A process for the production of a nonwoven fabric. In particular, it relates to the production of a nonwoven fabric having desirable tactile and haptic as well as mechanical properties, as well as to the nonwoven fabric itself. The process requires the selection of specific polylactic acid polymers and corresponding process conditions.

The disclosure relates to a pleatable nonwoven fabric including greater than 50% by weight of a majority polymer component, based on total weight of the fabric, and a minority polymer component, wherein there is a difference of at least 10° C. in melting point between the majority polymer component and the minority polymer component, and wherein the fabric is arranged in layers with a first layer, a second layer, and a mid-layer positioned between the first layer and the second layer, and wherein the top layer and the bottom layer comprise a plurality of bicomponent fibers comprising both the majority polymer component and the minority polymer component; and wherein the mid-layer comprises monocomponent fibers constructed from either the majority polymer component or the minority polymer component. A method of making the pleatable nonwoven fabric is also provided.

The disclosure relates to a pleatable nonwoven fabric including greater than 50% by weight of a majority polymer component, based on total weight of the fabric, and a minority polymer component, wherein there is a difference of at least 10° C. in melting point between the majority polymer component and the minority polymer component, and wherein the fabric is arranged in layers with a first layer, a second layer, and a mid-layer positioned between the first layer and the second layer, and wherein the top layer and the bottom layer comprise a plurality of bicomponent fibers comprising both the majority polymer component and the minority polymer component; and wherein the mid-layer comprises monocomponent fibers constructed from either the majority polymer component or the minority polymer component. A method of making the pleatable nonwoven fabric is also provided.

A spunbond non-woven fabric includes a thermoplastic continuous filament. Bending resistance in a machine direction of the spunbond non-woven fabric is 40 mN or more and 80 mN or less, the spunbond non-woven fabric includes a nonbonded projected part and a bonded recessed part, and in a non-woven fabric cross-section, a thickness from one surface to another surface of the projected part is determined to be t.sub.A, a thickness from one surface to another surface of the recessed part is determined to be t.sub.B, and respective distances from one surface of the projected part to one surface of the recessed part are determined to be t.sub.C and t.sub.D (t.sub.C<t.sub.D), and the spunbond non-woven fabric has a relation represented by formulas (1) and (2) below:

0.5≤1−t.sub.B/t.sub.A<1.0   (1)

0.65<t.sub.C/t.sub.D<1.0   (2).

A spunbond non-woven fabric includes a thermoplastic continuous filament. Bending resistance in a machine direction of the spunbond non-woven fabric is 40 mN or more and 80 mN or less, the spunbond non-woven fabric includes a nonbonded projected part and a bonded recessed part, and in a non-woven fabric cross-section, a thickness from one surface to another surface of the projected part is determined to be t.sub.A, a thickness from one surface to another surface of the recessed part is determined to be t.sub.B, and respective distances from one surface of the projected part to one surface of the recessed part are determined to be t.sub.C and t.sub.D (t.sub.C<t.sub.D), and the spunbond non-woven fabric has a relation represented by formulas (1) and (2) below:

0.5≤1−t.sub.B/t.sub.A<1.0   (1)

0.65<t.sub.C/t.sub.D<1.0   (2).

A synthetic radiator fabric with permanent mechanical wicking defines an inner surface and has a raised knit body defining an opposite outer surface. The fabric includes hydrophilic and hydrophobic fiber-containing yarns. At the inner surface, the hydrophilic fiber-containing yarns collect liquid sweat from a wearer's skin surface and maintain the collected sweat at the inner surface, generally in the vicinity of and/or in contact with the wearer's skin, for encouraging evaporation of sweat and providing evaporative cooling. The raised knit body extends from the inner surface toward, and defines, the opposite outer surface. The hydrophobic fiber-containing yarns are arranged in a radiator-like construction forming egg-crate or honey-comb like cells or pores, defined by the knit body and open to the inner surface. At the outer fabric surface, the hydrophobic fibers receive excess sweat from the wearer's body, thereby to encourage rapid evaporation and drying, for improved breathability.

A synthetic radiator fabric with permanent mechanical wicking defines an inner surface and has a raised knit body defining an opposite outer surface. The fabric includes hydrophilic and hydrophobic fiber-containing yarns. At the inner surface, the hydrophilic fiber-containing yarns collect liquid sweat from a wearer's skin surface and maintain the collected sweat at the inner surface, generally in the vicinity of and/or in contact with the wearer's skin, for encouraging evaporation of sweat and providing evaporative cooling. The raised knit body extends from the inner surface toward, and defines, the opposite outer surface. The hydrophobic fiber-containing yarns are arranged in a radiator-like construction forming egg-crate or honey-comb like cells or pores, defined by the knit body and open to the inner surface. At the outer fabric surface, the hydrophobic fibers receive excess sweat from the wearer's body, thereby to encourage rapid evaporation and drying, for improved breathability.

The invention relates to a respirator mask comprising a filter material piece made of an air-permeable material and at least one securing band, wherein the air-permeable material comprises at least one layer of a non-woven fabric and the at least one securing band is designed to secure the respirator mask to the head, wherein the air-permeable material and the at least one securing band are made of the same plastic material.

The invention relates to a respirator mask comprising a filter material piece made of an air-permeable material and at least one securing band, wherein the air-permeable material comprises at least one layer of a non-woven fabric and the at least one securing band is designed to secure the respirator mask to the head, wherein the air-permeable material and the at least one securing band are made of the same plastic material.

Provided are bicomponent fibers with improved curvature. The bicomponent fibers comprise a first polymer region or first region and a second polymer region or second region. The first region according to embodiments of the present disclosure comprises an ethylene/alpha-olefin interpolymer and has a light scattering cumulative detector fraction (CDF.sub.LS) of greater than 0.1200, wherein the CDF.sub.LS is computed by measuring the area fraction of a low angle laser light scattering (LALLS) detector chromatogram greater than, or equal to, 1,000,000 g/mol molecular weight using Gel Permeation Chromatography (GPC). The second region comprises a polyester. The bicomponent fibers can be used for forming nonwovens.