Nonwoven fabrics including a first spunmelt through-air-bonded (TAB) nonwoven layer comprising a first plurality of spunmelt fibers, in which the first plurality of spunmelt fibers comprise a biopolymer. The first plurality of spunmelt fibers may be physically entangled with cellulosic fibers, such by hydroentangling. Methods of forming a nonwoven fabric including a first spunmelt TAB nonwoven layer are also provided.

A nonwoven composite for high temperature applications requiring Sow flammability, smoke, and/or toxicity, including a fibrous structure having one or more nonwoven material layers including a scrim layer. The scrim is formed from inorganic fibers, at least some of which are adapted to withstand temperatures of up to about 1150 C. The scrim is formed from a wet-laying process. The composite further comprises one or more fiber matrix layers.

A dual layer nonwoven acoustic insulating material having a more densified layer and a less densified layer that is comprised of shoddy fibers and other fibers.

A process and apparatus for producing a dimensionally stable melt blown nonwoven fibrous web. The process includes forming a multiplicity of melt blown fibers by passing a molten stream including molecules of at least one thermoplastic semi-crystalline (co)polymer through at least one orifice of a melt-blowing die, subjecting at least a portion of the melt blown fibers to a controlled in-flight heat treatment operation at a temperature below a melting temperature of the at least one thermoplastic semi-crystalline (co)polymer immediately upon exiting from the at least one orifice, and collecting at least some of the melt blown fibers subjected to the controlled in-flight heat treatment operation on a collector to form a non-woven fibrous structure. The nonwoven fibrous structure exhibits a Shrinkage less than a Shrinkage measured on an identically-prepared structure including only fibers not subjected to the controlled in-flight heat treatment operation, and generally less than 15%.

A process and apparatus for producing a dimensionally stable melt blown nonwoven fibrous web. The process includes forming a multiplicity of melt blown fibers by passing a molten stream including molecules of at least one thermoplastic semi-crystalline (co)polymer through at least one orifice of a melt-blowing die, subjecting at least a portion of the melt blown fibers to a controlled in-flight heat treatment operation at a temperature below a melting temperature of the at least one thermoplastic semi-crystalline (co)polymer immediately upon exiting from the at least one orifice, and collecting at least some of the melt blown fibers subjected to the controlled in-flight heat treatment operation on a collector to form a non-woven fibrous structure. The nonwoven fibrous structure exhibits a Shrinkage less than a Shrinkage measured on an identically-prepared structure including only fibers not subjected to the controlled in-flight heat treatment operation, and generally less than 15%.

An article of apparel including insulation material is discussed. The insulation material includes an insulating layer formed of waterfowl fibers and synthetic fibers. The waterfowl fibers are present in an amount of at least 20% by weight of the insulating layer. The insulating layer is generally free of waterfowl plumage.

A thermally bonded filtration media that can be used in high temperature conditions in the absence of any loss of fiber through thermal effects or mechanical impact on the fiber components is disclosed. The filter media can be manufactured and used in a filter unit or structure, can be placed in a stream of removable fluid, and can remove a particulate load from the mobile stream at an increased temperature range. The combination of bi-component fiber, other filter media fiber, and other filtration additives provides an improved filtration media having unique properties in high temperature, high performance applications.

A thermally bonded filtration media that can be used in high temperature conditions in the absence of any loss of fiber through thermal effects or mechanical impact on the fiber components is disclosed. The filter media can be manufactured and used in a filter unit or structure, can be placed in a stream of removable fluid, and can remove a particulate load from the mobile stream at an increased temperature range. The combination of bi-component fiber, other filter media fiber, and other filtration additives provides an improved filtration media having unique properties in high temperature, high performance applications.

Provided is batting that includes a bonded nonwoven web made from a fiber mixture containing: (a) 20 to 55 wt % of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm; (b) 10 to 45 wt % of hollow conjugate fibers having a spiral crimp, and having a denier of 1.5 to 10.0 and a length of 51 to 84 mm; (c) 10 to 45 wt % of a first population of binder fibers which are elastomeric co-polyester binder fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110? C. to 180? C.; and (d) 1 to 20 wt % of a second population of binder fibers, which have a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and a bonding temperature of 80? C. to 135? C.

Provided is batting that includes a bonded nonwoven web made from a fiber mixture containing: (a) 20 to 55 wt % of siliconized fibers having a denier of 1.5 to 10.0 and a length of 51 mm to 84 mm; (b) 10 to 45 wt % of hollow conjugate fibers having a spiral crimp, and having a denier of 1.5 to 10.0 and a length of 51 to 84 mm; (c) 10 to 45 wt % of a first population of binder fibers which are elastomeric co-polyester binder fibers having a denier of 1.5 to 8.0, a length of 51 mm to 84 mm, and a bonding temperature of 110? C. to 180? C.; and (d) 1 to 20 wt % of a second population of binder fibers, which have a denier of 1.5 to 6.0, a length of 51 mm to 84 mm, and a bonding temperature of 80? C. to 135? C.