A nonwoven substrate. The nonwoven substrate can have a first surface defining a plane of the first surface and a plurality of three-dimensional features extending outwardly from the plane of the first surface. The plurality of three-dimensional features can have a first three-dimensional feature having a first intensive property having a first value and a second three-dimensional feature having the first intensive property having a second value different from the first value. The nonwoven substrate can have an MD Fuzz Value of less than 0.25 mg/cm.sup.2 when tested according to the Fuzz Level Test herein.

A nonwoven substrate. The nonwoven substrate can have a first surface defining a plane of the first surface and a plurality of three-dimensional features extending outwardly from the plane of the first surface. The plurality of three-dimensional features can have a first three-dimensional feature having a first intensive property having a first value and a second three-dimensional feature having the first intensive property having a second value different from the first value. The nonwoven substrate can have an MD Fuzz Value of less than 0.25 mg/cm.sup.2 when tested according to the Fuzz Level Test herein.

Provided is a fiber structure in which an extra-fine fiber layer and a substrate layer are integrated deeply. The fiber structure includes an extra-fine fiber layer 10 spreading in a plane direction, and a substrate layer 20 adjoining the extra-fine fiber layer, wherein the extra-fine fiber layer 10 includes extra-fine fibers having a number average single fiber diameter of 5 μm or less; the substrate layer 20 includes non-extra-fine fibers having a number average single fiber diameter of 7 μm or more; and in a cross section along a thickness direction of the fiber structure, the substrate layer 20 contains mixture portions 12 in each of which some of the extra-fine fibers pushed between the non-extra-fine fibers are widened in a crosswise direction.

Provided is a fiber structure in which an extra-fine fiber layer and a substrate layer are integrated deeply. The fiber structure includes an extra-fine fiber layer 10 spreading in a plane direction, and a substrate layer 20 adjoining the extra-fine fiber layer, wherein the extra-fine fiber layer 10 includes extra-fine fibers having a number average single fiber diameter of 5 μm or less; the substrate layer 20 includes non-extra-fine fibers having a number average single fiber diameter of 7 μm or more; and in a cross section along a thickness direction of the fiber structure, the substrate layer 20 contains mixture portions 12 in each of which some of the extra-fine fibers pushed between the non-extra-fine fibers are widened in a crosswise direction.

A process for producing nonwoven materials is provided. The process includes: providing a three-phase (gas-liquid-solid) suspension, providing a first moving carrier sieve, applying the three-phase suspension onto the first moving carrier sieve to produce a fibrous web, removing aqueous residue of the three-phase suspension through the first carrier sieve, recycling the aqueous residue, pre-integrating the fibrous web by flushing the web with water and collecting flushed water, transferring the pre-integrated fibrous web from the first moving carrier sieve to a second moving carrier sieve, and hydroentangling the fibrous web. The three-phase suspension contains natural and/or manmade fibres, a surfactant, and air.

A process for producing nonwoven materials is provided. The process includes: providing a three-phase (gas-liquid-solid) suspension, providing a first moving carrier sieve, applying the three-phase suspension onto the first moving carrier sieve to produce a fibrous web, removing aqueous residue of the three-phase suspension through the first carrier sieve, recycling the aqueous residue, pre-integrating the fibrous web by flushing the web with water and collecting flushed water, transferring the pre-integrated fibrous web from the first moving carrier sieve to a second moving carrier sieve, and hydroentangling the fibrous web. The three-phase suspension contains natural and/or manmade fibres, a surfactant, and air.

A nonwoven web for use in an absorbent article is described. The nonwoven web has first and second nonwoven layers. The first nonwoven layer has a first plurality of fibers, an additive disposed, at least in part, on a portion of the first plurality of fibers, a first side and an opposing second side, wherein second side has a plurality of discontinuities. The second nonwoven layer has a second plurality of fibers, a first surface and an opposing second surface, and a plurality of tufts extending through at least a portion of the discontinuities in the first nonwoven layer, wherein the second nonwoven layer is attached to the first nonwoven layer such that at least a portion of the second plurality of fibers are in liquid communication with the first nonwoven layer, wherein the first nonwoven layer is hydrophobic and the second nonwoven layer is hydrophilic.

The present invention provides a method of making a nonwoven fabric of continuous fibers that includes forming a nonwoven web on a highly porous woven or knitted forming fabric that defines a pattern of recesses that are bordered by spaced apart filaments extending between the outer surfaces of the fabric and that allows air to pass both downwardly and sidewardly through the forming fabric. Bonded nonwoven webs are formed having protrusions with very low density and high surface area.

The present invention provides a method of making a nonwoven fabric of continuous fibers that includes forming a nonwoven web on a highly porous woven or knitted forming fabric that defines a pattern of recesses that are bordered by spaced apart filaments extending between the outer surfaces of the fabric and that allows air to pass both downwardly and sidewardly through the forming fabric. Bonded nonwoven webs are formed having protrusions with very low density and high surface area.

Described is a module for the treatment of fibres for obtaining a non-woven fabric. The module comprises a fan unit configured for generating a flow of air through a closed path and a chamber for the treatment of the fibres positioned in fluid communication with the closed path, delimited on opposite sides by respective side panels. Each side panel comprises a first gap defining a blowing portion of the closed path and a second gap defining a suction portion of the closed path. Each side panel defines a branch of the closed path which extends between the fan unit and the treatment chamber. The module also comprises a first platform and a second platform comprising respective first and second channels placed in fluid communication with the first gap and second gap of each side panel and with the treatment chamber to define connecting portions of the closed path. The fan unit is positioned equidistant relative to the treatment chamber in such a way that the flow of air is divided symmetrically between the branches of the closed path.