PROCESSO PARA A FORMAÇÃO DE UM TECIDO NÃO TECIDO

Description

1 / 29 PROCESS FOR THE FORMATION OF A NON-WOVEN FABRIC Cross-referencing related patent applications.

[001] This patent application claims priority under 35 USC §119 to U.S. Patent Application No. 63 / 466,032 filed on May 12, 2023, which is expressly incorporated by reference herein in its entirety. TECHNICAL FIELD OF THE INVENTION

[002] The embodiments of the invention presented in this document generally refer to a process for forming nonwoven fabrics, in which the processes include subjecting a nonwoven fabric to a heat-fixing operation while the nonwoven fabric is physically restrained to mitigate or prevent shrinkage or relative movement between the individual spun fibers by melt-fixing to “thermally fix” the nonwoven fabric, followed by consolidation to form a nonwoven fabric. BACKGROUND OF THE INVENTION

[003] In nonwoven fabrics, bicomponent fibers can be used where one component of the bicomponent fibers, such as a coating component of bicomponent fibers having a coating / core configuration, can be formed from a polymer composition with a lower melting point while another component is formed from a different polymer composition that has a higher melting point. In this sense, the bicomponent fiber component formed from the polymer composition with the lower melting point can be used for consolidation while maintaining the structural integrity of the bicomponent fiber component formed from the polymer composition that has the higher melting point.Alternatively, nonwoven fabrics can be formed from a blend of fibers made from different polymeric materials, such as a first group of fibers formed from a polymeric composition with a lower melting point and a second group of fibers formed from a polymeric composition with a higher melting point. Each of these approaches, however, requires the use of multiple polymeric compositions as well as multiple polymer flow pathways from the respective polymer sources to the respective spinneret capillaries. Petition 870260064854, dated 01 / 07 / 2026, page 12 / 82 2 / 29

[004] Alternatively, as described in joint proprietary patent application pending registration 63 / 427,584 filed on November 23, 2022, which was converted into joint proprietary patent application pending registration 18 / 514,141 filed on November 20, 2023, a method is presented that uses specific spinnerets for melt spinning of a polymeric composition (e.g., a single polymeric composition) to provide nonwoven fabrics that include lower melting point fibers, and higher melting point fibers that may optionally remain in a solidified state during consolidation. SUMMARY OF THE INVENTION

[005] One or more embodiments of the invention may solve one or more of the problems mentioned above. Certain embodiments according to the invention provide a process for forming a nonwoven fabric that includes a deposition step of at least one first nonwoven layer comprising a plurality of melt-spun individual fibers intertwined directly or indirectly on a moving collection belt to provide a nonwoven fabric precursor having an initial average width in the transverse direction (CD,(according to its English acronym) and / or an initial average basis weight. The first plurality of interwoven melt-spun individual fibers may comprise (a) a combination of a first group of single-component fibers having a first initial melting temperature and a second group of single-component fibers having a second initial melting temperature that is lower than the first initial melting temperature, (b) two-component fibers comprising a first component having a first initial melting temperature and a second component having a second initial melting temperature that is lower than the first initial melting temperature, (c) a combination of a first group of two-component fibers having a first component with a higher melting point and a first component with a lower melting point,and a second group of bicomponent fibers having a second component with a higher melting point and a second component with a lower melting point that begins to melt before the first component with the lower melting point; or (d) any combination of (a)-(c). The process may also comprise transporting the nonwoven precursor via a heat fixation operation (HSO) comprising (a) immobilizing the nonwoven precursor directly or indirectly within a narrower zone where heat fixation occurs defined between the mobile collection conveyor and a portion of a workbench surface, such as a, Petition 870260064854, dated 01 / 07 / 2026, page 13 / 82 3 / 29 phase of a heat-fixing apparatus, to mitigate the relative movement of individual melt-spun fibers during HSO, and (b) subjecting the nonwoven precursor to a sufficiently high temperature to increase the tackiness of the second group of monocomponent fibers and / or the second component of bicomponent fibers having the second initial melting point to provide an intermediate nonwoven and / or the second component with the lower melting point of the second group of bicomponent fibers. The process may also comprise removing the intermediate nonwoven from the HSO, where the intermediate nonwoven has an average post-heat-fixing CD width and / or an average post-heat-fixing base weight, and consolidating the intermediate nonwoven to provide that nonwoven having a final average CD width and / or a final average base weight.According to certain embodiments of the invention, HSO can lightly bond or consolidate together one phase of the fused fiber to provide sufficient integrity for handling, while the consolidation step more completely bonds the fused fibers together to provide a significantly more durable and strong final nonwoven fabric compared to the intermediate nonwoven fabric formed after HSO.

[006] In another aspect, the present invention provides a thermally fixed nonwoven fabric comprising at least a plurality of interwoven melt-spun individual fibers comprising (a) a combination of a first group of single-component fibers having a first initial melting point and a second group of single-component fibers having a second initial melting point that is lower than the first initial melting point, (b) two-component fibers comprising a first component having a first initial melting point and a second component having a second initial melting point that is lower than the first initial melting point, (c) a combination of a first group of two-component fibers having a first component with a higher melting point and a first component with a lower melting point,and a second group of bicomponent fibers having a second component with a higher melting point and a second component with a lower melting point that begins to melt before the first component with the lower melting point; or (d) any combination of (a)-(c). Nonwoven fabric may be an air-flow bonded nonwoven fabric, a chemically bonded nonwoven fabric, a mechanically consolidated nonwoven fabric, and / or a thermally bonded nonwoven fabric. In this sense, nonwoven fabrics (e.g., melt-spun fabrics) may be consolidated by means of a fluid bonding process (e.g., the fluid includes hot air or steam) in which, optionally, only the, Petition 870260064854, dated 01 / 07 / 2026, page 14 / 82 4 / 29 Lower melting point fibers (or components) are softened, fused, and / or flowed through a phase of the nonwoven fabric to form bonds with higher melting point fibers. In this sense, the structural integrity of the resulting nonwoven fabric, according to certain embodiments of the invention, can be provided by the higher melting point fibers (or components of the higher melting point fibers) remaining undeformed or substantially undeformed (e.g., the cross-section of the fiber components or the higher melting point fibers remains the same or substantially the same before, during, and after the consolidation operation).Conversely, lower melting point fibers (or fiber components) may have a deformed or individually indiscernible cross-section as individual fibers due to melting and / or flow to provide the bonding mechanism for consolidation. For example, lower melting point fibers (or fiber components) may at least partially melt and flow through at least some of the defined gaps between higher melting point fibers. To the extent that lower melting point fibers (or fiber components) flow through gaps between higher melting point fibers, the deformed and flowed lower melting point fibers (e.g., less crystalline or amorphous) coat the surfaces of the higher melting point fibers (or fiber components).After the material with the lower melting point solidifies (e.g., the molten and flowed fibers with a lower melting point) after coating the surfaces of the fibers with a higher melting point (or fiber components), the material with the lower melting point forms bonds with and between the material with a higher melting point (e.g., the deformed fibers with a lower melting point).

