A system for bonding a first layer having short fibers with a second layer having long fibers into a nonwoven web. The system includes a belt, a headbox, a depositing belt with a delivery strand, a transfer belt with a receiving strand, a device, a pre-bonding unit, and a bonding device. The short fibers are deposited on the depositing belt to form the first layer with the headbox. The transfer belt transfers the first layer to the second layer. The pre-bonding unit has spaced-apart compacting devices which act on the transfer belt to form a lower strand of the transfer belt there between. The bonding device is arranged between the compacting devices. The bonding device bonds the first and second layers. The compacting devices and the bonding device are operatively connected to one another so that they are each always either in an operating state or in a resting state.

An apparatus for bonding a first layer having short fibers with a second layer having long fibers into a non-woven web. The apparatus includes a first circulating belt on which the second layer is depositable and displacable, a second circulating belt via which the first layer is transferable at a transition point to the second layer, a pre-bonding unit arranged directly behind the transition point, and a bonding device. The pre-bonding unit has compactors which are spaced apart from one another. The compactors act in one region on the first or second circulating belt. The bonding device is arranged between the compactors and bonds together the first and second layers. The compactors and the bonding device are integrated into the apparatus to together be in an operating state when the first layer is transferred using the second circulating belt.

An apparatus for bonding a first layer having short fibers with a second layer having long fibers into a non-woven web. The apparatus includes a first circulating belt on which the second layer is depositable and displacable, a second circulating belt via which the first layer is transferable at a transition point to the second layer, a pre-bonding unit arranged directly behind the transition point, and a bonding device. The pre-bonding unit has compactors which are spaced apart from one another. The compactors act in one region on the first or second circulating belt. The bonding device is arranged between the compactors and bonds together the first and second layers. The compactors and the bonding device are integrated into the apparatus to together be in an operating state when the first layer is transferred using the second circulating belt.

Nonwoven fibrous webs including randomly oriented discrete fibers defining a multiplicity of non-hollow projections extending from a major surface of the nonwoven fibrous web (as considered without the projections), and a plurality of substantially planar land areas formed between each adjoining projection in a plane defined by and substantially parallel with the major surface. In some exemplary embodiments, the randomly oriented discrete fibers include multi-component fibers having at least a first region having a first melting temperature and a second region having a second melting temperature, wherein the first melting temperature is less than the second melting temperature. At least a portion of the oriented discrete fibers are bonded together at a plurality of intersection points with the first region of the multi-component fibers. In certain embodiments, the patterned air-laid nonwoven fibrous webs include particulates. Methods of making and using such patterned air-laid nonwoven fibrous webs are also disclosed.

A smokeless tobacco product includes smokeless tobacco and structural fibers. The structural fibers forming a network in which the smokeless tobacco is entangled. The structural fibers have a composition different from the smokeless tobacco. The tobacco-entangled fabric can have an overall oven volatiles content of at least 10 weight percent. In some embodiments, the structural fibers form a nonwoven network. In some embodiments, fibrous structures of the smokeless tobacco are entangled with the structural fibers.

A smokeless tobacco product includes smokeless tobacco and structural fibers. The structural fibers forming a network in which the smokeless tobacco is entangled. The structural fibers have a composition different from the smokeless tobacco. The tobacco-entangled fabric can have an overall oven volatiles content of at least 10 weight percent. In some embodiments, the structural fibers form a nonwoven network. In some embodiments, fibrous structures of the smokeless tobacco are entangled with the structural fibers.

Methods and systems are provided for a process to generate a nonwoven textile. In one example, the nonwoven textile may have layered, zonal properties resulting from entangling of two or more types of staple fibers through a merging region between the layers of staple fibers while maintaining distinct zones, each zone comprising a type of staple fiber. Furthermore, the process may include embedding a filament layer into the nonwoven textile via a continuous assembly line.

Methods and systems are provided for a process to generate a nonwoven textile. In one example, the nonwoven textile may have layered, zonal properties resulting from entangling of two or more types of staple fibers through a merging region between the layers of staple fibers while maintaining distinct zones, each zone comprising a type of staple fiber. Furthermore, the process may include embedding a filament layer into the nonwoven textile via a continuous assembly line.

Provided are an air filter medium and an air filter product that can have a long life. The air filter medium includes a filter medium layer that includes first fibers having an average fiber diameter of not less than 5 μm and not greater than 50 μm and second fibers disposed in gaps between the first fibers and having an average fiber diameter of not less than 30 nm and not greater than 1 μm.

A hydroformed expanded spun bonded nonwoven has a first substantially planar surface on one side thereof and a second surface on an opposite side thereof. The second surface includes a plurality of protuberances in a pattern. The hydroformed expanded spun bonded nonwoven web has an average loft of at least about 1.3 times greater than an original average loft of an original unexpanded spun bonded nonwoven web from which the hydroformed expanded spun bonded nonwoven web was created and an air permeability of at least about 1.2 times greater than an original air permeability of the original unexpanded spun bonded nonwoven web. The hydroformed expanded spun bonded nonwoven web includes bicomponent fibers combining a polymer with PLA in a ratio of polymer/PLA within a range of about 20/80 to 80/20.