Nonwoven fabric and its use, nonwoven article, composite sheet material, absorbent article, bonding unit, system for preparing a nonwoven fabric, method of preparing a nonwoven fabric

Description

Nonwoven fabric and its use, nonwoven article, composite sheet material, absorbent article, bonding unit, system for preparing a nonwoven fabric, method of preparing a nonwoven fabric CROSS-REFERENCE FOR RELATED APPLICATION

[0001] This application claims the benefit of U.S. Application No. 63 / 454,941, filed March 27, 2023, the contents of which are incorporated herein by reference in their entirety. FIELD

[0002] The invention now disclosed relates generally to nonwoven fabrics and, more particularly, to bonded nonwoven fabrics that exhibit improvements in abrasion resistance and softness. STATE OF THE ART

[0003] Nonwoven fabrics are used in a variety of applications, such as apparel, disposable medical products, and absorbent items like diapers and personal hygiene products, among others. New products developed for these applications have stringent performance requirements, including comfort, body conformability, freedom of movement, good softness and drape, adequate tensile strength and durability, as well as resistance to surface abrasion, pilling, or fraying. Consequently, the nonwoven fabrics used in these types of products must be designed to meet these performance requirements.

[0004] Despite significant efforts in the development of nonwoven fabrics, there is still a need for products that Petition 870250088344, dated 09 / 29 / 2025, page 21 / 234 2 / 165 offer improvements in abrasion resistance and mechanical properties without sacrificing other beneficial properties, such as softness. SUMMARY

[0005] One or more embodiments of the invention may provide a nonwoven fabric with desirable properties with respect to abrasion resistance and softness, while maintaining good mechanical properties such as tensile strength and elongation.

[0006] Certain embodiments refer to a nonwoven fabric comprising a plurality of fibers bonded together with a bonding pattern on its surface to form a coherent weave in which the nonwoven fabric has a vertical axis extending in the machine direction and a horizontal axis extending in the transverse direction. The bonding pattern comprises a plurality of spaced pairs of matrices extending in the machine, transverse and diagonal directions of the nonwoven fabric, wherein each set comprises a plurality of spaced bonding points with an oblong shape, and wherein the nonwoven fabric has a bonded percentage surface area of ​​less than about 12% and an average bonding point compaction value greater than 3.5 mm-1, such as from about 6.5 to 8.0 mm-1.

[0007] In certain embodiments of nonwoven fabric, the bonding points have an average surface area of ​​about 0.15 to 0.25 mm2.

[0008] In certain embodiments of nonwoven fabric, the nonwoven fabric has a bonding point density of about 50 to 60 individual bonding points per square centimeter. Petition 870250088344, dated 09 / 29 / 2025, page 22 / 234 3 / 165

[0009] In certain embodiments of nonwoven fabric, the nonwoven fabric has a Martindale abrasion score of about 1.0 to 1.5, a cross-direction Handle-o-Meter of about 6.6 to 7.2 grams, a machine-direction Handle-o-Meter of about 3.5 to 3.95 grams, and an average abrasion resistance, as determined by the weight of material removed, of 3.2 to 5.5 grams.

[0010] In certain embodiments of nonwoven fabric, the percentage of bonded surface area of ​​the nonwoven fabric is about 9.8 to 10%, the average surface area of ​​the bonding point is about 0.16 to 0.2 mm2, the average compaction value at the bonding point is about 6.75 to 7.25 mm-1, and the density of the bonding point of the nonwoven fabric is about 52 to 58 individual bonding points per square centimeter.

[0011] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits a Martindale abrasion score of 1 to 2, a Handle-o-Meter in the transverse direction of about 6.7 to 7.0 grams, a Handle-O-Meter in the machine direction of about 3.6 to 3.9 grams, and an average abrasion resistance, as determined by the weight of the material removed, of 3.4 to 3.6 grams.

[0012] In certain embodiments of nonwoven fabric, the bonding pattern comprises alternating first and second matrices of individual bonding points extending in the transverse direction of the nonwoven fabric, wherein the individual bonding points of the first matrix and the second matrix each have a length and a width, and wherein the lengths of the individual bonding points of the first matrix are aligned substantially in the same direction and at an angle that is about 43 to 47 degrees with respect to the horizontal axis of the nonwoven fabric. Petition 870250088344, dated 09 / 29 / 2025, page 23 / 234 4 / 165 fabric, and the lengths of the individual gluing points of the second die are rotated approximately 88 to 92 degrees relative to the alignment of the lengths of the individual gluing points of the first die, and the individual gluing points of the second die are offset in the transverse direction of the adjacent individual gluing points of the first die.

[0013] In certain embodiments of nonwoven fabric, the number of individual bonding points per cm2 is about 45 to 60, and in particular, about 50 to 58, and more particularly, about 54 to 56.

[0014] In certain embodiments of nonwoven fabric, the percentage of bonded area of ​​the nonwoven fabric is about 9 to 10.5% and, in particular, about 9.8 to 10.2% and, more particularly, about 9.9 to 10%.

[0015] In certain embodiments of nonwoven fabric, the distance between adjacent bonds in the transverse direction is about 1.4 to 1.6 mm and, in particular, about 1.45 to 1.55 mm and, more particularly, about 1.48 to 1.52 mm.

[0016] In certain embodiments of nonwoven fabric, the distance between adjacent bonding points on the same matrix in a diagonal direction of the nonwoven fabric is about 0.7 to 0.95 mm and, in particular, about 0.75 to 0.90 and, more particularly, about 0.80 to 0.85.

[0017] In certain nonwoven fabric embodiments, the bonding points have an oval-elliptical, rectangular, rod-shaped form, or a combination thereof. Petition 870250088344, dated 09 / 29 / 2025, p. 24 / 234 5 / 165

[0018] In certain embodiments of nonwoven fabric, the bonding pattern further defines a plurality of alternating and repeated third and fourth matrices of individual bonding points that extend in the direction of the nonwoven fabric machine, and in which the individual bonding points of the third matrix are displaced in the direction of the machine from the adjacent individual bonding points of the fourth matrix.

[0019] In certain embodiments of nonwoven fabric, the bonding pattern further defines a plurality of alternating fifth and sixth matrices of individual bonding points that extend in a diagonal direction relative to the direction of the nonwoven fabric machine.

[0020] In certain embodiments of nonwoven fabric, adjacent bonding points on each of the fifth and sixth dies are directionally aligned at an angle that is about 88 to 92 degrees relative to a directional alignment of an adjacent individual bonding point on the same die.

[0021] In certain embodiments of nonwoven fabric, three adjacent matrices of individual collages further define a plurality of collage patterns in both the machine and cross directions, having a quincunx-type collage pattern in which four individual collage points that define the corners of the quincunx-type collage pattern share a directional orientation that is substantially the same with respect to the cross or machine directions of the nonwoven fabric, and in which an individual collage point that defines a central point of the quincunx-type collage pattern has a directional orientation that is rotated by about 88 to 92 degrees with respect to the directional orientation of the collage points. Petition 870250088344, dated 09 / 29 / 2025, page 25 / 234 6 / 165 individual pieces that define the corners of the quincunx-type collage pattern.

[0022] In certain embodiments of nonwoven fabric, an angle formed by a matrix extending in the diagonal direction and a matrix extending in the transverse direction is about 43 to 47 degrees, and in particular, about 45 degrees.

[0023] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits a Martindale abrasion score of less than 1.5 and, in particular, of 1.2 to 1.5, and more particularly, of about 1.40 to 1.45.

[0024] In certain embodiments of nonwoven fabric, the nonwoven fabric has a base weight of about 20 to 30 g / m2 and exhibits a softness, as demonstrated by a cross-direction gauge, of less than 7.0 grams (g), such as less than 7.9 grams or less than 7.5 grams.

[0025] In certain embodiments of nonwoven fabric, the nonwoven fabric has a base weight of about 20 to 30 g / m2 and exhibits a softness, as demonstrated by a machine direction gauge, of less than 3.9 grams (g), such as less than 3.8 grams or less than 3.78 grams.

[0026] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength, percent elongation, abrasion resistance and softness compared to a similarly prepared nonwoven fabric, except that the similar fabric was joined by stitches with a bonding pattern having a compaction at the bonding point of less than 3.5 mm-1. Petition 870250088344, dated 09 / 29 / 2025, page 26 / 234 7 / 165

[0027] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits a tensile strength that is 10% or more greater compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1, such as an increase in tensile strength that is 10% to 50%, such as 12 to 30%, 12 to 25%, 12 to 24% or 12 to 20% greater than the tensile strength of a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

[0028] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength that is 10% or more compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%,

[0029] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength that is 10% to 30%, as well as 12 to 20%, greater than the tensile strength of a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

[0030] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength in the machine direction that is about 10 to 50% greater compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

[0031] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength in the machine direction of about 10 to 30%, as well as about 12 to 20%, or about 12 to 15% compared to a nonwoven fabric. Petition 870250088344, dated 09 / 29 / 2025, page 27 / 234 8 / 165 similarly prepared fabric having a compaction at the bonding point of less than 3.5 mm-1.

[0032] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength in the transverse direction that is about 10 to 50% greater compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1.

[0033] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength in the transverse direction that is about 10 to 30%, as of about 15 to 25%, about 18 to 24% or about 19 to 21% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1.

[0034] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength in the machine direction that is about 10 to 50% greater compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

[0035] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength in the machine direction that is about 10 to 30%, as well as about 12 to 20%, or about 12 to 15% compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

[0036] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength in the transverse direction that is about 10 to 50% greater compared to a Petition 870250088344, dated 09 / 29 / 2025, page 28 / 234 9 / 165 nonwoven fabric similarly prepared with a bonded surface area greater than 12%.

[0037] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in tensile strength in the transverse direction that is about 10 to 30%, as well as about 15 to 25%, about 18 to 24%, or about 19 to 21% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

[0038] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in percent elongation that is about 4 to 50% compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

[0039] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits a percentage increase in elongation that is about 4 to 25%, as well as about 5 to 20%, or about 5 to 15%, compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

[0040] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in percentage elongation that is about 4 to 50% compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

[0041] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in percentage elongation that is about 4 to 25%, such as about 5 to 20%, or about Petition 870250088344, dated 09 / 29 / 2025, page 29 / 234 10 / 165 at 15%, compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

[0042] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in abrasion resistance, as exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1.

[0043] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in abrasion resistance, as exemplified by a percentage difference in the Martindale Abrasion Index of about 10 to 25%, as of about 12 to 24%, or about 18 to 22%, compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1.

[0044] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in abrasion resistance exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

[0045] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in abrasion resistance, as exemplified by a percentage difference in the Martindale Abrasion Index of about 10 to 25%, as of about 12 to 24%, or about 18 to 22%, compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%. Petition 870250088344, dated 09 / 29 / 2025, page 30 / 234 11 / 165

[0046] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1.

[0047] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 8 to 120%, as well as 9 to 95% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1.

[0048] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

[0049] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 8 to 120%, as well as 9 to 95% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

[0050] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 5 to 20% compared to a nonwoven fabric prepared in a different way. Petition 870250088344, dated 09 / 29 / 2025, page 31 / 234 12 / 165 similar, having a compaction at the bonding point of less than 3.5 mm-1.

[0051] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 6 to 15%, as well as 8 to 10% compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

[0052] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 5 to 20% compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

[0053] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 6 to 15%, such as 8 to 10% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

[0054] In certain embodiments of nonwoven fabric, the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 5 to 20% compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

[0055] In certain embodiments of nonwoven fabric, the nonwoven fabric has a spliced ​​area percentage of about 9.6 to 10.4%, an average surface area of ​​the spliced ​​point. Petition 870250088344, dated 09 / 29 / 2025, page 32 / 234 13 / 165 individual of about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, a bonding point density of about 50 to 60 individual bonding points per square centimeter, a Martindale abrasion score of about 1.0 to 1.5, a cross-direction Handle-o-Meter of about 6.6 to 7.2 grams, a machine-direction Handle-o-Meter of about 3.5 to 3.95 grams, and an average abrasion resistance, as determined by the weight of the material removed, of 3.2 to 5.5 grams.

[0056] In certain embodiments of nonwoven fabric, the nonwoven fabric has a spliced ​​percentage area of ​​about 9.8 to 10%, an average individual spliced ​​point surface area of ​​about 0.15 to 0.2 mm2, an average spliced ​​point compaction value of about 7 to 7.2 mm-1, a spliced ​​point density of about 52 to 58 individual spliced ​​points per square centimeter, a Martindale abrasion score of about 1.42 to 1.45, a cross-direction Handle-o-Meter of about 6.7 to 7.0 grams, a machine-direction Handle-o-Meter of about 3.6 to 3.9 grams, and an average abrasion resistance, as determined by the weight of the material removed, of 3.4 to 3.6 grams.

[0057] In certain embodiments of nonwoven fabric, the nonwoven fabric has a bonded percentage area of ​​about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and an average increase in tensile strengths that are 10% greater, such as about 10 to 50%, about 12 to 24%, or about 12 to 22%, compared to a similarly prepared nonwoven fabric. Petition 870250088344, dated 09 / 29 / 2025, page 33 / 234 14 / 165 having a compaction at the bonding point of less than 3.5 mm-1

[0058] In certain embodiments of nonwoven fabric, the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and an average increase in tensile strengths that are 10% greater, such as about 10 to 50%, about 12 to 24%, or about 12 to 22%, compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%.

[0059] In certain embodiments of nonwoven fabric, the nonwoven fabric has a spliced ​​percentage area of ​​about 9.6 to 10.2%, an average individual spliced ​​surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the splicing point of about 6.75 to 7.25 mm-1, and an average increase in percent elongation that is about 4 to 50%, such as about 4 to 20%, about 4 to 15%, or about 4 to 14%, compared with a similarly prepared nonwoven fabric having a compaction at the splicing point of less than 3.5 mm-1.

[0060] In certain embodiments of nonwoven fabric, the nonwoven fabric has a spliced ​​percentage area of ​​about 9.6 to 10.2%, an average individual spliced ​​surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the splicing point of about 6.5 to 7.5 mm-1 and an average increase in percentage elongation that is about 4 to 50%, as well as about 4 to 20%, about 4 to 15% or about 4 to 14%, in Petition 870250088344, dated 09 / 29 / 2025, page 34 / 234 15 / 165 comparison to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%.

[0061] In certain embodiments of nonwoven fabric, the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and one or more of the following properties:

[0062] an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared with a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1;

[0063] an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, as of about 8 to 120% or 9 to 95% compared with a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1; and

[0064] improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of about 5 to 20%, as of about 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1.

[0065] In certain embodiments of nonwoven fabric, the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the point Petition 870250088344, dated 09 / 29 / 2025, page 35 / 234 16 / 165 bonding thickness of approximately 6.75 to 7.25 mm-1, and one or more of the following properties: An improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%; an average percentage reduction in the weight of material removed during the abrasion test (according to NWSP Test Method 20.5) of 5 to 150%, such as approximately 8 to 120% or 9 to 95% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%; and improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of approximately 5 to 20%, such as approximately 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

[0066] In certain embodiments of nonwoven fabric, the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and one or more of the following properties: an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1; Petition 870250088344, dated 09 / 29 / 2025, page 36 / 234 17 / 165 an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, such as approximately 8 to 120% or 9 to 95% compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1; Improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of approximately 5 to 20%, as well as approximately 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1; an increase in tensile strengths in the machine direction (MD) that are about 10 to 50% higher, as well as about 10 to 30%, as well as about 12 to 20%, or about 12 to 15% higher, compared with a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1; an increase in tensile strengths in the transverse direction (CD) that are about 10 to 50% greater, such as about 10 to 30%, such as about 15 to 25%, about 18 to 24%, or about 19 to 21%, compared with a similarly prepared nonwoven fabric with a bonding point compaction of less than 3.5 mm-1; and an increase in percent elongation that is about 4 to 50%, such as about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric having a bonding point compaction of less than 3.5 mm-1.

[0067] In certain embodiments of nonwoven fabric, the nonwoven fabric has a spliced ​​area percentage of about 9.6 to Petition 870250088344, dated 09 / 29 / 2025, page 37 / 234 18 / 165 10.2%, an average individual bonding surface area of ​​approximately 0.15 to 0.25 mm2, an average compaction value at the bonding point of approximately 6.75 to 7.25 mm-1, and one or more of the following properties:

[0068] an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%;

[0069] an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, such as approximately 8 to 120% or 9 to 95% compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%;

[0070] an improvement in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of about 5 to 20%, such as about 6 to 15% or 8 to 10%, compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%;

[0071] an increase in tensile strengths in the machine direction (MD) that are about 10 to 50% higher, such as about 10 to 30%, such as about 12 to 20%, or about 12 to 15% higher, compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%;

[0072] an increase in tensile strengths in the transverse direction (CD) that are about 10 to 50% greater, as of Petition 870250088344, dated 09 / 29 / 2025, p. 38 / 234 19 / 165 approximately 10 to 30%, such as approximately 15 to 25%, approximately 18 to 24% or approximately 19 to 21%, compared with a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%; and

[0073] an increase in percentage elongation which is about 4 to 50%, such as about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%.

[0074] In certain embodiments of nonwoven fabric, the nonwoven fabric comprises a spunbond layer.

[0075] In certain embodiments of nonwoven fabric, the nonwoven fabric comprises a first spunbond layer with low or non-existent crimp filaments and a second layer comprising crimp filaments.

[0076] In certain embodiments of nonwoven fabric, the nonwoven fabric comprises at least two layers, wherein one of the layers is selected from the group of blow-melted material layer; carded fabric layer, spunbond layer, resin-bonded layer, airlaid fabric layer and a spunlace layer.

[0077] In certain embodiments of nonwoven fabric, the nonwoven fabric is in an absorbent article.

[0078] In certain embodiments, the embodiments of the invention provide an absorbent article comprising nonwoven fabric. In certain embodiments, the invention relates to the use of nonwoven fabric, wherein the nonwoven fabric is in an absorbent article. Petition 870250088344, dated 09 / 29 / 2025, page 39 / 234 20 / 165

[0079] In certain embodiments, embodiments of the invention provide a nonwoven article comprising nonwoven fabric. In certain embodiments of the nonwoven fabric, the nonwoven is a component of a sheet composite material. In certain embodiments, embodiments of the invention provide a sheet composite material comprising nonwoven fabric. In some embodiments, the nonwoven fabric comprises a sheet composite material. In some embodiments, a sheet material comprises a layer of blown-melted material comprising nonwoven fabric according to an embodiment of the invention. In certain embodiments, the layer of blown-melted material is sandwiched between two spunbond layers, wherein at least one of the spunbond layers conforms to the nonwoven fabric layer of the present disclosure.

[0080] Additional aspects are directed to a calender gluing unit that has an engraved pattern roll configured to print a pattern according to one or more embodiments of the disclosure.

[0081] In certain embodiments, a calender gluing unit is provided for spot gluing of a sheet material, wherein the calender gluing unit comprises a pair of cooperating cylindrical rolls, in which at least one of the rolls includes an engraved pattern, the engraved pattern comprising a plurality of individual and spaced gluing points extending radially outward from a roll surface, the plurality of gluing points defining a pattern comprising a plurality of spaced matrices extending in the transverse and radial direction of the roll, and are configured and arranged for thermal spot gluing. Petition 870250088344, dated 09 / 29 / 2025, page 40 / 234 21 / 165 nonwoven fabric in which a percentage of the bonded surface area of ​​the nonwoven fabric is less than about 12% and an average compaction value at the bonding point of the nonwoven fabric is about 6.5 to 8 mm-1.

[0082] In certain embodiments, the engraved pattern further comprises a plurality of spaced pairs of matrices that extend circumferentially around the roll in a spiral-like shape.

[0083] In certain embodiments, the bonding points have a continuous side wall and a raised surface, the raised surfaces have an average surface area of ​​about 0.15 to 0.25 mm2.

