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%.

Abstract: A nonwoven having a high affinity for an active ingredient is proved, the nonwoven having at least one high surface area fiber in addition to the active ingredient.

Abstract: Elastic nonwoven composites suitable for a wide variety of uses are provided. The composite includes at least one extensible nonwoven layer, including a first extensible nonwoven layer, and at least one elastic nonwoven layer, in which the nonwoven layer comprises elastic continuous filaments. The composite may be bonded and activated by, at least in part, a stretching operation. The elastic continuous filaments may comprise an additive, such as a slip additive.

Abstract: Absorbent composites suitable for a wide variety of uses (e.g., sorbent drapes, sorbent patches around a fenestration area, tray liners for surgical tools, incontinence pads and liners, other liners, etc.) are provided. The composite includes an absorbent nonwoven. The absorbent nonwoven may comprise a hydroentangled spunbond web. The composite also may comprise a liquid-impermeable film. One or more absorbent nonwovens of a composite may additionally comprise a three-dimensional pattern, for example, a three-dimensional pattern that has been imaged using hydroentanglement. Optionally, any one or more layers of the composites may comprise an antimicrobial additive.

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: A fiber defined by a surface having a concentration of antimicrobial and a center having another concentration of antimicrobial is provided. The concentration of antimicrobial at the surface of the fiber is greater than the concentration of antimicrobial at the center of the fiber. Nonwovens manufactured from the fiber are also provided. The antimicrobial may include an antimicrobial heat labile component in conjunction with a carrier.

Abstract: A spinneret, apparatus, and method are provided for making filaments for fibrous nonwoven fabrics with more uniform filament and fabric formation while minimizing filament breaks and hard spot defects in webs and fabrics made therefrom. The spinneret has a spinneret body that has an overall length to hydraulic diameter ratio and defines orifices that extend through the spinneret body, wherein the orifices comprise capillaries that open at a face of the spinneret body for polymer filament extrusion therefrom, wherein the capillaries are arranged in a plurality of different rows at the face of the spinneret body, and wherein the plurality of different rows are arranged into a plurality of different zones at the face of the spinneret body.

Abstract: A liquid management layer constructed from large diameter uncrimped fibers in the form of a spunbond nonwoven web is described. Embodiments of the liquid management layer can include a plurality of thermoplastic fibers in the form of a spunbond nonwoven web where the plurality of thermoplastic fibers are randomly oriented and uncrimped, where the liquid management layer has a maximum void volume of 25 cc/g and a web density of at least 0.05 g/cc, where the liquid management layer has a maximum thickness of 1.5 mm, a basis weight of at least 30 g/m2 and a rewet value of less than 0.4 g according to test method WSP 70.8, and where the liquid management layer has an average fiber diameter of at least 40 microns based on the number of thermoplastic fibers in the liquid management layer and where less than 10% by count of the plurality of thermoplastic fibers in the liquid management layer have an absolute fiber diameter less than 30 microns.

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: A liquid management layer constructed from large diameter uncrimped fibers in the form of a spunbond nonwoven web is described. Embodiments of the liquid management layer can include a plurality of thermoplastic fibers in the form of a spunbond nonwoven web where the plurality of thermoplastic fibers are randomly oriented and uncrimped, where the liquid management layer has a maximum void volume of 25 cc/g and a web density of at least 0.05 g/cc, where the liquid management layer has a maximum thickness of 1.5 mm, a basis weight of at least 30 g/m2 and a rewet value of less than 0.4 g according to test method WSP 70.8, and where the liquid management layer has an average fiber diameter of at least 40 microns based on the number of thermoplastic fibers in the liquid management layer and where less than 10% by count of the plurality of thermoplastic fibers in the liquid management layer have an absolute fiber diameter less than 30 microns.

Abstract: The present invention is directed to a hydroentangled nonwoven fabric, and more specifically, to a lofty three-dimensional nonwoven fabric hydroentangled on a three-dimensional image transfer device, wherein the image imparted into the fabric comprises a distinctive internal void space lending to the loft and resiliency of the image.

Abstract: The present invention is directed to a nonwoven composite fabric comprising one or more layers of discontinuous filaments or nano-fiber filaments positioned between at least one continuous filament web and one cellulosic fiber web that are subsequently hydroentangled, wherein the discontinuous filaments or nano-fiber filaments provide a barrier to prevent the loss of the cellulosic fibrous material through the highly porous continuous filament web.

