Abstract: A composite structure including at least one paper web layer bonded to at least one nonwoven web layer by a hydroentanglement process. The paper web layer is made of natural fibers processed to have a specified kappa number depending on desired smoothness and hydrophilicity of the composite structure. In an exemplary embodiment, the paper web layer is made of a structured paper web, and the structure of the paper web is imparted to the nonwoven web layer by the hydroentanglement process. In an exemplary embodiment, the composite structure is a wipe product, comprised of a two or three layer structure, with at least one natural fiber layer. Higher machine speeds to produce a two-layer composite web comprised of one natural fiber web is achieved using a protective layer during the hydro-entangling process.

Abstract: A nonwoven web made up of continuous fibers that include a polymer component, the web being bonded by a bond pattern including spaced apart closed figures arranged in a repeating pattern, the web having an abrasion rating of 3 or higher and an average HOM of less than 6 grams.

Abstract: An absorbent article having improved softness signals is disclosed. The article may include a topsheet or a backsheet including a nonwoven web. The web may have a basis weight of 30 gsm or less, may be formed of spunlaid fibers including polyolefin and up to 5 percent by weight TiO2, and may be impressed with a pattern of bond impressions to a bond area percentage of at least 10 percent forming a pattern of bonded regions and raised regions. The web may have opacity of 42 or greater; have an average height difference between bonded regions and raised regions of at least 280 ?m; be hydroengorged; and/or have a cross-direction tensile strength of 350 gf/cm. A nonwoven web manufactured to have a suitable combination of such features exhibits an enhanced appearance of softness, soft tactile feel and satisfactory mechanical attributes, while being relatively cost effective.

Abstract: A method of manufacturing a nonwoven including the steps of: forming a nonwoven web substantially comprised of continuous fibers; applying a bonding pattern to said nonwoven web using a smooth roll and a calender roll wherein said bonding pattern comprises a pattern having unbonded areas; and subjecting the side of said nonwoven web contacted by said smooth roll to a hydraulic treatment at a pressure of between 25 and 75 bars and a total energy of about 0.01-0.04 kwhr/kg., wherein said continuous fibers are comprised of between 97% and 98.5% by weight of an olefin resin comprising substantially of polypropylene and between 1.5% and 3% by weight of a whitener.

Abstract: A method of manufacturing an embossed nonwoven sheet comprising feeding a sheet comprising spunmelt fibers through a nip region of a forming station, the forming station comprising a rigid cylinder having a surface with raised elements that form a 3D pattern and a deformable opposing surface which is not part of the rigid cylinder, so that the sheet is in contact with both the rigid cylinder and the deformable opposing surface at the nip region as the sheet moves through the forming station and the 3D pattern is embossed onto the sheet.

Abstract: A method of manufacturing a nonwoven including the steps of: forming a nonwoven web substantially comprised of continuous fibers; applying a bonding pattern to said nonwoven web using a smooth roll and a calender roll wherein said bonding pattern comprises a pattern having unbonded areas; and subjecting the side of said nonwoven web contacted by said smooth roll to a hydraulic treatment at a pressure of between 25 and 75 bars and a total energy of about 0.01-0.04 kwhr/kg., wherein said continuous fibers are comprised of between 97% and 98.5% by weight of an olefin resin comprising substantially of polypropylene and between 1.5% and 3% by weight of a whitener.

Abstract: An absorbent article having improved softness signals is disclosed. The article may include a topsheet or a backsheet including a nonwoven web. The web may have a basis weight of 30 gsm or less, may be formed of spunlaid fibers including polyolefin and up to 5 percent by weight TiO2, and may be impressed with a pattern of bond impressions to a bond area percentage of at least 10 percent forming a pattern of bonded regions and raised regions. The web may have opacity of 42 or greater; have an average height difference between bonded regions and raised regions of at least 280 ?m; be hydroengorged; and/or have a cross-direction tensile strength of 350 gf/cm. A nonwoven web manufactured to have a suitable combination of such features exhibits an enhanced appearance of softness, soft tactile feel and satisfactory mechanical attributes, while being relatively cost effective.

