Abstract: Filter media comprising a pre-filter layer and related components, systems, and methods associated therewith are provided. In some embodiments, the pre-filter layer may be designed to impart desirable properties to the filter media, such as a high gamma and/or long service life, while having relatively minimal or no adverse effects on another property of the filter media that is important for a given application. For instance, a pre-filter layer may be used to improve the upstream removal of fine particulate matter, which may clog a downstream efficiency layer comprising submicron fibers and reduce filtration performance. The pre-filter layer may be configured to increase service life and/or increase the gamma of the filter media. Filter media, as described herein, may be particularly well-suited for applications that involve filtering air, though the media may also be used in other applications.

Abstract: Polymer compositions that may be used to form fibers for a fiber web are generally described. In some embodiments, certain properties of the polymer compositions (e.g., molecular weight distribution, melt flow index, melt elasticity, and/or melt toughness) may allow the formation of fiber webs having fine fibers and a relatively low amount of process defects. In some instances, these properties of the polymer composition may be achieved by combining two or more polymer components. Fiber webs formed using the polymer composition may have increased performance and/or better structural characteristics compared to fibers webs formed using a single polymer component.

Abstract: The invention provides durable nonwoven fabrics comprising staple fibers. Methods of preparing durable nonwoven fabrics based on staple fibers are also provided. The methods can include the steps of at least one of needle punching and hydroentangling. The durable nonwoven fabric can be subjected to additional bonding techniques, such as resin bonding and/or thermal bonding. The durable nonwoven fabrics of the invention provide improved durability over conventional nonwoven fabrics. Further advantages of the inventive nonwoven fabrics include maintaining the smooth surface qualities of the fabric and desirable feel of the fabric even with the enhanced durability. The inventive nonwoven fabrics can also be subjected to additional post-processing techniques that conventional nonwoven fabrics would otherwise be unable to withstand. Further, inks and/or dyes can more readily become adhered to the smooth nature of the surfaces of the inventive durable nonwoven fabrics.

Abstract: The invention provides durable nonwoven fabrics comprising staple fibers. Methods of preparing durable nonwoven fabrics based on staple fibers are also provided. The methods can include the steps of at least one of needle punching and hydroentangling. The durable nonwoven fabric can be subjected to additional bonding techniques, such as resin bonding and/or thermal bonding. The durable nonwoven fabrics of the invention provide improved durability over conventional nonwoven fabrics. Further advantages of the inventive nonwoven fabrics include maintaining the smooth surface qualities of the fabric and desirable feel of the fabric even with the enhanced durability. The inventive nonwoven fabrics can also be subjected to additional post-processing techniques that conventional nonwoven fabrics would otherwise be unable to withstand. Further, inks and/or dyes can more readily become adhered to the smooth nature of the surfaces of the inventive durable nonwoven fabrics.

Abstract: A system for hydroentangling a fabric material, while reducing the incidence of jet streaks therein, is provided. Various embodiments of the present invention provide an elongate hydroentangling jet strip spaced apart from the fabric material and extending substantially across a width of the fabric perpendicular to the processing direction. The strip defines a first row of orifices, each having a first diameter. The first plurality of orifices is spaced apart along a width of the elongate strip. The strip further defines a second plurality of orifices disposed downstream from the first plurality of orifices in the processing direction and offset therefrom along the width of the elongate strip. The second plurality of orifices each define a second diameter smaller than the first diameter such that fluid streams generated thereby impart a correspondingly smaller impact force on the fabric material than fluid streams generated by the first plurality of orifices.