[0084] In certain embodiments, the number of glue points is about 50 to 60 individual glue points per square centimeter.

[0085] In certain embodiments, the average length of the glue points is about 0.74 to 0.78 mm, and the average width of the glue points is about 0.24 to 0.36 mm.

[0086] In a further aspect of the disclosure, the embodiments are directed to a system for preparing a bonded nonwoven fabric.

[0087] In certain embodiments, a system for preparing a nonwoven fabric is provided, in which the system includes:

[0088] a first source of polymer.

[0089] a rotating beam in communication with the first polymer source, the rotating beam configured and arranged to produce a plurality of polymer fibers; Petition 870250088344, dated 09 / 29 / 2025, page 41 / 234 22 / 165

[0090] a collection surface arranged below the spinning bundle to deposit the plurality of polymer fibers onto it to form a fiber web; and

[0091] a thermal bonding unit disposed downstream of the yarn bundle, the thermal bonding unit comprising a pair of cooperating cylindrical rolls in which at least one of the rolls includes an engraved pattern thereon, the engraved pattern comprising a plurality of individual and spaced bonding points extending radially outward from a roll surface, the plurality of bonding points defining a pattern comprising a plurality of spaced matrices extending in the transverse and radial direction of the roll, and are configured and arranged to thermally bond by points the fiber weft to form a nonwoven fabric in which a percentage of bonded surface area of ​​the nonwoven fabric is less than about 12% and an average compaction value at the bonding point of the nonwoven fabric is about 6.5 to 8 mm-1.

[0092] Other aspects of the invention are also directed to methods of preparing a nonwoven fabric, including the step of passing a nonwoven fabric through a heated calender roll, wherein the calender roll comprises a pair of cooperating cylindrical rolls, wherein at least one of the rolls includes an engraved pattern, the engraved pattern comprising a plurality of individual and spaced bonding points extending radially outward from a surface of the roll, the plurality of bonding points defining a pattern comprising a plurality of spaced matrices extending in the transverse and radial direction of the roll, and are configured and arranged to thermally bond the fiber fabric by points to form Petition 870250088344, dated 09 / 29 / 2025, p. 42 / 234 23 / 165 a nonwoven fabric in which a percentage of the bonded surface area of ​​the nonwoven fabric is less than about 12% and an average compaction value at the bonding point of the nonwoven fabric is about 6.5 to 8 mm-1.

[0093] In certain aspects, the embodiments of the invention are directed to a nonwoven fabric comprising a plurality of fibers bonded with a bonding pattern on a surface to form a coherent weave, the nonwoven fabric having a vertical axis extending in a machine direction and a horizontal axis extending in a transverse direction, the bonding pattern comprising a plurality of spaced pairs of matrices extending in the machine, transverse and diagonal directions of the nonwoven fabric, wherein each matrix comprises a plurality of spaced bonding points having an oblong shape, and wherein the nonwoven fabric has a percentage bonded surface area of ​​less than about 14%, a collective average bonding distance of about 1.5 to 1.7 mm and an average compaction value at the bonding point of about 3.0 to 5.0 mm-1.

[0094] Additional aspects of the invention are directed to a method, system and associated apparatus for preparing a nonwoven fabric in which the nonwoven fabric has a spliced ​​surface area percentage of less than about 14%, a collective average splicing distance of about 1.5 to 1.7 mm and an average compaction value at the splicing point of about 3.0 to 5.0 mm-1.

[0095] In certain embodiments, the fibers of nonwoven fabrics comprise a mixture of a polypropylene resin and less than 20% by weight of a polypropylene copolymer. Petition 870250088344, dated 09 / 29 / 2025, page 43 / 234 24 / 165 BRIEF DESCRIPTION OF THE VARIOUS DRAWINGS

[0096] Having thus described the invention in general terms, we will now refer to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0097] FIG. 1 illustrates a bonded nonwoven fabric containing a bonding pattern that conforms to at least one embodiment of the invention;

[0098] FIGS. 2A and 2B illustrate a gluing point that is in accordance with one or more embodiments of the present invention;

[0099] FIGS. 3A-3C illustrate various bonding matrices of a bonding pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention;

[00100] FIG. 4 illustrates a bonding pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention;

[00101] FIGS. 5A and 5B illustrate a secondary bonding pattern formed on the surface of a nonwoven fabric according to at least one embodiment of the present invention;

[00102] FIG. 6 illustrates a bonding pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention;

[00103] FIGS. 7A-7D illustrate an additional bonding pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention;

[00104] FIGS. 8A-8C illustrate an additional bonding pattern on the surface of a nonwoven fabric according to at least one embodiment of the present invention; Petition 870250088344, dated 09 / 29 / 2025, page 44 / 234 25 / 165

[00105] FIG. 9A illustrates a system for preparing a bonded nonwoven fabric according to at least one embodiment of the present invention;

[00106] FIG. 9B illustrates a system for preparing a bonded nonwoven fabric according to at least one embodiment of the present invention;

[00107] FIG. 10 illustrates a system for preparing a bonded nonwoven fabric according to at least one embodiment of the present invention;

[00108] FIG. 11 illustrates a calender gluing unit according to at least one embodiment of the present invention;

[00109] FIG. 12 illustrates a standardized roll of the calender gluing unit of FIG. 11;

[00110] FIGS. 13A-13C illustrate various views of a gluing point according to at least one embodiment of the present invention; and

[00111] FIGS. 14A-14B illustrate multilayer nonwoven fabrics according to at least one embodiment of the present invention. DETAILED DESCRIPTION

[00112] The invention will be described in more detail below, with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. In fact, this invention can be embodied in many different forms and should not be interpreted as limited to the embodiments set forth herein; rather, these embodiments are provided. Petition 870250088344, dated 09 / 29 / 2025, p. 45 / 234 26 / 165 so that this disclosure meets applicable legal requirements. Equal numbers refer to equal elements throughout the document. As used in the specification and accompanying claims, the singular forms a, an, or include plural referents, unless the context clearly indicates otherwise.

[00113] The terms first, second and similar, primary, exemplar, secondary and similar do not denote any order, quantity or importance, but rather are used to distinguish one element from another. Furthermore, the terms a, an and the do not denote a limitation of quantity, but rather the presence of at least one of the referenced items.

[00114] Each embodiment disclosed herein is considered applicable to each of the other embodiments disclosed herein. All combinations and subcombinations of the various elements described herein are within the scope of the invention.

[00115] It is understood that when a range of parameters is provided, all whole numbers within that range, and their tenths and hundredths, are also provided by the invention. For example, 5-10% includes 5%, 6%, 7%, 8%, 9% and 10%; 5.0%, 5.1%, 5.2%, 9.8%, 9.9% and 10.0%; and 5.00%, 5.01%, 5.02%, 9.98%, 9.99% and 10.00%.

[00116] As used herein, the terms about, approximately and substantially in the context of a numerical value or range mean ±10% of the stated or claimed numerical value or range and, in particular, cover values ​​within a standard margin of measurement error (by Petition 870250088344, dated 09 / 29 / 2025, page 46 / 234 27 / 165 example, SEM) of a declared value or variations of ±0.5%, 1%, 5% or 10% of a specified value.

[00117] For the purposes of this application, the following terms shall have the following meanings:

[00118] The term fiber can refer to a fiber of finite length or a filament of infinite length.

[00119] As used herein, the term single-component refers to fibers formed from a single polymer or a single mixture of polymers. Obviously, this does not exclude fibers to which additives have been added to impart color, antistatic properties, lubrication, hydrophilicity, liquid repellency, etc.

[00120] As used herein, the term multicomponent refers to fibers formed from at least two polymers (e.g., bicomponent fibers) that are extruded by separate extruders. At least two polymers may independently be the same or different from each other, or be a mixture of polymers. The polymers are arranged in distinct zones, positioned substantially consistently along the cross-section of the fibers. The components may be arranged in any desired configuration, such as sheath-core, side-by-side, pie, island-in-sea, and so forth. Several methods for forming multicomponent fibers are described in U.S. Patent No. 4,789,592 to Taniguchi et al. and U.S. Patent No. 5,336,552 to Strack et al. , in US Patent No. 5,108,820 to Kaneko et al., in US Patent No. 4,795,668 to Kruege et al., in US Patent No. 5,108,820 to Kaneko et al. , in US Patent No. 4,795,668 to Kruege et al., in US Patent No. 5,108,820 to Kruege Petition 870250088344, dated 09 / 29 / 2025, page 47 / 234 28 / 165 et al., in U.S. Patent No. 5,108,820 by Kaneko et al., U.S. Patent No. 5,382,400 by Pike et al., U.S. Patent No. 5,336,552 by Strack et al., and U.S. Patent No. 6,200,669 by Marmon et al., which are incorporated herein in full by reference. Multicomponent fibers with various irregular shapes can also be formed, as described in U.S. Patent No. 5,277,976 by Hogle et al., U.S. Patent No. 5,162,074 by Hills, U.S. Patent No. 5,466,410 by Hills, U.S. Patent No. 5,069,970 by Largman et al., and U.S. Patent No. 5,057,368 by Largman et al., which are incorporated herein in full by reference.

[00121] As used herein, the terms nonwoven, nonwoven fabric and nonwoven fabric refer to a material structure or weave that has been formed without the use of weaving or knitting processes to produce a structure of individual interwoven fibers or yarns, but not in an identifiable and repetitive manner. Nonwoven fabrics have, in the past, been formed by a variety of conventional processes, such as meltblown blowing processes, spunbond processes and carding processes of chopped fibers.

[00122] As used herein, the term meltblown refers to a process in which fibers are formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, capillaries in a high-speed gas stream (e.g., air) that attenuates the molten thermoplastic material and forms fibers, which can have diameters down to microfibers. Subsequently, the meltblown fibers are carried by the gas stream and deposited onto a collecting surface to form a meltblown fiber weave. Petition 870250088344, dated 09 / 29 / 2025, page 48 / 234 29 / 165 random. This process is disclosed, for example, in US Patent No. 3,849,241 by Buntin et al.

[00123] As used herein, the term machine direction or MD refers to the direction of movement of the nonwoven weft during manufacturing.

[00124] As used herein, the term cross direction or CD refers to a direction that is perpendicular to the machine direction and extends laterally across the width of the nonwoven fabric.

[00125] As used herein, the term diagonal direction or DD refers to a direction that is angled from greater than 0° to less than 90° with respect to one or more of the transverse and machine directions.

[00126] As used herein, and unless otherwise indicated, the term “molecular weight” refers to the weight-average molecular weight (WM) and is expressed in grams / mol. The weight-average molecular weight can be determined using commonly known techniques such as gel permeation chromatography (GPC).

[00127] As used herein, the term spunbond refers to a process involving the extrusion of a molten thermoplastic material as filaments from a plurality of fine, usually circular, capillaries in a spinneret, the filaments then being attenuated and drawn mechanically or pneumatically. The filaments are deposited onto a collecting surface to form a web of substantially continuous, randomly arranged filaments, which can subsequently be joined together to form a coherent nonwoven fabric. The production of spunbond nonwoven fabrics is illustrated in patents such as, for example, Petition 870250088344, dated 09 / 29 / 2025, page 49 / 234 30 / 165 U.S. Patents Nos. 3,338,992; 3,692,613; 3,802,817; 4,405,297 and 5,665,300. In general, these spunbond processes include extruding the filaments from a spinneret, quenching the filaments with an airflow to accelerate the solidification of the molten filaments, attenuating the filaments by applying a stretching stress, either by dragging the filaments pneumatically in an air current or mechanically by winding them onto mechanical stretching rolls, depositing the stretched filaments onto a foramina-collecting surface to form a web, and bonding the web of loose filaments into a nonwoven fabric. Bonding can be any thermal or chemical treatment, with thermal spot bonding being the most common.

[00128] As used herein, thermal spot bonding involves passing a material, such as one or more fiber weaves to be joined, between a heated calender roll and an anvil roll. The calender roll is typically engraved with a pattern so that the fabric is joined at discrete bonding points, rather than being joined across its entire surface.

[00129] As used herein, the term “bond density” refers to the number of individual bond points in a given surface area of ​​the nonwoven fabric.

[00130] As used herein, the term polymer generally includes, but is not limited to, homopolymers, copolymers, such as, for example, block, graft, random and alternating copolymers, terpolymers, etc., and mixtures and modifications thereof. Furthermore, unless specifically limited otherwise, the term polymer shall include all possible geometric configurations of the material, including isotactic, syndiotactic and random symmetries. Petition 870250088344, dated 09 / 29 / 2025, page 50 / 234 31 / 165

[00131] Nonwoven fabric

[00132] In one aspect, the embodiments of this disclosure are directed to thermally bonded nonwoven fabrics exhibiting improved abrasion resistance and softness. Generally, improvements in the surface abrasion resistance of a nonwoven fabric can be achieved by increasing the percentage of bonded area of ​​the nonwoven fabric. That is, the greater the percentage of fiber area on the fabric surface subjected to thermal bonding, the greater the abrasion resistance of the fabric, due to the greater number of fibers bonded to adjacent fibers. However, such improvements in abrasion resistance usually result in a decrease in the softness of the bonded nonwoven fabric. Consequently, there is generally a recognized trade-off between improvements in abrasion resistance and improvements in the softness of the bonded nonwoven fabric.

[00133] Advantageously and surprisingly, the inventors of the present invention have discovered that improvements in both abrasion resistance and softness can be obtained with nonwoven fabrics that are thermally bonded by dots with bonding patterns according to one or more embodiments of the present invention. In particular, it has been found that a nonwoven fabric bonded with a first bonding pattern comprising a plurality of alternating matrices composed of individual bonding dots in both the machine direction and the transverse direction of the nonwoven fabric, wherein the total percentage of the bonded surface area of ​​the nonwoven fabric is less than 12%, the surface area of ​​the individual bonding dots is about 0.10 to 0.60 square millimeters (mm2), the value of Petition 870250088344, dated 09 / 29 / 2025, page 51 / 234 32 / 165 compaction at the bonding point is greater than approximately 3.5 mm2 and the bonding density is approximately 20 to 60 individual bonding points per square centimeter (cm2), providing a nonwoven fabric with enhanced softness and abrasion resistance compared to a similar nonwoven fabric with a higher percentage of bonded surface area.

[00134] With reference to FIG. 1, a bonded nonwoven fabric, according to one or more embodiments of the invention, is shown and broadly designated by the reference character 10. The bonded nonwoven fabric 10 comprises a surface 12 comprising a plurality of individual bonding points 14. The bonding points 14 are spaced apart and are configured and arranged to define a first pattern comprising a plurality of matrices extending in the machine direction (MD), transverse direction (CD) and diagonal direction (DD) of the nonwoven fabric 10. The nonwoven fabric 10 also includes a vertical axis (V) that is substantially aligned with the machine direction of the nonwoven fabric 10, and a horizontal axis (H) that is substantially aligned with the transverse direction of the nonwoven fabric 10.

[00135] In the illustrated embodiment, the individual bonding points 14 define regions of the nonwoven fabric 10 in which the fibers are thermally bonded to form a coherent weave.

[00136] The matrices extending in the transverse direction of the nonwoven fabric 10 comprise a plurality of individual bonding points 14, in which the bonding points 14 are spaced apart and extend laterally in the transverse direction of the nonwoven fabric. Furthermore, the matrices that Petition 870250088344, dated 09 / 29 / 2025, page 52 / 234 33 / 165 extending in the transverse direction comprise a plurality of matrix pairs 20, in which each matrix pair comprises a first matrix A1, which defines a first member of the matrix pair 20, and a second matrix A2, which defines a second member of the matrix pair. The plurality of matrix pairs 20 defines a pattern in which the first matrix A1 and the second matrix A2 alternate in a repetitive pattern in the direction of the nonwoven fabric machine.

[00137] As shown in FIG. 1, the individual gluing points 14 may have a generally oblong shape, such as oval-elliptical, rectangular, rod / bar or similar. In an oblong-shaped gluing point, the gluing point includes a major axis and a minor axis, in which the major axis has a greater length than the minor axis (see, for example, FIGS. 2A and 2B, reference characters 30 and 32, respectively). In certain embodiments, the major axis of the gluing points in the same array (e.g., the first array A1) is oriented / aligned in the same direction, while the major axis of the individual gluing points in the array forming the second member (e.g., the second array A2) of the array pair is oriented / aligned in an alignment that is oriented at about 85° to 95° relative to the major axis alignment of the gluing points 14 in the first array A1.In certain embodiments, the individual gluing points in the first matrix are oriented / aligned in an alignment that is oriented at approximately 86° to 94°, such as approximately 87° to 93°, 88° to 92°, 86° to 94°, 89° to 91°, or 90° relative to the alignment of the main axis of the gluing points 14 in the second matrix A2. Petition 870250088344, dated 09 / 29 / 2025, page 53 / 234 34 / 165

[00138] Similarly, the matrices extending in the direction of the nonwoven fabric machine 10 comprise a plurality of individual bonding points 14, wherein the bonding points 14 are spaced apart and extend longitudinally in the direction of the nonwoven fabric machine. Furthermore, the matrices extending in the direction of the machine comprise a plurality of matrix pairs 22, wherein each matrix pair comprises a third matrix A3, which defines a first member of the matrix pair 22, and a fourth matrix A4, which defines a second member of the matrix pair 22. The plurality of matrix pairs 22 defines a pattern in which the third matrix A3 and the fourth matrix A4 alternate in a repetitive pattern in the transverse direction of the nonwoven fabric.

[00139] With respect to the pair of matrices 22, the principal axis of the gluing points 14 in the same matrix (e.g., third matrix A3) are oriented / aligned in the same direction, while the principal axis of the individual gluing points in the matrix that forms the second member (e.g., fourth matrix A4) of the pair of matrices are oriented / aligned in an alignment that is oriented approximately 85° to 95° relative to the alignment of the principal axis of the gluing points 14 in the third matrix A3. In certain embodiments, the individual gluing points in the third matrix A3 are oriented / aligned in an alignment that is oriented approximately 86° to 94°, such as approximately 87° to 93°, 88° to 92°, 86° to 94°, 89° to 91°, or 90° relative to the alignment of the principal axis of the gluing points 12 in the fourth matrix A4.

[00140] As noted earlier, nonwoven fabric may also include matrices of individual bonding points 14 Petition 870250088344, dated 09 / 29 / 2025, page 54 / 234 35 / 165 that extend in the diagonal direction of the nonwoven fabric. These diagonal matrices are also arranged in a plurality of pairs of 24 matrices that extend across the surface of the nonwoven fabric at an angle aligned diagonally with respect to the vertical and / or horizontal axis of the nonwoven fabric.

[00141] Each pair of 24 matrices comprises a fifth matrix A5 and a sixth matrix A6, wherein the plurality of pairs of 24 matrices defines a pattern in which the fifth matrix A5 and the sixth matrix A6 alternate in a repetitive pattern in the diagonal direction of the nonwoven fabric.

[00142] As shown in FIG. 1, the principal axis of each successive gluing point 14 in the diagonally aligned matrices A5 and A6 is rotated from about 85° to 95° relative to the alignment of the principal axis of the preceding gluing point 14 in the same matrix. In certain embodiments, the principal axis of each successive gluing point 14 in the diagonally oriented matrices A5 and A6 is rotated from about 86° to 94°, such as from about 87° to 93°, 88° to 92°, 86° to 94°, 89° to 91° or 90° relative to the alignment of the principal axis of the preceding gluing point 14 in the same matrix.

[00143] In certain embodiments, the intersection of the matrices extending in the diagonal direction (DD) and the horizontal axis H of the nonwoven fabric 10 defines an angle a1. The angle a1 is typically between about 25° and 55°, and more typically from about 28° to 48°, and even more typically from about 30° to 45°.

[00144] In certain realizations, the angle a1 is greater than approximately 25°, 26°, 27°, 28°, 29°, 30°, 31°, 32°, 33°, 34°, Petition 870250088344, dated 09 / 29 / 2025, p. 55 / 234 36 / 165 or , 36 , 37 , 38 , 39 , 40 , 41 , 42 , 43 , 44 , 45 , 46 , 47 , 48 , 49 , 50 , 51 , 52 , 53 54 or .

