Importance

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Abstract

A nonwoven composite web consists of 15 to 50 wt. % of first polyester fibers having a length of 5 mm to 3/4 inch and a denier of 0.3 to 3, 5 to 50 wt. % of second polyester fibers having a length of 5 mm to 1-1/2 inches and a denier of 3 to 15, and 10 to 40 wt. % of binder fibers comprising thermoplastic binder material having a melting temperature which is less than the first and second melting temperatures respectively. The first and second polyester fibers are bonded to each other at least in part by solidification of the thermoplastic binder material after subjecting the web to temperatures in excess of the melting temperature of the binder material but not in excess of the melting temperature of either the first or second polyester fibers. In particular, the web is thermally bonded by calendaring at a temperature of in the range of 360.degree. to 410.degree. F. and at a pressure in the range of 40 to 70 psi. Preferably the binder fibers comprise bicomponent fibers having a co-polyester sheath and a polyester core.

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First Claim