Abstract: An absorbent article having improved softness signals is disclosed. The article may include a topsheet or a backsheet including a nonwoven web. The web may have a basis weight of 30 gsm or less, may be formed of spunlaid fibers including polyolefin and up to 5 percent by weight TiO2, and may be impressed with a pattern of bond impressions to a bond area percentage of at least 10 percent forming a pattern of bonded regions and raised regions. The web may have opacity of 42 or greater; have an average height difference between bonded regions and raised regions of at least 280 ?m; be hydroengorged; and/or have a cross-direction tensile strength of 350 gf/cm. A nonwoven web manufactured to have a suitable combination of such features exhibits an enhanced appearance of softness, soft tactile feel and satisfactory mechanical attributes, while being relatively cost effective.

Abstract: An absorbent article having improved softness signals is disclosed. The article may include a topsheet or a backsheet including a nonwoven web. The web may have a basis weight of 30 gsm or less, may be formed of spunlaid fibers including polyolefin and up to 5 percent by weight TiO2, and may be impressed with a pattern of bond impressions to a bond area percentage of at least 10 percent forming a pattern of bonded regions and raised regions. The web may have opacity of 42 or greater; have an average height difference between bonded regions and raised regions of at least 280 ?m; be hydroengorged; and/or have a cross-direction tensile strength of 350 gf/cm. A nonwoven web manufactured to have a suitable combination of such features exhibits an enhanced appearance of softness, soft tactile feel and satisfactory mechanical attributes, while being relatively cost effective.

Abstract: An absorbent article having improved softness signals is disclosed. The article may include a topsheet or a backsheet including a nonwoven web. The web may have a basis weight of 30 gsm or less, may be formed of spunlaid fibers including polyolefin and up to 5 percent by weight TiO2, and may be impressed with a pattern of bond impressions to a bond area percentage of at least 10 percent forming a pattern of bonded regions and raised regions. The web may have opacity of 42 or greater; have an average height difference between bonded regions and raised regions of at least 280 ?m; be hydroengorged; and/or have a cross-direction tensile strength of 350 gf/cm. A nonwoven web manufactured to have a suitable combination of such features exhibits an enhanced appearance of softness, soft tactile feel and satisfactory mechanical attributes, while being relatively cost effective.

Abstract: A method of manufacturing a nonwoven including the steps of: forming a nonwoven web substantially comprised of continuous fibers; applying a bonding pattern to said nonwoven web using a smooth roll and a calender roll wherein said bonding pattern comprises a pattern having unbonded areas; and subjecting the side of said nonwoven web contacted by said smooth roll to a hydraulic treatment at a pressure of between 25 and 75 bars and a total energy of about 0.01-0.04 kwhr/kg., wherein said continuous fibers are comprised of between 97% and 98.5% by weight of an olefin resin comprising substantially of polypropylene and between 1.5% and 3% by weight of a whitener.

Abstract: An absorbent article having improved softness signals is disclosed. The article may include a topsheet or a backsheet including a nonwoven web. The web may have a basis weight of 30 gsm or less, may be formed of spunlaid fibers including polyolefin and up to 5 percent by weight TiO2, and may be impressed with a pattern of bond impressions to a bond area percentage of at least 10 percent forming a pattern of bonded regions and raised regions. The web may have opacity of 42 or greater; have an average height difference between bonded regions and raised regions of at least 280 ?m; be hydroengorged; and/or have a cross-direction tensile strength of 350 gf/cm. A nonwoven web manufactured to have a suitable combination of such features exhibits an enhanced appearance of softness, soft tactile feel and satisfactory mechanical attributes, while being relatively cost effective.

Abstract: An absorbent article having improved softness signals is disclosed. The article may include a topsheet or a backsheet including a nonwoven web. The web may have a basis weight of 30 gsm or less, may be formed of spunlaid fibers including polyolefin and up to 5 percent by weight TiO2, and may be impressed with a pattern of bond impressions to a bond area percentage of at least 10 percent forming a pattern of bonded regions and raised regions. The web may have opacity of 42 or greater; have an average height difference between bonded regions and raised regions of at least 280 ?m; be hydroengorged; and/or have a cross-direction tensile strength of 350 gf/cm. A nonwoven web manufactured to have a suitable combination of such features exhibits an enhanced appearance of softness, soft tactile feel and satisfactory mechanical attributes, while being relatively cost effective.

