Aspects herein are directed to a recyclable, asymmetrical-faced composite nonwoven textile suitable for use in apparel and other articles and methods of making the same. In example aspects, the asymmetrical-faced composite nonwoven textile includes a first face formed, at least in part from a first entangled web of fibers and an opposite second face formed, at least in part from a second entangled web of fibers. When incorporated into an article of apparel, the first face forms an outer-facing surface of the article of apparel, and the second face forms an inner-facing surface of the article of apparel. The first face includes features making it suitable to form the outer-facing surface such as resistance to abrasion, and the second face includes features making it suitable to form an inner-facing surface such as a soft hand.

Provided is a reusable outer cover. The reusable outer cover is suitable for use as a cover to an absorbent article. The reusable outer cover according to embodiments disclosed herein can be a single layer. It can be fully compatible with polyethylene recycling streams and can exhibit improved, maintained, or desirable properties in comparison to existing commercially available reusable outer covers. The reusable outer cover is formed from a nonwoven, where the nonwoven comprises a bicomponent fiber comprising a first and second region.

A 3D shaped packaging product (20) for cushioning and/or thermal insulation of packaged goods is formed by hot pressing at an average pressure equal to or below 200 kPa of an air-laid blank (10) comprising natural fibers at a concentration of at least 70% by weight of the air-laid blank (10) and a thermoplastic polymer binder at a concentration selected within an interval of from 4 up to 30% by weight of the air-laid blank (10). The 3D shaped packaging product (20) has a density that is less than four times a density of the air-laid blank (10) and the density of the 3D shaped packaging product (20) is selected within an interval of from 15 to 240 kg/m.sup.3. The 3D shaped packaging product (20) maintains at least a significant portion of the porosity of the air-laid blank (10) even after hot pressing and therefore provides excellent shock absorbing and damping properties and thermal insulation.

A folded 3D shaped packaging product (30) is folded at at least one crease (22A, 22B, 22C, 22D, 22E) constituting a folding line in a 3D shaped product (20) formed by hot pressing of an air-laid blank (10) comprising natural fibers at a concentration of at least 70% by weight of the air-laid blank (10) and a thermoplastic polymer binder at a concentration selected within an interval of from 4 up to 30% by weight of the air-laid blank (10). The folded 3D shaped packaging product (30) is useful for cushioning and/or thermal insulation of packaged goods and can protect multiple sides of the packaged goods.

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%.

The present invention relates to an elastic nonwoven fabric comprising a nonwoven web that is made of a plurality of fibers, which fibers are bicomponent fibers which each comprise a first component and a second component, wherein the first component is present in an amount in the range of from 80-95% by weight and the second component is present in an amount in the range of from 5-20% by weight, both weights based on the total weight of each fiber; wherein the first component comprises an ethylene/α-olefin copolymer and the second component comprises a low density polyethylene having a density in the range of from 0.90-0.95 g/cm.sup.3 (as determined with ASTM D792); wherein the first component and the second component both have a melt flow rate in the range of from 10-40 g/10 min (as determined by ASTM D1238 (190° C., 2.16 kg)); and wherein the nonwoven web comprises a side which is provided with a pattern of individualized bonded areas, wherein the surface of the bonded areas is in the range of 8-25%, based on the total surface of the side. The present invention further relates to a process for preparing the nonwoven fabric, and an article comprising the nonwoven fabric.

A method for making a high topography nonwoven substrate includes generating a foam including water and synthetic binder fibers; depositing the foam on a planar surface; disposing a template form on the foam opposite the planar surface to create a foam/form assembly; heating the foam/form assembly to dry the foam and bind the synthetic binder fibers; and removing the template from the substrate after heating the foam/form assembly, wherein the substrate includes a planar base layer having an X-Y surface and a backside surface opposite the X-Y surface; and a plurality of projection elements integral with and protruding in a Z-direction from the X-Y surface, wherein the projection elements are distributed in both the X- and Y-directions, and wherein the density of a projection element is the same as the density of the base layer.

An airlaid substrate includes at least one bicomponent fiber having a first region and a second region. The first region includes polypropylene and the second includes a blend of an ethylene-base polymer and an ethylene acid copolymer. The ethylene-base polymer has a density from 0.920 g/cm.sup.3 to 0.970 g/cm.sup.3 and a melt index (I.sub.2) from 0.5 g/10 min to 150 g/10 min. The ethylene acid copolymer includes the polymerized reaction product of from 60 wt % to 99 wt % ethylene monomer and from 1 wt % to 40 wt % unsaturated dicarboxylic acid comonomer, based on the total weight of the monomers in the ethylene acid copolymer. The ethylene acid copolymer having a melt index (I.sub.2) from 0.5 g/10 min to 500 g/10 min.

[Problem] To provide a process for producing a needle-punched nonwoven fabric with which, when finished by embossing, it is possible to obtain a hardly fluffing and distinct rugged pattern. [Solution] Sheath-core composite fibers are accumulated and a fibrous web is formed. The core component of the sheath-core composite fiber is formed from a copolymer of ethylene glycol and terephthalic acid. The sheath component is formed from a copolymer of ethylene glycol, adipic acid, terephthalic acid, isophthalic acid and diethylene glycol. The sheath-core composite fibers are three dimensionally interlaced with each other by needle-punching the web, to obtain the needle-punched nonwoven fabric. The needle-punched nonwoven fabric is passed through heated embossed roll to provide a rugged pattern on a surface. During the process, the sheath component are softening melted and melt bonded between the sheath-core composite fibers to obtain an embossed nonwoven fabric having a distinct rugged pattern.

A fibrous nonwoven material which is vertically lapped in its entirety or which includes one or more lapped regions which include vertically lapped fibers provides for padding to be applied to a substrate (e.g., an article of interest such as a handle for sporting equipment or tool, or on the inside of a motorcycle or bicycle helmet, etc.). The skin contacting surface of the nonwoven has regions which are relatively thicker than other regions, and air, sweat, and the like are allowed to easily pass through these regions for cooling, wicking of fluid and enhanced breathability. The lapped nonwoven includes a backing material which helps define the pad shape and which permits securing to a substrate. A hook and loop fastener may be affixed to the lapped nonwoven at the backing material so as to allow retrieval and replacement of the nonwoven on the substrate. An acquisition layer on the surface can be used on the surface of the nonwoven, and a carded consolidated web may be positioned within the nonwoven. The nonwoven may take a variety of shapes including the shape of a strip and the shape of a koozie.