Abstract: A process for forming a nonwoven fabric is provided. The process includes depositing at least a first nonwoven layer comprising a first plurality of interlaid individual meltspun fibers, which may comprise a plurality of monocomponent fibers having different onset of melting temperatures, bicomponent fibers having distinct fiber components having different onset of melting temperatures, and/or a plurality of different bicomponent fibers having one or more distinct components having different onset of melting temperatures, directly or indirectly onto a moving collection belt to form a precursor nonwoven. The process includes subjecting the precursor nonwoven web to a heat-setting operation (HSO) to heat-set the first plurality of interlaid individual meltspun fibers to form an intermediate nonwoven fabric, followed by consolidating the intermediate nonwoven fabric to provide that nonwoven fabric.

Abstract: A nonwoven fabrics and composite nonwoven fabrics having a three-dimensional (3D) image imparted therein are provided. The nonwoven fabrics and composite nonwoven fabrics include a plurality of meltblown fibers physically entangled together either alone or in combination with a plurality of cellulosic fibers, and/or a plurality of spunbond fibers.

Abstract: Nonwoven fabrics are provided that include a first nonwoven layer comprising a first plurality of fine fibers. The first plurality of fine fibers comprises a first polymeric material including (i) a first polymer component and (ii) optionally one or more first additives, wherein the first polymer component comprises a first recycled-polypropylene (rPP) comprising a visbroken spunbond grade polypropylene having a first melt flow rate (MFR) before visbreaking and second MFR after visbreaking, and wherein the second MFR is larger than the first MFR.

Abstract: A fabric suitable as an alcohol repellent fabric is provided. The fabric includes a fibrous substrate including a first outermost surface and a second outermost surface, in which a non-fluorinated barrier coating (NFBC) or a fluorinated barrier coating (FBC) is located on at least a portion of a first outermost surface of the fabric, at least a portion of a second outermost surface of the fabric, or both.

Abstract: Nonwoven fabrics having liquid barrier properties are provided. The nonwoven fabrics may include one or more nonwoven layers, in which one or more of the nonwoven layers may include a liquid-barrier-enhancing-additive (LBEA) comprising an amide. The nonwoven fabrics may be suitable for use in a wide variety of liquid barrier applications, including facemasks, surgical gowns, surgical drapes, lab coats, and barrier components of absorbent articles (e.g., barrier leg cuffs).

Abstract: A spinneret for melt-spinning polymeric fibers including a spinneret body defining a plurality of orifices extending through the spinneret body, wherein the plurality of orifices each comprise a capillary that open at a face of the spinneret body for polymer filament extrusion therefrom. The plurality of orifices include (i) a first group of orifices each having a first capillary having a first capillary length (L) and first capillary hydraulic diameter (DH) defining a first L/DH ratio; and (ii) a second group of orifices each having a second capillary having a second capillary length (L) and second capillary hydraulic diameter (DH) defining a second L/DH ratio, in which the first L/DH ratio is larger than the second L/DH ratio. The first group of orifices define at least one first zone at the face of the spinneret body, and the second group of orifices define at least one second zone at the face of the spinneret body.

Abstract: Nonwoven fabrics having desirable wiping properties while also providing pleasant tactile properties are provided. The nonwoven fabrics may include a first nonwoven outer layer, a second nonwoven outer layer, and a core layer located between the first nonwoven layer and the second nonwoven outer layer. At least one of the first nonwoven outer layer and the second nonwoven outer layer may include a plurality of blended filaments comprising a blend of a polymer and an elastomeric polyolefin.

Abstract: Nonwoven fabrics including a first spunmelt through-air-bonded (TAB) nonwoven layer comprising a first plurality of spunmelt fibers, in which the first plurality of spunmelt fibers comprise a biopolymer. The first plurality of spunmelt fibers may be physically entangled with cellulosic fibers, such by hydroentangling. Methods of forming a nonwoven fabric including a first spunmelt TAB nonwoven layer are also provided.

Abstract: Nonwoven fabrics having desirable wiping properties while also providing pleasant tactile properties are provided. The nonwoven fabrics may include a first nonwoven outer layer, a second nonwoven outer layer, and a core layer located between the first nonwoven layer and the second nonwoven outer layer. At least one of the first nonwoven outer layer and the second nonwoven outer layer may include a plurality of blended filaments comprising a blend of a polymer and an elastomeric polyolefin.

Abstract: A spinneret for melt-spinning polymeric fibers including a spinneret body including a plurality of spinning orifices formed through a thickness of spinneret body is provided. The plurality of spinning orifices include (i) a plurality of multicomponent spinning orifices comprising a first multicomponent opening and a separate second multicomponent opening, and (ii) a plurality of monocomponent spinning orifices comprising a single monocomponent opening. Nonwoven fabrics having regions of monocomponent and multicomponent fibers are provided as well as methods of forming such nonwoven fabrics utilizing a zoned-spinneret.

Abstract: Nonwoven fabrics having liquid barrier properties are provided. The nonwoven fabrics may include one or more nonwoven layers, in which one or more of the nonwoven layers may include a liquid-barrier-enhancing-additive (LBEA) comprising an amide. The nonwoven fabrics may be suitable for use in a wide variety of liquid barrier applications, including facemasks, surgical gowns, surgical drapes, lab coats, and barrier components of absorbent articles (e.g., barrier leg cuffs).