[007] In another aspect, the present invention provides a method for forming a compound comprising forming or providing a nonwoven fabric, such as that described and presented herein, and bonding a film layer to the nonwoven fabric. In another aspect, the present invention provides a compound that includes a nonwoven fabric, such as that described and presented herein, and a film. BRIEF DESCRIPTION OF THE FIGURE(S)

[008] The invention will now be described in more detail from here on with reference to the accompanying figures, in which some, but not all, embodiments of the invention are shown. In fact, this invention can be embodied in many different ways. Petition 870260064854, dated 01 / 07 / 2026, page 15 / 82 5 / 29 and should not be interpreted as limited to the embodiments set forth herein; preferably, these embodiments are made available in such a way that this disclosure meets applicable legal requirements. Equal numbers refer to completely identical elements, and where: Figure 1 illustrates a schematic of a general process according to certain embodiments of the invention; Figure 2 illustrates a schematic of another general process according to certain embodiments of the invention; Figure 3 illustrates a schematic of another general process according to certain embodiments of the invention; Figure 4 illustrates a schematic of another general process according to certain embodiments of the invention; Figure 5 illustrates a nonwoven fabric comprising a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) according to certain embodiments of the invention; Figure 6 illustrates a nonwoven fabric that includes a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines two high-melting-point regions and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines a low-melting-point region according to certain embodiments of the invention; Figure 7 illustrates a nonwoven fabric comprising a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines an interior region with a high melting point and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines two regions with a low melting point according to certain embodiments of the invention; Figure 8 illustrates a nonwoven fabric that includes a first group of melt-spun fibers (e.g., a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines a plurality of regions. Petition 870260064854, dated 01 / 07 / 2026, page 16 / 82 6 / 29 with a high melting point and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines a plurality of low-melting-point regions, in which the high-melting-point regions and the low-melting-point regions are located alternately in a z-direction, according to certain embodiments of the invention; Figure 9 illustrates another nonwoven fabric that includes a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines a plurality of high-melting-point regions and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines a plurality of low-melting-point regions, in which the high-melting-point regions and the low-melting-point regions are located alternately in a z-direction, according to certain embodiments of the invention; Figure 10 illustrates a nonwoven fabric comprising a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines a plurality of high-melting-point regions and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines a plurality of low-melting-point regions, in which the high-melting-point regions and the low-melting-point regions are located alternately in the transverse direction, according to certain embodiments of the invention; Figure 11 illustrates a nonwoven fabric comprising a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines a plurality of high-melting-point regions and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines a plurality of low-melting-point regions, in which the high-melting-point regions and the low-melting-point regions are located alternately in both the z-direction and the transverse direction, according to certain embodiments of the invention; Figure 12 illustrates a nonwoven fabric that has a second group of melt-spun fibers (e.g., a second group of single-component melt-spun fibers). Petition 870260064854, dated 01 / 07 / 2026, page 17 / 82 7 / 29 and / or a second group of bicomponent fibers) that defines a continuous low-melting-point region and a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of bicomponent fibers) that defines a plurality of high-melting-point regions dispersed throughout the low-melting-point region according to certain embodiments of the invention; and Figure 13 illustrates a nonwoven fabric having a first group of melt-spun fibers (e.g., a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines a continuous high-melting-point region and a second group of melt-spun fibers (e.g., a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines a plurality of low-melting-point regions dispersed throughout the high-melting-point region according to certain embodiments of the invention. DETAILED DESCRIPTION

[009] The invention will now be described in more detail hereafter with reference to the accompanying figures, in which some, but not all, embodiments of the invention are shown. In fact, this invention can be embodied in many different ways and should not be interpreted as limited to the embodiments set forth herein; preferably, these embodiments are made available in such a manner that this disclosure meets applicable legal requirements. As used in the specification and in the accompanying claims, the singular forms “a”, “the”, “an”, “an” include plural referents unless the context clearly indicates otherwise.

[010] The invention presented herein relates, in general, to a process for forming a nonwoven fabric that has been subjected to a heat-setting operation (HSO). The nonwoven fabric may comprise a plurality of melt-spun individual fibers, such as different groups of single-component fibers having different initial melting temperatures, two-component fibers having a high-melting-point component and a low-melting-point component, different groups of two-component fibers each having their respective high-melting-point and low-melting-point components, directly or indirectly collected on a mobile collection conveyor. The nonwoven fabric may then be subjected to an HSO comprising subjecting the nonwoven fabric to an elevated temperature for at least Petition 870260064854, dated 01 / 07 / 2026, page 18 / 82 8 / 29 Increase the tackiness of the lower-melting-point material present in the nonwoven fabric, while the nonwoven fabric remains under sufficient compaction or containment to reduce thermal shrinkage during subsequent consolidation. HSO may include, for example, the use of thermally heated press rolls or hot air guns to increase the tackiness of the lower-melting-point material in the nonwoven fabric. HSO beneficially “thermally fixes” the higher-melting-point material to reduce shrinkage during heating cycles that maintain fabric widths and further shrinkage in subsequent bonding cycles such as calendering, ultrasonic bonding, chemical bonding, or air bonding.A high-speed sliding (HSD) system can provide this benefit by modifying the path of the collection conveyor using, for example, a porous drum, which allows the collected fabric to be transported (before any heat application) and the fabric to minimally involve the drum, for example, 180-340°, preferably around 270°. In this way, the deposition of unconsolidated nonwoven fabric remains undisturbed. The nonwoven fabric (weft) is trapped between the conveyor (e.g., collection conveyor) and the drum, where it is then heated (tempered) to achieve heat fixation of the polymer at a higher melting temperature. Furthermore, the HSD system can also include a cooling phase or step, in which a shorter radial length cools the nonwoven fabric before it exits the narrowing zone formed by the conveyor belt and the drum.This approach, according to certain embodiments of the invention, provides nonwoven fabric integrity by softening / melting the lower molten polymer fibers (or fiber components), providing pre-bonding for further unsupported transport to the final bonding unit. The final bonding or consolidation unit may include, for example, airflow drum bonding, thermal calendering, ultrasonic bonding, or chemical bonding. According to certain embodiments of the invention, the process provides undisturbed nonwoven fabric formation by lightly bonding under slight compression of the nonwoven fabric while also allowing the heat-setting process to prevent shrinkage of any fiber blend with high glass transition temperatures.According to certain embodiments of the invention, the construction of fibers with different melting points can be created by means of bicomponent fibers, or a blend of monocomponent fibers that have different melting points created through a bicomponent extrusion, but also by means of a plurality of monocomponent or bicomponent fibers with different processing conditions as described above in relation to melt spinning dies presented in the joint proprietary application and pending patent registration 63 / 427,584 filed on November 23, 2022, which was converted into an application for... Petition 870260064854, dated 01 / 07 / 2026, page 19 / 82 9 / 29 jointly owned and pending patent registration 18 / 514,141 registered on November 20, 2023, the complete contents of each are incorporated herein by reference, to create fibers with different melting temperatures from a single matrix and / or single polymer composition.

[011] In this sense, the extruded fibers from the respective capillaries, such as from melt spinning dies presented in the joint property application and pending patent registration 63 / 427,584, which was converted into joint property application and pending patent registration 18 / 514,141 registered on November 20, 2023, may define the respective corresponding zones or regions thereof and may provide a resulting nonwoven fabric that has fibers formed from a polymeric material and that presents a variety of fibers with different melting points and / or melting ranges, which may be distinct and / or unique (for example, non-overlapping melting ranges) and / or have overlapping melting point ranges. By way of example only, a single spinneret may include a first zone of holes and a second zone of holes.Therefore, fibers formed or extruded from one zone will have a more crystalline nature or degree and a higher melting point, while fibers formed or extruded from other zones will have a less crystalline nature or degree (e.g., amorphous) and a lower melting point. In this sense, the resulting nonwoven fabric (e.g., melt-spun fabric) will be composed of at least two separate groups of fibers as determined by degree of crystallinity and / or melting point or melting range.This resulting nonwoven fabric could therefore be initially heat-treated (e.g., tempered, lightly consolidated) at a temperature sufficient to melt the fibers formed from the second capillary zone (e.g., fibers with the lowest melting point) and lightly consolidate this nonwoven fabric to impart sufficient durability for subsequent processing (e.g., transport, coupling with other materials such as films, nonwovens, etc.). The final consolidation step can subsequently be carried out by heating the fibers to a temperature that melts the fibers more completely, to provide a more robust level of consolidation.