[00145] In certain realizations, the angle a1 is less than approximately 55°, 54°, 53°, 52°, 51°, 50°, 49°, 48°, 47°, 46°, 45°, 44°, 43°, 42°, 41°, 40°, 39°, 38°, 37°, 36°, 35°, 34°, 33°, 32°, 31°, 30°, 29°, 28°, 27° and 26°.

[00146] In certain embodiments, the individual oblong-shaped glue points have an average length of about 0.65 mm to 1.25 mm and, in particular, about 0.70 to 1.20 mm and, more particularly, about 1.15 to 0.72 mm and, even more particularly, about 0.74 to 1.10 mm.

[00147] In a preferred embodiment, the individual glued points which have an oblong shape have an average length of about 0.74 to 0.78 mm, with an average length of about 0.76 mm being somewhat more preferred.

[00148] In certain embodiments, the individual gluing points which have an oblong shape have an average width which is about 0.24 mm to 0.60 mm and, in particular, about 0.25 to 0.55 mm and, more particularly, about 0.27 to 0.50 mm and, even more particularly, about 0.28 to 0.48 mm.

[00149] In preferred embodiments, the individual oblong-shaped gluing points have an average width of about 0.24 to 0.36 mm, and in particular, about 0.26 to 0.32 mm, and more particularly, about 0.28 to 0.31 mm. In a slightly more preferred embodiment, the individual gluing points have an average width of about 0.30 mm.

[00150] In certain embodiments, the individual gluing points have a length / width ratio that is about Petition 870250088344, dated 09 / 29 / 2025, p. 56 / 234 37 / 165 from 1.5 to 8 and, in particular, from about 1.75 to 4 and, more particularly, from about 2 to 2.8.

[00151] In certain embodiments, the average distance of the collective bonding point varies from about 1.10 to 2.25 mm. The average distance of the bonding point refers to the proximity of the bonding points in a given bonding pattern with respect to the machine, transverse, and diagonal directions of the nonwoven fabric. The average distance of the bonding point can be calculated from the average of the distances between adjacent bonds in the machine direction, adjacent bonds in the transverse direction, and adjacent bonds in the diagonal direction of the nonwoven fabric. In some embodiments, the average bonding distance varies from about 1.15 to 2.10 mm, and in particular, from about 1.20 to 2.0 mm. Unless otherwise specified, the distance between adjacent bonds is measured at the shortest distance between the two adjacent bonds.

[00152] It was further discovered that a bonded nonwoven fabric comprising a bonding pattern with an average compaction value at the bonding point greater than about 3.5 mm-1 provides improvements in softness and abrasion resistance, as well as improvements in mechanical properties compared to a bonded nonwoven fabric having a higher % bonded area and an average compaction value at the bonding point less than 3.5 mm-1.

[00153] The average compaction value at the bonding point for a given bonding pattern is calculated by dividing the average collective distance from the bonding point by the average surface area of ​​the bonding point for the bonding pattern. Petition 870250088344, dated 09 / 29 / 2025, page 57 / 234 38 / 165

[00154] In certain embodiments, the bonded nonwoven fabric has an average compaction value at the bonding point of approximately 3.5 to 10 mm-1, such as from about 4.5 to 9 mm-1 and from 5 to 7.5 mm-1.

[00155] Referring to FIGS. 2A and 2B, the individual gluing points 14 include a length L1 and a width W1. The length of the gluing point extends in a substantially straight line between the opposite ends of the gluing points and defines a major axis 30 of the gluing point. The width of the gluing point is the measurement between the opposite sides of the gluing point and defines a minor axis 32 of the gluing point. The major axis 30 of an individual gluing point extends through the points furthest from the gluing point, and the minor axis 32 extends through the points closest to the gluing point. Generally, the major and minor axes of an individual gluing point are substantially perpendicular to each other.

[00156] In the illustrated embodiments, the individual gluing points generally have an oval-elliptical shape. It should be recognized that other shapes may be used, such as oblong-shaped gluing points and variations thereof. For example, gluing points may have a rectangular shape, a rod / bar shape, an oval-elliptical shape, and combinations thereof. In certain embodiments, oblong-shaped gluing points may also be used in combination with other gluing point shapes, such as square, diamond, or circular gluing points.

[00157] Example of Implementation A Petition 870250088344, dated 09 / 29 / 2025, p. 58 / 234 39 / 165

[00158] With reference to FIGS. 3A-3C, a preferred embodiment of the bonded nonwoven fabric is shown and generally indicated by the reference character 10a. The nonwoven fabric 10a comprises a plurality of fibers that are joined together by points with a plurality of individual bonding points 14 to form a coherent weave. The nonwoven fabric includes a horizontal axis H that is substantially aligned with the transverse direction CD of the nonwoven fabric and a vertical axis V that is substantially aligned with the machine direction MD of the nonwoven fabric.

[00159] In the embodiment of FIGS. 3A-3C, the overall percentage of bonded surface area of ​​the nonwoven fabric is less than about 10%, the surface area of ​​the individual bonding points is about 0.1 to 0.30 square millimeters (mm2), the compaction value at the bonding point is about 6 to 8 mm-1, and the bonding density is about 45 to 60 individual bonding points per square centimeter (cm2).

[00160] The plurality of individual bonding points 14 defines a first pattern 34 on the surface 12 of the nonwoven fabric 10a. As shown in FIG. 2A, the first pattern 34 comprises a series of alternating first and second matrices A1, A2 of individual bonding points 14 extending in the transverse direction of the nonwoven fabric 10 and arranged in matrix pairs 20. In certain embodiments, the individual bonding points 14 defining the second matrices of the first pattern are offset in the transverse direction relative to the adjacent bonding points of the first matrices. In other words, the adjacent bonding points of the first and second matrices are not aligned with each other in the direction of Petition 870250088344, dated 09 / 29 / 2025, page 59 / 234 40 / 165 nonwoven fabric machine. This configuration and arrangement can be seen in FIG. 3A, where the vertical axis V extends only through the gluing points of the second die and not through the gluing points of the first die. In the embodiment shown in FIG. 3A, the first and second dies A1, A2 are substantially aligned with the transverse direction of the nonwoven fabric 10a.

[00161] In a preferred embodiment, the individual gluing points of the first dies do not overlap in the machine direction with the individual gluing points of the second dies. However, it should be recognized that, in some embodiments, the individual gluing points of the first and second dies may overlap in the machine direction with gluing points in an adjacent set.

[00162] In certain embodiments, the individual gluing points have an average length of about 0.65 mm to 0.85 mm, and in particular, about 0.70 to 0.80 mm, and more particularly, about 0.74 to 0.78 mm. In a preferred embodiment, the individual gluing points have an average length of about 0.76 mm.

[00163] In certain embodiments, the individual gluing points have an average width of about 0.24 to 0.36 mm, and in particular, about 0.26 to 0.32 mm, and more particularly, about 0.28 to 0.31 mm. In a preferred embodiment, the individual gluing points have an average width of about 0.30 mm.

[00164] In certain embodiments, the individual gluing points have a length / width ratio that is about Petition 870250088344, dated 09 / 29 / 2025, p. 60 / 234 41 / 165 from 2 to 3, and in particular, from about 2.15 to 2.85, and more particularly, from about 2.45 to 2.65.

[00165] Referring again to FIG. 3A, the lengths (i.e., principal axes) of the individual bonding points of the first die are typically aligned at a diagonal angle relative to the machine direction of the nonwoven fabric. That is, the intersection of the principal axis 30 of the individual bonding points of the first die with the horizontal axis H of the nonwoven fabric defines an angle greater than 0° and less than 90°. In certain embodiments, the angle formed by the intersection of the horizontal axis H with the principal axis of the individual bonding point of the first die A1 is about 43° to 47° degrees, and in particular, about 44° to 46°, and more particularly, about 45°.

[00166] In certain embodiments, the individual gluing points of the first matrix have their lengths (e.g., principal axes) aligned substantially in the same direction as the others.

[00167] The lengths of the individual bonding points of the second die are typically aligned at a diagonal angle to the direction of the nonwoven fabric machine. That is, the intersection of the principal axis 30 of the individual bonding points of the second die with the horizontal axis H of the nonwoven fabric defines an angle greater than 0° and less than 90°. In certain embodiments, the angle formed by the intersection of the horizontal axis H with the principal axis of the individual bonding point of the second die A2 is about 43° to 47° degrees, and in particular, about 44° to 46°, and more particularly, about 45°. Petition 870250088344, dated 09 / 29 / 2025, page 61 / 234 42 / 165

[00168] In certain embodiments, the lengths (e.g., major axis) of the individual gluing points of the second matrix are typically rotated from about 88° to 92°, as from about 89° to 91°, and more particularly, about 90° relative to the alignment of the lengths (e.g., major axis) of the individual gluing points of the first matrix.

[00169] In a preferred embodiment, the intersection of a line segment extending along the major axis of the individual gluing points of the first matrix and a line segment extending along the major axis of the individual gluing points of the second matrix defines an angle that is approximately 90°.

[00170] In certain embodiments, the individual gluing points of the second matrix have their lengths (e.g., principal axes) aligned substantially in the same direction as each other.

[00171] With reference to FIG. 3B, the first pattern 30 of bonding points further comprises a series of alternating third and fourth matrices A3, A4 of individual bonding points 14 extending in the direction of the nonwoven fabric machine 10, and arranged in pairs of matrices 22. In the embodiment shown in FIG. 3B, the third and fourth matrices A3, A4 are substantially aligned with the direction of the nonwoven fabric machine 10a. Similarly to the first and second matrices A1, A2, the individual bonding points 14 defining the fourth matrices of the first pattern are offset in the direction of the machine relative to the adjacent bonding points of the third matrices. In other words, the adjacent bonding points of Petition 870250088344, dated 09 / 29 / 2025, p. 62 / 234 43 / 165 The third and fourth dies are not aligned with each other in the direction of the nonwoven fabric machine.

[00172] In certain embodiments, the lengths of the individual bonding points of the third matrix A3 are typically aligned at a diagonal angle to the vertical axis of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the third matrix with the vertical axis V of the nonwoven fabric defines an angle greater than 0° and less than 90°. In certain embodiments, the angle formed by the intersection of the horizontal axis V with the major axis of the individual bonding point of the third matrix A3 is about 43° to 47°, and in particular, about 44° to 46°, and more particularly, about 45°.

[00173] In certain embodiments, the individual gluing points of the third matrix A3 have their lengths (e.g., principal axes) aligned substantially in the same direction as each other.

[00174] Similarly, the lengths of the individual bonding points of the fourth matrix are typically aligned at a diagonal angle to the vertical axis of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the fourth matrix with the vertical axis V of the nonwoven fabric defines an angle greater than 0° and less than 90°. In certain embodiments, the angle formed by the intersection of the vertical axis V with the major axis of the individual bonding point of the fourth matrix A4 is about 43° to 47° degrees, and in particular, about 44° to 46°, and more particularly, about 45°. Petition 870250088344, dated 09 / 29 / 2025, p. 63 / 234 44 / 165

[00175] In certain embodiments, the lengths (i.e., principal axis) of the individual gluing points of the fourth matrix are typically rotated from about 88° to 92°, as from about 89° to 91°, and more particularly, about 90° relative to the alignment of the lengths (i.e., principal axis) of the individual gluing points of the third matrix.

[00176] In a preferred embodiment, the intersection of a line segment of the main axis of individual gluing points of the third matrix and a line segment of the main axis of individual gluing points of the fourth matrix defines an angle that is approximately 90°.

[00177] In certain embodiments, the individual gluing points of the fourth matrix have their lengths (e.g., principal axes) aligned substantially in the same direction as each other.

[00178] Returning now to FIG. 3C, the first pattern 34 of bonding points further comprises a series of alternating fifth and sixth matrices A5, A6, in which the matrices extend diagonally across the surface of the nonwoven fabric relative to the direction of the weaving machine. The fifth and sixth matrices A5, A6 are arranged in pairs of matrices 24. As shown in FIG. 3C, the intersection of the fifth or sixth matrices with the horizontal axis H defines an angle a2. Generally, the angle a2 is about 40° to 50°, and in particular, about 42° to 43°, more particularly about 43° to 47°, and even more particularly, about 44° to 46°. In a preferred embodiment, the angle a2 is about 45°. Petition 870250088344, dated 09 / 29 / 2025, p. 64 / 234 45 / 165

[00179] Similarly, the intersection of the fifth and sixth matrices with the vertical axis V defines an angle a3. Generally, the angle a3 varies from about 40° to 50°, and in particular, from about 42° to 48°, more particularly from about 43° to 47°, and even more particularly, from about 44° to 46°. In a preferred embodiment, the angle a3 varies from about 45°.

[00180] As shown in FIG. 3C, each successive bonding point in the fifth and sixth dies is rotated approximately 90° relative to the preceding bonding point in the same set. In this sense, it can be observed that the lengths of bonding points 14a and 14c are aligned substantially in the same direction relative to the horizontal axis H of the nonwoven fabric 10a, and that the lengths of bonding points 14b and 14d are rotated approximately 90° relative to the lengths of bonding points 14a and 14c. Thus, the principal axis of each successive bonding point in the same die is substantially perpendicular to the principal axis of the preceding or subsequent bonding point in the same set.

[00181] Continuing with the reference to FIG. 3C, the distance d1 between adjacent gluing points on the same matrix, in the transverse direction of the first and second matrices, can vary from about 1.40 to 1.60 mm, and in particular, from about 1.45 to 1.55 mm, and more particularly, from about 1.48 to 1.52 mm. In a preferred embodiment, the distance d1 between adjacent gluing points in the transverse direction of the first and second matrices is about 1.51 mm.

[00182] In certain embodiments, the distance d2 between adjacent gluing points in the machine direction on the same die of the third and fourth dies can vary from about 1.40 to 1.60 Petition 870250088344, dated 09 / 29 / 2025, p. 65 / 234 46 / 165 mm and, in particular, about 1.45 to 1.55 mm and, more particularly, about 1.48 to 1.52 mm. In a preferred embodiment, the distance d2 between adjacent gluing points on the same die in the machine direction of the third and fourth dies is about 1.51 mm.

[00183] In certain embodiments, the distance d5 between adjacent gluing points on the same dies of the fifth and sixth dies can vary from about 0.70 to 0.95 mm and, in particular, from about 0.75 to 0.90 and, more particularly, from about 0.80 to 0.85. In a preferred embodiment, the distance d5 between adjacent gluing points on the same die of the fifth and sixth dies is about 0.82 to 0.84 mm.

[00184] Similarly, for diagonally aligned dies that are rotated approximately 90° relative to the fifth and sixth dies (not identified by reference characters), the distance d6 between adjacent gluing points on the same die can vary from about 0.70 to 0.95 mm and, in particular, from about 0.75 to 0.90 mm and, more particularly, from about 0.80 to 0.85 mm. In a preferred embodiment, the distance d6 between adjacent gluing points on the same die is about 0.82 to 0.84 mm.

[00185] In certain embodiments, the average distance of the collective bonding point for embodiments of FIGS. 3A-3C may vary from about 1.15 to 1.45 mm. As discussed earlier, the average distance of the bonding point is calculated from the average of the distances between the bonding points in the machine, transverse, and nonwoven fabric diagonal directions. For example, the average distance of the collective bonding point can be calculated from the average distance of d1, d2, d5, and d6. Petition 870250088344, dated 09 / 29 / 2025, p. 66 / 234 47 / 165

[00186] In certain embodiments, the average distance from the collective gluing point is about 1.20 mm to 1.40 mm and, in particular, about 1.25 to 1.35 mm and, more particularly, about 1.26 to 1.30 mm, with an average distance of 1.27 to 1.29 mm being somewhat more preferred.

[00187] In certain embodiments, according to the embodiments in FIGS. 3A-3C, the bonded nonwoven fabric has an average compaction value at the bonding point of about 6 to 10.0 mm-1, as well as about 6.5 to 9.5 mm-1 and 7.0 to 8.0 mm-1. In a preferred embodiment, the bonded nonwoven fabric has an average compaction value at the bonding point of about 7.0 to 7.25 mm-1.

[00188] More specifically, in certain embodiments in accordance with the embodiments of the FIGS.In groups 3A-3C, the bonded nonwoven fabric has an average compaction value at the bonding point greater than 6.0 mm⁻¹, greater than 6.1 mm⁻¹, greater than 6.2 mm⁻¹, greater than 6.3 mm⁻¹, greater than 6.4 mm⁻¹, greater than 6.5 mm⁻¹, greater than 6.6 mm⁻¹, greater than 6.7 mm⁻¹, greater than 6.8 mm⁻¹, greater than 6.9 mm⁻¹, greater than 7.0 mm⁻¹, greater than 7.1 mm⁻¹, greater than 7.2 mm⁻¹, greater than 7.3 mm⁻¹, greater than 7.4 mm⁻¹, greater than 7.5 mm⁻¹, greater than 7.6 mm⁻¹, greater than 7.7 mm⁻¹, greater than 7.8 mm⁻¹, greater than 7.9 mm⁻¹, greater than 8.0 mm⁻¹, greater than 8.1 mm⁻¹, greater greater than 8.2 mm-1, greater than 8.3 mm-1, greater than 8.4 mm-1, greater than 8.5 mm-1, greater than 8.6 mm-1, greater than 8.7 mm-1, greater than 8.8 mm-1, greater than 8.9 mm-1, greater than 9.0 mm-1, greater than 9.1 mm-1, greater than 9.2 mm-1, greater than 9.3 mm-1, greater than 9.4 mm-1, greater than 9.5 mm-1, greater than 9.6 mm-1, greater than 9.7 mm-1, greater than 9.8 mm-1, greater than 9.9 mm-1 and greater than 10.0 mm-1. Petition 870250088344, dated 09 / 29 / 2025, page 67 / 234 48 / 165

[00189] In certain embodiments, according to the embodiments of the FIGS. 3A-3C, the bonded nonwoven fabric has an average compaction value at the bonding point that is less than 10.0 mm-1, less than 9.9 mm-1, less than 9.8 mm-1, less than 9.7 mm-1, less than 9.6 mm-1, less than 9.5 mm-1, less than 9.4 mm-1, less than 9.3 mm-1, less than 9.2 mm-1, less than 9.1 mm-1, less than 9.0 mm-1, less than 8.9 mm-1, less than 8.8 mm-1, less than 8.7 mm-1, less than 8.6 mm-1, less than 8.5 mm-1, less than 8.4 mm-1, less than 8.3 mm-1, less than 8.2 mm-1, less than 8.1 mm-1, less than 7.0 mm-1, less than 6.9 mm-1, less than 6.8 mm-1, smaller than 6.7 mm-1, less than 6.6 mm-1, less than 6.5 mm-1, less than 6.4 mm-1, less than 6.3 mm-1, less than 6.2 mm-1, less than 6.1 mm1, less than 6.0 mm-1, less than 5.9 mm-1, less than 5.8 mm-1, less than 5.7 mm-1, less than 5.6 mm-1, less than 5.5 mm-1, less than 5.4 mm-1, less than 5.3 mm-1, less than 5.2 mm-1, less than 5.1 mm-1 and less than 5.0 mm-1.

[00190] In certain embodiments, the matrices extending in the transverse direction of the nonwoven fabric may not be parallel to the horizontal axis H of the nonwoven fabric. In this sense, Figure 4 illustrates an embodiment in which the first gluing pattern comprises a plurality of matrices of individual gluing points, in which the matrices are not aligned with the horizontal axis of the nonwoven fabric 10. As shown, the matrix A7 defines a set in which the individual gluing points 16 extend in the transverse direction of the nonwoven fabric at an angle greater than 0° with respect to the horizontal axis. In particular, the intersection of the set A7 with the horizontal axis defines the angle a3, which can vary from greater than 0° to less than 6°. In a preferred embodiment, the angle a3 varies from Petition 870250088344, dated 09 / 29 / 2025, p. 68 / 234 49 / 165 approximately 0.5° to 4° and, in particular, approximately 1° to 3°, with an angle of approximately 2° being preferred.

