Abstract: The present invention can provide a distinctive method and process for making polymer fibers (62) and nonwoven fabric webs (60). The method can include providing a fiber material that exhibits a low crystallization rate. In a particular aspect, the fiber material can be subjected to an anneal-quench at an anneal-quench temperature that approximates a prime-temperature at which the polymer material most rapidly crystallizes. In another aspect, the fiber material can be subjected to a fiber-draw at a selected fiber-draw temperature, and in a further aspect, the fiber-draw temperature can be configured to approximate the prime-temperature of the polymer material. In still other aspects, the fiber material can be subjected to a relatively small amount of fiber-draw, and the fiber-draw can be provided at a relatively low fiber-draw speed.

Abstract: A dispersible nonwoven web having at least three layers including a first outer layer, a middle layer, and a second outer layer. The first and the second outer layers including a plurality of short fibers, a triggerable binder, and at least one of the first or second outer layers including a plurality of long fibers. The middle layer including a plurality of short fibers, a triggerable binder, and optionally a plurality of long fibers. The dispersible nonwoven web having a weight percent of the long fibers in at least one of the first or the second outer layers that is greater than a weight percent of the long fibers in the middle layer.

Abstract: A dispersible nonwoven web having at least three layers including a first outer layer, a middle layer, and a second outer layer. The first and the second outer layers including a plurality of short fibers, a triggerable binder, and at least one of the first or second outer layers including a plurality of long fibers. The middle layer including a plurality of short fibers, a triggerable binder, and optionally a plurality of long fibers. The dispersible nonwoven web having a weight percent of the long fibers in at least one of the first or the second outer layers that is greater than a weight percent of the long fibers in the middle layer.

Abstract: A method of forming 3-dimensional fibers is disclosed along with a web formed from such fibers. The method includes the steps of co-extruding a first component and a second component. The first component has a recovery percentage R1 and the second component has a recovery percentage R2, wherein R1 is higher than R2. The first and second components are directed through a spin pack to form a plurality of continuous molten fibers. The molten fibers are then routed through a quenching chamber to form a plurality of continuous cooled fibers. The cooled fibers are then routed through a draw unit to form a plurality of continuous, solid linear fibers. The solid fibers are then accumulated and stretched by at least about 50 percent. The plurality of stretched fibers are then cut and allowed to relax such that a plurality of 3-dimensional, coiled fibers is formed.