Disclosed herein a stitch-bonded fabric comprising at least one fibrous web layer having a plurality of the fibers with a first length of more than about 25 mm, oriented substantially in a cross-direction (XD) of the stitch-bonded fabric wherein a density of the at least one fibrous web layer is less than about 0.12 g/cm.sup.3. The at least one fibrous web layer is stitch-bonded with yarns following a pattern of linear stitches along a machine direction (MD) spaced from about 1.4 mm to about 4.0 mm along XD, and repeating with a spacing front about 0.8 mm to about 2.5 mm in MD, wherein the plurality of fibers having said first length are captured by multiple stitches. A density of fibers and yarn enclosed within the stitches is above about 0.10 g/cm.sup.3 and below about 5.0 g/cm.sup.3 and the linear stiches are depressed below exposed the wales between the linear stitches along MD. The stitch-bonded yarns can be heat set to stabilize the stitch-bonded fabric.

Disclosed herein a stitch-bonded fabric comprising at least one fibrous web layer having a plurality of the fibers with a first length of more than about 25 mm, oriented substantially in a cross-direction (XD) of the stitch-bonded fabric wherein a density of the at least one fibrous web layer is less than about 0.12 g/cm.sup.3. The at least one fibrous web layer is stitch-bonded with yarns following a pattern of linear stitches along a machine direction (MD) spaced from about 1.4 mm to about 4.0 mm along XD, and repeating with a spacing front about 0.8 mm to about 2.5 mm in MD, wherein the plurality of fibers having said first length are captured by multiple stitches. A density of fibers and yarn enclosed within the stitches is above about 0.10 g/cm.sup.3 and below about 5.0 g/cm.sup.3 and the linear stiches are depressed below exposed the wales between the linear stitches along MD. The stitch-bonded yarns can be heat set to stabilize the stitch-bonded fabric.

One or more aspects of the disclosure provides a nonwoven fabric comprising a single layer in which the single fabric layer comprises a plurality of different fibers in which each fiber type has desired functionality. In one aspect, a system for preparing a nonwoven fabric having a single fabric layer in which the single fabric layer comprises a plurality of different fiber types, is provided. The system includes a spin beam having a zoned distribution plate disposed upstream of a spinneret, the zoned distribution plate includes a plurality of distribution apertures arranged in zones, wherein each zone is configured and arranged to extrude a plurality of polymer streams that are of a different polymer type than polymer streams extruded by an adjacent zone to the spinneret to form a single layer having two or more types of fibers that are of a different type from each other.

Nonwovens, films, and composites thereof are provided, in which at least the nonwoven or film has a plurality of small-sized calcium carbonate (CaCO.sub.3) particles having generally narrow distribution.

An absorbent article comprising an absorbent core sandwiched between a liquid permeable topsheet and a liquid impermeable backsheet, and an acquisition distribution system positioned between said topsheet and said absorbent core, wherein the absorbent core comprises absorbent material selected from the group consisting of cellulose fibers, superabsorbent polymers and combinations thereof, wherein said absorbent material is contained within at least one core wrap substrate enclosing said absorbent material, and wherein a top layer of said core wrap is adhered to a bottom layer of said core wrap to form one or more channels substantially free of said absorbent material, wherein said channels have a length extending along a longitudinal axis and the absorbent core has a length extending along said longitudinal axis and wherein the length of said channels is from 10% to 95% of the length of said absorbent core and wherein said channels each follow a substantially continuous path such as from a first end of a channel to a second end of the same channel wherein the acquisition distribution system is multi-layered and comprises at least one spunbond layer and at least one meltblown layer, and wherein said acquisition distribution system is positioned between said absorbent core and said topsheet such that said spunbond and/or meltblown layers are in direct contact with said absorbent core and said topsheet.

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.

A method for forming a fiber is provided. The method comprises extruding a matrix polymer and a nanoinclusion additive to form a thermoplastic composition in which the nanoinclusion additive is dispersed within a continuous phase of the matrix polymer. The extruded thermoplastic composition is thereafter passed through a spinneret to form a fiber having a porous network containing a plurality of nanopores, wherein the average percent volume occupied by the nanopores within a given unit volume of the fiber is from about 3% to about 15% per cm.sup.3.

An apparatus for continuously making a spunbond web of filaments comprises a spinneret, a cooling chamber into which process air for can be introduced for the purpose of cooling the filaments, a monomer suction device between a spinneret and cooling chamber, a stretcher and a deposition device for depositing the filaments of the spunbond web. The cooling chamber is divided into two cooling compartments, and process air can be suctioned out from a first upper cooling compartment at a volumetric flow rate (V.sub.M) to a monomer suction device. Process air exits from the first upper cooling compartment at a volumetric flow rate (V.sub.1) into a second lower cooling compartment and from the first upper cooling compartment at a volumetric flow rate (V.sub.1) into a second lower cooling compartment. A ratio (V.sub.M/V.sub.1) is 0.1 to 0.35.

An apparatus for continuously making a spunbond web of filaments comprises a spinneret, a cooling chamber into which process air for can be introduced for the purpose of cooling the filaments, a monomer suction device between a spinneret and cooling chamber, a stretcher and a deposition device for depositing the filaments of the spunbond web. The cooling chamber is divided into two cooling compartments, and process air can be suctioned out from a first upper cooling compartment at a volumetric flow rate (V.sub.M) to a monomer suction device. Process air exits from the first upper cooling compartment at a volumetric flow rate (V.sub.1) into a second lower cooling compartment and from the first upper cooling compartment at a volumetric flow rate (V.sub.1) into a second lower cooling compartment. A ratio (V.sub.M/V.sub.1) is 0.1 to 0.35.

Functional spunlaid fabrics incorporating fibers made from non-meltable polymers containing permanently one or more functional additives are provided. The fibers are entangled and interlocked to form a firm nonwoven composite, have different lengths, and aspect ratios above 1,000. The fibers have a mean diameter of 0.1 to 500 micrometres and diameter variations within a single fiber and among each other of at least 30%. The fibers contain more than 40 wt % of finely distributed functional additives in solid and/or liquid form. The spunlaid fabric is produced from a spinning solution containing the non-meltable polymer dissolved in a direct solvent and at least one functional additive. The spinning solution is extruded out of a spinneret, and the resulting strands are drawn in the longitudinal direction to form fibers, stabilized and laid down to form a nonwoven fabric with permanent functional properties. Exemplary spunlaid fabrics include clothing, technical textiles and filters.