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.

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.

A nonwoven comprising a pattern of thermal bonds with anti-fuzz properties according to at least three and preferably all four of the following conditions: a) the pattern comprises thermal bonds disposed in parallel rows having a pitch angle (P) of from 0.5 to 15 relative to the machine direction or the cross-machine direction; and/or b) the bonding area of all the thermal bonds ranges from 17% to 30% of the area of the nonwoven, and/or c) the pattern comprises larger bonds and smaller bonds having different individual area, and/or d) the pattern comprises elongated bonds having different major directions.

A nonwoven comprising a pattern of thermal bonds with anti-fuzz properties according to at least three and preferably all four of the following conditions: a) the pattern comprises thermal bonds disposed in parallel rows having a pitch angle (P) of from 0.5 to 15 relative to the machine direction or the cross-machine direction; and/or b) the bonding area of all the thermal bonds ranges from 17% to 30% of the area of the nonwoven, and/or c) the pattern comprises larger bonds and smaller bonds having different individual area, and/or d) the pattern comprises elongated bonds having different major directions.

High quality melt-blown webs having improved barrier properties (3rd drop, cm H2O resp. mbar) and a widened process window. The melt-blown webs show a specific chain structure.

High quality melt-blown webs having improved barrier properties (3rd drop, cm H2O resp. mbar) and a widened process window. The melt-blown webs show a specific chain structure.

Shown are thermo-fusible conjugate fibers having a high degree of crystallinity, while a degree of orientation is suppressed, and a bulky and soft nonwoven fabric using the same. The thermo-fusible conjugate fibers have, as a first component, a polyester-based resin, and as a second component, an olefin-based resin having a melting point lower than a melting point of the first component, in which the degree of orientation in the polyester-based resin is 6.0 or less, and the degree of crystallinity therein is 20% or more. The conjugate fibers are preferably sheath-core conjugate fibers in which the first component is a core component and the second component is a sheath component.

Shown are thermo-fusible conjugate fibers having a high degree of crystallinity, while a degree of orientation is suppressed, and a bulky and soft nonwoven fabric using the same. The thermo-fusible conjugate fibers have, as a first component, a polyester-based resin, and as a second component, an olefin-based resin having a melting point lower than a melting point of the first component, in which the degree of orientation in the polyester-based resin is 6.0 or less, and the degree of crystallinity therein is 20% or more. The conjugate fibers are preferably sheath-core conjugate fibers in which the first component is a core component and the second component is a sheath component.

The present invention relates to a nonwoven fabric comprising a plurality of polypropylene-containing fibers that form a nonwoven web, which fibers in addition contain a slip agent, the web has a side which is provided with an alternating pattern which consists of individualized bonded areas which bonded areas are in the form of rods which are arranged in the cross direction of the web, the alternating pattern of individualized bonded areas defines a non-bonded area, the web has a basis weight on the range of from 5-25 g/m.sup.2, the surface of the bonded areas is in the range of 5-20% of the total surface of the side, and the surface of the non-bonded area is in the range of 80-95% of the total surface of the side. The present invention further relates to a process for forming the nonwoven fabric.

The present invention relates to a nonwoven fabric comprising a plurality of polypropylene-containing fibers that form a nonwoven web, which fibers in addition contain a slip agent, the web has a side which is provided with an alternating pattern which consists of individualized bonded areas which bonded areas are in the form of rods which are arranged in the cross direction of the web, the alternating pattern of individualized bonded areas defines a non-bonded area, the web has a basis weight on the range of from 5-25 g/m.sup.2, the surface of the bonded areas is in the range of 5-20% of the total surface of the side, and the surface of the non-bonded area is in the range of 80-95% of the total surface of the side. The present invention further relates to a process for forming the nonwoven fabric.