[012] The terms “substantial” or “substantially” may encompass the total value as specified, according to certain embodiments of the invention, or a large part, but not all, of the specified value (for example, 95%, 96%, 97%, 98%, or 99% of the total specified value) according to other embodiments of the invention. Petition 870260064854, dated 01 / 07 / 2026, page 20 / 82 10 / 29

[013] The terms “polymer” or “polymeric,” as used interchangeably herein in this document, may include homopolymers, copolymers, such as, for example, block, graft, random, and alternating copolymers, terpolymers, etc., and blends and modifications thereof. Furthermore, unless specifically limited otherwise, the term polymer or “polymeric” shall include all possible structural isomers; stereoisomers which include, without limitation, geometric isomers, optical isomers, or enantiomers; and / or any chiral molecular configuration of such polymer or polymeric material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic configurations of such polymer or polymeric material. The term "polymer" or "polymeric" should also include polymers woven from various catalytic systems, including, without limitation, the Ziegler-Natta catalyst system and the metallocene / single-site catalytic system.The term "polymer" or "polymeric" should also include, according to certain embodiments of the invention, polymers produced by fermentation or of biological origin.

[014] The terms “nonwoven” and “nonwoven fabric,” as used herein, may encompass a fabric having a structure of individual fibers, fibers, and / or yarns that are interwoven, but not in a repetitively identifiable manner as in a knitted or woven fabric. Nonwoven fabrics or weaves, according to certain embodiments of the invention, may be formed by any process conventionally known in the art, such as, for example, blow melt processes, melt spinning processes, needle punching processes, hydraulic interlacing, airflow interlacing, and carded and spliced ​​weaving processes. A “nonwoven fabric,” as used herein, may comprise a plurality of individual fibers that have not been subjected to a consolidation process.In certain cases, "nonwoven fabric" may comprise a plurality of layers, such as one or more melt-spun layers and / or one or more blow-melt layers. For example, a "nonwoven fabric" may comprise a melt-spun-blown-melt-spun structure.

[015] The terms “woven” and “nonwoven fabric,” as used herein in this document, may encompass a fabric of fibers in which a plurality of fibers are mechanically interwoven or interconnected, fused together, and / or joined by chemical bonding. For example, a nonwoven fabric of individually arranged fibers may be subjected to a bonding or consolidation process to join at least one phase of the fibers. Petition 870260064854, dated 01 / 07 / 2026, page 21 / 82 11 / 29 individually joined together to form a coherent (e.g., bonded) network of interconnected fibers.

[016] The terms “consolidated” and “consolidation,” as used herein in this document, may comprise the joining of at least one phase of the fibers of a nonwoven fabric into closer proximity or bonding to each other (e.g., thermally fused together, chemically bonded, and / or mechanically interwoven together) to form a bonding site, or bonding sites, that function to increase resistance to external forces (e.g., abrasion and tensile forces) compared to the unconsolidated fabric. The bonding site or sites, for example, may comprise a discrete or localized region of the fabric material that has been softened or fused and optionally subsequently or simultaneously compressed to form a discrete or localized deformation in the fabric material.Furthermore, the term “consolidated” may encompass a whole nonwoven fabric that has been processed in such a way that at least one phase of the fibers is brought into closer proximity or bonded together (e.g., thermally fused together, chemically bonded, and / or mechanically interlaced together), such as by means of thermal bonding or mechanical interlacing (e.g., hydraulic interlacing), to name just a few examples. Additionally, the terms “consolidated” and “consolidation” may encompass bonding by means of an airflow bonding operation. The terms “airflow bonded” and “airflow bonding,” as used herein in this document, may encompass a nonwoven fabric consolidated by means of a bonding process in which hot air is used to fuse the fibers on the surface of the fabric and optionally internally within the fabric.By way of example only, hot air can be blown through the fabric in a conveyor oven or sucked into the fabric as it passes over a porous drum as a vacuum develops. The temperature and rate of hot air are parameters that can determine the level or extent of bonding in the nonwoven fabric. According to certain embodiments of the invention, the temperature of the hot air can be high enough to melt, induce flow, and / or fuse a plurality of fibers that have a lower melting point temperature or lower initial melting point temperature (e.g., amorphous fibers) into a plurality of fibers that have a higher melting point temperature or lower initial melting point temperature (e.g., semicrystalline or crystalline fibers).Such fabric may be considered a "non-consolidated fabric", "non-woven fabric" or simply as a "fabric" according to certain embodiments of the invention. Petition 870260064854, dated 01 / 07 / 2026, page 22 / 82 12 / 29

[017] As used herein in this document, “melt yarn” or “melt spinning” generally refers to a process of forming fibers by melt spinning or blow melting.

[018] The term “melt spinning,” as used herein, may encompass fibers which are formed by extruding molten thermoplastic material as fibers from a plurality of fine, usually circular, capillaries in a spinneret, with the diameter of the extruded fibers then being rapidly reduced. According to one embodiment of the invention, the melt spinning fibers are generally not sticky when deposited on a collecting surface and may generally be continuous, as presented and described herein. It is worth noting that the melt spinning used in certain compounds of the invention may include a nonwoven described in the literature as SPINLACE®. The melt spinning fibers, for example, comprise continuous fibers.

[019] As used herein in this document, the term “continuous fibers” refers to fibers that are not cut from their original length before being transformed into a woven or nonwoven fabric. Continuous fibers may have average lengths ranging from approximately 15 centimeters to over one meter, and up to the length of the weft or fabric being formed. For example, a continuous fiber, as used herein in this document, may comprise a fiber in which the fiber length is at least 1,000 times greater than the average fiber diameter, such as a fiber length that is at least approximately 5,000, 10,000, 50,000, or 100,000 times greater than the average fiber diameter.

[020] The term “machine direction” or “MD, according to its English abbreviation”, as used herein in this document, comprises the direction in which the fabric is produced or transported. The term “cross direction” or “CD, according to its English abbreviation”, as used herein in this document, comprises the direction of the fabric substantially perpendicular to the MD.

[021] Certain embodiments according to the invention provide a process for forming a nonwoven fabric that includes a deposition step of at least one first nonwoven layer comprising a plurality of interwoven melt-spun individual fibers directly or indirectly intertwined on a moving collection belt to provide a nonwoven fabric precursor having an initial average width in the transverse direction (CD) and / or an initial average base weight. The first plurality of interwoven melt-spun individual fibers may Petition 870260064854, dated 01 / 07 / 2026, p. 23 / 82 13 / 29 understand (a) the combination of a first group of single-component fibers having a first initial melting point and a second group of single-component fibers having a second initial melting point that is lower than the first initial melting point, (b) the two-component fibers comprising a first component having a first initial melting point and a second component having a second initial melting point that is lower than the first initial melting point, (c) the combination of a first group of two-component fibers having a first component with a higher melting point and a first component with a lower melting point,and a second group of bicomponent fibers having a second component with a higher melting point and a second component with a lower melting point that begins to melt before the first component with the lower melting point; or (d) any combination of (a)-(c). The process may also comprise transporting the nonwoven precursor via a heat fixation operation (HSO) comprising (a) immobilizing the nonwoven precursor directly or indirectly within a narrower zone where heat fixation takes place between the moving take-up conveyor and a portion of a benchtop surface, such as a stage of a heat fixation apparatus, to mitigate the relative movement of the individual melt-spun fibers during the HSO,(b) subjecting the nonwoven precursor to a temperature high enough to increase the tackiness of the second group of monocomponent fibers and / or the second component of the bicomponent fibers having the second initial melting point to provide an intermediate nonwoven and / or the second component with a lower melting point of the second group of bicomponent fibers. The process may also comprise removing the intermediate nonwoven from the HSO, wherein the intermediate nonwoven has an average post-heat-fixation CD width and / or an average post-heat-fixation base weight, and consolidating the intermediate nonwoven to provide this nonwoven having a final average CD width and / or a final average base weight. According to certain embodiments of the invention,HSO can lightly bond or consolidate one phase of the fused fiber together to provide sufficient integrity for handling, while the consolidation step more completely bonds the fused fibers together to provide a significantly more durable and strong final nonwoven fabric compared to the intermediate nonwoven fabric formed after HSO.

