Abstract: Non-woven fabrics and methods and apparatus for their manufacture are disclosed. The fabrics have excellent mechanical strength and hand, and have a substantial uniformity of constituent fibers even at low basis weights. The fabric comprises chopped fibers of a synthetic polymeric thermoplastic material, which serve as binder fibers, and chopped fibers of a synthetic polymeric material which need not be a thermoplastic, which serve as bonded fibers. No extraneous binder materials need be present in the fabric. During manufacture, the binder fibers are uniformly dispersed in an aqueous liquid with the bonded fibers. The fibers are wet laid to form a web which is subsequently dried. During drying, the web is physically supported to prevent fracture. Also, during drying, the web is heated sufficiently to cause the binder fibers to bond to the bonded fibers, thereby forming the finished fabric.

Abstract: A composite absorbent article is described having a plural layer absorbent core comprising a bonded insert pad and a dispersion pad. The insert pad preferably comprises binder coated fibers to which superabsorbent particles are adhered. By using heat fusible binders, a heat bonded superabsorbent containing insert pad is provided. The dispersion pad also typically comprises fibers and enhances the wicking of liquid throughout the insert pad. In addition, the insert pad may be bound to the dispersion pad at the interface between the pads to provide a stronger composite structure and to also entangle the fibers of the two pads at their interface to improve the wicking of liquid from the dispersion pad into the insert pad. In addition, hydrophilic fibers may be included in the insert pad to enhance the wicking of liquid into the insert pad. The use of surfactant materials in the binder enhances the vertical wicking characteristics of the composite pad.

Abstract: A durable launderable towel has a thermobonded core of thermoplastic and other fibers. The towel has at least one cover sheet which is preferably formed with apertures and has a limited stretchability. Limited stretchability may be achieved by prestretching and heat setting the cover sheet prior to assembly into a towel. The towel is also densified in a field pattern and is typically densified at the peripheral edge. Embossing is preferably used to form these densified areas. The combination of thermobonding the core, embossing and the use of apertured cover sheets results in a towel having the softness, drape and feel approaching that of cloth. By controlling the embossing on the wiping surface of the towel, a towel with surfaces having different wipe dry characteristics and textures can be produced.

Abstract: A durable launderable towel has a thermobonded core of thermoplastic and other fibers. The towel has at least one cover sheet which is preferably formed with apertures. The towel is also densified in a field pattern and is typically densified at the peripheral edge. Embossing is preferably used to form these densified areas. The combination of thermobonding the core, embossing and the use of apertured cover sheets results in a towel having the softness, drape and feed approaching that of cloth. By controlling the embossing on the wiping surfaces of the towel, a towel with surfaces having different wipe dry characteristics and textures can be produced.