This document presents a novel method of manufacturing multilayered nonwoven fabrics consisting of submicron fibers, hydroentangled, meltfibrillated, and/or spunlaid web layers. The composite multilayered webs contain one or more submicron fiber webs placed between inner and outer layers of hydroentangled, meltfibrillated, and/or spunlaid web, forming a fabric that may be utilized in the manufacture of articles which serve as barriers, wipes or sorbent materials, or may have other potential applications. The created novel composite multilayered fabric may have increased loft, softness and bending length, may not be solely dependent upon an electrostatic charge to repel small particles and microbes, and may be formed from a broad selection of natural, synthetic, and recycled polymers, including petroleum- and plant-based, allowing polymer selection based on article lifecycle.

An installation and method for producing a multilayer web includes a first circulating belt on which at least a first web is deposited. A cylinder mould former includes a second circulating belt and is disposed following the first device in a material transport direction for producing a layer of wet laid fibres having a top side for contacting the second circulating cylinder and being transported thereby for being deposited on the first web. An entangling and bonding device follows the cylinder mould former entangling and/or bonding the first web to the layer of wet laid fibres. A distance of 10 m maximum is maintained between the point of depositing the first web the layer of wet laid fibres. In another embodiment a second device following the first device for depositing a second web. The cylinder mould former is arranged between the first and second devices to deposit the layer of wet laid fibres on the first web before the second web is deposited. A distance of 25 m maximum exists between point where the first and second webs are deposited.

An installation and method for producing a multilayer web includes a first circulating belt on which at least a first web is deposited. A cylinder mould former includes a second circulating belt and is disposed following the first device in a material transport direction for producing a layer of wet laid fibres having a top side for contacting the second circulating cylinder and being transported thereby for being deposited on the first web. An entangling and bonding device follows the cylinder mould former entangling and/or bonding the first web to the layer of wet laid fibres. A distance of 10 m maximum is maintained between the point of depositing the first web the layer of wet laid fibres. In another embodiment a second device following the first device for depositing a second web. The cylinder mould former is arranged between the first and second devices to deposit the layer of wet laid fibres on the first web before the second web is deposited. A distance of 25 m maximum exists between point where the first and second webs are deposited.

A process for manufacturing a water soluble product including the steps of: providing a water soluble fibrous first ply; providing a water soluble fibrous second ply formed on a surface other than the first ply, wherein the second ply is separate from the first ply; superposing the first ply and the second ply; and joining a first portion of the first ply to a second portion of the second ply to form the water soluble product.

A process for manufacturing a water soluble product including the steps of: providing a water soluble fibrous first ply; providing a water soluble fibrous second ply formed on a surface other than the first ply, wherein the second ply is separate from the first ply; superposing the first ply and the second ply; and joining a first portion of the first ply to a second portion of the second ply to form the water soluble product.

A composite structure including at least one natural fiber web layer and at least one nonwoven web layer. In an exemplary embodiment, the natural fiber web layer is made of cotton fibers and the nonwoven web layer is a spunbond or spunmelt layer. The composite structure may be used to form components of an absorbent article, such as top sheets or back sheets of a diaper.

A ballistic material is made from spunlace nonwoven fibers mechanically entangled into a woven ballistic fabric. The spunlace nonwoven may comprise low denier fibers providing for a highly dense ballistic product.

A ballistic material is made from spunlace nonwoven fibers mechanically entangled into a woven ballistic fabric. The spunlace nonwoven may comprise low denier fibers providing for a highly dense ballistic product.

Disclosed is a multilayer nonwoven fabric for foam molding containing a dense layer and a reinforcing layer provided on at least one side of the dense layer, the reinforcing layer is a staple fiber nonwoven fabric containing thermoplastic resin staple fibers (A) having a fiber diameter of more than 20 m, in an amount of 5% by mass to 50% by mass, and hermoplastic resin staple fibers (B) having a fiber diameter of 20 m or less, in an amount of 95% by mass to 50% by mass, and conjugate polyester-based staple fibers (C) are contained in an amount of 10% by mass to 40% by mass, the dense layer is a nonwoven fabric having bulk density in a range of from 0.05 g/cm.sup.3 to 0.3 g/cm.sup.3, and the dense layer and the reinforcing layer are entangled with each other by needle punching.

Disclosed is a multilayer nonwoven fabric for foam molding containing a dense layer and a reinforcing layer provided on at least one side of the dense layer, the reinforcing layer is a staple fiber nonwoven fabric containing thermoplastic resin staple fibers (A) having a fiber diameter of more than 20 m, in an amount of 5% by mass to 50% by mass, and hermoplastic resin staple fibers (B) having a fiber diameter of 20 m or less, in an amount of 95% by mass to 50% by mass, and conjugate polyester-based staple fibers (C) are contained in an amount of 10% by mass to 40% by mass, the dense layer is a nonwoven fabric having bulk density in a range of from 0.05 g/cm.sup.3 to 0.3 g/cm.sup.3, and the dense layer and the reinforcing layer are entangled with each other by needle punching.