[022] Each of Figures 1-4 illustrates a schematic of the respective general processes according to certain embodiments of the invention. Although Figures 1-4 illustrate two rotating fusion beams, this is for illustrative purposes only, as it may vary from, by Petition 870260064854, dated 01 / 07 / 2026, page 24 / 82 14 / 29 For example, 1 to 10 individual bundles can be used. Each of the processes includes the HSO and a consolidation or bonding unit located downstream of the HSO. These separate units can utilize any hot fluid in the process (e.g., hot air or steam) to achieve different degrees of melt flow from the lower-melting fibers (or fiber components) to flow and bond to the higher-melting fibers (or fiber components) for different degrees of bonding. For example, the HSO step is configured to achieve heat-induced heating, which has temperatures above the glass transition temperature of the upper polymer for a limited time during which the nonwoven fabric is physically prevented from moving, in which the elevated temperature is also above the softening or melting point (e.g., onset of melting temperature) of the lower-melting polymer enabling pre-bonding.Furthermore, the “HSO” step may contain a section for cooling the nonwoven fabric before the physical constraint is released and the fabric is removed from the HSO. According to certain embodiments of the invention, the cooling step may be particularly useful for completing the heat fixation process for the high-temperature polymer (e.g., higher initial melting temperature associated with a group of single-component fibers, two-component fibers, etc.), and for ensuring the integrity of the fabric for subsequent transport to the final bonding.

[023] Figure 1, for example, illustrates a process 1 that includes two melt-spinning beams 3,5 that deposit continuous melt-spinning fibers 4,6 onto a mobile collection belt 7 to form an unconsolidated nonwoven fabric 10, which is transported in and through an HSO 20. The nonwoven fabric 10 is physically contained by the heat-fixing zone 22 defined between the mobile collection belt 7 and a phase of the HSO 20 and remains substantially under constant tension or physical constraint in the nonwoven fabric until it exits the HSO to provide an intermediate nonwoven fabric 30. The HSO of Figure 1 comprises a porous continuous flow drum, which may rotate or remain stationary, which has a heating phase 24 and a cooling phase 28. The intermediate nonwoven fabric 30 may then be transported to a sizing unit 50, which may be a sizing drum as illustrated in Figure 1, for consolidation to provide a final nonwoven fabric 60.Optionally, the final nonwoven fabric can be collected on a winding turbine 70. Figure 2 illustrates another process 1 which is essentially the same as in Figure 1, but the HSO 20 includes hot air guns in place of the porous drum of Figure 1. Figures 3 and 4 are essentially the same as in Figures 1 and 2, respectively, but replace the gluing unit 50 with the thermal calendering operation. Petition 870260064854, dated 01 / 07 / 2026, p. 25 / 82 15 / 29

[024] According to certain embodiments of the invention, the elevated temperature associated with HSO may be within approximately 7°C below the second initial melting temperature or the second lowest melting point component of the second group of bicomponent fibers, such as within approximately any of the following: 6°C, 5°C, 4°C, 3°C, and 2°C below the second initial melting temperature of the second lowest melting point component of the second group of bicomponent fibers. Furthermore, or alternatively, subjecting the nonwoven fabric precursor to elevated temperature comprises a residence time from approximately 3 seconds to approximately 120 seconds, such as at least approximately any of the following: 3, 5, 8, 10, 15, 20, 30, 40, 50, and 60 seconds, and / or at most approximately any of the following: 120, 100, 90, 80, 70, and 60 seconds.In addition, or alternatively, the HSO may also comprise a cooling step that reduces the temperature of the nonwoven fabric precursor from approximately 20°C to approximately 40°C before exiting the heat-fixation zone, such as at least approximately any of the following: 20, 22, 25, 28, and 30°C, and / or at most approximately any of the following: 40, 38, 35, 32, and 30°C.

[025] According to certain embodiments of the invention, the HSO comprises a rotating or stationary porous drum, wherein the heat-fixing zone is defined by the drum and the moving collection conveyor. For example, the heat-fixing zone defines a path of displacement of the nonwoven fabric precursor extending around from approximately 180° to approximately 340°, such as at least approximately any of the following: 180, 190, 200, 210, 220, 230, 240, 250, 260, and 270°, and / or at most approximately any of the following: 340, 330, 320, 310, 300, 290, 280, and 270°. In addition, or alternatively, the drum (e.g., stationary or rotating) also includes a cooling phase, in which the nonwoven fabric precursor has undergone a heating phase before being transported beyond the cooling phase.In this sense, the heating phase comprises from approximately 70 to approximately 95% of the travel distance, such as at least approximately any of the following: 70, 75, 80, and 85%, and / or at most approximately any of the following: 95, 90, and 85%, and the cooling phase comprises from approximately 5 to approximately 30% of the travel distance, such as at least approximately any of the following: 5, 10, and 15%, and / or at most approximately any of the following: 30, 25, 20, and 15%. According to certain embodiments of the invention, the heating phase comprises discharging hot air outwards from there towards... Petition 870260064854, dated 01 / 07 / 2026, p. 26 / 82 16 / 29 corresponding section of the displacement path, or a thermal heating calender.

[026] According to certain embodiments of the invention, the HSO comprises a linear airflow bonding unit that includes a heating phase and a cooling phase, wherein the heat-fixing zone defines a path for the nonwoven precursor between the linear airflow bonding unit and the mobile collection conveyor, and wherein the nonwoven precursor has passed through the heating phase before being transported beyond the cooling phase.For example, the heating phase comprises from approximately 70 to approximately 95% of the travel distance, such as at least approximately any of the following: 70, 75, 80, and 85%, and / or at most approximately any of the following: 95, 90, and 85%, and the cooling phase comprises from approximately 5 to approximately 30% of the travel distance, such as at least approximately any of the following: 5, 10, and 15%, and / or at most approximately any of the following: 30, 25, 20, and 15%.

[027] According to certain embodiments of the invention, the consolidation of the intermediate nonwoven fabric may comprise a variety of consolidation means, such as thermal calendering, airflow bonding, ultrasonic bonding, thermal area bonding, chemical bonding, or any combination thereof, wherein the first plurality of interwoven individual melt yarns may optionally be subjected to an elevated temperature equal to or greater than the second initial melting temperature or melting point associated with the second highest melting point of the component of the second group of bicomponent fibers, and optionally where the elevated temperature is less than the second initial melting temperature or melting point associated with the component with the highest melting point of the first group of bicomponent fibers.For example, fibers or fiber components with higher melting points can remain in a substantially undeformed shape according to certain embodiments of the invention.

[028] The consolidation step of the intermediate nonwoven fabric may comprise a thermal calendering operation that provides a plurality of discrete bonding sites that define a bonding area, where the bonding area may comprise from approximately 3 to approximately 30%, such as at least, approximately any of the following: 3, 5, 6, 8, 10, 12, 15, 18, and 20%, and / or at most Petition 870260064854, dated 01 / 07 / 2026, page 27 / 82 17 / 29 approximately any of the following: 30, 28, 26, 25, 24, 22, and 20%. Alternatively, the consolidation of the intermediate nonwoven fabric may comprise an area thermal bonding operation where at least one first outermost surface is completely bonded to define a continuous bond that defines a microporous film structure.

