A process for forming a high loft, nonwoven web is disclosed. The process includes introducing a single molten polymer to a die having a plurality of nozzles. Emitting the molten polymer through the nozzles to form a plurality of filaments. Using air streams to facilitate movement and drawing of the filaments. Directing the filaments, which are transformed into fibers, towards a pair of heated moving surfaces. The pair of heated moving surfaces forming a convergent passage having an entry and an exit. Depositing the fibers into the entry of the convergent passage and routing the fibers between the pair of heated moving surfaces in a machine direction to form a high loft, non-woven web. The web having a fiber size distribution of from 0 m to about 15 m with at least about 25% of the fibers being above 4 m.

A method of reversible swelling and collapsing of the latent pores of natural fiber welded biopolymer by way of sequential solvent treatment to i) regenerate mesoporous biopolymeric structures, comprising the steps of providing a nonporous natural fiber welded biopolymer composite, submerging the nonporous composite in polar solvent, exchanging submersion solvents, typically starting from a solvent of polar identity and ending with a solvent of nonpolar identity, then removing the solvent; and ii) regenerate nonporous biopolymeric structures, comprising the steps of providing a mesoporous natural fiber welded biopolymer composite, submerging the mesoporous composite in polar solvent, then removing the solvent. A mesoporous biopolymeric structure wherein the NFW nonporous composite expresses a BET surface area change of <5 m.sup.2 g.sup.1 to >40 m.sup.2 g.sup.1. A nonporous biopolymeric structure wherein the NFW mesoporous composite expresses a BET surface area change of >40 m.sup.2 g.sup.1 to <5 m.sup.2 g.sup.1.

A method of reversible swelling and collapsing of the latent pores of natural fiber welded biopolymer by way of sequential solvent treatment to i) regenerate mesoporous biopolymeric structures, comprising the steps of providing a nonporous natural fiber welded biopolymer composite, submerging the nonporous composite in polar solvent, exchanging submersion solvents, typically starting from a solvent of polar identity and ending with a solvent of nonpolar identity, then removing the solvent; and ii) regenerate nonporous biopolymeric structures, comprising the steps of providing a mesoporous natural fiber welded biopolymer composite, submerging the mesoporous composite in polar solvent, then removing the solvent. A mesoporous biopolymeric structure wherein the NFW nonporous composite expresses a BET surface area change of <5 m.sup.2 g.sup.1 to >40 m.sup.2 g.sup.1. A nonporous biopolymeric structure wherein the NFW mesoporous composite expresses a BET surface area change of >40 m.sup.2 g.sup.1 to <5 m.sup.2 g.sup.1.

A moldable composite sheet having improved thermal and mechanical property characteristics. In one aspect, the composite sheet may be a porous fiber-reinforced thermoplastic resin comprising discontinuous mineral reinforcing fibers, and one or more skin layer materials. Generally, the composite sheet may have a void content or porosity from about 5% to about 95% by volume of the sheet, an areal weight between about 400 g/m.sup.2 to about 4000 g/m.sup.2 (gsm), a mineral fiber content from about 20% to about 80% by weight, and a thermoplastic resin content from about 20% to about 80% by weight of the composite sheet. The composite sheet can be molded via low pressure processes, such as thermoforming, match metal molding on stops, vacuum forming and pressure forming, to produce durable automotive interior trim parts and construction articles having improved thermal and mechanical properties in addition to other beneficial characteristics.

A moldable composite sheet having improved thermal and mechanical property characteristics. In one aspect, the composite sheet may be a porous fiber-reinforced thermoplastic resin comprising discontinuous mineral reinforcing fibers, and one or more skin layer materials. Generally, the composite sheet may have a void content or porosity from about 5% to about 95% by volume of the sheet, an areal weight between about 400 g/m.sup.2 to about 4000 g/m.sup.2 (gsm), a mineral fiber content from about 20% to about 80% by weight, and a thermoplastic resin content from about 20% to about 80% by weight of the composite sheet. The composite sheet can be molded via low pressure processes, such as thermoforming, match metal molding on stops, vacuum forming and pressure forming, to produce durable automotive interior trim parts and construction articles having improved thermal and mechanical properties in addition to other beneficial characteristics.

Provided herein are nonwoven composite articles including a first layer including a first nonwoven web including a first plurality of fibers having a first diameter, a second layer including a second nonwoven web including a second plurality of fibers having a second diameter, and a first interface including at least a portion of the first nonwoven web and at least a portion of the second nonwoven web, wherein the portion of the first nonwoven web and the portion of the second nonwoven web are fused, and wherein the second diameter is smaller than the first diameter and the first plurality of fibers, the second plurality of fibers, or both include a water-soluble polyvinyl alcohol fiber forming material. Also provided are flushable wipes and absorbent articles including nonwoven webs including fibers including a water-soluble polyvinyl alcohol fiber forming material.