A method for forming porous fibers is provided. The fibers are formed from a thermoplastic composition containing a continuous phase, which includes a matrix polymer, and a nanoinclusion additive that is at least partially incompatible with the matrix polymer so that it becomes dispersed within the continuous phase as discrete nano-scale phase domains. The method includes traversing a bundle of the fibers through a multi-stage drawing system that includes at least a first fluidic drawing stage and a second fluidic drawing stage. The first drawing stage employs a first fluidic medium having a first temperature and the second drawing stage employs a second fluidic medium having a second temperature. The first and second temperatures are both lower than the melting temperature of the matrix polymer, and the first temperature is greater than the second temperature.

A method for forming porous fibers is provided. The fibers are formed from a thermoplastic composition containing a continuous phase, which includes a matrix polymer, and a nanoinclusion additive that is at least partially incompatible with the matrix polymer so that it becomes dispersed within the continuous phase as discrete nano-scale phase domains. The method includes traversing a bundle of the fibers through a multi-stage drawing system that includes at least a first fluidic drawing stage and a second fluidic drawing stage. The first drawing stage employs a first fluidic medium having a first temperature and the second drawing stage employs a second fluidic medium having a second temperature. The first and second temperatures are both lower than the melting temperature of the matrix polymer, and the first temperature is greater than the second temperature.

A hydro-formed film includes a polymeric web having a first substantially planar surface and a second substantially planar surface opposite the first substantially planar surface, and a plurality of three-dimensional micro-apertures extending from the first substantially planar surface. The plurality of three-dimensional micro-apertures have a mesh count in a range of about 40 to about 75 apertures per linear inch. The hydro-formed film has a Compression Sensor Point (CSP) count of at least about 80.

A hydro-formed film includes a polymeric web having a first substantially planar surface and a second substantially planar surface opposite the first substantially planar surface, and a plurality of three-dimensional micro-apertures extending from the first substantially planar surface. The plurality of three-dimensional micro-apertures have a mesh count in a range of about 40 to about 75 apertures per linear inch. The hydro-formed film has a Compression Sensor Point (CSP) count of at least about 80.

An absorbent article having a topsheet; an absorbent core; and a secondary topsheet positioned between the topsheet and the absorbent core is described. The secondary topsheet has a basis weight of about 35 grams per square meter (gsm) to about 65 gsm, and a hydroentangled fibrous structure having a machine direction (MD) bending stiffness of 0.2 mN.Math.cm to 12 mN.Math.cm according to EDANA Test Method WSP 090.5, and a substantially homogenous blend of fibers. The blend of fibers has a first fibrous component, a second fibrous component, and a third fibrous component, wherein the first fibrous component includes cellulose fibers of from between about 1.3 to 7.0 dtex; wherein the second fibrous component has a second dtex, wherein the third fibrous component comprises a third dtex which is smaller than the second dtex.

An absorbent article having a topsheet; an absorbent core; and a secondary topsheet positioned between the topsheet and the absorbent core is described. The secondary topsheet has a basis weight of about 35 grams per square meter (gsm) to about 65 gsm, and a hydroentangled fibrous structure having a machine direction (MD) bending stiffness of 0.2 mN.Math.cm to 12 mN.Math.cm according to EDANA Test Method WSP 090.5, and a substantially homogenous blend of fibers. The blend of fibers has a first fibrous component, a second fibrous component, and a third fibrous component, wherein the first fibrous component includes cellulose fibers of from between about 1.3 to 7.0 dtex; wherein the second fibrous component has a second dtex, wherein the third fibrous component comprises a third dtex which is smaller than the second dtex.

The invention relates to a nonwoven fabric material having sufficient strength to be used in a pre-moistened state but also having dispersibility properties which allow the product to be flushed. The material comprises at least two nonwoven webs, at least one of which is hydroentangled. Each of the individual webs comprise 50%-95% wood pulp and 5%-50% of short cut man-made fibers and/or natural fibers and has a basis weight of 20-100 gsm. After forming the webs, the two nonwoven webs are dried and then joined together by particle binders through size press or spraying. The particle binder joined webs separate into individual webs after flushing due to the breakage of particle binder-nonwoven hydrogen bond which makes the material highly dispersible.

The invention relates to a nonwoven fabric material having sufficient strength to be used in a pre-moistened state but also having dispersibility properties which allow the product to be flushed. The material comprises at least two nonwoven webs, at least one of which is hydroentangled. Each of the individual webs comprise 50%-95% wood pulp and 5%-50% of short cut man-made fibers and/or natural fibers and has a basis weight of 20-100 gsm. After forming the webs, the two nonwoven webs are dried and then joined together by particle binders through size press or spraying. The particle binder joined webs separate into individual webs after flushing due to the breakage of particle binder-nonwoven hydrogen bond which makes the material highly dispersible.

An apparatus for bonding a first layer having short fibers with a second layer having long fibers into a non-woven web. The apparatus includes a first circulating belt on which the second layer is depositable and displacable, a second circulating belt via which the first layer is transferable at a transition point to the second layer, a pre-bonding unit arranged directly behind the transition point, and a bonding device. The pre-bonding unit has compactors which are spaced apart from one another. The compactors act in one region on the first or second circulating belt. The bonding device is arranged between the compactors and bonds together the first and second layers. The compactors and the bonding device are integrated into the apparatus to together be in an operating state when the first layer is transferred using the second circulating belt.

An apparatus for bonding a first layer having short fibers with a second layer having long fibers into a non-woven web. The apparatus includes a first circulating belt on which the second layer is depositable and displacable, a second circulating belt via which the first layer is transferable at a transition point to the second layer, a pre-bonding unit arranged directly behind the transition point, and a bonding device. The pre-bonding unit has compactors which are spaced apart from one another. The compactors act in one region on the first or second circulating belt. The bonding device is arranged between the compactors and bonds together the first and second layers. The compactors and the bonding device are integrated into the apparatus to together be in an operating state when the first layer is transferred using the second circulating belt.