An improved method of preparing a carbon fiber-reinforced thermoplastic nonwoven web using recycled carbon fibers employs resonant acoustic mixing to combine the recycled carbon fibers with the thermoplastic fibers, followed by carding of the fiber mixture to form the carbon-fiber reinforced nonwoven web. The method provides a low-cost way to make carbon-fiber reinforced nonwoven webs that have sufficient mechanical properties to enable widespread use in the automotive industry and other high-volume industries.

In an aspect, provided herein are 3D-printed textiles, such as spacer fabrics. The textiles can have structures and properties that are not possible when made using conventional technologies having knitting, weaving, or sewing needles. For example, the textiles described herein can have variable yarn thickness, variable connectivity between sheets, and even sheets that intersect each other. Also provided herein are methods for making such textiles.

The disclosure relates to nonwoven fabric including a nonwoven material having a first surface and an opposing second surface, wherein the first surface has a first average surface charge and the second surface has a second average surface charge, the first average surface charge being different from the second average surface charge, wherein the nonwoven material includes a first plurality of fibers including a first polymer and a second plurality of fibers including a second polymer different from the first polymer. A method for imparting surface charge to a nonwoven N61824_1570Wabric is also provided.

A process for forming a nonwoven fabric is provided. The process includes depositing at least a first nonwoven layer comprising a first plurality of interlaid individual meltspun fibers, which may comprise a plurality of monocomponent fibers having different onset of melting temperatures, bicomponent fibers having distinct fiber components having different onset of melting temperatures, and/or a plurality of different bicomponent fibers having one or more distinct components having different onset of melting temperatures, directly or indirectly onto a moving collection belt to form a precursor nonwoven. The process includes subjecting the precursor nonwoven web to a heat-setting operation (HSO) to heat-set the first plurality of interlaid individual meltspun fibers to form an intermediate nonwoven fabric, followed by consolidating the intermediate nonwoven fabric to provide that nonwoven fabric.

An absorbent article such as a diaper comprising as component a carded calendered nonwoven comprising synthetic staple fibers, wherein the synthetic staple fibers comprise a polypropylene polymer matrix, an ethylene-propylene copolymer and a fatty acid amide, and optionally natural fibers. The nonwovens may be used in application where a soft and affordable nonwoven is desired, for example in the topsheet or backsheet outer cover nonwoven.

A carded calendered nonwoven comprising synthetic staple fibers. The synthetic staple fibers comprise a polypropylene polymer matrix, an ethylene-propylene copolymer and a fatty acid amide. The nonwovens of the present disclosure may be used in application where a soft and affordable nonwoven is desired, for example disposable absorbent articles, such as pants or diapers.

The invention relates to methods for providing crimped bast fibers which may include providing an input of bast fibers, adjusting the moisture content of the bast fibers to be in the range of about 10% to about 40% by weight to form a fiber mat, and contacting the fiber mat with a pair of heated crimping rolls to provide crimped bast fibers having a crimp of about 1 to about 10 crimps per centimeter. The invention further provides for a nonwoven fabric comprising at least 5% of the crimped bast fibers. The crimping of the bast fibers in these nonwoven fabrics is beneficial to forming a drylaid, airlaid or wetlaid nonwoven fabric that has desirable properties related to performance in a variety of nonwoven product applications.

A fluid management layer having an integrated, carded, nonwoven is described. The fluid management layer has a basis weight of between about 40 grams per square meter (gsm) and about 75 gsm; a plurality of absorbent fibers, a plurality of stiffening fibers and a plurality of resilient fibers; wherein the fluid management layer exhibits a total compression of greater than 0.40 mm and has a total recovery of at least 0.35 mm, and wherein the fluid management layer has a density of less than or equal to 0.08 g/cc.

A nonwoven textile can be treated with a laser to construct bonding structures between fibers of the nonwoven textile. In examples, the nonwoven textile can have fibers including a material that absorbs electromagnetic radiation emitted by a laser. In addition, based on absorbing the electromagnetic radiation, the fibers can soften, and the softened portions of the fibers can contact one or more other fibers of the nonwoven textile. When the softened portions re-solidify (e.g., after removal of the electromagnetic radiation), the re-solidified portions of the fiber can at least partially encapsulate the other fiber(s) to form the bonding structure between the re-solidified portions and the other fiber(s). In some examples, the bonding structure can reduce the likelihood of the fibers that are associated with the bonding structure from migrating through a face of the nonwoven textile and forming pills.

A thermal insulation batt is created from recycled carpet fibers and fire resistant cotton shoddy bonded by staples of bi-component fiber having a polyester core and low melting polymeric sheath. The low melting polymeric sheath melts at a temperature well below the melting or degradation temperature of any of the carpet fibers from the recycled carpets. Since the sheath has a small thickness, the amount of melt created is small and bonding occurs only between the bi-component staple fiber and adjacent carpet fiber or fire resistant cotton shoddy without melt overflow. The rigidized thermal insulation batt can be used in a building between studs and may be used in an automobile door for sound proofing. This product is particularly well suited for use as acoustic and thermal insulation in buildings as non-load bearing partitions in interior offices of commercial buildings. This bonded low density composite fibrous structure has fire retarding constituents incorporated within the batt to retard propagation of building fire. These stated uses are non-limiting; and other uses are contemplated, including automobile interior structures.