Abstract: A biodegradable nonwoven web comprising substantially continuous multicomponent filaments is provided. The filaments comprise a first component and a second component. The first component contains at least one high-melting point aliphatic polyester having a melting point of from about 160° C. to about 250° C. and the second component contains at least one low-melting point aliphatic polyester. The melting point of the low-melting point aliphatic polyester is at least about 30° C. less than the melting point of the high-melting point aliphatic polyester. The low-melting point aliphatic polyester has a number average molecular weight of from about 30,000 to about 120,000 Daltons, a glass transition temperature of less than about 25° C., and an apparent viscosity of from about 50 to about 215 Pascal-seconds, as determined at a temperature of 160° C. and a shear rate of 1000 sec?1.

Abstract: Fibers are hydroentangled at temperatures near or above their glass transition temperature, the resultant fabrics are then rapidly cooled. A process of preparing a nonwoven fabric that includes depositing fibers on a foraminous support; impinging hot or warm water upon the fibers to hydroentangle them; and then rapidly cooling the resultant fabric is disclosed. The hydroentangled fabric resulting from this process, products made from the hydroentangle fabric, and the equipment used to prepare the fabrics are described.

Abstract: A biodegradable nonwoven web comprising substantially continuous multicomponent filaments is provided. The filaments comprise a first component and a second component. The first component contains at least one high-melting point aliphatic polyester having a melting point of from about 160° C. to about 250° C. and the second component contains at least one low-melting point aliphatic polyester. The melting point of the low-melting point aliphatic polyester is at least about 30° C. less than the melting point of the high-melting point aliphatic polyester. The low-melting point aliphatic polyester has a number average molecular weight of from about 30,000 to about 120,000 Daltons, a glass transition temperature of less than about 25° C., and an apparent viscosity of from about 50 to about 215 Pascal-seconds, as determined at a temperature of 160° C. and a shear rate of 1000 sec?1.

Abstract: Fibers are hydroentangled at temperatures near or above their glass transition temperature, the resultant fabrics are then rapidly cooled. A process of preparing a nonwoven fabric that includes depositing fibers on a foraminous support; impinging hot or warm water upon the fibers to hydroentangle them; and then rapidly cooling the resultant fabric is disclosed. The hydroentangled fabric resulting from this process, products made from the hydroentangle fabric, and the equipment used to prepare the fabrics are described.

Abstract: A lofty, nonwoven material having a nonwoven web having a plurality of substantially continuous fibers oriented in a z-direction of the nonwoven web and a method for producing the lofty, nonwoven material from as-formed z-direction fibers. The method is fast, having no mechanical manipulation of the fibers to slow it down, easily adjustable and allows for in-line processing. The material can be varied from preponderantly open to preponderantly closed in its web structure.

Abstract: An in-line formed, non-laminated web is suitable for use as a composite fluid distribution and fluid retention layer in a disposable absorbent article. The web can be formed by selective deposition of airlaid materials including absorbents, such as pulp and superabsorbents, together with binder fibers. The web so constructed will have a plurality of intermingled lower basis weight areas and higher basis weight areas coexisting and distributed in at least a central region of the web, the alternations crossing the X axis or Y axis, or both, of the web, with the higher basis weight areas being a greater thickness in the Z-direction than the lower basis weight areas. The web so constructed will further have no discrete material boundaries between the lower basis weight stripes and the higher basis weight stripes. Further the necessity of later processing on the web to achieve a ridged structure is removed and the fibers will remain whole and undisturbed.

Abstract: A method for producing a material having z-direction waves in which a layer of continuous fibers is conveyed on a first moving surface into a nip formed by the first moving surface and a second moving surface which is traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction loops in the fibers giving loft to the material and a wave pattern producing ridges on both major surfaces of the resultant nonwoven web. The method permits easy real time alignment of manufacturing parameters to produce a variety of materials. The method further produces lofty nonwovens at a commercially viable rate.

Abstract: A lofty, nonwoven material having a nonwoven web having a plurality of substantially continuous fibers oriented in a z-direction of the nonwoven web and a method for producing the lofty, nonwoven material from as-formed z-direction fibers. The method is fast, having no mechanical manipulation of the fibers to slow it down, easily adjustable and allows for in-line processing. The material can be varied from preponderantly open to preponderantly closed in its web structure.

Abstract: A method for producing a material having z-direction ridges or folds in which a layer of continuous fibers is conveyed on a first moving surface into a nip formed by the first moving surface and a second moving surface which is traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction loops in the fibers giving loft to the material and a wave pattern producing ridges on both major surfaces of the resultant nonwoven web. The method permits easy real time adjustment of manufacturing parameters to produce a variety of materials. The method further produces lofty nonwovens at a commercially viable rate.

Abstract: A lofty, nonwoven material having a nonwoven web having a plurality of substantially continuous fibers oriented in a z-direction of the nonwoven web and a method for producing the lofty, nonwoven material from as-formed z-direction fibers. The method is fast, having no mechanical manipulation of the fibers to slow it down, easily adjustable and allows for in-line processing. The material can be varied from preponderantly open to preponderantly closed in its web structure.

Abstract: An in-line formed, non-laminated web is suitable for use as a composite fluid distribution and fluid retention layer in a disposable absorbent article. The web can be formed by selective deposition of airlaid materials including absorbents, such as pulp and superabsorbents, together with binder fibers. The web so constructed will have a plurality of intermingled lower basis weight areas and higher basis weight areas coexisting and distributed in at least a central region of the web, the alternations crossing the X axis or Y axis, or both, of the web, with the higher basis weight areas being a greater thickness in the Z-direction than the lower basis weight areas. The web so constructed will further have no discrete material boundaries between the lower basis weight stripes and the higher basis weight stripes. Further the necessity of later processing on the web to achieve a ridged structure is removed and the fibers will remain whole and undisturbed.

Abstract: A method for producing a material having z-direction ridges or folds in which a layer of continuous fibers is conveyed on a first moving surface into a nip formed by the first moving surface and a second moving surface which is traveling at a slower speed than the first moving surface, resulting in formation of a plurality of z-direction loops in the fibers giving loft to the material and a wave pattern producing ridges on both major surfaces of the resultant nonwoven web. The method permits easy real time adjustment of manufacturing parameters to produce a variety of materials. The method further produces lofty nonwovens at a commercially viable rate.