Multi-denier hydraulically treated nonwoven fabrics and method of making the same

A method of making a nonwoven composite fabric, comprising:

• forming a first nonwoven web comprising continuous spunbond fibers having a first denier;
• forming a second nonwoven web comprising continuous spunbond fibers having a second average diameter of at most 75% of first denier;
• calender bonding the first and second nonwoven webs at a pressure of between 30 newtons per meter (N/m) and 90 N/m to form a composite fabric with a regular bond pattern;
• and
• hydraulically treating the composite fabric such that the fibers of the first nonwoven web and fibers of the second nonwoven web are intermingled.

A nonwoven composite fabric, comprising:

• first and second outer nonwoven layers comprising spunbond fibers, and
• a third inner nonwoven layer comprising spunbond fibers having a denier of less than 1.5,
• wherein the nonwoven composite fabric is thermally bonded with a regular bond pattern having a percentage bond area of 8% or greater, and
• the nonwoven composite fabric is hydroengorged.

A nonwoven composite fabric, comprising:

• first and second outer nonwoven layers comprising spunbond fibers;
• and
• a third inner nonwoven layer comprising meltblown fibers,
• wherein the nonwoven composite fabric is thermally bonded with a regular bond pattern having a percentage bond area of 8% or greater,
• the nonwoven composite fabric is hydraulically treated,
• the meltblown fibers comprise a polymer resin having a mean flow rate of less than 1800 g/10 min, and
• the nonwoven composite fabric has an abrasion rating of 4.0 or higher and an average Handle-O-Meter measurement (HOM) of 6.0 grams (g) or lower.