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.

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.

This document presents a novel method of manufacturing multilayered nonwoven fabrics consisting of micron fibers, hydroentangled, meltfibrillated, and/or spunlaid web layers. The composite multilayered webs contain one or more micron fiber web layers (fibers with a diameter from 1-10 microns) placed between inner and outer layers of hydroentangled, meltfibrillated, and/or spunlaid web, forming a fabric that may be utilized in the manufacture of articles which serve as barriers, wipes or sorbent materials, or may have other potential applications. The created novel composite multilayered fabric may have increased loft, softness and bending length, and may be formed from a broad selection of natural, synthetic, and recycled polymers, including petroleum- and plant-based, allowing polymer selection based on article lifecycle.

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.

A thermally adhesive fiber web implemented by including the steps of: (1) preparing respectively a first spinning solution in which a support component and a second spinning solution in which a thermally adhesive component; (2) performing electrospinning such that the first spinning solution is discharged to a portion of the end surface of a discharge port and the second spinning solution is discharged to the remaining portion, thereby accumulating side-by-side type thermally adhesive composite fibers having a diameter of less than 1 m; and (3) applying heat to the accumulated side-by-side type thermally adhesive composite fibers. The thermally adhesive fiber web enables easy interfacial bonding to a heterogeneous material with a different material and structural specification and prevents pores formed in an initial stage from being closed during thermal bonding.

A sound absorbing material comprising a nonwoven fibrous acoustic insulation material and a flow resistive nonwoven facing, wherein the flow resistive nonwoven facing is bonded to the insulation material and has an air flow resistance of from about 600 to about 1800 Rayls and a surface mass of from about 20 to about 150 g/m.sup.2.

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.