Nonwoven fabric with high CD elongation and method of making same

A method of making a nonwoven fabric of substantially randomly oriented continuous spun fibers wherein the density of the fabric formed by the spun fibers varies between strips of relatively high density and strips of relatively low density, the strips extending along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips, the alternating high density and low density strips providing the fabric with a higher percent elongation in the cross direction than in the machine direction, comprising the steps of:

• (A) forming a flowing stream of substantially randomly oriented continuous spun fibers on an air permeable member;
• (B) moving the air permeable member across the path of the fiber stream and over a suction box to intercept and collect the fibers on one face of the air permeable member and to bond the collected fibers together to form a nonwoven fabric;
• (C) providing a pattern screen, the pattern screen defining a plurality of elongated air permeable regions separated by elongated substantially air impermeable regions, the elongated regions extending in the machine direction in an alternating pattern, with the air permeable regions separated from each other by the substantially air impermeable regions;
• (D) positioning the pattern screen in relation to the air permeable member and the suction box to cause the fibers to be collected on the one face of the air permeable member so as to form a fabric having a density that varies between strips of relatively high density and strips of relatively low density, the strips extending along the length of the fabric in the machine direction in an alternating pattern, with the high density strips separated from each other by low density strips, the alternating high density and low density strips providing the fabric with a higher percent elongation in the cross direction than in the machine direction;
• and
• (E) separating the collected fibers from the air pervious member;
• the pattern screen comprising longitudinally extending and transversely spaced substantially air impermeable baffle bars disposed below, in the plane of or above the suction box cover for disrupting the air flow directly above the air pervious member.

A method of making a nonwoven fabric embodying substantially randomly oriented continuous spun fibers deposited in a patterned formation of fabric density providing a higher percent elongation in CD than in MD, comprising the steps of

• (A) forming a flowing stream of substantially randomly oriented continuous spun fibers on an air permeable member;
• (B) moving the air pervious member across the path of the fiber stream and over a suction box cover to intercept and collect the fibers on one face of the air pervious member and to bond the collected fibers together to form a nonwoven fabric;
• (C) disposing a pattern screen as the suction box cover, thereby to cause the fibers to be collected on the one face of the air pervious member in a pattern of fabric density determined by the pattern on the pattern screen, the pattern defining a relatively air pervious area/relatively air impervious area ratio which is greater in MD than in CD, thereby to provide a fabric with a higher percent elongation in CD than in MD;
• and
• (D) separating the collected fibers from the air pervious member.

A method of making a nonwoven fabric embodying substantially randomly oriented continuous spun fibers deposited in a patterned formation of fabric density providing a higher percent elongation in CD than in MD, comprising the steps of

• (A) forming a flowing stream of substantially randomly oriented continuous spun fibers on an air permeable member;
• (B) moving the air pervious member defining a regular non-oriented pattern of apertures across the path of the fiber stream and over a suction box cover to intercept and collect the fibers on one face of the air pervious member and to bond the collected fibers together to form a nonwoven fabric;
• (C) disposing a pattern screen defining air pervious and substantially air impervious areas as the suction box cover, thereby to cause the fibers to be collected on the one face of the air pervious member in a pattern of fabric density determined by the pattern on the pattern screen, the pattern defining an air pervious area/substantially air impervious area ratio which is greater in MD than in CD, thereby to provide a fabric with a higher percent elongation in CD than in MD;
• and
• (D) separating the collected fibers from the air pervious member.