Nonwoven fabric having high thermal resistance and barrier properties

A nonwoven fabric, comprising:

• (i) a first outermost spunbond layer comprising a first plurality of continuous fibers that are thermally fused and compacted against one another and define a microporous film on an outermost surface of the nonwoven fabric, the first plurality of continuous fibers comprises a first polymeric composition having a first melting point;
• (ii) a second outermost spunbond layer comprising a second plurality of continuous fibers;
• (iii) (a) at least a first meltblown layer comprising a first plurality of meltblown fibers, (b) a first melt-fibrillated layer comprising a first plurality of melt-fibrillated fibers, or (c) both (a) and (b) located directly or indirectly between the first outermost spunbond layer and the second outermost spunbond layer, the first plurality of meltblown fibers, or the first plurality of melt-fibrillated fibers, or both comprise a third polymeric composition having a third melting point, wherein the first melting point is lower than the third melting point;
• wherein the first plurality of continuous fibers have a deformed configuration due to softening and at least partially flowing to form the microporous film, and wherein the first plurality of meltblown fibers and/or melt-fibrillated fibers have a substantially non-deformed configuration;
• wherein the first outermost spunbond layer, the second outermost spunbond layer, or both comprise a thermally area-bonded layer at a nip pressure from 1500 to 3000 pounds per lineal inch wherein, and wherein the nonwoven fabric has (a) a hydrostatic head from about 140 to about 250 mbar as determined by AATCC™ 127, and (b) a water-vapor-transmission-rate (WVTR) from about 1300 to about 2500 g/m2/24 hour as determined by ASTM E96D.