[00191] In certain embodiments, the first pattern defines a plurality of second patterns within the first pattern. In this sense, FIGS. 5A and 5B illustrate a second pattern 40 comprising individual gluing points that collectively define a gluing pattern with a quincunx-like shape. As seen in FIGS.5A and 5B, three adjacent arrays (e.g., A1, A2, A1) of individual bonding points further define a plurality of bonding patterns in both the machine direction and the cross direction, having a quincunx shape in which four individual bonding points defining corners (40a, 40b, 40c, 40d) of the quincunx-type bonding pattern 40 share a directional orientation that is substantially the same with respect to the cross or machine directions of the nonwoven fabric, and in which an individual bonding point 44 defining a central point of the quincunx-type bonding pattern has a directional orientation that is rotated from about 88° to 92° (e.g., from about 89° to 91° and, in particular, about 90°) with respect to the directional orientation of the individual bonding points defining the corners of the quincunx-type bonding pattern.

[00192] FIG. 5B illustrates a partial bonding pattern 46 of the first bonding pattern, with a plurality of quincunx-type bonding patterns extending both in the machine direction and in the transverse direction of the nonwoven fabric. Each quincunx-type bonding pattern shares corner bonding points with adjacent quincunx-type bonding patterns in the machine and transverse directions. In this sense, Petition 870250088344, dated 09 / 29 / 2025, page 69 / 234 50 / 165 quincunx type bonding pattern 40a shares corner bonding points 48a and 48b with quincunx type bonding pattern 40b in the transverse direction. Similarly, quincunx type bonding pattern 40a shares corner bonding points 48c and 48b with the adjacent quincunx type bonding pattern 40c in the nonwoven fabric machine direction.

[00193] As discussed previously, the inventors of the present invention have surprisingly found that abrasion resistance is improved compared to similarly prepared nonwoven fabrics comprising oval bonds with a higher percentage of bonded area of ​​the nonwoven fabric. In particular, the embodiments of the present invention provide improvements in abrasion resistance while exhibiting a lower percentage of bonded area compared to similar nonwoven fabrics.

[00194] The surface area of ​​each individual bonding point 14, according to the embodiments shown in Figures 3A3C, is typically about 0.10 to 0.40 mm2, and more typically about 0.12 to 0.3 mm2, and even more typically about 0.15 to 0.25 mm2. In a preferred embodiment, the surface area of ​​each individual bonding point is about 0.18 mm2.

[00195] In certain embodiments, the average surface area of ​​each individual bonding point 14, according to the embodiments shown in FIGS. 3A-3C, is greater than 0.1, greater greater than 0, 11, greater than 0, 12, greater than 0, 13, greater than 0, 14, greater than 0, 15, greater than 0, 16, greater than 0, 17, greater than 0, 17, greater than 0, 18, greater than 0, 19, greater than 0, 20, greater than 0, 21, greater Petition 870250088344, dated 09 / 29 / 2025, page 70 / 234 51 / 165 greater than 0.22, greater than 0.23, greater than 0.24, greater than 0.25, greater than 0.26, greater than 0.27, greater than 0.28, greater than 0.29, and greater than 0.30.

[00196] In certain embodiments, the average surface area of ​​each individual bonding point 14, according to the embodiments shown in FIGS. 3A-3C, is less than 0.30, less than 0.29, less than 0.28, less than 0.27, less than 0.26, less than 0.25, less than 0.25, less than 0.23, less than 0.22, less than 0.21, less than 0.20, less than 0.19, less than 0.18, less than 0.17, less than 0.16, less than 0.15, less than 0.14, less than 0.13, less than 0.12, less than 0.11 and less than 0.10.

[00197] In certain embodiments of the invention, the number of individual bonding points per cm2 is about 45 to 60, and in particular, about 50 to 58, and more particularly, about 54 to 56.

[00198] In some embodiments, the percentage of bonded area of ​​the nonwoven fabric is about 9 to 10.5%, and in particular, about 9.5 to 10.4%, and more particularly, about 9.8 to 10.2%. In a preferred embodiment, the percentage of bonded area of ​​the nonwoven fabric is about 9.9 to 10%. Example of Implementation B

[00199] With reference to FIG. 6, an embodiment of nonwoven fabric is shown and broadly designated by the reference character 10b. As in the embodiments shown in FIGS. 3A-3C, the nonwoven fabric 10b comprises a plurality of fibers that are joined together by points with a plurality of individual bonding points 14 to form a coherent weave. The nonwoven fabric also includes a surface 12 comprising Petition 870250088344, dated 09 / 29 / 2025, p. 71 / 234 52 / 165 a plurality of individual bonding points 14 in the same. The bonding points 14 are spaced apart and are configured and arranged to define a plurality of matrices that extend in the machine direction (MD), transverse direction (CD) and diagonal direction (DD) of the nonwoven fabric 10b. The nonwoven fabric 10b also includes a vertical axis (V) that is substantially aligned with the machine direction of the nonwoven fabric 10, and a horizontal axis (H) that is substantially aligned with the transverse direction of the nonwoven fabric 10.

[00200] Similar to the embodiment discussed previously, the nonwoven fabric 10b further comprises pairs (20) of alternating first and second matrices (reference characters A1, A2) extending laterally in the transverse direction of the nonwoven fabric; pairs (22) of alternating third and fourth matrices (reference characters A3, A4) extending longitudinally in the direction of the nonwoven fabric machine; and pairs (24) of alternating fifth and sixth matrices (reference characters A5, A6) extending diagonally across the surface of the nonwoven fabric relative to the direction of the nonwoven fabric machine.

[00201] In the embodiment illustrated in FIG. 6, the lengths (e.g., principal axes) of the individual bonding points of the first die are typically aligned at a diagonal angle to the direction of the nonwoven fabric machine. That is, the intersection of the principal axis 30 of the individual bonding points of the first die with the horizontal axis H of the nonwoven fabric defines an angle greater than 0° and less than °. In certain embodiments, the angle formed by the intersection Petition 870250088344, dated 09 / 29 / 2025, page 72 / 234 53 / 165 of the horizontal axis H with the main axis of the individual gluing point of the first matrix varies from about 43° to 47° degrees, and in particular, from about 44° to 46°, and more particularly, from about 45°.

[00202] In certain embodiments, the individual gluing points of the first matrix have their lengths (e.g., principal axes) aligned substantially in the same direction as the others.

[00203] The lengths (e.g., principal axes) of the individual bonding points of the second die are typically aligned at a diagonal angle relative to the direction of the nonwoven fabric machine. That is, the intersection of the principal axis 30 of the individual bonding points of the second die with the horizontal axis H of the nonwoven fabric defines an angle greater than 0° and less than 90°. In certain embodiments, the angle formed by the intersection of the horizontal axis H with the principal axis of the individual bonding point of the second die varies from about 43° to 47° degrees, and in particular, from about 44° to 46°, and more particularly, from about 45°.

[00204] In certain embodiments, the lengths (e.g., major axis) of the individual gluing points of the second matrix are typically rotated from about 88° to 92°, as from about 89° to 91°, and more particularly, about 90° relative to the alignment of the lengths (e.g., major axis) of the individual gluing points of the first matrix.

[00205] The intersection of the set extending in the diagonal direction (DD) (for example, matrices A5, A6) with the horizontal axis H defines an angle a5. Generally, the angle a5 is Petition 870250088344, dated 09 / 29 / 2025, p. 73 / 234 54 / 165 approximately 28° to 36°, and in particular, approximately 29° to 35°, more particularly approximately 30° to 34°, and even more particularly, approximately 31° to 33°. In a preferred embodiment, angle a5 is approximately 32°.

[00206] In the embodiment of FIG. 6, the percentage of bonded surface area of ​​the nonwoven fabric is less than about 12%, the average surface area of ​​the individual bonding points is about 0.2 to 0.6 square millimeters (mm2), and the bonding density is about 30 to 30 individual bonding points per square centimeter (cm2).

[00207] In certain embodiments, the percentage of bonded surface area of ​​the nonwoven fabric is about 10 to 10.5%, the average surface area of ​​individual bonding points is about 0.35 to 0.45 mm2, the compaction value at the bonding point is about 4.5 to 6.5 mm-1, and the bonding density is about 24 to 26 individual bonding points per square centimeter (cm2).

[00208] In certain embodiments, the individual gluing points have an average length of about 1.04 mm to 1.14 mm and, in particular, about 1.06 to 1.12 mm and, more particularly, about 1.08 to 1.10 mm. In a preferred embodiment, the individual gluing points have an average length of about 1.09 mm.

[00209] In certain embodiments, the individual gluing points have an average width of about 0.44 to 0.50 mm, and in particular, about 0.45 to 0.49 mm, and more particularly, about 0.46 to 0.48 mm. In one embodiment Petition 870250088344, dated 09 / 29 / 2025, p. 74 / 234 55 / 165 preferred, the individual bonding points have an average width of approximately 0.47 mm.

[00210] In certain embodiments, the average surface area of ​​the individual bonding points is about 0.3 to 0.8 square millimeters (mm2), and in particular, about 0.35 to 0.7 mm2, and more particularly, about 0.38 to 0.5 mm2. In some embodiments, the average surface area of ​​the individual bonding points is about 0.4 mm2.

[00211] In some embodiments, the gluing density (number of individual gluing points per square cm) is about 20 to 30, and in particular, about 22 to 28, and more particularly, 24 to 26 gluing points per cm2.

[00212] The distance d7 between adjacent point bonds in matrices extending in the transverse direction (e.g., matrices A1 and A2) in the same matrix is ​​typically about 2.90 to 3.2 mm, and in particular, about 2.95 to 3.15 mm, and more particularly, about 3.0 to 3.12 mm, and even more particularly, about 3.05 to 3.10 mm. In a preferred embodiment, the distance d7 between adjacent point bonds in matrices extending in the transverse direction is about 3.08 mm.

[00213] The distance d8 between adjacent dot collages in dies that extend in the machine direction (e.g., A3 and A4 dies) on the same die is typically about 1.65 to 1.85 mm, and in particular about 1.70 to 1.80 mm, and more typically about 1.72 to 1.78 mm. In a preferred embodiment, the distance d8 between adjacent dot collages in Petition 870250088344, dated 09 / 29 / 2025, p. 75 / 234 56 / 165 dies extending towards the machine is approximately 1.75 mm.

[00214] The distance d9 between adjacent point bondings in dies extending in the diagonal direction (e.g., dies A5, A6) on the same die is typically about 1.25 to 1.55 mm, and in particular about 1.30 to 1.45 mm, and more typically about 1.34 to 1.44 mm. In a preferred embodiment, the distance d9 between adjacent point bondings in dies extending in the machine direction on the same die is about 1.38 to 1.40 mm.

[00215] In certain embodiments, the average distance of the collective bonding point for embodiments according to FIG. 6 may vary from about 1.90 to 2.25 mm. As discussed earlier, the average distance of the bonding point is calculated from the average of the distances between the bonding points in the machine, transverse and diagonal directions of the nonwoven fabric. For example, the average distance of the collective bonding point can be calculated from the average distance of d7, d8 and d9.

[00216] In certain embodiments, the average collective distance from the gluing point is about 1.95 mm to 2.20 mm and, in particular, about 2.05 to 2.15 mm and, more particularly, about 2.06 to 2.12 mm, with an average distance of 2.07 to 2.08 mm being somewhat more preferred.

[00217] In certain embodiments, according to the embodiments in FIG. 6, the bonded nonwoven fabric has an average compaction value at the bonding point of about 4 to 6.5 mm-1, as well as about 4.5 to 6 mm-1 and 4.75 to 5.5 mm-1. In a preferred embodiment, the bonded nonwoven fabric exhibits Petition 870250088344, dated 09 / 29 / 2025, p. 76 / 234 57 / 165 an average compaction value at the bonding point of approximately 5.0 to 5.25 mm-1. Example of Implementation C

[00218] Returning now to FIGS. 7A-7D, a further embodiment of a bonded nonwoven fabric according to at least one embodiment of the disclosure is illustrated and designated by reference character 10c.

[00219] As in the embodiments shown in FIG. 1, the nonwoven fabric 10c comprises a plurality of fibers that are joined together by points with a plurality of individual bonding points 72, 74 to form a coherent weave. The nonwoven fabric further includes a surface 70 comprising a plurality of individual bonding points 72, 74 that collectively define a bonding pattern 78 on the surface of the nonwoven fabric 10c. The bonding points 14 are spaced apart and are configured and arranged to define a plurality of matrices that extend in the machine direction (MD), transverse direction (CD), and diagonal direction (DD) of the nonwoven fabric 10c. The nonwoven fabric 10c also includes a vertical axis (V) that is substantially aligned with the machine direction of the nonwoven fabric 10c, and a horizontal axis (H) that is substantially aligned with the transverse direction of the nonwoven fabric 10c.

[00220] The embodiment of FIG. 7B comprises a plurality of a first set of matrices 76 in which each of the matrices of the first set of matrices 76 comprises a plurality of individual bonding points extending laterally in the transverse direction of the nonwoven fabric 10c. The first set Petition 870250088344, dated 09 / 29 / 2025, p. 77 / 234 58 / 165 of 76 matrices includes four matrices (A10, A11, A12, A13) that extend laterally in the transverse direction of the 10c nonwoven fabric and are successively spaced from each other in the direction of the 10c nonwoven fabric machine. That is, when matrix A10 is the first matrix of the first set of 76 matrices, then the next successive matrix in the direction of the 10c nonwoven fabric machine will be matrix A11, and the next successive matrix after matrix A11 will be matrix A12, and finally, the next successive matrix of the first set of 76 matrices after matrix A12 is matrix A13. At this point, the pattern repeats in the direction of the 10c nonwoven fabric machine.

[00221] In the illustrated embodiment, the A10 matrix comprises a plurality of individually spaced bonding points 72, generally oblong in shape, such as an oval-elliptical shape. Additional variations of oblong bonding points that may be used in embodiments of the invention have been discussed previously. The lengths (e.g., principal axes) of the individual bonding points of the first A10 matrix are typically aligned at a diagonal angle relative to the direction of the nonwoven fabric machine. That is, the intersection of the principal axis 30 of the individual bonding points 72 of the first matrix with the horizontal axis H of the nonwoven fabric defines an angle greater than 0° and less than 90°. In certain embodiments, the angle formed by the intersection of the horizontal axis H with the principal axis of the individual bonding point of the first A10 matrix varies from about 26° to 34° degrees, and in particular, from about 29° to 31°, and more particularly, from 29° to 31°.In a slightly more preferred embodiment, the angle formed by... Petition 870250088344, dated 09 / 29 / 2025, p. 78 / 234 The angle between the horizontal axis H and the principal axis of the individual gluing point of the first matrix A10, 59 / 165, is approximately 30°.

[00222] In certain embodiments, the individual gluing points 72 of the A10 matrix have their lengths (e.g., principal axes) aligned substantially in the same direction as each other.

[00223] Next, matrix A10 is matrix A11. Matrix A11 comprises a plurality of individually spaced 72 bonding points, generally oblong in shape, such as an oval-elliptical shape. Similar to matrix A10, the lengths (e.g., principal axes) of the individual bonding points of matrix A11 are typically aligned at a diagonal angle to the direction of the nonwoven fabric machine. In certain embodiments, the angle formed by the intersection of the horizontal axis H and the principal axis of the individual bonding points 74 of matrix A11 is about 26° to 34° degrees, and in particular, about 28° to 32°, and more particularly, 29° to 31°. In a somewhat more preferred embodiment, the angle formed by the intersection of the horizontal axis H and the principal axis of the individual bonding point of the first matrix A11 is about 30°.

[00224] However, in the A11 matrix, the alignment of the lengths (e.g., principal axes) of the individual bonding points of the A11 matrix is ​​rotated in a directional orientation opposite to the alignment of the A10 matrix with respect to the vertical axis of the nonwoven fabric. In particular, the lengths (e.g., principal axis) of the individual bonding points 72 of the A11 matrix are typically rotated from about 85° to 95°, as from about 88° to 92°, and more Petition 870250088344, dated 09 / 29 / 2025, page 79 / 234 60 / 165 in particular, from about 88° to 92° in relation to the alignment of the lengths (e.g., major axis) of the individual bonding points of the A10 matrix.

[00225] The A12 die successively follows the A11 die in the direction of the nonwoven fabric machine 10c. The configuration and arrangement of the bonding points of the A12 die are substantially similar to those of the A10 die. That is, the lengths (e.g., principal axes) of the bonding points 72 of the A10 and A12 dies are substantially aligned in the same direction with respect to the horizontal axis of the nonwoven fabric 10c. Furthermore, adjacent bonding points in the A10 and A12 dies are substantially aligned in the direction of the nonwoven fabric machine 10c.

[00226] It is also possible to observe that the position of the individual gluing points in die A11 is offset in the transverse direction of the adjacent gluing points in dies A10 and A12. In other words, the gluing points of die A11 are not aligned in the machine direction with the gluing points of dies A10 and A12.

[00227] The average distances d10 between adjacent gluing points 74 within the same matrix A10 can vary from 2.2 to 2.6 mm, and in particular, from 2.3 to 2.55 mm, and more particularly, from about 2.45 to 2.50 mm. Similarly, the average distances d12 between adjacent gluing points 74 within the same matrix A12 can vary from 2.3 to 2.6 mm, and in particular, from 2.3 to 2.55 mm, and more particularly, from about 2.45 to 2.50 mm. The average distances d11 between adjacent gluing points 74 within the same matrix A11 can vary from Petition 870250088344, dated 09 / 29 / 2025, p. 80 / 234 61 / 165 2.2 to 2.6 mm, and in particular, from 2.3 to 2.55 mm, and more particularly, from about 2.45 to 2.50 mm.

[00228] The A13 assembly comprises a plurality of 74 circular / square shaped bonding points extending laterally in the transverse direction of the nonwoven fabric 10c. Typically, the bonding points 74 have a length / width ratio ranging from approximately 0.9:1.1 to 1:1.

[00229] In certain embodiments, the individual 74 bonding points of the A13 die are substantially aligned in the machine direction with adjacent 74 bonding points in the A11 die.

[00230] The average distances d13 between adjacent gluing points 74 within the same matrix A13 can vary from 2.45 to 2.75 mm, and in particular, from 2.50 to 2.70 mm, and more particularly, from about 2.55 to 2.65 mm, with a distance of about 2.58 to 2.62 mm being somewhat more preferred.

[00231] The average distances d14 between adjacent bonding points in the diagonal direction of the nonwoven fabric can vary from about 1.20 to 1.50 mm and, in particular, from about 1.25 to 1.45 mm and, more particularly, from about 1.30 to 1.40 mm. In a preferred embodiment, the average distance d14 is about 1.32 to 1.36 mm.

[00232] With reference to FIG. 7C, the bonded pattern 78 may further comprise a second set of matrices 80, comprising a pair of alternating matrices extending longitudinally in the direction of the nonwoven fabric machine 10c. The second set of matrices 80 comprises a pair of alternating matrices A14 and A15, spaced in the direction Petition 870250088344, dated 09 / 29 / 2025, p. 81 / 234 62 / 165 transverse and extending in the direction of the nonwoven fabric machine. Each matrix comprises a plurality of individual bonding points 72 and 74, spaced apart from each other.

[00233] The A14 matrix comprises a plurality of 72 bonding points, generally oblong in shape, such as an elliptical oval bonding point. Other variations of oblong bonding points have been discussed previously. In certain embodiments, and as shown in FIG. 7C, the oblong-shaped 72 bonding points of the A14 matrix are aligned substantially in the same direction relative to the nonwoven fabric machine direction. In some embodiments, the angle formed by the intersection of the horizontal axis H and the principal axis of the individual bonding point of the A14 matrix may be from about 26° to 34° degrees, and in particular, from about 28° to 32°, and more particularly, from 29° to 31°. In a somewhat more preferred embodiment, the angle formed by the intersection of the horizontal axis H and the principal axis of the individual bonding point of the first A14 matrix is ​​about 30°.

