A technology provides a full-surface, bonded, nonwoven fabric with a tensile strength suitable for packaging, bubble packs, and other applications requiring tear resistance. Fullwidth bonding, compared to the more common patterned point bonding, produces the high-strength fabric. The thin, low-cost material can be easily manufactured in smooth calendaring plants. Low voids reinforce the fabric.
The nonwoven fabrics include melt-spun, multiple-component fibers. The fibers can be selected from multiple-component staple fibers and/or multiple-component continuous fibers. First and second polymeric components are arranged in distinct zones across the cross-section of the multiple-component fibers. The technology also includes a process for preparing the thermally bonded, multiple-component, nonwoven fabric.
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