Abstract: A method of forming an apertured hydro-patterned nonwoven web including the steps of forming a nonwoven batt comprising continuous spunmelt fibers, calender bonding the nonwoven batt to form a fully bonded precursor nonwoven web with a regular bond pattern that defines individual bond impressions and unbonded areas between the individual bond impressions, the regular bond pattern having a percentage bond area of 10% to 25%, and hydraulically imparting the fully bonded precursor nonwoven web with a plurality of apertures, the step of hydraulically imparting comprising hydraulically treating the fully bonded precursor nonwoven web by a plurality of steps of water injection as the fully bonded nonwoven web passes over a plurality of pins.

Abstract: A nonwoven fabric including a first layer made of spunbond fibers and a second layer made of meltblown fibers, wherein the first layer is bonded with the second layer, and wherein the spunbond fibers of the first layer are interspersed with the meltblown fibers of the second layer so that the nonwoven fabric exhibits enhanced breathability and filtration properties. In exemplary embodiments, the nonwoven fabric may be used in personal protective equipment, such as, for example, face masks and respirators.

Abstract: The present invention relates to a process of forming a soft bulky nonwoven web from a batt using thermobonding and to a soft bulky nonwoven web with a bond impression pattern and shape. The process comprises several steps including feeding a batt to a nip between first and second surface of first and second roller, where at least the first of the surfaces comprises spaced apart bonding protrusions surrounded by recessed areas. The bonding protrusions and the bond impression shape in the web exhibit a ratio of the greatest measurable width to the greatest measurable length of at least 1:2.5 and the perimeters thereof comprise a convex portion. The bonding protrusions are symmetric and/or have a certain angle to the machine direction.