[00234] Matrix A15 comprises a repetitive pattern of oblong, oval-elliptical, glue points 72, preceded and followed by circular / square / diamond glue points 74. Thus, all other glue points in the matrix are oblong in shape and all other glue points are circular / square in shape.

[00235] Similar to the A14 matrix, the lengths (e.g., principal axes) of the individual oblong-shaped bonding points of the A15 matrix are typically aligned at a diagonal angle to the direction of the nonwoven fabric machine. In certain embodiments, the angle formed by the intersection of Petition 870250088344, dated 09 / 29 / 2025, page 82 / 234 The angle formed by the intersection of the horizontal axis H and the principal axis of the individual gluing points 74 of the A15 matrix is ​​approximately 26° to 34°, and in particular, approximately 28° to 32°, and more particularly, 29° to 31°. In a slightly more preferred embodiment, the angle formed by the intersection of the horizontal axis H and the principal axis of the individual gluing point of the first A15 matrix is ​​approximately 30°.

[00236] However, in the A15 matrix, the alignment of the lengths (e.g., principal axes) of the individual bonding points of the A15 matrix is ​​rotated in a directional orientation opposite to the alignment of the A14 matrix with respect to the vertical axis of the nonwoven fabric. In particular, the lengths (e.g., principal axis) of the individual bonding points 72 of the A11 matrix are typically rotated from about 85° to 95°, as from about 88° to 92°, and more particularly, from about 88° to 92° with respect to the alignment of the lengths (e.g., principal axis) of the individual bonding points of the A14 matrix.

[00237] The average distances d15 between adjacent bonding points 74 and 72 within the same matrix A15 can vary from 1.30 to 1.48 mm and, in particular, from 1.34 to 1.44 mm, with an average distance d15 varying from approximately 1.36 to 1.40 mm. Similarly, the average distances d16 between adjacent bonding points 74 within the same matrix A14 can vary from 1.30 to 1.48 mm and, in particular, from 1.34 to 1.44 mm, with an average distance d16 varying from approximately 1.36 to 1.40 mm.

[00238] With reference to FIG. 7D, the glued pattern 78 may further comprise a third set of matrices 82, comprising a pair of alternating matrices extending in Petition 870250088344, dated 09 / 29 / 2025, p. 83 / 234 64 / 165 a diagonal direction in relation to the horizontal and vertical axes of the nonwoven fabric 10c. The third set of dies 82 comprises a pair of alternating dies A16 and A17, spaced apart in the machine direction and extending in the diagonal direction of the nonwoven fabric. Each die comprises a plurality of individual bonding points 72 and 74, spaced apart.

[00239] Matrix A16 comprises a repeating pattern of three oblong gluing points 72 and one circular / square gluing point 74. In particular, matrix A16 comprises a first gluing point 72a with its principal axes aligned in the same way as the gluing points 72 of A10. This is successively followed by the second gluing point 72b with its principal axes aligned in the same way as the gluing points 72 of matrix A11. Matrix A11 is successively followed by the third gluing point 74c with the same alignment as the first gluing point 72a. Finally, a circular / square gluing point 74a successively follows the third gluing point 72c.

[00240] The intersection of the set extending in the diagonal direction (DD) (e.g., matrices A16, A17) with the horizontal axis H defines an angle a6. Generally, the angle a6 is about 26° to 34°, and in particular, about 27° to 33°, more particularly about 28° to 32°, and even more particularly about 29° to 31°. In a preferred embodiment, the angle a6 is about 30°.

[00241] In certain embodiments, the average collective distance from the gluing point for embodiments according to FIGS. 7A-7D may vary from about 1.65 to 1.85 mm. As discussed Petition 870250088344, dated 09 / 29 / 2025, p. 84 / 234 Previously, the average distance between the bonding points (65 / 165) was calculated from the average of the distances between the bonding points in the machine, transverse, and diagonal directions of the nonwoven fabric. For example, the collective average distance between the bonding points (c) can be calculated from the average distance of d10-d16.

[00242] In some embodiments, the gluing density (number of individual gluing points per square cm) is about 28 to 38, and in particular, about 30 to 36, and more particularly, 32 to 34 gluing points per cm2.

[00243] In certain embodiments, the average distance of the collective gluing point is about 1.70 mm to 1.82 mm and, in particular, about 1.72 to 1.80 mm and, more particularly, about 1.74 to 1.75 mm, with an average distance of 1.75 mm being somewhat more preferred.

[00244] In certain embodiments, according to the embodiments in FIGS. 7A-7D, the bonded nonwoven fabric has an average compaction value at the bonding point of about 4.0 to 6.5 mm-1, as well as about 4.5 to 5.75 mm-1 and 4.75 to 5.5 mm-1. In a preferred embodiment, the bonded nonwoven fabric has an average compaction value at the bonding point of about 5.0 to 5.25 mm-1.

[00245] In certain embodiments, the percentage of bonded surface area of ​​nonwoven fabrics according to the embodiments of FIGS. 7A-7D is about 11 to 12%, the average surface area of ​​the individual bonding points is about 0.25 to 0.5 mm2, the compaction value at the bonding point is about 4.5 to 5.5 mm-1, and the bonding density is about Petition 870250088344, dated 09 / 29 / 2025, page 85 / 234 66 / 165 to 38 individual stitches per square centimeter (cm2).

[00246] In certain embodiments, the percentage of bonded surface area of ​​nonwoven fabrics according to the embodiments of FIGS. 7A-7D is about 11.4 to 11.6%, the average surface area of ​​individual bonding points is about 0.3 to 0.4 mm2, the compaction value at the bonding point is about 5.05 to 5.15 mm-1, and the bonding density is about 32 to 34 individual bonding points per square centimeter (cm2).

[00247] Sample of Implementation D

[00248] With reference to FIGS. 8A-8C, another embodiment of the bonded nonwoven fabric is shown and generically indicated by the reference character 10d. The nonwoven fabric 10d comprises a plurality of fibers that are joined together by points with a plurality of individual bonding points 14 to form a coherent weave. The nonwoven fabric includes a horizontal axis H that is substantially aligned with the transverse direction CD of the nonwoven fabric and a vertical axis V that is substantially aligned with the machine direction MD of the nonwoven fabric.

[00249] With regard to nonwoven fabrics according to certain embodiments, the inventors of the present disclosure have discovered that improvements in both abrasion resistance and softness can be obtained with nonwoven fabrics that are thermally bonded by dots with bonding patterns according to one or more embodiments of the present invention. In particular, it has been discovered that a bonded nonwoven fabric having a first Petition 870250088344, dated 09 / 29 / 2025, page 86 / 234 A 67 / 165 bonding pattern comprising a plurality of alternating matrices composed of individual bonding points in both the machine direction and the transverse direction of the nonwoven fabric, wherein the overall percentage of bonded surface area of ​​the nonwoven fabric is less than 14%, the surface area of ​​the individual bonding points is about 0.10 to 0.60 square millimeters (mm2), the compaction value at the bonding point is greater than about 2.0 mm-1, such as between 3 and 5 mm-1, and the bonding density is about 20 to 60 individual bonding points per square centimeter (cm2), provides a nonwoven fabric with improved softness and abrasion resistance compared to a similar nonwoven fabric with a higher percentage of bonded surface area.

[00250] In the embodiment of FIGS. 8A-8C, the overall percentage of bonded surface area of ​​the nonwoven fabric is less than about 14%, the surface area of ​​the individual bonding points is about 0.2 to 0.60 square millimeters (mm2), the compaction value at the bonding point is about 2 to 6 mm-1, and the bonding density is about 28 to 40 individual bonding points per square centimeter (cm2).

[00251] The plurality of individual bonding points 14 defines a first pattern 90 on the surface 12 of the nonwoven fabric 10d. As shown in FIG. 8A, the first pattern 90 comprises a series of alternating first and second matrices A18, A19 of individual bonding points 14 extending in the transverse direction of the nonwoven fabric 10d and arranged in pairs of matrices 92a. In certain embodiments, the individual bonding points 14 defining the second matrices of the first pattern are displaced in the transverse direction relative to the Petition 870250088344, dated 09 / 29 / 2025, p. 87 / 234 68 / 165 adjacent bonding points of the first dies. In other words, the adjacent bonding points of the first and second dies are not aligned with each other in the direction of the nonwoven fabric machine. This configuration and layout can be seen in FIG. 8A, where the vertical axis V extends only through the bonding points of the second die and not through the bonding points of the first die. In the embodiment shown in FIG. 8A, the first and second dies A18, A19 are substantially aligned with the transverse direction of the nonwoven fabric 10d.

[00252] In a preferred embodiment, the individual gluing points of the first dies do not overlap in the machine direction with the individual gluing points of the second dies. However, it should be recognized that, in some embodiments, the individual gluing points of the first and second dies may overlap in the machine direction with gluing points on an adjacent die.

[00253] In certain embodiments, the percentage of bonded surface area of ​​the nonwoven fabric is about 13 to 14%, the average surface area of ​​individual bonding points is about 0.44 to 0.50 mm2, the compaction value at the bonding point is about 3 to 5 mm-1, and the bonding density is about 30 to 35 individual bonding points per square centimeter (cm2).

[00254] In certain embodiments, the individual gluing points have an average length of about 1.04 mm to 1.14 mm and, in particular, about 1.06 to 1.12 mm and, more particularly, about 1.08 to 1.10 mm. In one embodiment Petition 870250088344, dated 09 / 29 / 2025, p. 88 / 234 69 / 165 preferred, the individual bonding points have an average length of approximately 1.09 mm.

[00255] In certain embodiments, the individual gluing points have an average width of about 0.44 to 0.50 mm, and in particular, about 0.45 to 0.49 mm, and more particularly, about 0.46 to 0.48 mm. In a preferred embodiment, the individual gluing points have an average width of about 0.47 mm.

[00256] In certain embodiments, the average surface area of ​​the individual bonding points is about 0.3 to 0.8 square millimeters (mm2), and in particular, about 0.35 to 0.7 mm2, and more particularly, about 0.38 to 0.5 mm2. In some embodiments, the average surface area of ​​the individual bonding points is about 0.4 mm2.

[00257] Referring again to FIG. 8A, the lengths (e.g., principal axes) of the individual bonding points of the first die are typically aligned at a diagonal angle relative to the direction of the nonwoven fabric machine. That is, the intersection of the principal axis (see FIG. 2A, reference character 30) of the individual bonding points of the first die and the vertical axis V of the nonwoven fabric defines an angle α8 that is greater than 45° and less than 55°. In certain embodiments, the angle formed by the intersection of the vertical axis V and the principal axis of the individual bonding point of the first die α8 is about 48° to 53°, and in particular, about 49° to 51°, and more particularly, about 50°.

[00258] In certain embodiments, the individual gluing points of the first matrix have their lengths (by Petition 870250088344, dated 09 / 29 / 2025, p. 89 / 234 70 / 165 example, main axes) aligned substantially in the same direction as the others.

[00259] The lengths of the individual bonding points of the second die are typically aligned at a diagonal angle to the direction of the nonwoven fabric machine. That is, the intersection of the principal axis 30 of the individual bonding points of the second die with the horizontal axis H of the nonwoven fabric defines an angle greater than 0° and less than 90°. In certain embodiments, the angle formed by the intersection of the horizontal axis H with the principal axis of the individual bonding point of the second die A19 is about 43° to 47° degrees, and in particular, about 44° to 46°, and more particularly, about 45°.

[00260] In certain embodiments, the lengths (e.g., major axis) of the individual gluing points of the second matrix are typically rotated from about 88° to 92°, as from about 89° to 91°, and more particularly, about 90° relative to the alignment of the lengths (e.g., major axis) of the individual gluing points of the first matrix.

[00261] In a preferred embodiment, the intersection of a line segment extending along the major axis of the individual gluing points of the first matrix and a line segment extending along the major axis of the individual gluing points of the second matrix defines an angle that is approximately 90°.

[00262] In certain embodiments, the individual gluing points of the second matrix have their lengths (by Petition 870250088344, dated 09 / 29 / 2025, pp. 90 / 234 71 / 165 example, main axes) aligned substantially in the same direction as the others.

[00263] With reference to FIG. 8B, the first pattern 90 of bonding points further comprises a series of alternating third and fourth matrices A20, A21 of individual bonding points 14 extending in the direction of the nonwoven fabric machine 10, and arranged in pairs of matrices 92b. In the embodiment shown in FIG. 8B, the third and fourth matrices A20, A21 are substantially aligned with the direction of the nonwoven fabric machine 10d. Similarly, to the first and second matrices A18, A19, the individual bonding points 14 defining the fourth matrices of the first pattern are offset in the direction of the machine relative to the adjacent bonding points of the third matrices. In other words, the adjacent bonding points of the third and fourth matrices are not aligned with each other in the direction of the nonwoven fabric machine.

[00264] In certain embodiments, the lengths of the individual bonding points of the third A20 matrix are typically aligned at a diagonal angle to the vertical axis of the nonwoven fabric. That is, the intersection of the major axis 30 of the individual bonding points of the third matrix with the vertical axis V of the nonwoven fabric defines an angle greater than 0° and less than 90°. In certain embodiments, the angle formed by the intersection of the horizontal axis V with the major axis of the individual bonding point of the third A20 matrix is ​​about 43° to 47°, and in particular, about 44° to 46°, and more particularly, about 45°.

[00265] In certain embodiments, the individual gluing points of the third A3 set have their lengths (by Petition 870250088344, dated 09 / 29 / 2025, pp. 91 / 234 72 / 165 example, main axes) aligned substantially in the same direction as the others.

[00266] Similarly, the lengths of the individual bonding points of the fourth A21 matrix are typically aligned at a diagonal angle to the vertical axis of the nonwoven fabric. That is, the intersection of the principal axis 30 of the individual bonding points of the fourth matrix with the vertical axis V of the nonwoven fabric defines an angle greater than 0° and less than 90°. In certain embodiments, the angle formed by the intersection of the vertical axis V with the principal axis of the individual bonding point of the fourth A21 matrix is ​​about 43° to 47° degrees, and in particular, about 44° to 46°, and more particularly, about 45°.

[00267] In certain embodiments, the lengths (i.e., principal axis) of the individual gluing points of the fourth matrix are typically rotated from about 88° to 92°, as from about 89° to 91°, and more particularly, about 90° with respect to the alignment of the lengths (i.e., principal axis) of the individual gluing points of the third matrix.

[00268] In a preferred embodiment, the intersection of a line segment of the main axis of individual gluing points of the third matrix and a line segment of the main axis of individual gluing points of the fourth matrix defines an angle that is approximately 90°.

[00269] In certain embodiments, the individual gluing points of the fourth matrix have their lengths (e.g., principal axes) aligned substantially in the same direction as each other. Petition 870250088344, dated 09 / 29 / 2025, page 92 / 234 73 / 165

[00270] Returning now to FIG. 8C, the first pattern 90 of bonding points further comprises a series of alternating fifth and sixth matrices A22, A23, in which the matrices extend diagonally across the surface of the nonwoven fabric relative to the direction of the weaving machine. The fifth and sixth matrices A5, A6 are arranged in pairs of matrices 92c. As shown in FIG. 3C, the intersection of the fifth or sixth matrices with the horizontal axis H defines an angle a9. Generally, the angle a9 is about 25° to 35°, and in particular, about 27° to 33°, more particularly about 28° to 32°, and even more particularly, about 29° to 31°. In a preferred embodiment, the angle a9 is about 30°.

[00271] Similarly, the intersection of the fifth and sixth matrices with the vertical axis V defines an angle a10. Generally, the angle a10 varies from approximately 55° to 65°, and in particular, from approximately 56° to 34°, more particularly from approximately 58° to 62°, and even more particularly, from approximately 59° to 61°. In a preferred embodiment, the angle a10 varies from approximately 60°.

[00272] As shown in FIG. 8C, each successive bonding point in the fifth and sixth layers is rotated approximately 90° relative to the preceding bonding point in the same matrix. In this sense, it can be observed that the lengths of bonding points 14a and 14c are aligned substantially in the same direction relative to the horizontal axis H of the nonwoven fabric 10a, and that the lengths of bonding points 14b and 14d are rotated approximately 90° relative to the lengths of bonding points 14a and 14c. Thus, the principal axis of each successive bonding point in the same matrix is Petition 870250088344, dated 09 / 29 / 2025, page 93 / 234 74 / 165 substantially perpendicular to the principal axis of the preceding or subsequent gluing point in the same matrix.

[00273] Continuing with the reference to FIG. 8C, the distance d16 between adjacent gluing points on the same die, in the transverse direction of the first and second dies, can vary from about 2.3 to 2.7 mm and, in particular, from about 2.4 to 2.6 mm and, more particularly, from about 2.48 to 2.52 mm. In a preferred embodiment, the distance d16 between adjacent gluing points in the transverse direction of the first and second dies is about 2.5 mm.

[00274] In certain embodiments, the distance d17 between adjacent gluing points in the machine direction on the same die of the third and fourth dies can vary from about 1.20 to 1.40 mm and, in particular, from about 1.25 to 1.35 mm and, more particularly, from about 1.28 to 1.32 mm. In a preferred embodiment, the distance d17 between adjacent gluing points on the same die in the machine direction of the third and fourth dies is about 1.3 mm.

[00275] In certain embodiments, the distance d18 between adjacent gluing points on the same dies of the fifth or sixth dies (diagonally oriented dies) can vary from about 0.80 to 1.2 mm and, in particular, from about 0.9 to 1.1 mm and, more particularly, from about 0.95 to 1.05 mm. In a preferred embodiment, the distance d18 between adjacent gluing points on the same die of the fifth or sixth dies is about 0.98 to 1.02 mm.

[00276] Similarly, for diagonally aligned matrices that are rotated approximately 90° with respect to the fifth and sixth Petition 870250088344, dated 09 / 29 / 2025, pp. 94 / 234 In 75 / 165 matrices (not identified by reference characters), the distance d18 between adjacent gluing points on the same matrix can vary from about 0.80 to 1.2 mm, and in particular from about 0.9 to 1.1 mm, and more particularly from about 0.95 to 1.05 mm. In a preferred embodiment, the distance d18 between adjacent gluing points on the same matrix of the fifth or sixth matrix is ​​about 0.98 to 1.02 mm.

[00277] In certain embodiments, the average distance of the collective bonding point for embodiments of FIGS. 8A-8C may vary from about 1.4 to 1.8 mm. As discussed earlier, the average distance of the bonding point is calculated from the average of the distances between the bonding points in the machine, transverse, and nonwoven fabric diagonal directions. For example, the average distance of the collective bonding point can be calculated from the average distance of d16, d17, and d18.

[00278] In certain embodiments, the average distance of the collective gluing point is about 1.45 mm to 1.75 mm and, in particular, about 1.5 to 1.7 mm and, more particularly, about 1.55 to 1.65 mm, with an average distance of 1.58 to 1.62 mm being somewhat more preferred.

