A nonwoven web for use in an absorbent article is described. The nonwoven web has first and second nonwoven layers. The first nonwoven layer has a first plurality of fibers, an additive disposed, at least in part, on a portion of the first plurality of fibers, a first side and an opposing second side, wherein second side has a plurality of discontinuities. The second nonwoven layer has a second plurality of fibers, a first surface and an opposing second surface, and a plurality of tufts extending through at least a portion of the discontinuities in the first nonwoven layer, wherein the second nonwoven layer is attached to the first nonwoven layer such that at least a portion of the second plurality of fibers are in liquid communication with the first nonwoven layer, wherein the first nonwoven layer is hydrophobic and the second nonwoven layer is hydrophilic.

A nonwoven web for use in an absorbent article is described. The nonwoven web has first and second nonwoven layers. The first nonwoven layer has a first plurality of fibers, an additive disposed, at least in part, on a portion of the first plurality of fibers, a first side and an opposing second side, wherein second side has a plurality of discontinuities. The second nonwoven layer has a second plurality of fibers, a first surface and an opposing second surface, and a plurality of tufts extending through at least a portion of the discontinuities in the first nonwoven layer, wherein the second nonwoven layer is attached to the first nonwoven layer such that at least a portion of the second plurality of fibers are in liquid communication with the first nonwoven layer, wherein the first nonwoven layer is hydrophobic and the second nonwoven layer is hydrophilic.

A nonwoven web for use in an absorbent article is described. The nonwoven web has first and second nonwoven layers. The first nonwoven layer has a first plurality of fibers, an additive disposed, at least in part, on a portion of the first plurality of fibers, a first side and an opposing second side, wherein second side has a plurality of discontinuities. The second nonwoven layer has a second plurality of fibers, a first surface and an opposing second surface, and a plurality of tufts extending through at least a portion of the discontinuities in the first nonwoven layer, wherein the second nonwoven layer is attached to the first nonwoven layer such that at least a portion of the second plurality of fibers are in liquid communication with the first nonwoven layer, wherein the first nonwoven layer is hydrophobic and the second nonwoven layer is hydrophilic.

A nonwoven web for use in an absorbent article is described. The nonwoven web has first and second nonwoven layers. The first nonwoven layer has a first plurality of fibers, an additive disposed, at least in part, on a portion of the first plurality of fibers, a first side and an opposing second side, wherein second side has a plurality of discontinuities. The second nonwoven layer has a second plurality of fibers, a first surface and an opposing second surface, and a plurality of tufts extending through at least a portion of the discontinuities in the first nonwoven layer, wherein the second nonwoven layer is attached to the first nonwoven layer such that at least a portion of the second plurality of fibers are in liquid communication with the first nonwoven layer, wherein the first nonwoven layer is hydrophobic and the second nonwoven layer is hydrophilic.

The present invention generally relates to composites and articles made from nonwoven structures. One aspect of the invention is generally directed to nonwoven structures which are heated and/or pressed to form a substantially rigid article. In some cases, the nonwoven structure may be heated to temperatures greater than the glass transition temperature but less than the melting temperature of a polymer within the nonwoven structure. Such articles may exhibit creep of the polymer around other fibers in the nonwoven structure, but without any evidence of melting and/or flow. In addition, in some embodiments, such articles may have relatively large void volumes, or exhibit properties such as low flammability, smoke resistance, or acoustic insulation. Other aspects of the present invention are generally directed to systems and methods for making such articles, methods of use of such articles, kits comprising such articles, etc.

A continuous filament spun-laid web includes a plurality of polymer fibers within the web, the web having a first thickness and the web being free of any thermal or mechanical bonding treatment. Activation of the web results in at least one of an increase from the first thickness prior to activation to a second thickness post activation in which the second thickness is at least about two times greater than the first thickness, a decrease in density of the web post activation in relation to a density of the web prior to activation, the web being configured to withstand an elastic elongation from about 10% to about 350% in at least one of a machine direction (MD) of the web and a cross-direction (CD) of the web, and the web having a tensile strength from about 50 gram-force/cm.sup.2 to about 5000 gram-force/cm.sup.2.

A continuous filament spun-laid web includes a plurality of polymer fibers within the web, the web having a first thickness and the web being free of any thermal or mechanical bonding treatment. Activation of the web results in at least one of an increase from the first thickness prior to activation to a second thickness post activation in which the second thickness is at least about two times greater than the first thickness, a decrease in density of the web post activation in relation to a density of the web prior to activation, the web being configured to withstand an elastic elongation from about 10% to about 350% in at least one of a machine direction (MD) of the web and a cross-direction (CD) of the web, and the web having a tensile strength from about 50 gram-force/cm.sup.2 to about 5000 gram-force/cm.sup.2.

A nonwoven web material including fibers formed of a polyolefin and a polyester is disclosed. The fibers may include fine fibers produced by, for example, a meltblowing process. The polyolefin may be polypropylene and the polyester may be polylactic acid. The polylactic acid may be obtained and included by recycling scrap nonwoven material containing a polylactic acid component, hydrolyzing the polylactic acid component to reduce its viscosity, blending the hydrolyzed polylactic acid with a polyolefin resin, and melt-spinning the blended material to form fibers. A related process is disclosed.