Method of making high loft and high strength nonwoven fabric

Abstract

High loft durable nonwoven material comprising facing and base components and corresponding process for preparation thereof and process for obtaining by (a) forming and compiling a facing component comprising one or more facing web(s) of staple fiber and/or fibrillated film; (b) lightly bonding the formed and compiled facing webs, utilizing a low density bonding pattern having a small bonding area relative to the corresponding surface area of said facing component; (c) laying a web comprising staple fiber and/or fibrillated film onto the lightly bonded facing component under conditions favoring arrangement in general cross or transverse direction relative to machine direction of the facing component; and (d) bonding said cross or transversely laid web to form a base component to said facing component, utilizing a substantially greater bonding density then employed for said facing component, to obtain the desired nonwoven material.

Dependencies are inferred from the claim text.