A method of creating a soft and lofty continuous fiber nonwoven web is provided. The method includes providing a first molten polymer and a second, different molten polymer 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 polymer components, in a direction toward the moving 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 moving porous member at a first location to produce an intermediate continuous fiber nonwoven web, and intermittently varying 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 a first molten polymer and a second, different molten polymer 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 polymer components, in a direction toward the moving 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 moving porous member at a first location to produce an intermediate continuous fiber nonwoven web, and intermittently varying 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.

An apertured nonwovens having a first nonwoven layer is described. The first nonwoven layer includes cellulose-based fibers and a plurality of apertures, wherein the plurality apertures have a minimum aperture distance between two adjacent apertures which has a relative standard deviation no greater than about 40%, as measured according to the Aperture Quality Test. The apertures have an aperture size no greater than about 2.2 mm.sup.2 and have an occlusion no greater than about 9%, as measured according to the Aperture Quality Test, or the apertures have an aspect ratio no greater than about 2.5 as measured according to the Aspect Ratio Test.

An apertured nonwovens having a first nonwoven layer is described. The first nonwoven layer includes cellulose-based fibers and a plurality of apertures, wherein the plurality apertures have a minimum aperture distance between two adjacent apertures which has a relative standard deviation no greater than about 40%, as measured according to the Aperture Quality Test. The apertures have an aperture size no greater than about 2.2 mm.sup.2 and have an occlusion no greater than about 9%, as measured according to the Aperture Quality Test, or the apertures have an aspect ratio no greater than about 2.5 as measured according to the Aspect Ratio Test.

A method for making nonwoven fabric. The nonwoven fabric can include three-dimensional features that 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. The nonwoven further has a plurality of apertures, wherein at least a portion of the aperture abuts at least one of the first region and the second region of the microzone.

A continuous fiber brake rotor preform and apparatuses and methods for manufacturing the preform are disclosed herein. The preform comprises a plurality of continuous fiber streams or filaments forming a substantially helical structure having layers or flights compressed together in the preform's longitudinal direction. Each continuous fiber stream or filament may comprise the same or different types of fiber, extends substantially between longitudinally disposed preform ends, and resides laterally adjacent to another continuous fiber stream or filament within each layer or flight of the helical structure. The radial distance between each continuous fiber stream or filament and the preform's longitudinal axis varies with angular location about the longitudinal axis. The preform further comprises web or z-direction fiber interspersed within the helical structure with certain of the web or z-direction fibers and continuous fiber streams or filaments extending at least partially in the longitudinal direction between the preform's layers or flights.

A continuous fiber brake rotor preform and apparatuses and methods for manufacturing the preform are disclosed herein. The preform comprises a plurality of continuous fiber streams or filaments forming a substantially helical structure having layers or flights compressed together in the preform's longitudinal direction. Each continuous fiber stream or filament may comprise the same or different types of fiber, extends substantially between longitudinally disposed preform ends, and resides laterally adjacent to another continuous fiber stream or filament within each layer or flight of the helical structure. The radial distance between each continuous fiber stream or filament and the preform's longitudinal axis varies with angular location about the longitudinal axis. The preform further comprises web or z-direction fiber interspersed within the helical structure with certain of the web or z-direction fibers and continuous fiber streams or filaments extending at least partially in the longitudinal direction between the preform's layers or flights.

A method for manufacturing a preform for producing a part made of composite material with an unchangeable final shape includes supplying a triaxial non-woven textile comprising a layer of fibers orientated in a first direction, a layer of fibers orientated in a second direction, a layer of fibers orientated in a third direction, and seams extending parallel to each other and forming sheaths for the circumferential fibers, arranging the textile on an element of unchangeable shape by placing the seams parallel to the circumferential direction of the element, and sliding the circumferential fibers into the sheaths so that the textile is in continuous contact with the element.

An apertured nonwovens having a first nonwoven layer is described. The first nonwoven layer includes cellulose-based fibers and a plurality of apertures, wherein the plurality apertures have a minimum aperture distance between two adjacent apertures which has a relative standard deviation no greater than about 40%, as measured according to the Aperture Quality Test. The apertures have an aperture size no greater than about 2.2 mm.sup.2 and have an occlusion no greater than about 9%, as measured according to the Aperture Quality Test, or the apertures have an aspect ratio no greater than about 2.5 as measured according to the Aspect Ratio Test.

An apertured nonwovens having a first nonwoven layer is described. The first nonwoven layer includes cellulose-based fibers and a plurality of apertures, wherein the plurality apertures have a minimum aperture distance between two adjacent apertures which has a relative standard deviation no greater than about 40%, as measured according to the Aperture Quality Test. The apertures have an aperture size no greater than about 2.2 mm.sup.2 and have an occlusion no greater than about 9%, as measured according to the Aperture Quality Test, or the apertures have an aspect ratio no greater than about 2.5 as measured according to the Aspect Ratio Test.