Self-crimped multi-component fibers (SMF) are provided that include (i) a first component comprising a first polymeric material, in which the first polymeric material comprises a first melt flow rate (MFR) that is less than 50 g/10 min; and (ii) a second component comprising a second polymeric material, in which the second component is different than the first component. The SMF includes one or more three-dimensional crimped portions. Also provided are nonwoven fabrics comprising a plurality of SMFs. Methods of manufacturing SMFs and nonwoven fabrics including SMFs are also provided.

A spunbonded non-woven fabric includes a fiber including a propylene homopolymer having a melting point of 140° C. or more, a polyethylene having a density of from 0.941 g/cm.sup.3 to 0.970 g/cm.sup.3, and at least one polymer selected from the group consisting of a polymer represented in (I) and a polymer represented in (II). In the spunbonded non-woven fabric, the fiber includes a sea-island structure, and the percentage of an island phase having a diameter of from 0.12 μm to less than 0.63 μm with respect to an island phase in a cross section orthogonal to the axis direction of the fiber on a number basis is 30% or more. (I) represents a random copolymer of propylene and at least one selected from ethylene or an α-olefin having a carbon number of from 4 to 20. (II) represents a propylene homopolymer with a melting point of less than 120° C.

A spunbonded non-woven fabric includes a fiber including a propylene homopolymer having a melting point of 140° C. or more, a polyethylene having a density of from 0.941 g/cm.sup.3 to 0.970 g/cm.sup.3, and at least one polymer selected from the group consisting of a polymer represented in (I) and a polymer represented in (II). In the spunbonded non-woven fabric, the fiber includes a sea-island structure, and the percentage of an island phase having a diameter of from 0.12 μm to less than 0.63 μm with respect to an island phase in a cross section orthogonal to the axis direction of the fiber on a number basis is 30% or more. (I) represents a random copolymer of propylene and at least one selected from ethylene or an α-olefin having a carbon number of from 4 to 20. (II) represents a propylene homopolymer with a melting point of less than 120° C.

The invention relates to a process (100) for the production of spunbonded nonwoven (1) wherein a spinning mass (2) is extruded through the nozzle holes (4) of at least one spinneret (3, 30) to form filaments (5, 50), the filaments (5, 50) are drawn in the extrusion direction and deposited on a first conveying device (9) to form the spunbonded nonwoven (1), and wherein the spunbonded nonwoven (1) is subjected to at least one washing (10). For increasing the throughput of the process without losses of quality, it is suggested that the spunbonded nonwoven (1) is subjected to the washing (10) at least partially on a perforated second conveying device (13) with a lower conveying speed with respect to that of the first conveying device (9), wherein the spunbonded nonwoven (1) is sprayed with washing liquid during the washing (10) and the washing liquid is discharged at least partially through the perforated second conveying device (13).

The invention relates to a process (100) for the production of spunbonded nonwoven (1) wherein a spinning mass (2) is extruded through the nozzle holes (4) of at least one spinneret (3, 30) to form filaments (5, 50), the filaments (5, 50) are drawn in the extrusion direction and deposited on a first conveying device (9) to form the spunbonded nonwoven (1), and wherein the spunbonded nonwoven (1) is subjected to at least one washing (10). For increasing the throughput of the process without losses of quality, it is suggested that the spunbonded nonwoven (1) is subjected to the washing (10) at least partially on a perforated second conveying device (13) with a lower conveying speed with respect to that of the first conveying device (9), wherein the spunbonded nonwoven (1) is sprayed with washing liquid during the washing (10) and the washing liquid is discharged at least partially through the perforated second conveying device (13).

A nonwoven web is made by displacing an air-permeable mesh-belt conveyor in a horizontal travel direction and spinning and then depositing crimped continuous filaments as a web at a deposit region on the air-permeable mesh-belt conveyor. A first preconsolidation stage is provided downstream of the deposit region and a second preconsolidation separated by a suction gap from the first stage. Air is drawn air through the web and the conveyor at the deposit region at a first predetermined speed, the first and second consolidation stages at a second and third predetermined speeds, and at the suction gap either not at all or at a fourth predetermined equal to at most substantially less than the second predetermined speed.

A nonwoven web is made by displacing an air-permeable mesh-belt conveyor in a horizontal travel direction and spinning and then depositing crimped continuous filaments as a web at a deposit region on the air-permeable mesh-belt conveyor. A first preconsolidation stage is provided downstream of the deposit region and a second preconsolidation separated by a suction gap from the first stage. Air is drawn air through the web and the conveyor at the deposit region at a first predetermined speed, the first and second consolidation stages at a second and third predetermined speeds, and at the suction gap either not at all or at a fourth predetermined equal to at most substantially less than the second predetermined speed.

Provided is a composite nonwoven fabric including: a silk region that contains crimped silk fibers as a main component; and a synthetic fiber nonwoven fabric region that contains polyolefin resin-containing synthetic fibers as a main component.

A rigid, channel-framed, pleated air filter, with a plurality of linear bridging filaments on at least an upstream face of the pleated air filter media of the filter.

A rigid, channel-framed, pleated air filter, with a plurality of linear bridging filaments on at least an upstream face of the pleated air filter media of the filter.