The invention relates to a patterned spunbonded nonwoven fabric sheet comprising a plurality of spunbonded crimped fibers bonded together at a plurality of bonding points, wherein all fibers of the patterned spunbonded nonwoven fabric sheet are spunbonded crimped fibers and wherein the configuration of the fibers within the sheet is inhomogeneous and varies according to a preferably regular pattern. The invention further relates to a method for forming such patterned spunbonded nonwoven fabric sheet from a flat spunbonded nonwoven fabric sheet starting material. Still further, the invention relates to such flat spunbonded nonwoven fabric sheet starting material.

A method of manufacturing a non-woven fabric includes the steps of: (a.) providing a substrate, wherein the substrate is air permeable in at least a portion of its surface; (b.) providing a fiber transfer device adapted to transfer fibers onto the substrate; (c.) transferring a first plurality of fibers onto the substrate; and (d.) applying a pressure differential to the air permeable portion of the substrate, wherein the strength of the pressure differential is varied across the surface of the substrate.

A method of manufacturing a non-woven fabric includes the steps of: (a.) providing a substrate, wherein the substrate is air permeable in at least a portion of its surface; (b.) providing a fiber transfer device adapted to transfer fibers onto the substrate; (c.) transferring a first plurality of fibers onto the substrate; and (d.) applying a pressure differential to the air permeable portion of the substrate, wherein the strength of the pressure differential is varied across the surface of the substrate.

A spunbond nonwoven fabric. The fabric has a first surface and a second surface and a visually discernible of three-dimensional features on one of the first and second surface, each of the three-dimensional features defining a microzone. Each microzone has a first region and a second region, the first and second regions having a difference in values for an intensive property. Fibers of the spunbond nonwoven fabric are thermally bonded at the second regions. The second regions are fluid permeable. The fibers of the spunbond nonwoven fabric are thermally bonded with point bonds within an area selected from the first regions, the second regions, or a combination thereof

A spunbond nonwoven fabric. The fabric has a first surface and a second surface and a visually discernible of three-dimensional features on one of the first and second surface, each of the three-dimensional features defining a microzone. Each microzone has a first region and a second region, the first and second regions having a difference in values for an intensive property. Fibers of the spunbond nonwoven fabric are thermally bonded at the second regions. The second regions are fluid permeable. The fibers of the spunbond nonwoven fabric are thermally bonded with point bonds within an area selected from the first regions, the second regions, or a combination thereof

A high loft, nonwoven web is disclosed having a three dimensional structure with fibers oriented in the x, y and z directions. The web has a fiber size distribution of from 0 m to about 15 m with at least about 25% of the fibers being above 4 m. The web has a thickness of less than about 250 millimeters and a basis weight ranging from about 20 g/m2 to about 3,000 g/m2. The web also has a vertical cross-section, when taken parallel to a machine direction, exhibiting a plurality of snugly stacked, approximately V, U or C-shaped structures, with each V, U or C-shaped structure having an apex facing in the machine direction. The web further has a recovery value ranging from about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes.

A high loft, nonwoven web is disclosed having a three dimensional structure with fibers oriented in the x, y and z directions. The web has a fiber size distribution of from 0 m to about 15 m with at least about 25% of the fibers being above 4 m. The web has a thickness of less than about 250 millimeters and a basis weight ranging from about 20 g/m2 to about 3,000 g/m2. The web also has a vertical cross-section, when taken parallel to a machine direction, exhibiting a plurality of snugly stacked, approximately V, U or C-shaped structures, with each V, U or C-shaped structure having an apex facing in the machine direction. The web further has a recovery value ranging from about 20% to about 99% after being compressed under a pressure of 0.25 psi for a time period of 30 minutes.

A three-dimensional net-like structure is provided that has a soft cushioning property and less variations of hardness and is less expensive.

The three-dimensional net-like structure is made from a thermoplastic resin including a mixture of a polypropylene copolymer (a) and a polypropylene copolymer (b) and has a spring structure formed by bonding continuous filaments partly in random in loops. The polypropylene copolymer (a) has a flexural modulus that is different from a flexural modulus of the polypropylene copolymer (b).

A three-dimensional net-like structure is provided that has a soft cushioning property and less variations of hardness and is less expensive.

The three-dimensional net-like structure is made from a thermoplastic resin including a mixture of a polypropylene copolymer (a) and a polypropylene copolymer (b) and has a spring structure formed by bonding continuous filaments partly in random in loops. The polypropylene copolymer (a) has a flexural modulus that is different from a flexural modulus of the polypropylene copolymer (b).

A spunbond nonwoven fabric. The fabric has a first surface and a second surface and at least a first and second visually discernible zone on at least one of the first and second surface, each of the first and second zones having a pattern of three-dimensional features, each of the three-dimensional features defining a microzone. Each microzone has a first region and a second region, the first and second regions having a difference in values for an intensive property, and wherein the difference in values for an intensive property for at least one of the microzones in the first zone is different from the difference in values for the intensive property for at least one of the microzones in the second zone.