A plant for making spunbond type polymeric filament defining an extrusion direction and including, in order along the extrusion direction, an extrusion head including at least one main channel to allow the passage of polymeric fluid through the extrusion head, a distributor including at least one distribution conduit in fluid passage connection with the main channel to distribute the fluid, at least one spinneret having holes each running parallel to the extrusion direction in fluid passage connection with the distribution conduit and suitable for extruding the fluid to make a respective polymeric filament, at least one distribution tank between the distributor, downstream of the conduit, and the spinneret, upstream of the holes, connecting, in fluid passage connection, the conduit and holes and defining a first thickness along the extrusion direction between 3 and 5 mm.

A plant for making spunbond type polymeric filament defining an extrusion direction and including, in order along the extrusion direction, an extrusion head including at least one main channel to allow the passage of polymeric fluid through the extrusion head, a distributor including at least one distribution conduit in fluid passage connection with the main channel to distribute the fluid, at least one spinneret having holes each running parallel to the extrusion direction in fluid passage connection with the distribution conduit and suitable for extruding the fluid to make a respective polymeric filament, at least one distribution tank between the distributor, downstream of the conduit, and the spinneret, upstream of the holes, connecting, in fluid passage connection, the conduit and holes and defining a first thickness along the extrusion direction between 3 and 5 mm.

A method of creating a soft and lofty continuous fiber nonwoven web is provided. The method includes providing first and second, different molten polymers to a spinneret defining a plurality of orifices and flowing a fluid intermediate the spinneret and a moving porous member. The method includes using the fluid to draw the first and second molten polymers, in a direction toward the porous member, through at least some of the plurality of orifices to form a plurality of individual continuous fiber strands. The method includes depositing the continuous fiber strands onto the porous member at a first location to produce an intermediate continuous fiber nonwoven web, and intermittently varying, in at least two different zones, a vacuum force applied to the moving porous member and to the intermediate web downstream of the first location and without the addition of more continuous fibers and without any heat applied.

A method of creating a soft and lofty continuous fiber nonwoven web is provided. The method includes providing first and second, different molten polymers to a spinneret defining a plurality of orifices and flowing a fluid intermediate the spinneret and a moving porous member. The method includes using the fluid to draw the first and second molten polymers, in a direction toward the porous member, through at least some of the plurality of orifices to form a plurality of individual continuous fiber strands. The method includes depositing the continuous fiber strands onto the porous member at a first location to produce an intermediate continuous fiber nonwoven web, and intermittently varying, in at least two different zones, a vacuum force applied to the moving porous member and to the intermediate web downstream of the first location and without the addition of more continuous fibers and without any heat applied.

Nonwoven fabrics are provided that include (i) a plurality of continuous matrix fibers comprising a first polymeric material having a first melting point and including a first polymer component, in which the first polymer component comprises a first recycled-polyester, and (ii) a plurality of binder fibers having an irregular cross-section randomly dispersed throughout the plurality of matrix fibers, in which the plurality of binder fibers comprising a second polymeric material having a second melting point including a second polymer component. The second melting point being less than the first melting point.

Nonwoven fabrics are provided that include (i) a plurality of continuous matrix fibers comprising a first polymeric material having a first melting point and including a first polymer component, in which the first polymer component comprises a first recycled-polyester, and (ii) a plurality of binder fibers having an irregular cross-section randomly dispersed throughout the plurality of matrix fibers, in which the plurality of binder fibers comprising a second polymeric material having a second melting point including a second polymer component. The second melting point being less than the first melting point.

Embossed fibrous structures containing a plurality of filaments and methods for making same are provided.

Embossed fibrous structures containing a plurality of filaments and methods for making same are provided.

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property, and wherein in at least one of the microzones, the first region is hydrophobic and the second region is hydrophilic.

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property, and wherein in at least one of the microzones, the first region is hydrophobic and the second region is hydrophilic.