstract: A relofted, spunbonded nonwoven web exhibiting a solidity of from less than 8.0%, to at least 3.0%, and exhibiting a Quality Factor of at least 0.30. Methods of making a relofted web; and, methods of using a relofted web as an air-filtration web, e.g. as a filter media or a layer thereof.

Abstract: A relofted, spunbonded nonwoven web exhibiting a solidity of from less than 8.0%, to at least 3.0%, and exhibiting a Quality Factor of at least 0.30. Methods of making a relofted web; and, methods of using a relofted web as an air-filtration web, e.g. as a filter media or a layer thereof.

Abstract: Disclosed herein are bicomponent fibers comprising first and second polymer components present in distinct portions of the cross section of the filament, wherein the first polymer component of the filaments is partially crystalline and serves as the matrix component of the filaments and the second polymer component of the filament is amorphous and serves as the binder component of the filaments, and wherein the fibers exhibit a single melting peak as evidenced by a differential scanning calorimetry (DSC) trace. Also disclosed herein are methods of making bicomponent fibers and nonwoven fabrics.

Abstract: A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.

Abstract: A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.

Abstract: A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.

Abstract: A nonwoven fabric is provided having a plurality of semi-crystalline filaments that are thermally bonded to each other and are formed of the same polymer and exhibit substantially the same melting temperature. The fabric is produced by melt spinning an amorphous crystallizable polymer to form two components having different levels of crystallinity. During spinning, a first component of the polymer is exposed to conditions that result in stress-induced crystallization such that the first polymer component is in a semi-crystalline state and serves as the matrix or strength component of the fabric. The second polymer component is not subjected to stress induced crystallization and thus remains in a substantially amorphous state which bonds well at relatively low temperatures. In a bonding step, the fabric is heated to soften and fuse the binder component. Under these conditions, the binder component undergoes thermal crystallization so that in the final product, both polymer components are semi-crystalline.

Abstract: Nonwoven fabric fabrics suitable for undergoing pleating to form filtration media are provided. The fabrics generally include at least three layers. The fibers forming the inner layer has a cross section providing greater stiffness, while the fibers forming the outer layers have a cross section providing greater durability. The resulting fabrics provide improved particulate holding and pressure drop characteristics at no sacrifice to durability.

Abstract: Nonwoven fabric fabrics suitable for undergoing pleating to form filtration media are provided. The fabrics generally include at least three layers. The fibers forming the inner layer has a cross section providing greater stiffness, while the fibers forming the outer layers have a cross section providing greater durability. The resulting fabrics provide improved particulate holding and pressure drop characteristics at no sacrifice to durability.

Abstract: The present invention provides a nonwoven fabric that is especially engineered to function as the substrate for a dryer activated fabric softener sheet. The substrate has a basis weight of 0.48 ounces per square yard or less, a thickness of from about 0.16 mm to about 0.38 mm, and comprises a nonwoven web of fibers, wherein at least some of the fibers are hollow. Preferably the fibers have a denier of from 2 to 8. In preferred embodiments of the invention, the hollow fibers have a void area at least 10 percent of the fiber cross-section, and the fibers have a noncircular trilobal cross-section.

Abstract: A spunbond nonwoven fabric is provided, formed from a multiplicity of substantially continuous bicomponent filaments randomly arranged and bonded to one another. The bicomponent filaments have a multilobal cross-sectional configuration including a first polymer component formed of a higher-melting composition occupying at least the central portion of the filament cross-section and a second polymer component formed of a lower-melting composition being present in at least one lobe of the multilobal cross-section.