Nonwoven sheets, adhesive articles, and methods for making the same

A method for making a nonwoven sheet material comprising:

• forming a randomly interlaced fibrous web of tensilized nonfracturable staple fibers and binder fibers;
• pattern embossing the fibrous web with a pattern selected from the group consisting of at least two rows of a plurality of depressions in a first direction aligned to form columns of the plurality of depressions in a second direction, wherein a distance between two depressions in one column varies from a distance between two depressions in a second column, and at least two rows of a plurality of depressions in a first direction aligned to form columns of the plurality of depressions in a second direction, wherein a distance between two depressions in at least one column varies along the first direction;
• subsequent to pattern embossing, smooth roll calendering the fibrous web;
• and
• subsequent to smooth roll calendering, uniformly interbonding the fibrous web throughout using a chemical binding agent.

A method for making a nonwoven sheet material comprising:

• forming a randomly interlaced fibrous web of tensilized nonfracturable staple fibers and binder fibers;
• first smooth roll calendering the fibrous web;
• pattern embossing the fibrous web with a pattern selected from the group consisting of at least two rows of a plurality of depressions in a first direction aligned to form columns of the plurality of depressions in a second direction, wherein a distance between two depressions in one column varies from a distance between two depressions in a second column, and at least two rows of a plurality of depressions in a first direction aligned to form columns of the plurality of depressions in a second direction, wherein a distance between two depressions in at least one column varies along the first direction;
• and
• uniformly interbonding the fibrous web throughout using a chemical binding agent, wherein smooth roll calendering is performed prior to pattern embossing or uniformly interbonding.

A method of making a pressure-sensitive adhesive article comprising:

• forming a first randomly interlaced fibrous web;
• smooth roll calendering the fibrous web;
• pattern embossing the fibrous web to form an embossed pattern comprising a plurality of discontinuous depressions in a first direction and a second direction;
• uniformly interbonding the fibrous web throughout using a chemical binding agent;
• and coating a first surface of the fibrous web with a pressure sensitive adhesive, wherein the pressure sensitive adhesive article has an Overtaping value of less than about 76 mm.

A method for making a nonwoven sheet material comprising:

• forming a randomly interlaced fibrous web comprising a first major surface and a second major surface, wherein the fibrous web comprises a longitudinal axis and a width generally perpendicular to the longitudinal axis;
• pattern embossing the fibrous web with a repeating pattern, the repeating pattern comprising:
• a plurality of first depressions forming a plurality of first columns aligned with the longitudinal axis, and
• a plurality of second depressions forming a plurality of second columns aligned with the longitudinal axis, wherein the plurality of first columns and the plurality of second columns alternate across the width of the fibrous web, and further wherein each first depression in the plurality of first depressions comprise a shape different than a shape of each second depression in the plurality of second depressions;
• smooth roll calendaring the fibrous web;
• uniformly interbonding the fibrous web throughout using a chemical binding agent;
• and coating the first major surface of the fibrous web with a pressure sensitive adhesive.

A method for making a pressure-sensitive adhesive article comprising:

• forming a first randomly interlaced fibrous web comprising a first major surface and a second major surface, wherein the fibrous web comprises a longitudinal axis and a width generally perpendicular to the longitudinal axis;
• smooth roll calendaring the fibrous web;
• pattern embossing the fibrous web to form a repeating pattern, the repeating pattern comprising:
• a plurality of first depressions forming a plurality of first columns aligned with the longitudinal axis, and
• a plurality of second depressions forming a plurality of second columns aligned with the longitudinal axis, wherein the plurality of first columns and the plurality of second columns alternate across the width of the fibrous web, and further wherein each first depression in the plurality of first depressions comprise a shape different than a shape of each second depression in the plurality of second depressions;
• uniformly interbonding the fibrous web throughout using a chemical binding agent;
• and
• coating the first major surface of the fibrous web with a pressure sensitive adhesive, wherein the pressure sensitive adhesive article has an Overtaping value of less than about 76 mm.

A method for making a pressure-sensitive adhesive article comprising:

• forming a first randomly interlaced fibrous web comprising a first major surface and a second major surface, wherein the fibrous web comprises a longitudinal axis and a width generally perpendicular to the longitudinal axis;
• pattern embossing the fibrous web with a repeating pattern, the repeating pattern comprising a plurality of depressions forming a plurality of columns aligned with the longitudinal axis and a plurality of rows across the width of the nonwoven backing, wherein the plurality of depressions comprises “+” signs;
• smooth roll calendaring the fibrous web;
• and
• uniformly interbonding the fibrous web throughout using a chemical binding agent.