A fibrous nonwoven structure formed of a blend of cellulose pulp fibers and melt spun polymer filaments is disclosed. The structure may include a distribution of a plurality of macroscopically visible shaped particles of substantially similar size and shape, included in the blend. The structure may also include outer scrim layers formed of melt spun polymer filaments. A method of manufacturing the fibrous nonwoven structure is also disclosed.

A fibrous nonwoven structure formed of a blend of cellulose pulp fibers and melt spun polymer filaments is disclosed. The structure may include a distribution of a plurality of macroscopically visible shaped particles of substantially similar size and shape, included in the blend. The structure may also include outer scrim layers formed of melt spun polymer filaments. A method of manufacturing the fibrous nonwoven structure is also disclosed.

A base sheet formed from a nonwoven web and having a microstructured topography is provided. A plurality of staple fibers modified with a cation are affixed to the nonwoven web via an adhesive modified with an anion in order to improve one or more attributes of the nonwoven web, such as softness, absorption, abrasion, and barrier properties. The present disclosure also provides a method of forming a base sheet which includes printing the adhesive on the nonwoven web, and passing the nonwoven web through an electroplating module.

A base sheet formed from a nonwoven web and having a microstructured topography is provided. A plurality of staple fibers modified with a cation are affixed to the nonwoven web via an adhesive modified with an anion in order to improve one or more attributes of the nonwoven web, such as softness, absorption, abrasion, and barrier properties. The present disclosure also provides a method of forming a base sheet which includes printing the adhesive on the nonwoven web, and passing the nonwoven web through an electroplating module.

Nonwoven fibrous webs including a multiplicity of (co)polymeric fibers made of a mixture including from about 50% w/w to about 99% w/w of at least one crystalline polyolefin (co)polymer, and from about 1% w/w to about 40% w/w of at least one hydrocarbon tackifier resin. A process for making the nonwoven fibrous webs includes heating the foregoing mixture to at least a Melting Temperature of the mixture to form a molten mixture, extruding this molten mixture through at least one orifice to form at least one filament, applying a gaseous stream to attenuate the at least one filament to form a plurality of discrete, discontinuous fibers, and cooling the plurality of discrete, discontinuous fibers to a temperature below the Melting Temperature and collecting the discrete discontinuous fibers as a nonwoven fibrous web. The nonwoven fibrous webs exhibit a Heat of Fusion measured using Differential Scanning Calorimetry of greater than 50 Joules/g.

Nonwoven materials having at least one layer are provided, as well as their use in cleaning articles. More particularly, the nonwoven materials can include a rough outer surface useful for scrubbing purposes. Alternatively or additionally, the nonwoven materials can include a carrier composition including a binder and a blocking agent. The carrier composition can repel a sanitizing agent, such as a quaternary ammonium compound, from the surface of the nonwoven material.

A system having a first polymer source and a spin beam in fluid communication with the first polymer source is provided. The spin beam includes a spinneret assembly having filament nozzles configured and arranged to extrude a plurality of filaments of a first polymer. A gas distribution plate is disposed downstream of the spinneret assembly, and includes a plurality of gas distribution slots that are configured and arranged to receive two or more corresponding filament nozzles of the spinneret assembly therein. A stream of gas is introduced into the plurality of slots to draw and attenuate the filaments extruded by the plurality of filament nozzles. The drawn and attenuated filaments are collected on a collection surface disposed downstream of the gas distribution plate to form a nonwoven fabric. A solid additive, such as pulp fibers may be blended with the filaments prior to collecting the filaments on the collection surface.

According to one embodiment, a method of forming a facer includes forming a first layer of nonwoven glass fibers and positioning a second layer of reinforcement fibers atop the first layer of nonwoven glass fibers. The method also includes coating the first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers with a binder composition and pressing the first layer of nonwoven glass fibers and the second layer of reinforcement fibers together between a pair of rollers. The binder composition is then dried to couple the first layer of nonwoven glass fibers and the second layer of reinforcement fibers to form the facer. The first layer of nonwoven glass fibers and/or the second layer of reinforcement fibers are free of a material coating prior to coating of the binder composition.

The presently disclosed subject matter relates to nonwoven materials and their use in cleaning articles. More particularly, the nonwovens are layered structures, which can include a tacky additive. The nonwoven materials can be used to attract and collect particles, and can have improved cleaning efficiency.

Knitted fabric is produced with a knitting machine and a roving drawing and strengthening unit. A roving supply unit provides a roving and an auxiliary thread supply unit provides an auxiliary thread. A stretching unit receives the roving and the auxiliary thread. A spinning nozzle following the stretching unit in a roving conveying direction forms a fiber strengthening segment by applying compressed air and an end thread gripping roller pair rotatable in opposite directions provided downstream from the spinning nozzle device in the roving conveying direction delimiting the fiber strengthening segment. A soft knitted fabric is formed by guiding an auxiliary thread through an auxiliary thread gripping roller pair with an adjustable rotational speed before the roving and auxiliary thread enter the stretching unit. The gripping roller pair holds the auxiliary thread so that the auxiliary thread is subjected to tension of no more than 2 cN.