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.

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.

A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.

A non-woven textile may be formed from a plurality of thermoplastic polymer filaments. The non-woven textile may have a first region and a second region, with the filaments of the first region being fused to a greater degree than the filaments of the second region. A variety of products, including apparel (e.g., shirts, pants, footwear), may incorporate the non-woven textile. In some of these products, the non-woven textile may be joined with another textile element to form a seam. More particularly, an edge area of the non-woven textile may be heatbonded with an edge area of the other textile element at the seam. In other products, the non-woven textile may be joined with another component, whether a textile or a non-textile.

A process for forming multi-layer fibrous web with good absorbent capacity and absorbent rate is disclosed. The multi-layer fibrous web can be used as absorbent articles, including wiping products, such as industrial wipers, food service wipers, and the like. The multi-layer fibrous web includes a first layer and a second layer, as well as a crossover zone, that has a capillary pressure between the capillary pressure of the first layer and the capillary pressure of the second layer.

The present invention discloses a nonwoven web and methods for manufacturing the nonwoven web. The present invention specifically discloses a nonwoven web that includes a co-forming process wherein a first gas stream includes meltblown fibers that are extruded from a first die head, a second gas stream that includes spunblown fibers that are extruded from a second die head and a third die head that includes pulp fibers that are extruded from a pulp nozzle. By sandwiching spunblown fibers between meltblown fibers during the co-forming processes, a nonwoven web having improved cross-machine direction tensile strength is formed.

The present invention discloses a nonwoven web and methods for manufacturing the nonwoven web. The present invention specifically discloses a nonwoven web that includes a co-forming process wherein a first gas stream includes meltblown fibers that are extruded from a first die head, a second gas stream that includes spunblown fibers that are extruded from a second die head and a third die head that includes pulp fibers that are extruded from a pulp nozzle. By sandwiching spunblown fibers between meltblown fibers during the co-forming processes, a nonwoven web having improved cross-machine direction tensile strength is formed.

A production method for a fiber article includes: a contact step of, while transferring a plurality of first fibers, bringing a plurality of resin particles formed of high molecules that can be fiberized into contact with the plurality of first fibers; a first processing step of applying an external force to the plurality of first fibers brought into contact with the plurality of resin particles and narrowing gaps between fibers; and a second processing step of, by relieving the external force applied to the plurality of first fibers brought into contact with the plurality of resin particles, forming second fibers from the plurality of resin particles, the second fibers each having an outer diameter that is smaller than each of the first fibers and is set to a value in a range of 30 nm or more to 1.0 μm or less, and forming a fiber composite including the first fibers and the second fibers.

A fiber article includes a plurality of first fibers and a plurality of second fibers each having an outer diameter smaller than that of each of the first fibers, the plurality of second fibers being supported in a dispersed state by the first fibers. A ratio D1/D2 of an outer diameter D1 of the first fiber to an outer diameter D2 of the second fiber is set to a value in a range of 15.0 or greater to 1666.7 or less. The outer diameter D1 is set to a value in a range of 5.0 μm or greater to 50.0 μm or less, and the outer diameter D2 is set to a value in a range of 30.0 nm or greater to 1.0 μm or less.