A method of electrospinning (40) is provided, and an electrospinning device (1; 30). The method comprises (i) holding (41) a liquid comprising a polymer melt or a polymer solution in a container (2), (ii) letting out (42) a stream of the liquid from the container through at least one nozzle (3), (iii) creating (43) a voltage difference between the nozzle (3) and a collecting surface (4), (iv) collecting (44) electro spun material coming from the nozzle (3) so as to form a fibrous structure (8) on the collecting surface (4), and (v) directing (45) a laser beam (13) towards the collecting surface (4) so as to locally remove a part of the fibrous structure (8).

A forming belt for use in making a nonwoven substrate. The forming belt includes a first surface defining a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction when in use. A plurality of discrete belt patterns can be ordered in sequential relationship with respect to the longitudinal direction. At least a majority of the plurality of discrete belt patterns can include a discrete belt pattern overall area, a first forming zone having a first pattern of three-dimensional raised elements extending outwardly from the plane of the first surface and a second forming zone having a second pattern of three-dimensional raised elements extending outwardly from the plane of the first surface. The first forming zone can have a first air permeability value and the second forming zone can have a second air permeability value. The first air permeability value can be different from the second air permeability value.

A forming belt for use in making a nonwoven substrate. The forming belt includes a first surface defining a plane of the first surface and an axis parallel to a longitudinal direction corresponding to a machine direction when in use. A plurality of discrete belt patterns can be ordered in sequential relationship with respect to the longitudinal direction. At least a majority of the plurality of discrete belt patterns can include a discrete belt pattern overall area, a first forming zone having a first pattern of three-dimensional raised elements extending outwardly from the plane of the first surface and a second forming zone having a second pattern of three-dimensional raised elements extending outwardly from the plane of the first surface. The first forming zone can have a first air permeability value and the second forming zone can have a second air permeability value. The first air permeability value can be different from the second air permeability value.

A nonwoven substrate. The nonwoven substrate can have a first surface defining a plane of the first surface and a plurality of three-dimensional features extending outwardly from the plane of the first surface. The plurality of three-dimensional features can have a first three-dimensional feature having a first intensive property having a first value and a second three-dimensional feature having the first intensive property having a second value different from the first value. The nonwoven substrate can have an MD Fuzz Value of less than 0.25 mg/cm.sup.2 when tested according to the Fuzz Level Test herein.

A nonwoven substrate. The nonwoven substrate can have a first surface defining a plane of the first surface and a plurality of three-dimensional features extending outwardly from the plane of the first surface. The plurality of three-dimensional features can have a first three-dimensional feature having a first intensive property having a first value and a second three-dimensional feature having the first intensive property having a second value different from the first value. The nonwoven substrate can have an MD Fuzz Value of less than 0.25 mg/cm.sup.2 when tested according to the Fuzz Level Test herein.

The present invention provides a method of making a nonwoven fabric of continuous fibers that includes forming a nonwoven web on a highly porous woven or knitted forming fabric that defines a pattern of recesses that are bordered by spaced apart filaments extending between the outer surfaces of the fabric and that allows air to pass both downwardly and sidewardly through the forming fabric. Bonded nonwoven webs are formed having protrusions with very low density and high surface area.

The present invention provides a method of making a nonwoven fabric of continuous fibers that includes forming a nonwoven web on a highly porous woven or knitted forming fabric that defines a pattern of recesses that are bordered by spaced apart filaments extending between the outer surfaces of the fabric and that allows air to pass both downwardly and sidewardly through the forming fabric. Bonded nonwoven webs are formed having protrusions with very low density and high surface area.

The invention relates to a manufacturing process of equipment for use in the production of nonwoven fabrics and paper products. According to the present invention, a sleeve for an embossing roller is produced using additive manufacturing, specifically 3D printing. These technologies permit the preparation of pattern-forming and dewatering details in the sleeve in a single operation. The dewatering properties may thus be optimised for the selected pattern, resulting in uniform dewatering tailored for the pattern. Preferably, the technique used is stereolithography.

The invention relates to a manufacturing process of equipment for use in the production of nonwoven fabrics and paper products. According to the present invention, a sleeve for an embossing roller is produced using additive manufacturing, specifically 3D printing. These technologies permit the preparation of pattern-forming and dewatering details in the sleeve in a single operation. The dewatering properties may thus be optimised for the selected pattern, resulting in uniform dewatering tailored for the pattern. Preferably, the technique used is stereolithography.

The invention relates to a patterned spunbonded nonwoven fabric sheet comprising a plurality of spunbonded crimped fibers bonded together at a plurality of bonding points, wherein all fibers of the patterned spunbonded nonwoven fabric sheet are spunbonded crimped fibers and wherein the configuration of the fibers within the sheet is inhomogeneous and varies according to a preferably regular pattern. The invention further relates to a method for forming such patterned spunbonded nonwoven fabric sheet from a flat spunbonded nonwoven fabric sheet starting material. Still further, the invention relates to such flat spunbonded nonwoven fabric sheet starting material.