Abstract: The present invention is directed to a method of making a laminate nonwoven fabric which entails integration of a continuous filament web with a web of cellulosic fiber material, typically wood pulp. In order to abate loss of cellulosic fiber material during integration by hydroentanglement, the present invention contemplates that the continuous filament web is first subjected to hydroentanglement, with the cellulosic fibrous material thereafter integrated, by hydroentangling, into the partially entangled continuous filament web.

Abstract: A three-dimensionally imaged nonwoven fabric, as formed in accordance with the principles of the present invention, contemplates a material formed by hydroentanglement of at least one lightly bonded continuous filament layer upon a device having a three-dimensional foraminous forming surface. The preferred continuous filament substrate is in the form of a precursor web comprising spunbond continuous polymeric filaments. A nonwoven fabric formed in accordance with the present invention may be formed to include substantially continuous filaments (from a relatively lightly bonded spunbond precursor web), with the resulting fabric having a machine direction tensile strength of at least about 1,472 grams per centimeter at 47% machine-direction elongation.

Abstract: The present invention is directed to a method of forming a two-sided nonwoven fabric, which exhibits a pronounced three-dimensional image that is durable to both converting and end-use application. In particular, the present invention contemplates that a fabric is formed from a first precursor web comprising a first fibrous matrix and a second precursor web comprising a second fibrous matrix. Between the first and second precursor web, a fluid-pervious support layer or scrim, is interposed and subjected to hydroentanglement on a moveable imaging surface having a three-dimensional image transfer device. By formation of a nonwoven fabric in this fashion, a three-dimensional image that is durable to abrasion and distortion due to elongation is imparted and a product formed which exhibits on its opposite surfaces the unique properties of the respective fibrous matrix used.

Abstract: The present invention is directed to a method of forming a nonwoven fabric, which exhibits a first three-dimensional image and a second three-dimensional image whereby the first and second three-dimensional images are dissimilar from one another. In particular, the present invention contemplates a fabric comprised of sequentially formed three-dimensional images that are formed from a pre-entangled precursor web entangled on a first three-dimensional transfer device so as to impart a first image therein, then subjected to hydroentanglement on a second three-dimensional image transfer device wherein a second three-dimensional image is imparted to the web that is different from the first three-dimensional image, the resulting nonwoven fabric presenting aesthetic and tactile qualities representative of both imparted images.

Abstract: The present invention is directed to mechanically extensible substrates, and more specifically relates to engineered substrates that exhibit functionality upon application of an external force, which in turn actuates the substrate, optionally releasing an underlying functional agent that assists a specific task or exposing an underlying layer. In accordance with the present invention, the mechanically extensible substrates exhibit a degree of controlled regional disentanglement, an expandable and retractable valve system, a limited degree of rupture, or a combination thereof.

Abstract: The present invention is directed to a hydroentangled nonwoven fabric, and more specifically, to a lofty three-dimensional nonwoven fabric hydroentangled on a three-dimensional image transfer device, wherein the image imparted into the fabric comprises a distinctive internal void space lending to the loft and resiliency of the image.

Abstract: The present invention is directed to a method of forming a nonwoven cleaning article, which exhibits a first three-dimensional image and a second three-dimensional image whereby the first and second three-dimensional images are dissimilar from one another. In particular, the present invention contemplates a fabric comprised of sequential three-dimensional images that are formed from a pre-entangled precursor web entangled on a first three-dimensional transfer device so as to impart a first image therein, then subjected to hydroentanglement on a second three-dimensional image transfer device wherein a second three-dimensional image is imparted to the web that is different from the first three-dimensional image, the resulting nonwoven cleaning article presenting aesthetic and tactile qualities representative of both imparted images.

Abstract: The present invention is directed to a method of making three-dimensionally imaged films, and more specifically to a method of making an imaged film by directly extruding the polymeric melt onto a three-dimensional surface. The present invention is further directed to a method of making three-dimensionally imaged nonwoven fabric comprising at least one layer of continuously extruded nonwoven filaments that are directly deposited onto the foraminous surface of a three-dimensional image transfer device.