The invention relates to a method for producing a nonwoven fabric from fibres, wherein the fibres are spun by means of at least one spinneret, are cooled and then deposited on a collection device to form a nonwoven web. The nonwoven web undergoes hot fluid bonding during at least two consecutive bonding steps. In a first bonding step, the surface of the nonwoven web is subjected to a hot fluid and, in a second bonding step, the surface of the nonwoven web is also subsequently subjected to a hot fluid and, in addition and at the same time, surface pressure is exerted on the nonwoven web.

The invention relates to a method for producing a nonwoven fabric from fibres, wherein the fibres are spun by means of at least one spinneret, are cooled and then deposited on a collection device to form a nonwoven web. The nonwoven web undergoes hot fluid bonding during at least two consecutive bonding steps. In a first bonding step, the surface of the nonwoven web is subjected to a hot fluid and, in a second bonding step, the surface of the nonwoven web is also subsequently subjected to a hot fluid and, in addition and at the same time, surface pressure is exerted on the nonwoven web.

A fiber structure includes crimped staple fibers and heat-bonding conjugate staple fibers mixed in a specific weight ratio, the heat-bonding conjugate staple fibers having, as a heat-bonding component disposed on the surface thereof, a thermoplastic resin having a melting point lower by 40 C. or more than that of a thermoplastic resin constituting the crimped staple fibers, the fiber structure having scattered fixing points in which the heat-bonding conjugate staple fibers are heat-fused and intersect together and/or scattered fixing points in which the heat-bonding conjugate staple fibers and the crimped staple fibers are heat-fused and intersect together, the fiber structure having a specified thickness and density and having a laminated structure of three or more layers, wherein the hardness ratio between an intermediate layer portion and a surface layer portion defined when the fiber structure is equally divided into three portions is 0.60 or more.

The purpose of the present invention is to provide a porous shaped nonwoven fabric, which has excellent texture and good liquid permeability, is bulky, and is less susceptible to liquid return. The present invention provides a shaped nonwoven fabric with sections of relatively low specific volume and sections of relatively high specific volume present in parallel lines on the surface of the nonwoven fabric, wherein the portion with a low specific volume have thermally compressed areas alternating with porous areas and the portion with a high specific volume have ridges that have not been thermally compressed.

A device for producing a three dimensional shaped consolidated product. The device includes a rotary drum, defined as a rotary conveyor with a peripheral surface extending in circumferential direction with at least one product shaping area in the form of a cavity on said peripheral surface, the peripheral surface is pervious to air at least in the product shaping area, at least one material feed device to feed a base material into the at least one cavity, a vacuum device designed to generate a negative pressure at least in the at least one cavity, whereby the generated suction is directed towards the interior of the rotary conveyor, and whereby downstream of the material feed device at least one consolidating device is located such that at least a part of the filled cavity is subjected to a consolidating treatment whereby the base material at least partly will adhere to neighboring material.

A device for producing a three dimensional shaped consolidated product. The device includes a rotary drum, defined as a rotary conveyor with a peripheral surface extending in circumferential direction with at least one product shaping area in the form of a cavity on said peripheral surface, the peripheral surface is pervious to air at least in the product shaping area, at least one material feed device to feed a base material into the at least one cavity, a vacuum device designed to generate a negative pressure at least in the at least one cavity, whereby the generated suction is directed towards the interior of the rotary conveyor, and whereby downstream of the material feed device at least one consolidating device is located such that at least a part of the filled cavity is subjected to a consolidating treatment whereby the base material at least partly will adhere to neighboring material.

Disclosed is a wearable article continuous in a longitudinal direction and a transverse direction comprising an elastic belt region, a crotch region, a waist opening and two leg openings; the elastic belt region is a laminate comprising an inner sheet made of nonwoven fiber, and an outer sheet made of nonwoven fiber, and a plurality of elastic bodies configured to stretch the elastic belt region in the transverse direction, the crotch region comprises an outer cover layer at the most garment facing side, the outer cover layer being the same material as the outer sheet; wherein the outer sheet has a Compression Work of more than about 550 gfmm, a Compression Average Rigidity of less than about 500 gf/mm.sup.3, a Surface Roughness Wavelength of more than about 1.7 mm, and a Glossiness of less than about 5.3, the Compression Work, the Compression Average Rigidity, the Surface Roughness Wavelength and the Glossiness according to the measurements herein.

Disclosed is a wearable article continuous in a longitudinal direction and a transverse direction comprising an elastic belt region, a crotch region, a waist opening and two leg openings; the elastic belt region is a laminate comprising an inner sheet made of nonwoven fiber, and an outer sheet made of nonwoven fiber, and a plurality of elastic bodies configured to stretch the elastic belt region in the transverse direction, the crotch region comprises an outer cover layer at the most garment facing side, the outer cover layer being the same material as the outer sheet; wherein the outer sheet has a Compression Work of more than about 550 gfmm, a Compression Average Rigidity of less than about 500 gf/mm.sup.3, a Surface Roughness Wavelength of more than about 1.7 mm, and a Glossiness of less than about 5.3, the Compression Work, the Compression Average Rigidity, the Surface Roughness Wavelength and the Glossiness according to the measurements herein.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

The present invention relates to a hyaluronate nonwoven fabric composed of hyaluronate fibers and a manufacturing method therefor, wherein a nonwoven fabric composed of only pure hyaluronate is provided without the addition of any heterogeneous fiber, such as PVA which is a binding fiber essentially added during a wet-laid nonwoven fabric manufacturing process, so that a nonwoven fabric composed of only hyaluronate fibers with excellent human compatibility and without cytotoxicity, skin irritation, and the like can be provided, and thus can be used as patches for cosmetic patches, wet wound dressings, tissue adhesion barrier membranes, and the like.