Non-woven structures and methods of making the same

Abstract

Provided are layered non-woven structures comprising a fibrous, water-permeable anchoring layer and a fibrous layer having fibers entangled about the anchoring layer, including patterned and non-patterned structures. Also provided are personal care products comprising the present structures and methods of making the structures.

1 . A method of producing a layered, composite material comprising urging a stream of fluid into contact with a layered structure comprising a layer of unbonded fibers and a fluid-permeable, anchoring layer having a tensile strength of at least about 5 N/5 cm, wherein said layered structure is supported on a topographic forming surface and wherein said layered structure is contacted for a time sufficient to conform such layered structure to said topographic forming surface. 
     
     
         2 . The method of  claim 1  wherein said anchoring layer is positioned in direct contact with said topographic forming member. 
     
     
         3 . The method of  claim 2  wherein said anchoring layer comprises a spunbond material. 
     
     
         4 . The method of  claim 2  wherein said layer of unbonded fibers comprises cellulose fibers. 
     
     
         5 . The method of  claim 4  wherein said cellulose fibers comprise wood pulp. 
     
     
         6 . The method of  claim 5  wherein said wood pulp comprises mercerized or crosslinked pulp. 
     
     
         7 . The method of  claim 2  wherein said layer of unbonded fibers comprises a layer of long fibers positioned between said anchoring layer and said stream. 
     
     
         8 . The method of  claim 7  further comprising a layer of cellulose fibers positioned between said layer of long fibers and said stream. 
     
     
         9 . The method of  claim 8  wherein said cellulose fibers comprise wood pulp. 
     
     
         10 . The method of  claim 1  wherein said method produces a composite material having an LSV of at least about 20 grams.