[00279] In certain embodiments, according to the embodiments of FIGS. 8A-8C, the bonded nonwoven fabric has an average compaction value at the bonding point of about 2 to 6 mm-1, as of about 2.5 to 5.5 mm-1 and 3.0 to 5.0 mm-1. In a preferred embodiment, the bonded nonwoven fabric has an average compaction value at the bonding point of about 3.75 to 4.25 mm-1. Petition 870250088344, dated 09 / 29 / 2025, p. 95 / 234 76 / 165

[00280] More particularly, in certain embodiments according to the embodiments of FIGS. 8A-8C, the bonded nonwoven fabric has an average compaction value of 2.0 mm at point 2, bonding greater than -1, greater than 2.1 mm -1, greater than 2 mm -1, greater than 2.3 mm -1, greater than 2.4 mm -1, greater than 2.5 mm -1, greater than 2.6 mm -1, greater than 2.7 mm -1, greater than 2.8 mm -1, greater than 2.9 mm -1, greater than 3.0 mm -1, greater than 3.1 mm -1, greater than 3.2 mm -1, greater than 3.3 mm -1, greater than 3.4 mm -1, greater than 3.5 mm -1, greater than 3.6 mm -1, greater than 3.7 mm -1, greater than 3.8 mm -1, greater than 3.9 mm -1, greater than 4.0 mm -1, greater greater than 4.1 mm, greater than 4.2 mm, greater than 4.3 mm, greater than 4.4 mm, greater than 4.5 mm, greater than 4.6 mm, greater than 4.7 mm, greater than 4.8 mm, greater than 4.9 mm, greater than 5.0 mm, greater than 5.1 mm, greater than 5.2 mm, greater than 5.3 mm, greater than 5.4 mm, greater than 5.5 mm, greater than 5.6 mm, greater than 5.7 mm, greater than 5.8 mm, greater than 5.9 mm 1e greater than 6.0 mm 1.

[00281] In certain embodiments, according to the embodiments of the FIGS. 8A-8C, the bonded nonwoven fabric has an average compaction value at the bonding point of less than 6.0 mm-1, less than 5.9 mm-1, less than 5.6 mm-1, less than 5.3 mm-1, less than 5.0 mm-1, less than 4.7 mm-1, less than 4.4 mm-1, less than 4.1 mm-1, less than 3.8 mm-1, less than 3.5 mm-1, less than 5.8 mm-1, less than 5.5 mm-1, less than 5.2 mm-1, less than 4.9 mm-1, less than 4.6 mm-1, less than 4.3 mm-1, less than 4.0 mm-1, less than 3.7 mm-1, less than 3.4 mm-1, less than 5.7 mm-1, less than 5.4 mm-1, less than 5.1 mm-1, less than 4.8 mm-1, less than 4.5 mm-1, less than 4.2 mm-1, less than 3.9 mm-1, less than 3.6 mm-1, less than 3.3 mm-1, less Petition 870250088344, dated 09 / 29 / 2025, page 96 / 234 77 / 165 less than 3.2 mm -1, less than 3.1 mm -1, less than 3.0 mm -1, less than 2.9 mm -1, less than 2.8 mm -1, less than 2.7 mm -1, less than 2.6 mm -1, less than 2.5 mm -1, less than 2.4 mm -1, less than 2.3 mm -1, less than 2.2 mm -1, less than 2.1 mm -1 and less than 2.0 mm -1.

[00282] In certain embodiments, the matrices extending in the transverse direction of the nonwoven fabric 10d may not be parallel to the horizontal axis H of the nonwoven fabric. As discussed earlier with reference to FIG. 4, the plurality of matrices of individual bonding points in the transverse direction may not be aligned with the horizontal axis of the nonwoven fabric. As shown in FIG. 4, matrix A7 defines a matrix in which the individual bonding points 14 extend in the transverse direction of the nonwoven fabric at an angle greater than 0° with respect to the horizontal axis. In particular, the intersection of the matrix (A7 of FIG. 4) with the horizontal axis defines the angle a3, which can vary from greater than 0° to less than 6°. In a preferred embodiment, the angle a3 varies from about 0.5° to 4° and, in particular, from about 1° to 3°, with an angle of about 2° being preferred.

[00283] As in the embodiments shown in FIGS. 3A-3C, the first pattern defines a plurality of second patterns within the first pattern. Referring again to FIGS. 5A and 5B, the nonwoven fabric 10d may comprise a second pattern 40 comprising individual bonding points which, collectively, define a bonding pattern with a quincunx-like shape. As in FIGS. 5A and 5B, three adjacent arrays (e.g., A18, A19, A18) of individual bonding points further define a plurality of bonding patterns. Petition 870250088344, dated 09 / 29 / 2025, page 97 / 234 78 / 165 in both the machine and cross directions, having a quincunx pattern in which four individual gluing points defining corners (40a, 40b, 40c, 40d) of the quincunx-type gluing pattern 40 share a directional orientation that is substantially the same with respect to the cross or machine directions of the nonwoven fabric, and in which an individual gluing point 44 defining a central point of the quincunx-type gluing pattern has a directional orientation that is rotated from about 88° to 92° (e.g., from about 89° to 91° and, in particular, about 90°) relative to the directional orientation of the individual gluing points defining the corners of the quincunx-type gluing pattern. Further details of the quincunx-type gluing pattern are discussed above.

[00284] As discussed previously, the inventors of the present invention have surprisingly found that abrasion resistance is improved compared to similarly prepared nonwoven fabrics comprising oval bonds with a higher percentage of bonded area of ​​the nonwoven fabric. In particular, embodiments of the present invention provide improvements in abrasion resistance while exhibiting a lower percentage of bonded area compared to similar nonwoven fabrics.

[00285] The surface area of ​​each individual bonding point 14, according to the embodiments shown in FIGS. 8A-8C, is typically about 0.2 to 0.60 mm2' and more typically about 0.3 to 0.5 mm2, and even more typically about 0.35 to 0.45 mm2. In a preferred embodiment, the area of Petition 870250088344, dated 09 / 29 / 2025, page 98 / 234 79 / 165 The surface area of ​​each individual bonding point is approximately 0.4 mm2.

[00286] In certain embodiments, the average surface area of ​​each individual bonding point 14 according to the embodiments shown in FIGS. 8A-8C is greater than 0.2, greater than 0.21, greater than 0.25, greater than 0.29, greater than 0.33, greater than 0.37, greater than 0.41, greater than 0.45, greater than 0.22, greater than 0.26, greater than 0.30, greater than 0.34, greater than 0.38, greater than 0.42, greater than 0.46, greater than 0.23, greater than 0.27, greater than 0.31, greater than 0.35, greater than 0.39, greater than 0.43, greater than 0.47, greater than 0.24, greater than 0.28, greater than 0.32, greater than 0.36, greater than 0.40, greater than 0.44, greater than 0.48, greater than 0.49, greater than 0.50, greater than 0.51, greater than 0.52, greater than 0.53, greater than 0.57, greater than 0.54, greater than 0.58, greater than 0.55, greater than 0.59, greater than 0.56, greater than 0.60 mm2.

[00287] In certain embodiments, the average surface area of ​​each individual bonding point 14 according to the embodiments shown in FIGS. 8A-8C, is less than 0.60, less than 0.59, less than 0.58, less than 0.57, less than 0.56, less than 0.55, less than 0.55, less than 0.53, less than 0.52, less than 0.51, less than 0.50, less than 0.49, less than 0.48, less than 0.47, less than 0.46, less than 0.45, less than 0.44, less than 0.43, less than 0.42, less than 0.41, less than 0.40, less than 0.39, less than 0.38, less than 0.37, less than 0.36, less than 0.35, less than 0.34, less than 0.33, less than 0.32, less than 0.31, less than, 0.30, less than, 0.29, less than, 0.28, less than, 0.27, less than, 0.26, less than, 0.25, less than, 0.24, less than, 0.23, less than, 0.22, less than, 0.21, less than, 0.20 mm2. Petition 870250088344, dated 09 / 29 / 2025, page 99 / 234 80 / 165

[00288] In certain embodiments of the invention, the number of individual bonding points per cm2 is from about 30 to 36, and in particular, from about 32.5 to 34.5, and more particularly, from about 33 to 24.

[00289] In some embodiments, the bonded area percentage of the 10d nonwoven fabric is about 13 to 14%, and in particular, about 13.1 to 13.9%, and more particularly, about 13.2 to 13.8%. In a preferred embodiment, the bonded area percentage of the nonwoven fabric is about 13.3 to 13.5%.

[00290] The bonding patterns described here can be used to thermally bond a variety of different nonwoven structures.

[00291] In one embodiment, the present disclosure provides a spunbond nonwoven fabric comprising a plurality of fibers that are thermally bonded together by stitches to form a coherent weave.

[00292] Although the present invention is generally discussed in the context of spunbond fabrics prepared from continuous filaments, it should be recognized that other woven and nonwoven fibers can be prepared according to embodiments of the invention, including melt-blown process fibers and melt-blown process fabrics, staple fibers and carded fabrics, wet-laid fabrics, resin-bonded fabrics and air-laid fabrics, and combinations thereof.

[00293] In certain embodiments, the fibers of nonwoven fabric may comprise single-component fibers, multi-component fibers, or combinations thereof. Petition 870250088344, dated 09 / 29 / 2025, pp. 100 / 234 81 / 165

[00294] In one embodiment, nonwoven fibers comprise multicomponent fibers that may include at least two polymeric components arranged in structured domains along the cross-section of the fiber. As is generally known to experts in the field, polymeric domains or components are arranged in zones positioned substantially continuously along the cross-section of the multicomponent fiber and extend continuously along the entire length of the multicomponent fiber. More than two components may be present in the multicomponent fiber.

[00295] A preferred configuration is a side-by-side arrangement, in which a first polymeric component defines a first distinct continuous zone extending along the length of the fiber, and a second polymeric component defines a second distinct continuous zone extending along the length of the fiber. Both the first and second polymeric components define at least a portion of the outer surface of the continuous fibers. In certain embodiments, the first and second distinct zones of the side-by-side continuous fibers are present in ratios ranging from 10:90 to 90:10, and in particular, from about 40:60 to 60:40, and more particularly, from about 50:50. Side-by-side configurations are particularly useful in the preparation of corrugated fibers. Other configurations that may be useful in the preparation of corrugated fibers include eccentric sheath / core and D-centric sheath core configurations.

[00296] Another preferred configuration is a sheath / core arrangement in which a first component, the sheath, substantially surrounds a second component, the core. The fiber Petition 870250088344, dated 09 / 29 / 2025, pp. 101 / 234 The resulting 82 / 165 bicomponent sheath / core can have a round or non-round cross-section. Other structured fiber configurations, as known in the art, can be used, including segmented cake structures, sea islands, and multilobal structures with spikes.

[00297] In certain embodiments, the fibers are bicomponent, in which a first polymeric component defines a fiber sheath and a second polymeric component defines a fiber core. Generally, the weight percentage of the sheath relative to the core in the fibers can vary widely, depending on the desired properties of the nonwoven fabric. For example, the weight ratio of the sheath to the core can vary from about 5:95 to 95:5, as from about 10:90 to 90:10 and, in particular, from about 20:80 to 80:20. In a preferred embodiment, the weight ratio of the sheath to the core is from about 25:75 to 35:65, with a weight ratio of about 30:70 to 50:50 being preferred.

[00298] The preferred bicomponent sheath / core fibers for use in the manufacture of fabrics of this invention may have the higher melting point component as the core and the lower melting point component as the sheath. For example, an aliphatic polyester component may be used as the sheath and the core may be a higher melting point polymer component comprising a polyolefin, such as polypropylene. Such a structure with an aliphatic polyester on the surface allows the use of a reduced calendering oil bonding temperature, thus conserving energy during the manufacture of the nonwoven fabric. Petition 870250088344, dated 09 / 29 / 2025, pp. 102 / 234 83 / 165

[00299] A wide variety of polymers can be used in the preparation of nonwoven fabrics according to the embodiments of this disclosure.

[00300] Nonwoven fabrics, according to the embodiments of the invention, can be prepared with a wide variety of different polymers and polymer blends. Examples of polymers suitable for the preparation of fibers include polyolefins, such as polypropylene and polyethylene, and their copolymers, polyesters, such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT) and polybutylene terephthalate (PBT), nylons, polystyrenes, polyurethanes, copolymers and their blends, and other synthetic polymers that can be used in the preparation of fibers.In some embodiments, the polymer may be selected from the group consisting of: polyolefins, polyesters, polyethylene terephthalates, polybutylene terephthalates, polycyclohexylene dimethylene terephthalates, polytrimethylene terephthalates, polymethyl methacrylates, polyamides, nylons, polyacrylics, polystyrenes, polyvinyls, polytetrafluoroethylenes, ultra-high molecular weight polyethylenes, very high molecular weight polyethylenes, high molecular weight polyethylenes, polyether ether ketones, non-fibrous plasticized celluloses, polyethylenes, polypropylenes, polybutylenes, polymethylpentenes, low-density polyethylenes, linear low-density polyethylenes, high-density polyethylenes, polystyrenes, acrylonitrile-butadiene-styrenes, styrene-acrylonitriles, styrene triblock and tetrastyrene-styrene block copolymers. Styrene-butadienes, styrene-maleic anhydrides, ethylene vinyl acetates, ethylene vinyl alcohols, chlorides. Petition 870250088344, dated 09 / 29 / 2025, pp. 103 / 234 84 / 165 polyvinyl acetates, cellulose acetate butyrates, plasticized cellulosics, cellulose propionates, ethylcellulose, natural fibers, any derivatives thereof, any mixture of polymers thereof, any copolymer thereof, or any combination thereof.

[00301] In certain embodiments, the polymers for use in the fibers preferably comprise a polyolefin, such as polypropylene, polyethylene, a mixture of polypropylene and polyethylene, and combinations thereof.

[00302] A wide variety of polypropylenes can be used in embodiments of the invention, typically with molecular weights greater than about 120,000 g / mol and, more typically, with molecular weights ranging from about 150,000 to about 300,000 g / mol. In one embodiment, the polypropylene may have molecular weights ranging from about 160,000 to about 250,000 g / mol and, in particular, from about 160,000 to about 180,000 g / mol.

[00303] In certain embodiments for the preparation of spunbond fibers, the polypropylenes that can be used typically have an MFR of about 10 to 100 g / 10 min and, in particular, about 20 to 40 g / 10 min, with an MFR of about 22 to 38 g / 10 min being somewhat more typical. Unless otherwise indicated, MFR is measured in accordance with ASTM D-1238.

[00304] Examples of such polypropylenes may include those available from ExxonMobil, such as PP3155 (36 MFR g / 10 min, density of 0.90 g / cm3 and MW 172 kg / mol); PP3155E5 (36 MFR g / 10 min, density of 0.90 g / cm3 and MW 172 kg / mol); and ACHIEVE™ 3854 (24 MFR g / 10 min, density of 0.90 g / cm3). Polypropylenes available from SABIC®, such as SABIC PP 511A (25 MFR g / 10 min, Petition 870250088344, dated 09 / 29 / 2025, pp. 104 / 234 85 / 165 density of 0.905 g / cm3), polypropylenes available from Borealis, such as HG475FB (27 MFR g / 10 min) and polypropylenes available from Braskem, such as CP360H (34 MFR g / 10 min) can also be used.

[00305] In certain embodiments of melt blow molding fiber preparation, polypropylenes that can be used typically have an MFR greater than about 500 g / 10 min. For example, polypropylene can exhibit an MFR of about 500 to 2500 g / 10 min and, in particular, about 1000 to 1500 g / 10 min, with an MFR of about 1200 to 1400 g / 10 min being somewhat more typical. An example of such polypropylene is available from Braskem, as H155 (1284 MFR) g / 10 min.

[00306] In certain embodiments, the fibers may comprise a multicomponent fiber, such as a bicomponent fiber comprising a first polymeric component and a second polymeric component, wherein the second polymeric component comprises a mixture of polyolefins, in which a first polyolefin in the mixture has a low MFR, such as less than 100 g / 10 min, and the second polyolefin in the mixture has a higher MFR than that of the first polyolefin, such as greater than 500 g / 10 min, and in particular, greater than 1,000 g / 10 min. Typically, the MFR of the mixture is less than 50 g / 10 min and the MFR ratio between the low MFR polyolefin and the high MFR polyolefin is 1:100, and in particular: 1:20 to 1:50. Typically, the amount of high MFR in the mixture is about 0.5 to 12 percent by weight, based on the total weight of the mixture, and in particular, about 2 to 8 percent by weight, and more particularly, about 3 to 6 percent by weight, based on the total weight of the mixture. Petition 870250088344, dated 09 / 29 / 2025, pp. 105 / 234 86 / 165

[00307] In one such embodiment, the first polymeric component comprises a polypropylene polymer with an MFR of about 20 to 40 g / 10 min, and the second polymeric component comprises a mixture of a low MFR polypropylene with an MFR of about 20 to 40 g / 10 min and a high MFR polypropylene with an MFR of about 1,100 to 1,400 g / 10 min, wherein the amount of high MFR polypropylene in the mixture is about 3 to 6 percent by weight, based on the total weight of the mixture. The polypropylene in the first polymeric component may be the same polypropylene or a different polypropylene from the low MFR polypropylene in the second polymeric component. These fibers, when prepared in a side-by-side, eccentric, or D-centric configuration, may be used to prepare a nonwoven fabric comprising crimped fibers.

[00308] In some embodiments, the polyolefin may comprise a polyethylene polymer. Several types of polyethylene polymers may be employed in the fibers of the present invention. For example, high-density polyethylene, branched (i.e., non-linear) low-density polyethylene, or linear low-density polyethylene (LLDPE) may be used. Polyethylenes may be produced from any of the well-known processes, including metallocene and Ziegler-Natta catalytic systems. In general, polyethylene polymers conventionally used in the production of spunbond fabrics may be suitable for use in the present invention.

[00309] In one embodiment of the invention, the polyethylene component comprises a polyethylene with a density ranging from about 0.90 to 0.97 g / cm3 (ASTM D-792). In particular, the Petition 870250088344, dated 09 / 29 / 2025, pp. 106 / 234 87 / 165 Preferred polyethylenes have densities ranging from 0.93 to 0.965 g / cm3, and more particularly from about 0.94 to 0.965 g / cm3. Examples of suitable polyethylenes include ASPUN™6834 (a polyethylene polymer resin with a melt flow rate of 17 g / 10 min (ISO 1133) and a density of 0.95 g / cm3 (ASTM D792)), available from Dow Chemical Company, and HD6908.19 (a polyethylene resin supplied by ExxonMobil with a melt flow rate in the range of 7.5 to 9 g / 10 min (ISO 1133) and a density of 0.9610 to 0.9680 g / cm3 (ASTM D-792)).

[00310] LDPE can also be used in some embodiments of the present invention. LDPE is typically produced by a catalytic solution or fluidized bed process under conditions established in the art. The resulting polymers are characterized by an essentially linear structure. The density is controlled by the level of comonomer incorporated into the polymeric structure, which would otherwise be linear. Several alpha-olefins are typically copolymerized with ethylene in the production of LDPE. The alpha-olefins, which preferably have four to eight carbon atoms, are present in the polymer in an amount of up to about 10% by weight. The most typical comonomers are butene, hexene, 4-methyl-1-pentene, and octene. In general, LDPE can be produced in such a way that various density and melt flow rate properties are obtained, making the polymer suitable for melt spinning with polypropylene.Preferably, LLDPE should have a melt flow rate greater than 10, and more preferably 15 or higher for spun filaments. Particularly preferred are LLDPE polymers with a density of 0.90 to 0.97 g / cm3 and a melt flow rate greater than 25. Petition 870250088344, dated 09 / 29 / 2025, pp. 107 / 234 88 / 165 Examples of commercially available linear low-density polyethylene polymers include those available from Dow Chemical Company, such as ASPUN™ Type 6811 (27 MFR g / 10 min, density 0.923 g / cm3), ASPUN™ Type 6834 (17 MFR g / 10 min, density 0.95 g / cm3), ASPUN™ Type 6000 (30 MFR g / 10 min, density 0.955 g / cm3), ASPUN™ Type 6850 (30 MFR g / 10 min, density 0.955 g / cm3), Dow LLDPE 2500 (55 MFR g / 10 min, density 0.923 g / cm3), Dow LLDPE Type 6808A (36 MFR g / 10 min, density 0.940 g / cm3), and the Exact series of... Linear low-density polyethylene polymers from Exxon Chemical Company, such as Exact 2003 (31 MFR g / 10 min, density 0.921 g / cm3).

[00311] In some embodiments, polymers can be extensible and / or elastic.

