Nonwoven fabric and method and apparatus for manufacturing same

An apparatus for forming a nonwoven sheet having a plurality of yarns substantially aligned in a warp direction, comprising:

• a rotatable beam containing a supply of roughly aligned warp yarns;
• a driven take up roll for pulling the warp yarns from the rotatable beam in a warp direction through the apparatus, wherein the take up roll pulls the warp yarns at a predetermined speed;
• an alignment station positioned between the rotatable beam and the driven take up roll, the alignment station comprising two sets of rollers aligned transversely to the warp direction, wherein the two sets of rollers rotate in opposite directions and are spaced apart to allow for passage of the warp yarns between the two sets of rollers, and wherein the predetermined speed of the warp yarns;
• and
• an adhesive application station positioned between the alignment station and the driven take up roll, the adhesive application station comprising a supply of adhesive and a carrier roller for applying the adhesive to one side of the substantially aligned warp yarns as the warp yarns exit the alignment station.

A method of aligning yarns in a warp direction, comprising steps of:

• pulling a plurality of roughly aligned warp yarns in a warp direction through an alignment station at a predetermined speed, wherein the alignment station comprises two sets of rollers aligned transversely to the warp direction and spaced apart to allow for passage of the warp yarns between the two sets of rollers;
• and
• rotating the two sets of rollers in opposite directions so that a surface of each roller engages the warp yarns as the roller surface is moving substantially in the warp direction, wherein a surface speed of the rollers is greater than the predetermined speed of the warp yarns;
• whereby contact between the roughly aligned warp yarns and the opposing sets of rotating rollers tends to substantially align the warp yarns.