[029] According to certain embodiments of the invention, the average width of the CD after heat fixing is at least approximately 95% of the initial average width of the CD, such as at least approximately any of the following: 95, 96, 97, 98, 99, and 99.5% of the initial average width of the CD, and / or at most approximately any of the following: 100, 99.9, 99.8, 99.7, 99.6, and 99.5% of the initial average width of the CD. Furthermore, or alternatively, the average weight after heat fixation is at least approximately 95% of the initial average basis weight, such as at least approximately any of the following: 95, 96, 97, 98, 99, and 99.5% of the initial average basis weight, and / or at most approximately any of the following: 100, 99.9, 99.8, 99.7, 99.6, and 99.5% of the initial average basis weight.Furthermore, or alternatively, the final average width of the CD is at least approximately 95% of the average CD width after heat fixation, such as at least approximately any of the following: 95, 96, 97, 98, 99, and 99.5% of the average CD width after heat fixation, and / or at most approximately any of the following: 100, 99.9, 99.8, 99.7, 99.6, and 99.5% of the average CD width after heat fixation. Furthermore, or alternatively, the final average base weight is at least approximately 95% of the average base weight after thermal fixation, such as at least approximately any of the following: 95, 96, 97, 98, 99, and 99.5% of the average base weight after thermal fixation, and / or at most approximately any of the following: 100, 99.9, 99.8, 99.7, 99.6, and 99.5% of the average base weight after thermal fixation.Furthermore, or alternatively, the final average width of the CD is at least approximately 95% of the initial average width of the CD, such as at least approximately any of the following: 95, 96, 97, 98, 99, and 99.5% of the initial width of the CD, and / or at most approximately any of the following: 100, 99.9, 99.8, 99.7, 99.6, and 99.5% of the initial average width of the CD. In addition, or alternatively, the final average baseline weight is at least approximately 95% of the initial average baseline weight, such as at least approximately any of the following: 95, 96, 97, 98, 99, and 99.5% of the initial average baseline weight, and / or at most approximately any of the following: 100, 99.9, 99.8, 99.7, 99.6, and 99.5% of the initial average baseline weight. Petition 870260064854, dated 01 / 07 / 2026, page 28 / 82 18 / 29

[030] According to certain embodiments of the invention, the weft or nonwoven fabric may include the first plurality of melt-spun individual fibers comprising the combination of the first group of single-component fibers or the first group of two-component fibers having the first initial melting temperature and the second group of single-component fibers or the first group of two-component fibers having the second initial melting temperature that is lower than the first initial melting temperature, and wherein the first group of single-component fibers or the first group of two-component fibers defines at least a first region, and the second group of single-component fibers or the first group of two-component fibers defines at least a second region, and wherein the first plurality of melt-spun individual fibers is formed from a single polymeric composition.

[031] According to certain embodiments of the invention, the first group of single-component fibers or the first component with the highest melting point of the first group of two-component fibers has a first melting point range, and the second group of single-component fibers or the second component with the lowest melting point of the second group of two-component fibers has a second melting point range; where the first melting point range and the second melting point range do not overlap. For example, the difference between values ​​closest to the first melting point range and the second melting point range can be from 2 to 60°C, such as at least approximately any of the following: 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 15, 18, and 20°C, and / or at most approximately any of the following: 60, 50, 40, 30, 28, 25, 22, and 20°C.Furthermore, or alternatively, the second group of single-component fibers or the second component with the lowest melting point of the second group of two-component fibers is deformed from a cross-section initially spun and fused with the first group of single-component fibers or the second group of two-component fibers during the consolidation of the intermediate nonwoven fabric.

[032] According to certain embodiments of the invention, the nonwoven fabric 100, as illustrated in Figure 5, may include a first group of single-component fibers or the first group of two-component fibers defines at least a first region with a higher melting point 110 and a second group of single-component fibers or the second group of two-component fibers defines at least a region with a lower melting point 210. Figure 6, for example, illustrates a nonwoven fabric 100 that includes a first group of melt-spun fibers (e.g., a Petition 870260064854, dated 01 / 07 / 2026, page 29 / 82 19 / 29 first group of single-component melt-spun fibers and / or a first group of two-component fibers) defining two high-melting-point regions 110a 110b and a second group of melt-spun fibers (e.g., second group of single-component melt-spun fibers and / or a second group of two-component fibers) defining a low-melting-point region 210 according to certain embodiments of the invention. In this sense, the first group of single-component fibers or the first group of two-component fibers may define two separate higher-melting-point regions that include, for example, a first outer surface and / or a second outer surface of the nonwoven fabric.In Figure 6, the second group of single-component fibers or the second group of two-component fibers defines at least a first region with a lower melting point 210 located adjacent to the first region with a higher melting point, the second region with a higher melting point, or both.

[033] The resulting nonwoven fabric may have a total basis weight from approximately 10 grams per square meter (g / m2) to approximately 200 g / m2, such as at least approximately any of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 g / m2, and / or at most approximately any of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 g / m2. Furthermore, or alternatively, the first group of single-component fibers or the first group of two-component fibers comprises from approximately 50 to approximately 90% by weight of the total base weight, such as at least approximately any of the following: 50, 55, 60, 65, and 70% by weight of the total base weight, and / or at most approximately any of the following: 90, 85, 80, 75, and 70% by weight of the total base weight.Furthermore, or alternatively, the second group of single-component fibers or the second group of two-component fibers comprises from approximately 10 to approximately 50% by weight of the total base weight, such as at least approximately any of the following: 10, 15, 20, 25, and 30% by weight of the total base weight, and / or at most approximately any of the following: 50, 45, 40, 35, and 30% by weight of the total base weight.

[034] According to certain embodiments of the invention, the second group of single-component fibers or the second group of two-component fibers may define at least the first region with a lower melting point that includes a first outermost surface of the nonwoven fabric. In addition, or alternatively, the second group of single-component fibers or the second group of two-component fibers also defines a second region with a lower melting point that includes a second surface Petition 870260064854, dated 01 / 07 / 2026, p. 30 / 82 20 / 29 outermost layer of the nonwoven fabric. Furthermore, or alternatively, the first group of single-component fibers or the first group of two-component fibers defines at least one region with a higher melting point located adjacent to the first region with a lower melting point, a second region with a lower melting point, or both. Figure 7, for example, illustrates such a resulting nonwoven fabric.Figure 7 illustrates a nonwoven fabric 100 comprising a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines an interior region with a high melting point 110 and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines two regions with a low melting point 210a, 210b according to certain embodiments of the invention.In addition, or alternatively, the nonwoven fabric may have a total base weight from approximately 10 grams per square meter (g / m2) to approximately 200 g / m2, such as at least approximately any of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 g / m2, and / or at most approximately any of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 g / m2. Furthermore, or alternatively, the first group of single-component fibers or the first group of two-component fibers comprises from approximately 50 to approximately 90% by weight of the total base weight, such as at least approximately any of the following: 50, 55, 60, 65, and 70% by weight of the total base weight, and / or at most approximately any of the following: 90, 85, 80, 75, and 70% by weight of the total base weight.Furthermore, or alternatively, the second group of single-component fibers or the second group of two-component fibers comprises from approximately 10 to approximately 50% by weight of the total base weight, such as at least approximately any of the following: 10, 15, 20, 25, and 30% by weight of the total base weight, and / or at most approximately any of the following: 50, 45, 40, 35, and 30% by weight of the total base weight.

