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Abstract

An apertured nonwoven fabric comprising one or two outer carded web(s) and a polymeric sheet thermally bonded thereto. The polymeric sheet has a lower melting temperature than the nonwoven layers and a property of shrinking when melted. Heat and pressure are applied to the combination of layers through a calender roll such that the polymeric sheet becomes bonded to the fibers of the carded web(s) and simultaneously shrinks and pulls back the fibers away from the calendering points, thereby generating apertures through the nonwoven fabric. Preferably, the fibers are polyethylene or polypropylene fibers, and the polymeric sheet is a thin plastic film of linear low density polyethylene, elastomeric, or heat shrink material. One outer carded web may be combined with the plastic film layer to form a bi-laminate product, or two outer carded webs may be combined with an intermediate plastic film to form a tri-laminate product. Low denier polypropylene/polyethylene bi-component fibers or a blend of higher and lower melting fibers may also be used. Apertured products can also be obtained with non-thermoplastic outer layers and an intermediate plastic film layer.

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First Claim