Extensible nonwoven fabrics having improved elongation, extensibility, abrasion resistance and toughness. In particular, embodiments of the invention are directed to extensible spunbond fabrics comprising a polymeric blend of a metallocene catalyzed polypropylene, polyethylene, and a third polymer component.

A protective pad or garment portion, garments, and individual layers, being a moisture wicking layer, a core moisture absorbing layer and a moisture impermeable layer, and combinations thereof are disclosed.

A method of making nonwoven webs comprising providing a spinneret including a pattern of conduits forming an extrusion region; directing only a first stream of molten propylene polymer into a region adjacent the first side of the spinneret, directing only a second stream of molten propylene polymer into a region distal to the first side of the spinneret, extruding only the first stream propylene polymer through the exit openings in a first zone where the exit opening comprises exit ports in the first zone having a first density; extruding only the second stream propylene polymer through the exit openings of a second zone where the exit opening comprises exit ports in the second zone having a second density less than the first density; and the second zone is distal to the first side with the first zone being between the second zone and the first side.

Patterned fibrous substrates having a plurality of individual fibers, a first region, and a second region are provided. The patterned fibrous substrates have a plurality of individual fibers of the first region having a first diameter and a plurality of individual fibers of the second region have a second diameter, wherein the first diameter is less than the second diameter. The individual fibers of the first region and the individual fibers of the second region are substantially free of bonds, other than primary bonds. The first region has a first C.I.E. L* score, and the second region has a second C.I.E. L* score, according to the Color Test Method. The first C.I.E. L* score is different than the second C.I.E. L* score.

A protective garment, gussets for protective garments, and individual gusset layers, being a moisture wicking layer, a core moisture absorbing layer and a moisture impermeable layer, and combinations thereof. The moisture wicking layer including a double knit fabric wherein a technical face of the fabric forms an eyelet mesh utilising both hydrophilic and hydrophobic yarns and a technical back of the fabric forms an interlock utilising only hydrophilic yarns. The moisture absorbing layer including a sinker terry fabric knit comprising sinker loops with plush loops made form synthetic fibres treated with a hydrolysing enzyme that splits the fibres into fibrils. The moisture impermeable layer including a base fabric knit laminated with a polyurethane sheet.

Methods and apparatuses for producing a zoned and/or layered substrate are described. A substrate can include a first layer including a first zone, a second zone, and an interface between zones. The first zone can include a plurality of fibers. The second zone can include a plurality of fibers and can be offset from the first zone in a cross-direction. The interface can include at least some of the plurality of fibers of the first zone and at least some of the plurality of fibers of the second zone to provide a purity gradient with a transition width less than 3.8 cm as defined by the Purity Gradient Test Method as described herein.

A fabric structure comprises a plurality of convex loops each made from a hairy fluffy yarn and formed on a first side of a fabric; and a plurality of concave loops, each consisting of a concave loop portion of the hairy fluffy yarn and plated with a base yarn formed on a second side of the fabric, thereby forming a fabric simultaneously having fluffy hand-feel and proper stiffness for comfortable uses.

A patterned apertured web is disclosed. The patterned apertured web includes a plurality of land areas in the patterned apertured web and a plurality of apertures defined in the patterned apertured web. At least some land areas of the plurality of land areas surround at least some apertures of the plurality of apertures. The patterned apertured web has an Effective Open Area in the range of about 3% to about 30%, according to the Aperture Test herein. The plurality of apertures include a first set of apertures defining a first shape and a second set of apertures defining a second shape. The first shape is positioned within the second shape.

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. 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.

Provided is a composite sheet material having a first layer and an airlaid nonwoven layer overlying the first layer wherein the airlaid nonwoven layer includes a blend of bamboo derived staple fibers and non-cellulose staple fibers, and in which the airlaid nonwoven layer includes a first surface disposed towards, and thermally bonded, to a surface of the first layer, and a second surface defining an outer surface of the composite sheet material.