[035] According to certain embodiments of the invention, the first group of single-component fibers or the first group of two-component fibers may define a plurality of the first region with a higher melting point, and the second group of single-component fibers or the second group of two-component fibers may define a plurality of the first region with a lower melting point. For example, the plurality of the first region with a higher melting point and the plurality of the first region with a lower melting point may be located in an alternating pattern along the machine direction of the nonwoven fabric, a z-direction that is perpendicular to the machine direction and the direction Petition 870260064854, dated 01 / 07 / 2026, page 31 / 82 21 / 29 transverse, or both. Alternatively, the plurality of the first region with the highest melting point and the plurality of the first region with the lowest melting point are located in an alternating pattern along a transverse direction of the nonwoven fabric, a z-direction that is perpendicular to the transverse direction, and a machine direction, or both. According to certain embodiments of the invention, the plurality of the first region with the highest melting point and the plurality of the first region with the lowest melting point are located in an alternating pattern along a transverse direction and a machine direction.According to certain embodiments of the invention, the plurality of the first region with the highest melting point and the plurality of the first region with the lowest melting point are also located in an alternating pattern in a z-direction of the nonwoven fabric, where the z-direction is perpendicular to the transverse direction and the machine direction. In addition, or alternatively, the nonwoven fabric may have a total base weight from approximately 10 grams per square meter (g / m2) to approximately 200 g / m2, such as at least approximately any of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 g / m2, and / or at most approximately any of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 g / m2.Furthermore, or alternatively, the first group of single-component fibers or the first group of two-component fibers comprises from approximately 50 to approximately 90% by weight of the total base weight, such as at least approximately any of the following: 50, 55, 60, 65, and 70% by weight of the total base weight, and / or at most approximately any of the following: 90, 85, 80, 75, and 70% by weight of the total base weight. Furthermore, or alternatively, the second group of single-component fibers or the second group of two-component fibers comprises from approximately 10 to approximately 50% by weight of the total base weight, such as at least approximately any of the following: 10, 15, 20, 25, and 30% by weight of the total base weight, and / or at most approximately any of the following: 50, 45, 40, 35, and 30% by weight of the total base weight.

[036] Figure 8, for example, illustrates a nonwoven fabric 100 that includes a first group of melt-spun fibers (e.g., a first group of single-component melt-spun fibers and / or a first group of bicomponent fibers) that defines a plurality of high-melting-point regions 110a, 110b and a second group of melt-spun fibers (e.g., a second group of single-component melt-spun fibers and / or a second group of bicomponent fibers) that defines a plurality of low-melting-point regions 210a, 210b, in which the high-melting-point regions Petition 870260064854, dated 01 / 07 / 2026, page 32 / 82 22 / 29 melting point and the low melting point regions are located alternately in a z direction, according to certain embodiments of the invention.

[037] Figure 9, for example, illustrates another nonwoven fabric 100 that includes a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines a plurality of high-melting-point regions 100a - 100c, and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines a plurality of low-melting-point regions 210a, 210b, in which the high-melting-point regions and the low-melting-point regions are located alternately in a z-direction, according to certain embodiments of the invention.

[038] Figure 10, for example, illustrates a nonwoven fabric 100 comprising a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) defining a plurality of high-melting-point regions 110a - 110e, and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) defining a plurality of low-melting-point regions 210a - 210f, in which the high-melting-point regions and the low-melting-point regions are located alternately in the transverse direction, according to certain embodiments of the invention;

[039] Figure 11, for example, illustrates a nonwoven fabric 100 comprising a first group of melt-spun fibers (for example, a first group of single-component melt-spun fibers and / or a first group of two-component fibers) defining a plurality of high-melting-point regions 110a - 110n, and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) defining a plurality of low-melting-point regions 210a - 210l, wherein the high-melting-point regions and the low-melting-point regions are located alternately in both the z-direction and the transverse direction, according to certain embodiments of the invention.

[040] According to certain embodiments of the invention, the first group of single-component fibers or the first group of two-component fibers may define a region with a higher melting point comprising a continuous region, and the second group Petition 870260064854, dated 01 / 07 / 2026, page 33 / 82 23 / 29 of single-component fibers or the second group of two-component fibers defines a plurality of regions with a lower melting point comprising separate islands dispersed throughout the continuous region. Alternatively, the second group of single-component fibers or the second group of two-component fibers may define a region with a lower melting point comprising a continuous region, and the first group of single-component fibers or the first group of two-component fibers defines a plurality of regions with a higher melting point comprising separate islands dispersed throughout the continuous region.According to certain embodiments of the invention, the nonwoven fabric has a total base weight from approximately 10 grams per square meter (g / m2) to approximately 200 g / m2, such as at least approximately any of the following: 10, 12, 15, 18, 20, 22, 25, 28, 30, 32, 35, 38, 40, 45, and 50 g / m2, and / or at most approximately any of the following: 200, 180, 150, 120, 100, 80, 70, 60, and 50 g / m2. Furthermore, or alternatively, the first group of single-component fibers or the first group of two-component fibers comprises from approximately 50 to approximately 90% by weight of the total base weight, such as at least approximately any of the following: 50, 55, 60, 65, and 70% by weight of the total base weight, and / or at most approximately any of the following: 90, 85, 80, 75, and 70% by weight of the total base weight.Furthermore, or alternatively, the second group of single-component fibers or the second group of two-component fibers comprises from approximately 10 to approximately 50% by weight of the total base weight, such as at least approximately any of the following: 10, 15, 20, 25, and 30% by weight of the total base weight, and / or at most approximately any of the following: 50, 45, 40, 35, and 30% by weight of the total base weight.

[041] Figure 12, for example, illustrates a nonwoven fabric 100 having a second group of melt-spun fibers (e.g., a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines a continuous low-melting-point region 210 and a first group of melt-spun fibers (e.g., a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines a plurality of high-melting-point regions 110a - 110e dispersed throughout the low-melting-point region according to certain embodiments of the invention.

[042] Figure 13, for example, illustrates a nonwoven fabric 100 having a first group of melt-spun fibers (e.g., a first group of single-component melt-spun fibers and / or a first group of two-component fibers) that defines Petition 870260064854, dated 01 / 07 / 2026, page 34 / 82 24 / 29 continuous high melting point region 110 and a second group of melt-spun fibers (for example, a second group of single-component melt-spun fibers and / or a second group of two-component fibers) that defines a plurality of low melting point regions 210a - 210i dispersed throughout the high melting point region according to certain embodiments of the invention;

[043] According to certain embodiments of the invention, the first group of single-component fibers or the first group of two-component fibers comprises a circular outer cross-section, a non-circular outer cross-section, or both. For example, the first group of single-component fibers or the first group of two-component fibers comprises an average diameter from approximately 8 to approximately 40 microns, such as at least approximately any of the following: 8, 10, 12, 15, 18, and 10 microns, and / or at most approximately any of the following: 40, 28, 35, 32, 30, 28, 25, 22, and 20 microns. Furthermore, or alternatively, the first group of single-component fibers or the first group of two-component fibers may comprise an outer circular cross-section having an aspect ratio of 0.8 to 1.2, such as approximately 0.8, 0.9, and 1, and / or at most approximately 1.2, 1.1, and 1.

[044] According to certain embodiments of the invention, the first group of single-component fibers or the first group of two-component fibers may comprise a non-circular outer cross-section having an aspect ratio of at least 1.5, such as at least approximately any of the following: 1.5, 2, 3, 4, and 5, and / or at most approximately any of the following: 10, 9, 8, 7, 6, and 5.

[045] According to certain embodiments of the invention, the first group of single-component fibers or the first group of two-component fibers comprises a combination of fibers with a circular outer cross-section and fibers with a non-circular outer cross-section. For example, fibers with an outermost circular cross-section comprise from 1 to approximately 99% of the total number of the first group of monocomponent fibers or the first group of bicomponent fibers, such as at least approximately any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of the total number of the first group of monocomponent fibers or the first group of bicomponent fibers, and / or at most approximately any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of the total number of the first group of monocomponent fibers or the first group of bicomponent fibers. Furthermore Petition 870260064854, dated 01 / 07 / 2026, page 35 / 82 25 / 29 of this, or alternatively, the fibers with the outermost non-circular cross-section comprise from 1 to approximately 99% of a total number of the first group of monocomponent fibers or the first group of bicomponent fibers, such as at least approximately any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the first group of monocomponent fibers or the first group of bicomponent fibers, and / or at most approximately any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the first group of monocomponent fibers or the first group of bicomponent fibers.