[00312] In certain embodiments, the nonwoven fabric comprises a mixture of an olefin polymer and an elastomeric olefin copolymer.

[00313] In applications aimed at preparing spunbond fabrics, the olefinic polymer typically exhibits an MFR of about 5 to 150 g / 10 min, with an MFR of about 15 to 50 g / 10 min being preferred, and more particularly, an MFR of about 20 to 40 g / 10 min being somewhat more preferred. The amount of olefinic polymer in the fibers is typically 75 to 95 percent by weight, based on the total weight of the fiber, and in particular, about 80 to 95 percent by weight, based on the total weight of the fiber.

[00314] Furthermore, polypropylenes that can be used as the first polypropylene can have an MFR of around 10 to 100 g / 10 min and, in particular, around 20 to 40 g / 10 min, with an MFR of around 22 to 38 g / 10 min being somewhat more typical. Except Petition 870250088344, dated 09 / 29 / 2025, pp. 108 / 234 89 / 165 unless otherwise indicated, MFR is measured in accordance with ASTM D-1238.

[00315] Examples of such polypropylenes may include those available from ExxonMobil, such as PP3155 (36 MFR g / 10 min, density of 0.90 g / cm3 and molecular weight of 172 kg / mol); PP3155E5 (36 MFR g / 10 min, density of 0.90 g / cm3 and molecular weight of 172 kg / mol); and ACHIEVE™ 3854 (24 MFR g / 10 min, density of 0.90 g / cm3). Polypropylenes available from SABIC®, such as SABIC PP 511A (25 MFR g / 10 min, density of 0.905 g / cm3), and polypropylenes available from Borealis, such as HG475FB (27 MFR g / 10 min) may also be used.

[00316] In a preferred embodiment, the olefinic polymer comprises polypropylene. A wide variety of polypropylenes can be used as the olefinic polymer in fibers. Suitable polypropylenes can be produced from any of the well-known processes, including metallocene and Ziegler-Natta catalytic systems.

[00317] In certain embodiments, the olefin copolymer comprises a propylene copolymer comprising at least two different types of monomeric units, one of which is propylene. Suitable examples of monomeric units include, for example, ethylene and higher α-olefins in the C4 to C20 range, such as 1-butene, 4-methyl-1-pentene, 1-hexene or 1-octene, and 1-decene, or mixtures thereof. Preferably, ethylene is copolymerized with propylene, so that the propylene copolymer comprises propylene units (polymer chain units derived from propylene monomers) and ethylene units (polymer chain units derived from ethylene monomers). Petition 870250088344, dated 09 / 29 / 2025, pp. 109 / 234 90 / 165

[00318] Olefin copolymer is present as a minor component in the polypropylene blend. The amount of olefin copolymer in the blend typically varies from 5 to 25 percent by weight, based on the total weight of the fiber, and in particular, from about 6 to 20 percent by weight, based on the total weight of the fiber. More specifically, the amount of olefin copolymer in the blend varies from about 1 to 25 percent by weight, based on the total weight of the blend. In particular, the amount of olefin copolymer can vary from about 2 to 20 percent by weight, as well as from about 4 to 16 percent by weight, from about 5 to 15 percent by weight, and from about 6 to 14 percent by weight, based on the total weight of the blend.

[00319] Typically, the propylene copolymer units or comonomers are derived from ethylene or at least one of the C4-10 alpha-olefins, constituting from 1% to 35%, or from 5% to about 35% by weight of the propylene-alpha-olefin copolymer. They may be present in amounts of % by weight, or from 7% by weight to 32% by weight, or from 8% to about 25% by weight, or from 8% by weight to 20% by weight, or even from 8% by weight to 18% by weight. The comonomer content is such that the propylene-to-olefin copolymer preferably has an isothermal heat of fusion (DSC) of 75,000 Gy (75 J / g) or less, a melting point of 100 °C or less, and a crystallinity of 2% to about 65%. It has tactile polypropylene and can preferably be adjusted to have a melt flow rate of 0.5 to 90 dg / min.

[00320] In certain embodiments, the propylene-olefin copolymer may consist of ethylene-derived units. The propylene-olefin copolymer contains 5% to 35%, or 5% to 20%, or 10% to 12%, or 15% to 20% by weight of the copolymer of Petition 870250088344, dated 09 / 29 / 2025, pp. 110 / 234 91 / 165 propylene-olefin. May contain a percentage by weight of ethylene-derived units. In some embodiments, the propylene-olefin copolymer consists essentially of propylene- and ethylene-derived units, i.e., the propylene-olefin copolymer is ethylene and / or propylene used in the polymerization.

[00321] In certain embodiments, the propylene-olefin copolymer may have a three-unit propylene triad tacticity (measured by 13C NMR) of at least 75%, at least 80%, at least 82%, at least 85%, or at least 90%. The triad tacticity is determined as follows. The tacticity ratio (denoted herein as m / r) is determined by 13C nuclear magnetic resonance (NMR). The m / r N tacticity ratio is calculated by Cheng as defined in 17 MACROMOLECULES 1950 (1984), which is incorporated herein by reference. The notation m or r represents the stereochemistry of a pair of adjacent propylene groups, m refers to meso and r refers to racemic. An m / r ratio of 1.0 generally represents a syndiotactic polymer, and an m / r ratio of 2.0 generally represents an atactic material. Isotactic materials theoretically have m / r ratios close to infinity, and many derived atactic polymers have sufficient isotactic content to produce m / r ratios greater than 50.

[00322] Examples of suitable propylene-olefin copolymers may include VISTAMAXX® (ExxonMobil Chemical Company, Houston, Texas, USA), VERSIFY® (The Dow Chemical Company, Midland, Michigan, USA), TAFMER® XM or NOSTIO® grades (Mitsui Company, Japan) and SOFTEL® grades (Basell Polyfins, Netherlands). Petition 870250088344, dated 09 / 29 / 2025, pp. 111 / 234 92 / 165

[00323] In certain embodiments, the nonwoven fabric may comprise fibers comprising a mixture of a first polypropylene polymer and an olefin copolymer wherein the olefin copolymer comprises a low isotacticity polypropylene (for example, a polypropylene with an isotacticity [mmmm] of 30 to 70 mol%.

[00324] Consequently, in certain embodiments, low isotacticity polypropylene may be present in amounts of about 1 to 25 percent by weight, 2 to 24 percent by weight, 3 to 22 percent by weight, 4 to 21 percent by weight, 5 to 20 percent by weight, 6 to 19 percent by weight, 7 to 18 percent by weight, 8 to 17 percent by weight, 9 to 16 percent by weight and 10 to 15 percent by weight, based on the total weight of the first polypropylene component.

[00325] Low isotacticity polypropylene can generally be characterized by one or more of the following properties: isotacticity: a mesopentate fraction [mmmm] of 20 to 70% by mole; average molecular weight (Mw) of 10,000 to 200,000; a melting temperature of approximately 60 to 120 °C; and a melt flow rate (MFR) greater than 40 g / 10 min.

[00326] In addition to the properties above, low isotacticity polypropylene may have a viscosity B of about 7,000 to 400,000 mPa and a tensile modulus of about 80 to 120 MPa.

[00327] Suitable low isotacticity polypropylene polymers generally exhibit an isotacticity [mmmm] (mol%) between about 20 and 70, and in particular, a [mmmm] between Petition 870250088344, dated 09 / 29 / 2025, pp. 112 / 234 93 / 165 and 60 mol%, and more particularly, a [mmmm] between 35 and 55 mol%. In one embodiment, low isotacticity polypropylene exhibits an isotacticity [mmmm] between about 40 and 50 mol%.

[00328] The stereochemistry (e.g., stereoregularity index [mm], mesopentate fraction [mmmm], racemic pentade fraction [rrrr], racemic-meso-racemic-mesopentate fraction [rmrm], and triad fractions [mm][rr] and [mr]) of low isotacticity polypropylene can be determined with a 13C NMR spectrum according to the peak assignment proposed by A. Zambelli, et al., Macromolecules, No. 8, p. 687 (1975). A 13C NMR, Model JNM-EX400, produced by JEOL Ltd. can be used to obtain the spectrum according to the following parameters:

[00329] Method: complete proton decoupling method;

[00330] Concentration: 220 mg / mL;

[00331] Solvent: mixed solvent of 1,2,4-trichlorobenzene and deuterated benzene (90 / 10 by volume);

[00332] Temperature: 130 °C;

[00333] Pulse width: 45o;

[00334] Pulse repetition time: 4 seconds;

[00335] Accumulation: 10,000 times; M=m / Sx100 R=y / Sx100 S= Ρββ + Ραβ+Ραγ<Expressão de Cálculo> S=Pee: 19.8-22.5 ppm Petition 870250088344, 09 / 29 / 2025, pág. 113 / 234 94 / 165 Pab: 18.0-17.5 ppm Ραγ: 17.5-17.1 ppm γ: racêmica cadeia pentada: 20.7-20.3 ppm m: meso pentada cadeia: 21.7-22.5 ppm.

[00336] In one embodiment, low isotactic polypropylene has an isotacticity [mmmm] (mol%) that is greater than about 30, greater than about 31, greater than about 32, greater than about 33, greater than about 34, greater than about 35, greater than about 36, greater than about 37, greater than about 38, greater than about 39, greater than about 40, greater than about 41, greater than about 42, greater than about 43, greater than about 44, greater than about 45, greater than about 45, greater than about 47, greater than about 48, greater than about 49, greater than about 50, greater than about 51, greater than about 52, greater than about 53, greater than about 54, greater than about 55, greater than approximately 56, greater than approximately 57, greater than approximately 58, greater than approximately 59, and greater than approximately 60.

[00337] In one embodiment, low isotacticity polypropylene has an isotacticity [mmmm] (mol%) that is less than about 60, less than about 59, less than about 58, less than about 57, less than about 56, less than about 55, less than about 54, less than about 53, less than about 52, less than about 51, less than about 50, less than about 49, less than about 48, less than about 47, less than about 46, less than about 45, less than about 44, less than about 43, less than about 42, less than about 41, less than about 40, less than about 39, less than about 38, less than about 37, less than about 36, less than Petition 870250088344, dated 09 / 29 / 2025, pp. 114 / 234 95 / 165 approximately 35, less than approximately 34, less than approximately 33, less than approximately 32, and less than approximately 31.

[00338] In some embodiments, low isotacticity polypropylene may have a crystallinity of about 30 to 60%, such as between 35 and 55%, between 40 and 50%, and preferably between 42 and 48%. In one embodiment, low isotacticity polypropylene may have a crystallinity of about 44 to 46%. The crystallinity of low isotacticity polypropylene may be measured in accordance with ASTM D-3418-15.

[00339] In one embodiment, low isotacticity polypropylene typically exhibits an MFR greater than 40 g / 10 min and a molecular weight less than 140,000 g / mol and, in particular, an MFR greater than 45 g / 10 min and a molecular weight less than 135,000 g / mol. In a preferred embodiment, low isotacticity polypropylene exhibits a molecular weight between 125,000 g / mol and 135,000 g / mol and an MFR of about 45 to 55 g / 10 min. Unless otherwise indicated, MFR is measured in accordance with ASTM D-1238.

[00340] In certain embodiments, low isotacticity polypropylene has a melting temperature that is greater than about 60 °C, and in particular, from about 60 to 120 °C, and more particularly, from about 60 to 100 °C. In one embodiment, low isotacticity polypropylene has a melting temperature that is from about 65 to 85 °C, and in particular, from about 70 to 80 °C. The melting temperature of low isotacticity polypropylene can be determined according to ISO 306 Method A50. Petition 870250088344, dated 09 / 29 / 2025, pp. 115 / 234 96 / 165

[00341] In certain embodiments, low isotacticity polypropylene has a molecular weight ranging from about 30,000 to about 150,000 g / mol and, in particular, from about 45,000 to about 140,000 g / mol and, more particularly, from about 70,000 to 135,000 g / mol. In a preferred embodiment, low isotacticity polypropylene has a molecular weight ranging from about 128,000 to about 132,000 g / mol.

[00342] In one embodiment, low isotacticity polypropylene may have a molecular weight less than one of the following: less than about 150,000 g / mol, less than about 145,000 g / mol, less than about 140,000 g / mol, less than about 138,000 g / mol, less than about 136,000 g / mol, less than about 134,000 g / mol, less than about 132,000 g / mol, less than about 130,000 g / mol, less than about 128,000 g / mol, less than about 126,000 g / mol, less than about 124,000 g / mol, less than about 122,000 g / mol, less than about 120,000 g / mol, less than about 118,000 g / mol, less than about 116,000 g / mol, less than about 114,000 g / mol, less than about 112,000 g / mol, less than about 110,000 g / mol, less than about 108,000 g / mol, less than about 106,000 g / mol, less than about 104,000 g / mol, less than about 102,000 g / mol, less than about 100,000 g / mol, less than about 98,000 g / mol, less than about 96,000 g / mol, less than about 94.000 g / mol, less than about 92,000 g / mol, less than about 90,000 g / mol, less than about 88,000 g / mol, less than about 86,000 g / mol, less than about 84,000 g / mol, less than about 82,000 g / mol, less than about 80,000 g / mol, less than about 78,000 g / mol, less than about 76,000 g / mol, less than about. Petition 870250088344, dated 09 / 29 / 2025, pp. 116 / 234 97 / 165 of 74,000 g / mol, less than about 72,000 g / mol or less than about 70,000 g / mol.

[00343] In some embodiments, the low isotacticity polypropylene has a lower molecular weight than the first polypropylene with which it is mixed. For example, in certain embodiments of the present invention, the percentage difference in molecular weight between the first polypropylene and the low isotacticity polypropylene is from 5 to 150%. In one embodiment, the percentage difference may be between 7 and 120%. In a preferred embodiment, the percentage difference in molecular weight between the first polypropylene and the low isotacticity polypropylene is about 20 to 35%, and more preferably, about 25 to 30%.

[00344] In the context of the present invention, the percentage difference is calculated as follows:

[00345] PERCENTAGE DIFFERENCE x 100

[00346] In one embodiment, the first polypropylene has a molecular weight of 172,000 g / mol and the low-isotacticity polypropylene has a molecular weight of about 130,000, providing a percentage difference of about 27.8%. In another embodiment, the first polypropylene may have a molecular weight of about 140,000 g / mol, and the low-isotacticity polypropylene may have a molecular weight of 130,000 g / mol, providing a percentage difference of about 7%. In another embodiment, the first polypropylene may have a weight Petition 870250088344, dated 09 / 29 / 2025, pp. 117 / 234 98 / 165 molecular weight of approximately 172,000 g / mol, and low isotacticity polypropylene can have a molecular weight of 45,000, providing a percentage difference of approximately 117%.

[00347] Examples of suitable low isotacticity polypropylenes are available from Idemitsu under the product name LMODU™. Examples include S400 (~2,600 MFR g / 10 min, density of 0.87 g / cm3 and molecular weight of 45 kg / mol); S600 (390 MFR g / 10 min, density of 0.87 g / cm3 and molecular weight of 75 kg / mol); and S901 (50 MFR g / 10 min, density of 0.87 g / cm3 and molecular weight of 130 kg / mol).

[00348] In other embodiments, low isotacticity polypropylene may comprise a copolymer of ethylene and propylene units.

[00349] As discussed above, low isotacticity polypropylene is blended with the first polypropylene. Typically, blending takes place in an extruder under heat and pressure to produce a homogeneous mixture before being introduced into the spin beam as a molten or semi-molten polymer stream.

[00350] The amount of low isotacticity polypropylene in the mixture typically varies from about 0.1 to 40 percent by weight, based on the total weight of the polypropylene component, and in particular from about 5 to 25 percent by weight, based on the total weight of the polypropylene component. In one embodiment, the amount of low isotacticity polypropylene in the mixture typically varies from about 5 to 20 percent by weight, and more typically from about 8 to 16 percent by weight, and even more Petition 870250088344, dated 09 / 29 / 2025, pp. 118 / 234 99 / 165 typically, about 10 to 15 percent by weight, based on the total weight of the propylene component.

[00351] In some embodiments, the polypropylene component may include additives such as pigments, antimicrobial agents, processing aids, fillers such as Ca20a, hydrophilic agents, antistatic agents, hydrophobic additives, botanicals such as aloe vera, vitamin E, flame retardants, biodegradable enhancing agents, slip agents and the like.

[00352] In some embodiments, polymers may comprise polymers derived from mechanically or chemically recycled raw materials. For example, up to 100% of the polymer that makes up nonwoven fabric may be derived from recycled polymers.

[00353] In other embodiments, nonwoven fabrics, according to one or more embodiments of the invention, can be prepared from materials of bio-based origin and, in particular, from polymers of bio-based origin. Unlike petroleum-derived polymers, polymers of bio-based origin are generally derived from a material of bio-based origin. In some embodiments, a polymer of bio-based origin can also be considered biodegradable. A special class of biodegradable product made with a material of bio-based origin can be considered compostable if it can be degraded in a composting environment. The European standard EN 13432, Test of Compostability of Plastic Products, can be used to determine whether a fabric or film composed of sustainable compost can be classified as compostable. Petition 870250088344, dated 09 / 29 / 2025, pp. 119 / 234 100 / 165

[00354] In one such embodiment, the nonwoven fabric comprises fibers comprising a polymer of bio-based origin. In certain embodiments, the fibers are substantially free of synthetic materials, such as petroleum-based materials and polymers. For example, the fibers comprising the nonwoven fabric may have less than 25% by weight of non-biological materials and, more preferably, less than 20% by weight, less than 15% by weight, less than 10% by weight and, even more preferably, less than 5% by weight of non-biological materials, based on the total weight of the nonwoven fabric.

[00355] In certain embodiments, nonwoven fabric may comprise fibers comprising a bio-based polymer and a polymer derived from a petroleum source.

[00356] In one embodiment, bio-based polymers for use may include aliphatic polyester polymers, such as polylactic acid, and bio-based derived polyethylene.

[00357] The aliphatic polyesters useful in the present invention may include homo- and copolymers of poly(hydroxyalkanoates) and homo- and copolymers of those aliphatic polyesters derived from the reaction product of one or more polyols with one or more polycarboxylic acids, which are typically formed from the reaction product of one or more alkanediols with one or more alkanedicarboxylic acids (or acyl derivatives). The polyesters may also be derived from multifunctional polyols, for example, glycerin, sorbitol, pentaerythritol and combinations thereof, to form branched, star and graft homo- and copolymers. Polyhydroxyalkanoates are generally formed from monomeric units of hydroxy acids or their Petition 870250088344, dated 09 / 29 / 2025, pages 120 / 234 101 / 165 derivatives. These include, for example, polylactic acid, polyhydroxybutyrate, polyhydroxyvalerate, polycaprolactone and the like. Miscible and immiscible mixtures of aliphatic polyesters with one or more additional semicrystalline or amorphous polymers may also be used.

[00358] A useful class of aliphatic polyesters are poly(hydroxyalkanoates), derived by condensation or ring-opening polymerization of hydroxy acids, or their derivatives. Suitable poly(hydroxyalkanoates) can be represented by the formula: H(O--R--C(O)--)nOH where R is an alkylene moiety that can be linear or branched, containing from 1 to 20 carbon atoms, preferably from 1 to 12 carbon atoms, optionally substituted by catenar oxygen atoms (attached to carbon atoms in a carbon chain); n is a number such that the ester is polymeric and, preferably, a number such that the molecular weight of the aliphatic polyester is at least 10,000, preferably at least 30,000 and, more preferably, at least 50,000 daltons. In certain embodiments, the molecular weight of the aliphatic polyester is typically less than 1,000,000, preferably less than 500,000, and most preferably less than 300,000 daltons.R may also comprise one or more oxygen atoms of a catenar (i.e., chain) ether. Generally, the R group of the hydroxy acid is such that the pendant hydroxyl group is either a primary or secondary hydroxyl group.

