Abstract: A method of forming a thermally bonded, nonwoven polypropylene fabric is provided and includes passing a web of thermally bondable skin-core polypropylene fibers through a calender nip under heat and pressure to produce a nonwoven fabric having elongation. The patterned calender roll is embossed with a plurality of spaced and staggered lands particularly dimensioned, configured and oriented to provide the desired bonding spot size and spacing between the bonding spots such that when utilized in the calender roll, an improved soft polypropylene fabric or cover sheet having a high elongation results.

Abstract: Finish compositions and methods for the manufacture of synthetic fibers and/or fabrics comprise hydrophobic esters of pentaerythritol homologs, such as hydrophobic pentaerythritol ester, as lubricants. These esters may be used by themselves or in conjunction with antistatic agents and/or other lubricants and permit the obtaining of high-strength nonwoven materials with increased production plant line speed and productivity. The finish may be used with a variety of fibers and fabrics.