Abstract: A method for making a fluid transfer layer has steps of depositing a first non-woven layer on a support, depositing a second non-woven layer on the first layer, with the two layers having a different melting point. The two layers are then thermally bonded to one another in a heated calender nip, during which differential shrinkage occurs because of the two layers' different melting points. A micro-bulked profile results. The composite, micro-bulked web is then mechanically bulked to provide a macro-bulked profile. The resulting non-woven fabric has a high bulk, high resistance to pore structure collapse, high resistance to compression deformation, and is more economical to produce than prior art carded or bicomponent webs. An absorbent article has a porous topsheet, the fluid transfer layer of the invention underlying the topsheet, and an absorbent core.

Abstract: The invention is directed to composite nonwoven laminate fabric having differential softness and flexibility properties. The nonwoven laminate fabric includes a polypropylene meltblown web sandwiched between and bonded to a spunbonded web of polypropylene filaments and a spunbonded web of polyethylene filaments.

Abstract: The invention provides high elongation thermally bonded nonwoven fabrics which exhibit elongation of at least about 130% in the cross-machine direction. The fabrics of the invention include a nonwoven a web of polyolefin staple fibers having an elongation of at least 400 percent, and a multiplicity of discrete thermal bonds throughout the web to provide a bond area of from 8 to 25 percent of the area of the fabric.