[046] According to certain embodiments of the invention, the second group of single-component fibers or the second group of two-component fibers comprises a circular outer cross-section, a non-circular outer cross-section, or both. In addition, or alternatively, the second group of single-component fibers or the second group of two-component fibers comprises an average diameter from approximately 8 to approximately 40 microns, such as at least approximately any of the following: 8, 10, 12, 15, 18, and 10 microns, and / or at most approximately any of the following: 40, 28, 35, 32, 30, 28, 25, 22, and 20 microns. Furthermore, or alternatively, the second group of single-component fibers or the second group of two-component fibers comprises an outer circular cross-section having an aspect ratio of 0.8 to 1.2, such as approximately 0.8, 0.9, and 1, and / or at most approximately 1.2, 1.1, and 1.

[047] According to certain embodiments of the invention, the second group of single-component fibers or the second group of two-component fibers comprises a non-circular outer cross-section having an aspect ratio of at least 1.5, such as at least approximately any of the following: 1.5, 2, 3, 4, and 5, and / or at most approximately any of the following: 10, 9, 8, 7, 6, and 5.

[048] According to certain embodiments of the invention, the second group of single-component fibers or the second group of two-component fibers comprises a combination of fibers with a circular outer cross-section and fibers with a non-circular outer cross-section. For example, the fibers with a circular outer cross-section comprise from 1 to approximately 99% of a total number of the second group of single-component fibers or the second group of two-component fibers, such as at least approximately any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the second group of single-component fibers or the Petition 870260064854, dated 01 / 07 / 2026, page 36 / 82 26 / 29 second group of bicomponent fibers, and / or at most approximately any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the second group of monocomponent fibers or the second group of bicomponent fibers. Furthermore, or alternatively, the fibers with the outermost non-circular cross-section comprise from 1 to approximately 99% of a total number of the second group of monocomponent fibers or the second group of bicomponent fibers, such as at least approximately any of the following: 1, 3, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50% of a total number of the second group of monocomponent fibers or the second group of bicomponent fibers, and / or at most approximately any of the following: 99, 98, 95, 90, 85, 80, 75, 70, 65, 60, 55, and 50% of a total number of the second group of monocomponent fibers or the second group of bicomponent fibers.

[049] According to certain embodiments of the invention, the first group of single-component fibers and the second group of single-component fibers may comprise a single polymer composition, wherein the single polymer composition comprises a component polymer comprising a polyolefin or copolymer thereof, a polyester or copolymer thereof, a polyamide or copolymer thereof, or a biopolymer, such as polylactic acid; or wherein the first component with a higher melting point and a first component with a lower melting point of the first group of two-component fibers independently of each other comprise a component polymer comprising a polyolefin or copolymer thereof, a polyester or copolymer thereof, a polyamide or copolymer thereof, or a biopolymer, such as polylactic acid;or where the second component with the higher melting point and the second component with the lower melting point of the second group of bicomponent fibers, independently of each other, comprise a component polymer comprising a polyolefin or copolymer thereof, a polyester or copolymer thereof, a polyamide or copolymer thereof, or a biopolymer, such as polylactic acid. For example, the polyolefin may comprise a polypropylene or copolymer thereof, a polyethylene or copolymer thereof, or blends thereof.

[050] As noted above, the resulting nonwoven fabric may comprise a nonwoven fabric bonded by airflow, a bonded area of ​​the nonwoven fabric, or a thermally calendered nonwoven fabric having a plurality of discrete bonding sites. According to certain embodiments of the invention, the second group of single-component fibers or the second group of two-component fibers has a deformed cross-section that is at least partially melted, flowed, and bonded to Petition 870260064854, dated 01 / 07 / 2026, page 37 / 82 27 / 29 first group of single-component fibers or to the first group of two-component fibers. According to certain embodiments of the invention, the first group of single-component fibers have an undeformed cross-section.

[051] According to certain embodiments of the invention, the first plurality of interwoven melt-spun individual fibers comprises melt-spun fibers, the melt-spun fibers, or both. Furthermore, or alternatively, the process may comprise depositing one or more additional layers of nonwoven fabric, such as 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 additional layers of melt-spun fibers directly or indirectly onto the first nonwoven layer. Furthermore, or alternatively, one or more additional layers of nonwoven fabric independently comprise (a), (b), or (c) as previously set forth.

[052] In another aspect, the present invention provides a thermally fixed nonwoven fabric comprising at least a plurality of interwoven melt-spun individual fibers comprising (a) a combination of a first group of single-component fibers having a first initial melting point and a second group of single-component fibers having a second initial melting point that is lower than the first initial melting point, (b) two-component fibers comprising a first component having a first initial melting point and a second component having a second initial melting point that is lower than the first initial melting point, (c) a combination of a first group of two-component fibers having a first component with a higher melting point and a first component with a lower melting point,and a second group of bicomponent fibers having a second component with a higher melting point and a second component with a lower melting point that begins to melt before the first component with the lower melting point; or (d) any combination of (a)-(c). Nonwoven fabrics may be air-flow bonded nonwoven fabrics, chemically bonded nonwoven fabrics, mechanically consolidated nonwoven fabrics, and / or thermally bonded nonwoven fabrics. In this sense, nonwoven fabrics (e.g., melt-spun fabrics) may be consolidated by means of a fluid bonding process (e.g., fluid includes hot air or steam) in which, optionally, only the lower melting point fibers (or component) are softened, fused, and / or flowed through a phase of the nonwoven fabric to form bonds with the higher melting point fibers. In this sense,The structural integrity of the resulting nonwoven fabric, according to certain embodiments of the invention, can be provided by, Petition 870260064854, dated 01 / 07 / 2026, page 38 / 82 28 / 29 Higher melting point fibers (or components of higher melting point fibers) that may remain undeformed or substantially undeformed (e.g., the cross-section of the fiber components or higher melting point fibers remains the same or substantially the same before, during, and after the consolidation operation). Conversely, lower melting point fibers (or fiber components) may have a deformed cross-section or be individually indiscernible as individual fibers due to melting and / or flow to provide the bonding mechanism for consolidation. For example, lower melting point fibers (or fiber components) may at least partially melt and flow through at least some of the gaps defined between the higher melting point fibers.As fibers (or fiber components) with lower melting points flow through gaps between fibers with higher melting points, the deformed and flowed lower-melting-point fibers (e.g., less crystalline or amorphous) coat the surfaces of the higher-melting-point fibers (or fiber components). After solidification of the lower-melting-point material (e.g., the melted and flowed lower-melting-point fibers) after coating the surfaces of the higher-melting-point fibers (or fiber components), the lower-melting-point material forms bonds with and between the higher-melting-point material (e.g., the deformed lower-melting-point fibers).

[053] In another aspect, the present invention provides a method for forming a compound comprising forming or providing a nonwoven fabric, such as that described and presented herein, and bonding a film layer to the nonwoven fabric. In another aspect, the present invention provides a compound that includes a nonwoven fabric, such as that described and presented herein, and a film.

[054] According to certain embodiments of the invention, the film layer is a single-layer film. For example, the single-layer film is a vapor-permeable and liquid-impermeable film (VPLI) that is permeable to vapor but impermeable to liquid water. The VPLI film, for example, can be a monolithic film or a microporous film.

[055] According to certain embodiments of the invention, the film layer may be a multilayer film that includes a core layer and at least one first skin layer. The multilayer film, for example, may include a second layer of Petition 870260064854, dated 01 / 07 / 2026, page 39 / 82 29 / 29 skin, where the central layer is located between and adjacent to the first skin layer and the second skin layer. For example, the central layer may be a microporous layer or a monolithic layer. The first skin layer, the second skin layer, or both may comprise a microporous layer or a monolithic layer. Additionally, or alternatively, the multilayer film may be a vapor-permeable and liquid-impermeable film (VPLI).

[056] According to certain embodiments of the invention, the film layer may have a base weight from approximately 5 to approximately 50 g / m2, such as at least approximately any of the following: 5, 10, 12, 15, 18, 20, 22, and 25 g / m2, and / or at most approximately any of the following: 50, 45, 40, 35, 30, 28, and 25 g / m2. Furthermore, or alternatively, the film layer is extruded melt directly onto the nonwoven fabric. Alternatively, the film layer is adhesively bonded to the nonwoven fabric by means of an adhesive layer.

