Multi-component fibers with improved inter-component adhesion

A method of forming a nonwoven fabric, comprising:

• (i) forming or providing at least one nonwoven layer including a first nonwoven layer comprising multi-component fibers;
• the multi-component fibers comprising at least a first component comprising a first polymeric material including a first polyolefin having from 50% to 100% by weight of ethylene monomer units and a first compatibilizer, and a second component comprising a second polymeric material including a second polyolefin;
• wherein the first polymeric material is different than the second polymeric material;
• and wherein the first compatibilizer consists of a copolymer, wherein the copolymer has a comonomer content including (i) amorphous ethylene regions in an amount from at least 10% to about 90% by weight of the first compatibilizer and (ii) crystalline polypropylene regions in an amount of at least 10% to about 90% by weight of the first compatibilizer;
• and
• (ii) forming the nonwoven fabric comprising a step of calendaring the at least one nonwoven layer to compact the multi-component fibers against one another forming a substantially smooth outer surface in the form a microporous film that permits gas to pass therethrough while also serving as a barrier to bacteriological contamination.

A nonwoven fabric, comprising:

• at least a first nonwoven layer comprising multi-component fibers densely arranged and compacted against one another to form a substantially smooth outer surface on at least a first side of the nonwoven fabric;
• the multi-component fibers comprising at least a first component comprising a first polymeric material including a first polyolefin having from 50% to 100% by weight of ethylene monomer units, and a second component comprising a second polymeric material including a second polyolefin and a second compatibilizer;
• wherein the first polymeric material is different than the second polymeric material;
• wherein the second compatibilizer consists of a copolymer, wherein the copolymer has a comonomer content including (i) amorphous ethylene regions in an amount from at least 10% to about 90% by weight of the second compatibilizer and (ii) crystalline polypropylene regions in an amount of at least 10% to about 90% by weight of the second compatibilizer.