Abstract: An absorbent article having improved softness signals is disclosed. The article may include a topsheet or a backsheet including a nonwoven web. The web may have a basis weight of 30 gsm or less, may be formed of spunlaid fibers including polyolefin and up to 5 percent by weight TiO2, and may be impressed with a pattern of bond impressions to a bond area percentage of at least 10 percent forming a pattern of bonded regions and raised regions. The web may have opacity of 42 or greater; have an average height difference between bonded regions and raised regions of at least 280 ?m; be hydroengorged; and/or have a cross-direction tensile strength of 350 gf/cm. A nonwoven web manufactured to have a suitable combination of such features exhibits an enhanced appearance of softness, soft tactile feel and satisfactory mechanical attributes, while being relatively cost effective.

Abstract: The present invention is directed to a cationic polymer emulsion binder that may be combined with a cationic active ingredient and used as a non-woven binder. This combination of cationic binder and cationic active ingredient may occur as a mixture of a cationic binder and at least one cationic active ingredient, which is then applied to loose fibers to form a non-woven; or the combination may occur after a non-woven is formed using a cationic binder, and said non-woven is then contacted with a cationic active ingredient. Non-woven wipes of the invention retain far less cationic active ingredients during use, resulting in less waste and less use of the active ingredients for the same effect as wipes made with anionic or non-ionic binders.

Abstract: A nonwoven fabric comprises: a first layer comprising hydrophilic spunbond fibers including a hydrophilic melt additive, the first layer forming at least one exposed outer surface of the nonwoven fabric; a second layer comprising hydrophobic spunbond fibers, the second layer forming an opposite exposed outer surface of the nonwoven fabric; and a third layer comprising meltblown fibers interposed between the first and second layers; wherein the nonwoven fabric has an absorptive capacity of at least 100%.

Abstract: The present invention is directed to a fibrous substrate made of chemically bonded fibers, where the fibers are bound with a polymeric binder in an amount which is sufficient to bind the fibers together to form a self-sustaining web, and where the binder is characterized as having a wet tensile strength of greater than 4500 grams per inch (g/in) when measured at a 20 percent add-on on Whatman #4 CHR chromatography paper which is drum dried for 90 seconds at 210 to 215° F. and cured for 2 minutes at 300 to 325° F. Preferably the level of free formaldehyde in the fibrous substrate is less than 15 ppm. The emulsion binders of the invention may be used to bind fibers together in a substrate; may be used to bind pigment, colors or other substances to a substrate; may be used as a backing material; or may be used to finish or surface-treat a substrate.

Abstract: Wallcoverings which include a nonwoven synthetic substrate and a water-based ground coating which is applied thereto. The ground coating includes emulsion polymer pigment binders and a mineral pigment composition. The ground coating provides the nonwoven substrate with superior printing and durability properties, enabling the production of wallcoverings which may be printed with a decorative design. The wallcoverings are desirable for environmental, health, and safety reasons.

Abstract: The present invention is directed to a fibrous substrate made of chemically bonded fibers, where the fibers are bound with a polymeric binder in an amount which is sufficient to bind the fibers together to form a self-sustaining web, and where the binder is characterized as having a wet tensile strength of greater than 4500 grams per inch (g/in) when measured at a 20 percent add-on on Whatman #4 CHR chromatography paper which is drum dried for 90 seconds at 210 to 215° F. and cured for 2 minutes at 300 to 325° F. Preferably the level of free formaldehyde in the fibrous substrate is less than 15 ppm. The emulsion binders of the invention may be used to bind fibers together in a substrate; may be used to bind pigment, colors or other substances to a substrate; may be used as a backing material; or may be used to finish or surface-treat a substrate.

Abstract: The present invention is directed to a fibrous substrate made of chemically bonded fibers, where the fibers are bound with a polymeric binder in an amount which is sufficient to bind the fibers together to form a self-sustaining web, and where the binder is characterized as having a wet tensile strength of greater than 4500 grams per inch (g/in) when measured at a 20 percent add-on on Whatman #4 CHR chromatography paper which is drum dried for 90 seconds at 210 to 215° F. and cured for 2 minutes at 300 to 325° F. Preferably the level of free formaldehyde in the fibrous substrate is less than 15 ppm. The emulsion binders of the invention may be used to bind fibers together in a substrate; may be used to bind pigment, colors or other substances to a substrate; may be used as a backing material; or may be used to finish or surface-treat a substrate.