Methods for manufacturing through-fluid bonded continuous fiber nonwoven webs are provided. The method may include providing a through-fluid bonding oven. The through-fluid bonding oven may have a first porous member and a second moving member. An intermediate continuous fiber nonwoven web may be conveyed into the through-fluid bonding oven intermediate the first and second moving porous members. A first surface of the intermediate continuous fiber nonwoven web may be in face-to-face contact with the first porous member. A second surface of the intermediate continuous fiber nonwoven web may be in face-to-face contact with the second porous member. A heated fluid may be flowed through the first and second porous members and the intermediate continuous fiber nonwoven web to create a continuous fiber nonwoven web.

A moisture vapor permeable, water impermeable composite sheet material is provided which is suitable for use as a housewrap material, and is also useful for other applications such as tarpaulins, or as covers for automobile, boats, patio furniture or the like. The composite sheet material includes a nonwoven substrate and an extrusion-coated polyolefin film layer overlying one surface of the substrate. The nonwoven substrate is comprised of polymeric fibers randomly disposed and bonded to one another to form a high tenacity nonwoven web. The nonwoven substrate has a grab tensile strength of at least 178 Newtons (40 pounds) in at least one of the machine direction (MD) or the cross-machine direction (CD). The extrusion coated polyolefin film layer is intimately bonded to the nonwoven substrate. The film layer has micropores formed therein to impart to the composite sheet material a moisture vapor transmission rate (MVTR) of at least 35 g/m.sup.2/24 hr. at 50% relative humidity and 23° C. and a hydrostatic head of at least 55 cm. In one embodiment, the nonwoven substrate comprises a spunbonded nonwoven fabric formed of randomly disposed substantially continuous polypropylene filaments. The spunbonded nonwoven fabric is an area bonded fabric in which the filaments are bonded to one another throughout the fabric at locations where the randomly disposed filaments overlie or cross one another.

Nonwoven fabrics including a first outermost spunbond layer, a second outermost spunbond layer, and at least a first meltblown and/or melt-fibrillated layer disposed directly or indirectly between the first outermost spunbond layer and the second outermost spunbond layer. The first outermost spunbond layer comprises a first plurality of continuous fibers that are thermally fused and compacted against one another and define a microporous film on an outermost surface of the nonwoven fabric. The first plurality of continuous fibers comprises a first polymeric composition having a first melting point and the first meltblown layer and/or melt-fibrillated layer comprises a first plurality of meltblown fibers and/or melt-fibrillated fibers comprising a third polymeric composition having a third melting point, in which the first melting point is lower than the third melting point.

Methods for manufacturing through-fluid bonded continuous fiber nonwoven webs are provided. The method may include providing a through-fluid bonding oven. The through-fluid bonding oven may have a first porous member and a second moving member. An intermediate continuous fiber nonwoven web may be conveyed into the through-fluid bonding oven intermediate the first and second moving porous members. A first surface of the intermediate continuous fiber nonwoven web may be in face-to-face contact with the first porous member. A second surface of the intermediate continuous fiber nonwoven web may be in face-to-face contact with the second porous member. A heated fluid may be flowed through the first and second porous members and the intermediate continuous fiber nonwoven web to create a continuous fiber nonwoven web.

To provide a sound-absorbing material that exhibits sound-absorbing property excellent in a low frequency region, and is also excellent in space-saving performance. The laminated sound-absorbing material contains a plurality of fiber layers, and a base material layer existing between the fiber layer and the fiber layer, in which the laminated sound-absorbing material contains at least three fiber layers, each fiber layer is formed of fibers having a fiber diameter of less than 450 nanometers, and has a basis weight of 0.1 to 50 g/m.sup.2, and the base material layer has a basis weight of 1 g/m.sup.2 or more and a thickness of 0.1 millimeter or more, and the base material layer is at least one selected from the group of a nonwoven fabric, a film, a glass fiber and paper.

A web modified according to the disclosed method has desirable breathability and liquid impermeability, as well as extensibility and a soft, cloth-like textured surface.

The present invention is directed to a nonwoven fabric made from a composite of nonwoven and pulp where the nonwoven has a high loft derived from a heat set three-dimensional relief structure and/or hydroengorged fiber structure. A nonwoven web is hydraulically treated to create a hydroengorged material having an increased loft. Alternatively a nonwoven web is treated to have a heat set three-dimensional relief structure. The treated web is then hydroentangled with pulp to form a cotendered nonwoven/pulp composite fabric.

A method is disclosed for modifying the physical characteristics of a web which involves passing the web between at least one pair of interengaged rolls to incrementally stretch the web, and then withdrawing the incrementally stretched web from between the rolls under tension. A web modified according to the disclosed method has desirable breathability and liquid impermeability, as well as extensibility and a soft, cloth-like textured surface.

Methods for manufacturing through-fluid bonded continuous fiber nonwoven webs are provided. The method may include providing a through-fluid bonding oven. The through-fluid bonding oven may have a first porous member and a second moving member. An intermediate continuous fiber nonwoven web may be conveyed into the through-fluid bonding oven intermediate the first and second moving porous members. A first surface of the intermediate continuous fiber nonwoven web may be in face-to-face contact with the first porous member. A second surface of the intermediate continuous fiber nonwoven web may be in face-to-face contact with the second porous member. A heated fluid may be flowed through the first and second porous members and the intermediate continuous fiber nonwoven web to create a continuous fiber nonwoven web.

The present invention is directed to a nonwoven fabric made from a composite of nonwoven and pulp where the nonwoven has a high loft derived from a heat set three-dimensional relief structure and/or hydroengorged fiber structure. A nonwoven web is hydraulically treated to create a hydroengorged material having an increased loft. Alternatively a nonwoven web is treated to have a heat set three-dimensional relief structure. The treated web is then hydroentangled with pulp to form a cotendered nonwoven/pulp composite fabric.