[057] These and other modifications and variations of the invention may be practiced by those having ordinary skill in the art without departing from the spirit and scope of the invention, which is more specifically set forth in the appended claims. Furthermore, it should be understood that aspects of the various embodiments may be interchangeable in whole or in part. Moreover, those having ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention as described in more detail in the appended claims. Therefore, the spirit and scope of the appended claims shall not be limited to the exemplary description of the versions contained herein. Petition 870260064854, dated 01 / 07 / 2026, p. 40 / 82

Claims

1 / 5 CLAIMS 1. Process for forming a nonwoven fabric, comprising: (i) depositing at least one first nonwoven layer comprising a plurality of melt-spun individual fibers intertwined directly or indirectly on a moving take-up conveyor to provide a nonwoven fabric precursor having an initial average width in the transverse direction (CD) and / or an initial average base weight, wherein the first plurality of melt-spun individual fibers comprises (a) a combination of a first group of single-component fibers having a first initial melt temperature and a second group of single-component fibers having a second initial melt temperature that is lower than the first initial melt temperature,(b) bicomponent fibers that include a first component having a first initial melting point and a second component having a second initial melting point that is lower than the first initial melting point, or (c) a combination of a first group of bicomponent fibers having a first component with a higher melting point and a first component with a lower melting point, and a second group of bicomponent fibers having a second component with a higher melting point and a second component with a lower melting point that begins to melt before the first component with the lower melting point; (ii) the transport of the nonwoven fabric precursor through a heat fixation operation (HSO); (iii) the removal of an intermediate nonwoven fabric from the HSO,where the intermediate nonwoven fabric has an average post-heat-fixation CD width and / or an average post-heat-fixation base weight; and (iv) the consolidation of the intermediate nonwoven fabric to provide the nonwoven fabric having an average final CD width and / or an average final base weight; CHARACTERIZED in that the HSO comprises: (a) the immobilization of the nonwoven fabric precursor directly or indirectly within a defined heat-fixation narrowing point between the mobile collection conveyor and a portion of a benchtop surface, such as a stage of a thermal fixation apparatus, to mitigate the relative movement of the individual melt-spun fibers during the HSO,(b) subjecting the nonwoven fabric precursor to a temperature high enough to increase the tackiness of (1) the second group of single-component fibers or (2) the second component of the two-component fibers having the second initial melting point or (3) the second component with the lowest melting point of the second group of two-component fibers to provide an intermediate nonwoven fabric, and (c) subjecting the nonwoven fabric precursor to a cooling step before exiting the heat-set zone.

2. Process according to claim 1, CHARACTERIZED in that (i) the elevated temperature is not within 7°C below the second initial melting temperature or the second lowest melting point component of the second group of bicomponent fibers, such as within any of the following: 6°C, 5°C, 4°C, 3°C, and 2°C below the second initial melting temperature of the second lowest melting point component of the second group of bicomponent fibers (ii) subjecting the nonwoven fabric precursor to an elevated temperature comprising a residence time from 3 seconds to 120 seconds, such as at least any of the following: 3, 5, 8, 10, 15, 20, 30, 40, 50, and 60 seconds, and / or at most any of the following: 120, 100, 90, 80, 70, and 60 seconds.

3. Process according to claim 1, CHARACTERIZED in that the cooling step reduces the temperature of the nonwoven fabric precursor from 20°C to 40°C before exiting the heat-fixing zone, such as at least any of the following: 20, 22, 25, 28, and 30°C, and / or at most any of the following: 40, 38, 35, 32, and 30°C.

4. Process according to claim 1, CHARACTERIZED in that the HSO comprises a rotating drum, where the heat-fixing zone is defined by the rotating drum and the mobile collection conveyor, and where the heat-fixing zone defines a path for the displacement of the nonwoven fabric precursor extending around Petition 870260064854, dated 01 / 07 / 2026, page 1. 42 / 82 3 / 5 180° to 340° of the rotating drum, such as at least any of the following: 180, 190, 200, 210, 220, 230, 240, 250, 260, and 270° of the rotating drum, and / or at most any of the following: 340, 330, 320, 310, 300, 290, 280, and 270° of the rotating drum.

5. Process according to claim 4, CHARACTERIZED in that the rotating drum comprises a heating phase and a cooling phase, wherein the nonwoven fabric precursor has passed through the heating phase before being transported beyond the cooling phase, and wherein the heating phase comprises from 70 to 95% of the travel distance, such as at least any of the following: 70, 75, 80, and 85%, and / or at most any of the following: 95, 90, and 85%, and the cooling phase comprises from 5 to 30% of the travel distance, such as at least any of the following: 5, 10, and 15%, and / or at most any of the following: 30, 25, 20, and 15%.

6. Process according to claim 1, CHARACTERIZED in that the HSO comprises a linear airflow bonding unit that includes a heating phase and a cooling phase, wherein the heat-fixing zone defines a path for the nonwoven precursor between the linear airflow bonding unit and the mobile collection conveyor, and wherein the nonwoven precursor has passed through the heating phase before being transported beyond the cooling phase, and wherein the heating phase comprises from 70 to 95% of the path, such as at least any of the following: 70, 75, 80, and 85%, and / or at most any of the following: 95, 90, and 85%, and the cooling phase comprises from 5 to 30% of the path, such as at least any of the following: 5, 10, and 15%, and / or at most any of the following: 30, 25, 20, and 15%.

7. Process according to claim 1, CHARACTERIZED in that the consolidation of the intermediate nonwoven fabric comprises a thermal calendering operation, an airflow bonding operation, an ultrasonic bonding operation, an area thermal bonding operation, a chemical bonding operation, or any combination thereof; wherein the first plurality of interwoven individual molten yarns is subjected to an elevated temperature equal to or greater than the second initial melting temperature or melting point associated with the second higher melting point component of the second group of bicomponent fibers, and optionally wherein the elevated temperature is lower than the first initial melting temperature or melting point associated with the first higher melting point component of the first group of bicomponent fibers.

8. Process according to claim 7, CHARACTERIZED in that the consolidation of the intermediate nonwoven fabric comprises a thermal calendering operation providing a plurality of discrete bonding sites that define a bonding area, where the bonding area can comprise from 3 to 30%.

9. Process according to claim 1, CHARACTERIZED in that (i) the average width of the CD after heat fixation is at least 95% of the initial average width of the CD, and / or (ii) the average weight after heat fixation is at least 95% of the initial average base weight.

10. Process according to claim 1, CHARACTERIZED in that (i) the final average width of the CD is at least 95% of the average width of the CD after heat fixation, and / or (ii) the final average base weight is at least 95% of the average base weight after heat fixation.

11. Process according to claim 1, CHARACTERIZED in that (i) the final average width of the CD is at least 95% of the initial average width of the CD, and / or (ii) the final average base weight is at least 95% of the initial average base weight.

12. Process according to claim 1, CHARACTERIZED in that the first plurality of melt-spun individual fibers includes the combination of the first group of single-component fibers or the first group of two-component fibers having a first initial melting temperature and the second group of single-component fibers or the first group of two-component fibers having a second initial melting temperature that is lower than the first initial melting temperature, and where the first group of single-component fibers or the first group of two-component fibers defines at least a first region, and the second group of single-component fibers or the first group of two-component fibers defines at least a second region, and where the first plurality of melt-spun individual fibers is formed from a single polymeric composition.

13. Process according to claim 12, CHARACTERIZED in that the second group of monocomponent fibers or the second component with the lowest melting point of the second group of bicomponent fibers is deformed from a cross-section initially spun and fused with the first group of monocomponent fibers or the second group of bicomponent fibers during the consolidation of the intermediate nonwoven fabric. Petition 870260064854, dated 01 / 07 / 2026, p. 45 / 82

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