Method of making a nonwoven web

Abstract

Soft point bonded nonwoven webs, and methods of making the same, are described that utilize a pattern of small, discrete bond points in a sequent pattern that together form macro-elements. The macro-elements are themselves positioned and aligned within a pattern such that mechanical stretching operations on the point bonded nonwoven webs yields soft and bulky fabrics but with reduced incidence of tearing or rupturing of the individual bond points.

What is claimed is: 
     
         1 . A fabric comprising:
 a nonwoven web of thermoplastic polymer fibers;   a pattern of discrete individual bond points having a maximum dimension less than about 1.25 the bond points are arranged in a sequent pattern with an edge-to-edge spacing of less than 0.8 mm and form individual macro-elements;   the macro-elements extend substantially in the machine-direction and have a machine-direction length between about 5 mm and about 25 mm;   adjacent the macro-elements are unbonded pockets having an area between about 20 and about 50 mm 2 ; and   wherein the nonwoven web has a total bond area of between about 5 and about 20% and wherein some but less than 2% of the individual bond points are ruptured from the nonwoven web being stretched in both cross-direction and the machine direction.   
     
     
         2 . The fabric of  claim 1 , wherein the macro-elements are positioned in a plurality of rows extending substantially in the cross direction. 
     
     
         3 . The fabric of  claim 2 , wherein the rows extend +/−15 degrees relative to the cross-direction. 
     
     
         4 . The fabric of  claim 2 , wherein the macro-elements partially overlie, in the machine direction, a macro-element in an adjacent row. 
     
     
         5 . The fabric of  claim 1 , wherein the spacing between individual bond points forming the macro-elements is between 0.03 and about 0.8 mm. 
     
     
         6 . The fabric of  claim 1 , wherein the macro-elements extends +/−20 degrees relative to the machine direction. 
     
     
         7 . The fabric of  claim 1 , wherein some but less than 0.5% of the individual bond points are ruptured.