Abstract: Nonwoven fabrics including a first spunmelt through-air-bonded (TAB) nonwoven layer comprising a first plurality of spunmelt fibers, in which the first plurality of spunmelt fibers comprise a biopolymer. The first plurality of spunmelt fibers may be physically entangled with cellulosic fibers, such by hydroentangling. Methods of forming a nonwoven fabric including a first spunmelt TAB nonwoven layer are also provided.

Abstract: Self-crimped multi-component fibers (SMF) are provided that include (i) a first component comprising a first polymeric material, in which the first polymeric material comprises a first melt flow rate (MFR) that is less than 50 g/10 min; and (ii) a second component comprising a second polymeric material, in which the second component is different than the first component. The SMF includes one or more three-dimensional crimped portions. Also provided are nonwoven fabrics comprising a plurality of SMFs. Methods of manufacturing SMFs and nonwoven fabrics including SMFs are also provided.

Abstract: Self-crimped multi-component fibers (SMF) are provided that include (i) a first component comprising a first polymeric material, in which the first polymeric material comprises a first melt flow rate (MFR) that is less than 50 g/10 min; and (ii) a second component comprising a second polymeric material, in which the second component is different than the first component. The SMF includes one or more three-dimensional crimped portions. Also provided are nonwoven fabrics comprising a plurality of SMFs. Methods of manufacturing SMFs and nonwoven fabrics including SMFs are also provided.

Abstract: Nonwoven fabrics are provided that include a plurality of crimped bicomponent fibers having a first component comprising a first polymeric material comprising a first polymer or a first polymeric blend and a second component comprising a second polymeric material, in which the second polymeric material comprises a second polymeric blend of (i) at least one polypropylene polymer, (ii) at least one polyethylene polymer, and (iii) at least one compatibilizer comprising or consisting of at least one polypropylene-polyethylene copolymer.

Abstract: Multi-component fibers or filaments that are ribbon shaped are provided having polymer components positioned in a side-by-side fashion. For example, the multi-component fibers may be bicomponent fibers having ribbon shape. The polymer components of the fibers are selected to have differential shrinkage behavior. Nonwovens are also provided that are manufactured from such ribbon shaped multi-component fibers or filaments.

Abstract: Nonwoven fabrics are provided that include a plurality of mono-component spunbond fibers comprising a polymeric material including a polymeric blend of (i) a TS7 value of at most about 30 as determined by a Tissue Softness Analyzer (TSA) from Emtec Innovative Testing Solutions; (ii) a HF value of at least about 40 as determined by a Tissue Softness Analyzer (TSA) from Emtec Innovative Testing Solutions; (iii) a delta value of at least 20, wherein the delta value is determined by subtracting the TS7 value from the HF value; (iv) a TS7 value that is from about 5% to about 35% lower than that of an identically constructed nonwoven fabric formed from 100% polypropylene; and (v) a HF value that is from about 5% to about 35% larger than that of an identically constructed nonwoven fabric formed from 100% polypropylene.

Abstract: Nonwoven fabrics are provided that include at least a first nonwoven layer. The first nonwoven layer includes multi-component fibers densely arranged and compacted against one another. The multi-component fibers comprise at least a first component comprising a first polymeric material including a first polyolefin and a second component comprising a second polymeric material including a second polyolefin, in which the first polymeric material is different than the second polymeric material. The first polymeric material, the second polymeric material, or both include a compatibilizer comprising a copolymer having a comonomer content including (i) at least 10% by weight of the compatibilizer of a first monomer corresponding to the first polyolefin and (ii) at least 10% by weight of the compatibilizer of a second monomer corresponding to the second polyolefin.

Abstract: A nonwoven fabric useful as a component in a personal hygiene product and a nonwoven personal hygiene component, which is substantially free or free of non-ribbon shaped (e.g., round-shaped) spunbond fibers and includes a meltblown layer between and in direct contact with ribbon-shaped spunbond layers. The meltblown layer has a basis weight of at least about 0.008 gsm and not greater than about 5 gsm, and the nonwoven fabric or component has a basis weight of at least about 8 gsm and not greater than about 40 gsm, a pore size of less than or equal to about 27 microns when measured at 10% of cumulative filter flow. The nonwoven fabric also can have a low surface tension liquid strike through flow of less than 0.9 ml per second, a ratio of low surface tension liquid strike through flow to air permeability of greater than or equal to about 0.016, or both. Personal hygiene articles can incorporate the nonwoven fabric or component.

Abstract: Fiber-reinforced nonwoven composites having a wide variety of uses (e.g., leisure goods, aerospace, electronics, equipment, energy generation, mass transport, automotive parts, marine, construction, defense, sports and/or the like) are provided. The fiber-reinforced nonwoven composite includes a plurality of carbon fibers and a polymer matrix. The plurality of carbon fibers have an average fiber length from about 50 mm to about 125 mm. The fiber-reinforced nonwoven composite comprises a theoretical void volume from about 0% to about 10%.