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, wherein the two sets of rollers are over-driven to provide a roller surface speed that is greater than the predetermined speed of the warp yarns, and wherein rollers closer to the rotatable beam have an outer surface that is coarser than an outer surface of rollers that are closer to the take up roll;
• 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.