Processes for making fibrous structures and more particularly processes for making fibrous structures comprising filaments are provided.

A spunbond non-woven fabric includes a plurality of fibers. The fibers are formed from a polymer blend that includes at least one first polymer and at least one second polymer. A melt flow rate of the at least one first polymer is greater than a melt flow rate of the at least one second polymer, and the melt flow rate of the at least one second polymer is about 9 g/10 min to less than 18 g/10 min. The blend may include a percentage by weight of the second polymer that is greater than a percentage by weight of the first polymer.

A method of creating a soft and lofty continuous fiber nonwoven web is provided. The method includes providing molten polymer to a spinneret defining a plurality of orifices, and flowing a fluid intermediate the spinneret and a moving porous member. The moving porous member is positioned below the spinneret. The method includes using the fluid to draw or push the molten polymer, in a direction that is toward the moving porous member, through at least some of the plurality of orifices to form a plurality of individual continuous fiber strands. The method includes depositing the continuous fiber strands on the moving porous member at a first location to create an intermediate continuous fiber nonwoven web, and removing and/or diverting some of the fluid proximate to the first location to maintain loft and softness in the deposited intermediate continuous fiber nonwoven web.

A method of creating a soft and lofty continuous fiber nonwoven web is provided. The method includes providing molten polymer to a spinneret defining a plurality of orifices, and flowing a fluid intermediate the spinneret and a moving porous member. The moving porous member is positioned below the spinneret. The method includes using the fluid to draw or push the molten polymer, in a direction that is toward the moving porous member, through at least some of the plurality of orifices to form a plurality of individual continuous fiber strands. The method includes depositing the continuous fiber strands on the moving porous member at a first location to create an intermediate continuous fiber nonwoven web, and removing and/or diverting some of the fluid proximate to the first location to maintain loft and softness in the deposited intermediate continuous fiber nonwoven web.

Nonwoven fabrics are provided that include at least a first nonwoven layer. The first nonwoven layer includes multi-component fibers densely arranged and compacted against one another. The multi-component fibers comprise at least a first component comprising a first polymeric material including a first polyolefin and a second component comprising a second polymeric material including a second polyolefin, in which the first polymeric material is different than the second polymeric material. The first polymeric material, the second polymeric material, or both include a compatibilizer comprising a copolymer having a comonomer content including (i) at least 10% by weight of the compatibilizer of a first monomer corresponding to the first polyolefin and (ii) at least 10% by weight of the compatibilizer of a second monomer corresponding to the second polyolefin.

Nonwoven fabrics are provided that include at least a first nonwoven layer. The first nonwoven layer includes multi-component fibers densely arranged and compacted against one another. The multi-component fibers comprise at least a first component comprising a first polymeric material including a first polyolefin and a second component comprising a second polymeric material including a second polyolefin, in which the first polymeric material is different than the second polymeric material. The first polymeric material, the second polymeric material, or both include a compatibilizer comprising a copolymer having a comonomer content including (i) at least 10% by weight of the compatibilizer of a first monomer corresponding to the first polyolefin and (ii) at least 10% by weight of the compatibilizer of a second monomer corresponding to the second polyolefin.

A composite nonwoven sheet material comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer, and wherein the pulp fibers are entangled with the reinforcement filaments and the microfibers. A process of producing a composite nonwoven sheet material, comprising: forming a fibrous web comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer; and hydroentangling the fibrous web to form the composite nonwoven sheet material.

A composite nonwoven sheet material comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer, and wherein the pulp fibers are entangled with the reinforcement filaments and the microfibers. A process of producing a composite nonwoven sheet material, comprising: forming a fibrous web comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer; and hydroentangling the fibrous web to form the composite nonwoven sheet material.

A fiber article includes a plurality of first fibers and a plurality of second fibers each having an outer diameter smaller than that of each of the first fibers, the plurality of second fibers being supported in a dispersed state by the first fibers. A ratio D1/D2 of an outer diameter D1 of the first fiber to an outer diameter D2 of the second fiber is set to a value in a range of 15.0 or greater to 1666.7 or less. The outer diameter D1 is set to a value in a range of 5.0 μm or greater to 50.0 μm or less, and the outer diameter D2 is set to a value in a range of 30.0 nm or greater to 1.0 μm or less.

A dermal dressing is provided that comprises a foam layer and an adhesive layer applied directly thereon. A textile fabric is arranged on a side of the foam layer facing away from the adhesive layer, and the textile fabric comprises a vertically-lapped nonwoven. A method for producing the dermal dressing of the first aspect is also provided. The method comprises: providing the foam layer; applying the adhesive layer to the foam layer; applying the textile fabric to a side of the foam layer facing away from the adhesive layer; and bonding the foam layer and the textile fabric. The dermal dressing has optimal properties for its use in preventing pressure ulcers.