Nonwoven materials having at least one layer comprising high core bicomponent fibers are provided. The nonwoven materials can have multiple layers and are suitable for use in a variety of applications, including in absorbent products. Such nonwoven materials can be patterned to create a three-dimensional topography including indentations formed of valleys and ridges. The nonwoven materials can have improved resiliency and strength and can retain their structure under wetted conditions and after tension and compression. The nonwoven materials can further facilitate the transfer of the liquid through the nonwoven material for improved liquid distribution and can also have improved liquid retention properties.

A primary base fabric for a tufted carpet includes a first non-woven web and a second non-woven web laminated on each other. The first non-woven web is constituted with a first constituent fiber formed with a first thermoplastic resin and containing carbon. The second non-woven web is constituted with a second constituent fiber formed with a second thermoplastic resin and having a carbon content lower than the carbon content of the first constituent fiber or containing no carbon. The primary base fabric is a product prepared by combining the first non-woven web and the second non-woven web through an emboss processing.

The invention addresses the problem of providing a filter medium for a liquid filter, which has a low weight per unit and yet has high strength, high collectability, and a long life, and also a liquid filter. As a means for resolution, using a main fiber having a fiber diameter of 4.0 m or less and an aspect ratio of 100 to 2,500 and a binder fiber having a fiber diameter of 3.0 m or less and an aspect ratio of 100 to 2,500, a filter medium for a liquid filter in which the weight proportion of the binder fiber relative to the weight of the filter medium is 10 to 50 wt %, and the weight per unit is within a range of 5 to 80 g/m.sup.2, and also a liquid filter are obtained.

Provided is a composite sheet that is particularly useful as an AQDL component in absorbent articles. The composite sheet includes a fluid acquisition component and an airlaid component. The airlaid component may include one or more airlaid layers that are successively formed overlying each other. Each of the airlaid layers are adjacent to, and in direct contact with, immediately adjacent layers of the airlaid component so that adjacent layers are in fluid communication with respect to each other. The fluid acquisition component includes a nonwoven fabric comprising a carded nonwoven fabric comprised of a plurality of staple fibers that are air through bonded to each other to form a coherent nonwoven fabric. The airlaid layer(s) include a blend of cellulose and non-cellulose staple fibers. The staple fibers may be bicomponent fibers having a polyethyelene sheath and a polypropylene or polyethylene terephthalate core, and mixtures of such fibers.

An object of the invention is to provide thermo-fusible conjugated fibers capable of suppressing damage to the fibers upon processing the fibers into a nonwoven fabric web. The thermo-fusible conjugated fibers of the invention contain a first component containing a polyester-based resin and a second component containing a polyolefin-based resin, in which a melting point of the second component is 10 C. or more lower than a melting point of the first component, and a work load at break obtained by a tensile test is 1.6 cN.Math.cm/dtex or more. The damage to the fibers is suppressed by the thermo-fusible conjugated fibers of the invention, and therefore the nonwoven fabric with higher quality can be obtained with higher productivity than ever before.

A method for producing a foam-formed multilayered substrate that includes producing an aqueous-based foam including at least 3% by weight non-straight synthetic binder fibers, wherein the non-straight synthetic binder fibers have an average length greater than 2 mm; forming together a wet sheet layer from the aqueous-based foam and a cellulosic fiber layer, wherein the cellulosic fiber layer includes at least 60 percent by weight cellulosic fibers; and drying the combined layers to obtain the foam-formed multilayer substrate. A multilayered substrate includes a first layer including at least 60 percent by weight non-straight synthetic binder fibers having an average length greater than 2 mm; and a second layer including at least 60 percent by weight cellulosic fiber, wherein the first layer is in a facing relationship with the second layer, and wherein the multilayered substrate has a wet/dry tensile ratio of at least 60%.

Methods and apparatuses for producing a zoned and/or layered substrate are described. A method can include providing a first supply of fibers, providing a second supply of fibers, and providing a headbox. The headbox can include a machine direction, a cross-direction, and a first cross-directional divider that separates a first zone of the headbox from a second zone of the headbox in a cross-directional manner. The method can further include transferring the first supply of fibers and the second supply of fibers to the headbox. The method can also include transferring the first supply of fibers and the second supply of fibers through the headbox to provide the substrate.

This disclosure relates to an article that includes a nonwoven substrate and a film supported by the nonwoven substrate. The film can include a first polymer and a polymer that is immiscible with the first polymer. The first polymer can include a polyolefin and the second polymer can include a polycycloolefin, a polymethylpentene, or a copolymer thereof.

A thermally conductive, electrical insulating nonwoven material is described that comprises 20 wt. %-50 wt. % organic components, wherein the organic components comprise wherein the organic components comprise organic drawn fibers, organic bi-component binder fibers, and a polymer latex binder comprising at least one of an acrylic latex, an acrylic copolymer latex, a nitrile latex, and a styrene latex; and 50 wt. %-80 wt. % inorganic components wherein the inorganic components comprise a blend of thermally conductive fillers and clay. The organic bi-component binder fibers have a polymeric core and a sheath layer surrounding the polymeric core wherein the sheath layer has a lower melting point than the core.

Fibrous elements, such as filaments and/or fibers, and more particularly to fibrous elements that contain a fast wetting surfactant, fibrous structures made therefrom, and methods for making same are provided.