[00359] Useful poly(hydroxyalkanoates) include, for example, homo- and copolymers of poly(3-hydroxybutyrate), poly(4-hydroxybutyrate), poly(3-hydroxyvalerate), poly(lactic acid) (also known as polylactide), poly(3-hydroxypropanoate), Petition 870250088344, dated 09 / 29 / 2025, pp. 121 / 234 102 / 165 poly(4-hydropentanoate), poly(3-hydroxypentanoate), poly(3-hydroxyhexanoate), poly(3-hydroxyheptanoate), poly(3-hydroxyoctanoate), polydioxanone, polycaprolactone and polyglycolic acid (i.e., polyglycolide). Copolymers of two or more of the above hydroxy acids may also be used, for example, poly(3-hydroxybutyrate-co-3-hydroxyvalerate), poly(lactate-co-3-hydroxypropanoate), poly(glycolide-co-pdioxanone) and poly(lactic acid-co-glycolic acid). Mixtures of two or more poly(hydroxyalkanoates) may also be used, as well as mixtures with one or more semicrystalline or amorphous polymers and / or copolymers.

[00360] 0 aliphatic polyester may be a poly(lactic acid-co-glycolic acid) block copolymer. Aliphatic polyesters useful in the compositions of the invention may include homopolymers, random copolymers, block copolymers, star-branched random copolymers, star-branched block copolymers, dendritic copolymers, hyperamphica copolymers, graft copolymers and combinations thereof.

[00361] Another useful class of aliphatic polyesters includes those aliphatic polyesters derived from the reaction of one or more alkanediols with one or more alkanedicarboxylic acids (or acyl derivatives). These polyesters have the general formula: OO 0 0 HO(CRC)„--[ORO — C—R—C — O]m'(R.' O)„H, where R' and R'' each represent an alkylene fraction that can be linear or branched, containing from 1 to 20 atoms of Petition 870250088344, dated 09 / 29 / 2025, pages 122 / 234 103 / 165 carbon, preferably from 1 to 12 carbon atoms, is a number such that the ester is polymeric, and preferably a number such that the molecular weight of the aliphatic polyester is at least 10,000, preferably at least 30,000 and, more preferably, at least 50,000 daltons, but less than 1,000,000, preferably less than 500,000 and, more preferably, less than 300,000 daltons. Each n is independently 0 or 1. R' and R'' may further comprise one or more catenar (i.e., chain) ether oxygen atoms.

[00362] Examples of aliphatic polyesters include those homo- and copolymers derived from (a) one or more of the following diacids (or derivatives thereof): succinic acid; adipic acid; 1,12-dicarboxidodecane; fumaric acid; glutaric acid; diglycolic acid; and maleic acid; and (b) one or more of the following diols: ethylene glycol; polyethylene glycol; 1,2-propanediol; 1,3-propanediol; 1,2-propanediol; 1,2-butanediol; 1,3-butanediol; 1,4-butanediol; 2,3-butanediol; 1,6-hexanediol; 1,2-alkane diols with 5 to 12 carbon atoms; diethylene glycol; polyethylene glycols with a molecular weight of 300 to 10,000 daltons, and preferably from 400 to 8,000 daltons; propylene glycols with a molecular weight of 300 to 4.000 daltons; block or random copolymers derived from ethylene oxide, propylene oxide or butylene oxide; dipropylene glycol; and polypropylene glycol, and (c) optionally a small amount, i.e., 0.5–7.0 molar percent of a polyol with a functionality greater than two, such as glycerol, neopentyl glycol and pentaerythritol.

[00363] Such polymers may include polybutylene succinate homopolymer, polybutylene adipate homopolymer, Petition 870250088344, dated 09 / 29 / 2025, pages 123 / 234 104 / 165 polybutylene adipate-succinate copolymer, polyethylene succinate-adipate copolymer, polyethylene glycol succinate homopolymer and polyethylene adipate homopolymer.

[00364] Commercially available aliphatic polyesters include poly(lactide), poly(glycolide), poly(lactide-coglycolide), poly(L-lactide-co-trimethylene carbonate), poly(dioxanone), poly(butylene succinate), and poly(butylene adipate).

[00365] The term aliphatic polyester encompasses — in addition to polyesters made exclusively of aliphatic and / or cycloaliphatic components — also polyesters that contain, in addition to aliphatic and / or cycloaliphatic units, aromatic units, provided that the polyester has a substantial bio-based content.

[00366] In addition to PLA-based resins, nonwoven fabrics, according to embodiments of the invention, may include other polymers derived from an aliphatic component possessing a carboxylic acid group and a hydroxyl group, also called polyhydroxyalkanoates (PHA). Examples of these are polyhydroxybutyrate (PHB), poly(hydroxybutyrate-cohydroxyvaletherate) (PHBV), poly-(hydroxybutyrate-co-polyhydroxyhexanoate) (PHBH), polyglycolic acid (PGA), poly(epsilon-caprolactone) (PCL) and, preferably, polylactic acid (PLA).

[00367] Examples of additional polymers that can be used in embodiments of the invention include polymers derived from a combination of an aliphatic component having two carboxylic acid groups with an aliphatic component having two Petition 870250088344, dated 09 / 29 / 2025, pages 124 / 234 105 / 165 hydroxyl groups, and are polyesters derived from aliphatic diols and aliphatic dicarboxylic acids, such as polybutylene succinate (PBS), polyethylene succinate (PES), polybutylene adipate (PBA), polyethylene adipate (PEA), polytetramethyl adipate / terephthalate (PTMAT).

[00368] Useful aliphatic polyesters include those derived from semicrystalline polylactic acid. Poly(lactic acid) or polylactide (PLA) has lactic acid as its main degradation product, which is commonly found in nature, is non-toxic, and is widely used in the food, pharmaceutical, and medical industries. The polymer can be prepared by ring-opening polymerization of the lactic acid dimer, lactide. Lactic acid is optically active, and the dimer appears in four different forms: L,L-lactide, D,D-lactide, D,L-lactide (meso-lactide), and a racemic mixture of L,L- and D,D-. By polymerizing these lactides as pure compounds or as mixtures, poly(lactide) polymers can be obtained with different stereochemistries and different physical properties, including crystallinity. OL,L- or D,D-lactide produces semicrystalline poly(lactide), while poly(lactide) derived from D,L-lactide is amorphous.

[00369] Generally, polylactic acid-based polymers are prepared from dextrose, a sugar source derived from corn. In North America, corn is used because it is the most economical source of vegetable starch for final conversion to sugar. However, it should be recognized that dextrose can be derived from sources other than corn. The sugar is converted to lactic acid or a lactic acid derivative through fermentation using microorganisms. The lactic acid can then be Petition 870250088344, dated 09 / 29 / 2025, pp. 125 / 234 106 / 165 polymerized to form PLA. In addition to corn, other sources of sugar of agricultural origin can be used, including rice, beet, sugar cane, wheat, cellulosic materials such as xylose recovered from wood pulping, and the like.

[00370] Polylactide preferably has a high enantiomeric ratio to maximize the intrinsic crystallinity of the polymer. The degree of crystallinity of a poly(lactic acid) is based on the regularity of the polymer's main chain and its ability to crystallize with other polymer chains. If relatively small amounts of one enantiomer (such as D-) are copolymerized with the opposite enantiomer (such as L-), the polymer chain acquires an irregular shape and becomes less crystalline. For these reasons, when crystallinity is favored, it is desirable to have a poly(lactic acid) that contains at least 85% of an isomer, at least 90% of an isomer, or at least 95% of an isomer to maximize crystallinity.

[00371] In some embodiments, an approximately equimolar mixture of D-polylactide and L-polylactide is also useful. In certain embodiments, this mixture forms a unique crystalline structure with a higher melting point than isolated D-poly(lactide) and L-(polylactide), and also exhibits improved thermal stability.

[00372] Copolymers, including block and random copolymers, of poly(lactic acid) with other aliphatic polyesters can also be used. Useful co-monomers include glycolide, beta-propiolactone, tetramethylglycolide, beta-butyrolactone, gamma-butyrolactone, pivalolactone, 2-hydroxybutyric acid, alpha-hydroxyisobutyric acid, alpha-hydroxyvaleric acid, alpha-hydroxyisovaleric acid, alpha-hydroxyisovaleric acid Petition 870250088344, dated 09 / 29 / 2025, pp. 126 / 234 107 / 165 hydroxycaproic acid, alpha-hydroxyethylbutyric acid, alpha-hydroxyisocaproic acid, alpha-hydroxy-beta-methylvaleric acid, alpha-hydroxyoctanoic acid, alpha-hydroxydecanoic acid, alpha-hydroxymyristic acid, and alpha-hydroxystearic acid.

[00373] Mixtures of poly(lactic acid) and one or more other aliphatic polyesters, or one or more other polymers, may also be used. Examples of useful mixtures include poly(lactic acid) and poly(vinyl alcohol), polyethylene glycol / polysuccinate, polyethylene oxide, polycaprolactone, and polyglycolide.

[00374] In certain preferred embodiments, the aliphatic polyester component comprises a PLA-based resin. A wide variety of different PLA resins can be used to prepare nonwoven fabrics according to the embodiments of the invention. The PLA resin must have suitable molecular properties to be spun in spunbond processes. Examples of suitable PLA resins are provided by NatureWorks LLC, Minnetonka, Minnesota, No. 55345, such as grades 6752D, 6100D, and 6202D, which are believed to be produced generally following the teachings of U.S. Patents Nos. 5,525,706 and 6,807,973, both by Gruber et al. Other examples of suitable PLA resins may include L130, L175, and LX175, all from Corbion, Arkelsedijk 46, 4206 AC Gorinchem, Netherlands.

[00375] In some embodiments, inventive nonwoven fabrics may comprise bio-based polymeric components of biodegradable products that are derived from an aliphatic component having a carboxylic acid group (or a polyester-forming derivative thereof, such as an ester group) and a hydroxyl group (or a polyester-forming derivative thereof, Petition 870250088344, dated 09 / 29 / 2025, pp. 127 / 234 108 / 165 as an ether group) or they may be derived from a combination of an aliphatic component having two carboxylic acid groups (or a polyester-forming derivative thereof, such as an ester group) with an aliphatic component having two hydroxyl groups (or a polyester-forming derivative thereof, such as an ether group).

[00376] Additional, but not limiting, examples of bio-based polymers include polymers produced directly from organisms, such as polyhydroxyalkanoates (e.g., poly(betahydroxyalkanoate), poly(3-hydroxybutyrate-co-3-hydroxyvalerate, NODAX™) and bacterial cellulose; polymers extracted from plants and biomass, such as polysaccharides and their derivatives (e.g., gums, cellulose, cellulose esters, chitin, chitosan, starch, chemically modified starch), proteins (e.g., zein, whey, gluten, collagen), lipids, lignins, and natural rubber; and current polymers derived from monomers and derivatives of natural origin, such as biopolyethylene, biopolypropylene, polytrimethylene terephthalate, polylactic acid, NYLON 11, alkyd resins, succinic acid-based polyesters, and biopolyethylene terephthalate.

[00377] In some embodiments, the bio-derived polymer may comprise bio-derived polyethylene, bio-derived polypropylene, and bio-derived polyesters such as bio-derived PET, which are derived from a biological source. For example, bio-derived polyethylene may be prepared from fermented sugars to produce ethanol, which in turn is dehydrated to yield ethylene. An example of a suitable sugarcane-derived polyethylene is available from Braskem SA under the name PE SHA7260. Petition 870250088344, dated 09 / 29 / 2025, pages 128 / 234 109 / 165 Optional components

[00378] In some embodiments, the fibers may include one or more additives that are mixed into the polymer(s) during the melt extrusion phase. Examples of suitable additives include one or more colorants, such as pigments (e.g., T1O2), UV stabilizers, hydrophobic agents, hydrophilic agents, antistatic agents, elastomers, compatibilizers, antioxidants, antiblocking agents, slip agents, surfactants, optical brighteners, flame retardants, antimicrobials, such as copper oxide and zinc oxide, and the like.

[00379] In some embodiments, it may also be useful to optionally treat the nonwoven fabric with finishes containing additives or other chemicals, such as antimicrobial agents, flame retardants, catalysts, lubricants, softeners, light stabilizers, antioxidants, colorants such as inks and / or pigments, antistatic agents, fillers, odor control agents, perfumes and fragrances, and the like, and combinations thereof. Other optional components may be included in the compositions described herein. Tissue Properties

[00380] According to certain embodiments, for example, the fabric may exhibit a maximum tensile strength in the machine direction (MD) of about 20 N / 5 cm to about 75 N / 5 cm. In other embodiments, for example, the fabric may exhibit a maximum tensile strength in the machine direction (MD) of about 22 N / 5 cm to about 65 N / 5 cm. In other embodiments, Petition 870250088344, dated 09 / 29 / 2025, pp. 129 / 234 For example, in 110 / 165, the fabric may exhibit a maximum tensile strength in the machine direction (MD) of approximately 50 N / 5 cm to approximately 65 N / 5 cm. Thus, in certain embodiments, the fabric may exhibit a maximum MD tensile strength of at least any of the following: 20, 25, 26, 27, 28, 29, 30, 50, 60, 70 and 80 N / 5 cm, and / or at most approximately 100, 75, 70, 65, 60, 55, 50 and 45 N / 5 cm (e.g., approximately 25-100 N / 5 cm, approximately 30-75 N / 5 cm, approximately 45-65 N / 5 cm, etc.). In general, it should be recognized that MD and CD tensile strengths may vary depending on the fabric weight. In particular, nonwoven fabrics according to the embodiments of the invention may exhibit higher MD and CD tensile strengths than those presented above at base weights above 30 g / m2.

[00381] In certain embodiments, for example, the fabric may exhibit a maximum tensile strength in the transverse machine direction (CD) of about 5 N / 5 cm to about 85 N / 5 cm. In other embodiments, for example, the fabric may exhibit a maximum tensile strength CD of about 6 N / 5 cm to about 75 N / 5 cm. In some embodiments, for example, the fabric may exhibit a maximum tensile strength CD of about 7 N / 5 cm to about 25 N / 5 cm. Thus, in certain embodiments, the fabric may comprise a tensile strength CD of at most any one of the following: 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29 and 30 N / 5 cm and / or at most about 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 29, 28, 27, 26 and 25 N / 5 cm (for example, about 15-85 N / 5 cm, about 15-30 N / 5 cm, etc.).

[00382] According to certain embodiments, for example, nonwoven fabric may have a base weight of about 5 grams per Petition 870250088344, dated 09 / 29 / 2025, pp. 130 / 234 111 / 165 per square meter (g / m2) to approximately 150 g / m2. In other embodiments, for example, the fabric may have a base weight of approximately 8 g / m2 to approximately 70 g / m2. In certain embodiments, for example, the fabric may have a base weight of approximately 10 g / m2 to approximately 50 g / m2. In other embodiments, for example, the fabric may have a base weight of approximately 11 g / m2 to approximately 30 g / m2. In one embodiment, the fabric may have a base weight of approximately 15 g / m2 to approximately 25 g / m2. Thus, in certain embodiments, the fabric may have a base weight of at least about any of the following: 5, 6, 7, 8, 9, 10 and 11 g / m2 and / or at most about 150, 100, 70, 60, 50, 40 and 30 g / m2 (for example, about 9-60 g / m2, about 11-40 g / m2, etc.).

[00383] According to certain embodiments, for example, the fibers may have a linear mass density of about 0.05 dtex to about 12 dtex. In other embodiments, for example, the fibers may have a linear mass density of about 1 dtex to about 10 dtex. In other embodiments, for example, the fibers may have a linear mass density of about 1.2 dtex to about 6 dtex. Thus, in certain embodiments, the fibers have a linear mass density of at least about any of the following: 0.6, 0.7, 0.8, 0.9, 1.0, 1, 1.1, 1.2, 1.3, 1.4, 1.5 and 1.6 dtex and / or at most about 2.5, 2.4, 2.3, 2.2, 2.1, 2.0, 1.9, 1.8 and 1.7 dtex (for example, about 1-2.5 dtex, about 1.1-1.8 dtex, etc.).

[00384] For melt-blown fibers, the fibers can have a linear mass density of about 0.05 dtex to about 2.0 dtex.

[00385] In certain embodiments, bonded nonwoven fabrics, according to the embodiments of the present invention, exhibit Petition 870250088344, dated 09 / 29 / 2025, pages 131 / 234 112 / 165 improvements in abrasion resistance. Abrasion resistance is often measured with a friction test, in which the fabric surface is rubbed in a fairly controlled manner, and then the loose fibers are removed and weighed. Fabrics with improved abrasion resistance will show a reduction in the weight of fibers removed compared to a less abrasion-resistant nonwoven fabric. In some embodiments, nonwoven fabrics have shown an average weight of material removed during the abrasion test of less than 5 mg and, in particular, less than 4 mg, as determined according to the NWSP 20.5 Abrasion Test Method. The NWSP 20.5 Abrasion Test Method is discussed in greater detail below in the Examples Section.

[00386] In certain embodiments, the nonwoven fabrics according to the invention may exhibit a Martindale Abrasion Index of less than 2 and, in particular, less than 1.5. In certain embodiments, the nonwoven fabrics according to the invention may exhibit a Martindale Abrasion Index of about 1.0 to 2.0 and, in particular, of 1.0 to 1.6 and, more particularly, of about 1.1 to 1.5. In a specific embodiment, the nonwoven fabrics according to the invention may exhibit a Martindale Abrasion Index of about 1.40 to 1.45. The test method for evaluating the Martindale Abrasion Index is discussed in greater detail below in the Examples Section.

[00387] In certain embodiments, the nonwoven fabrics according to the invention may exhibit a Martindale abrasion score greater than 1.0, greater than 1.05, greater than 1.10, greater than 1.15, greater than 1.20, greater than 1.25, greater than 1.30, greater Petition 870250088344, dated 09 / 29 / 2025, pages 132 / 234 113 / 165 greater than 1.35, greater than 1.40, greater than 1.45, greater than 1.50, greater than 1.55, greater than 1.60, greater than 1.65, greater than 1.70, greater than 1.75, greater than 1.80, greater than 1.85, greater than 1.90, greater that is 1.95 and greater than 1.99.

[00388] In certain embodiments, the nonwoven fabrics according to the invention may exhibit an abrasion score. Martindale less than 2.0, less than 1.95, less than 1.90, less than 1.85, less than 1.80, less than 1.75, less than 1.70, less than 1.65, less than 1.60, less than 1.55, greater than 1.50, less than 1.45, less than 1.40, less than 1.35, less than 1.30, less than 1.25, less than 1.20, less than 1.15, less than 1.10, less that is 1.05 and less than 1.01.

[00389] In certain embodiments, bonded nonwoven fabrics, according to the embodiments of the present invention, exhibit enhanced softness, as demonstrated by a nonwoven fabric with a base weight of 20 to 30 g / m2, exhibiting a The Handle-o-meter in the transverse direction was less than 7.0 grams (g), such as less than 7.9 grams or less than 7.5 grams. The Handle-o-meter was measured according to the NWSP 90.3 standard, which is discussed in more detail below in the Examples Section.

[00390] In certain embodiments, bonded nonwoven fabrics according to the embodiments of the present invention exhibit improved softness, as demonstrated by nonwoven fabrics with a base weight of 20 to 30 g / m2 exhibiting a machine-directed handle-o-meter of less than 3.9 grams (g), such as less than 3.8 grams or less than 3.78 grams.

[00391] In certain embodiments, nonwoven fabrics according to the embodiments of the invention exhibit improvements in Petition 870250088344, dated 09 / 29 / 2025, pp. 133 / 234 114 / 165 one or more of the tensile strengths, elongations, abrasion resistance and softness compared to a similarly prepared nonwoven fabric, except that the similar fabric was spot-bonded with a bonding pattern having a bonding point compaction of less than 3.5 mm-1, such as less than 4.0 mm-1. In certain embodiments, the similarly prepared nonwoven fabric was spot-bonded with a bonding pattern in which the percentage of bonding surface area of ​​the nonwoven fabric is 18.1%. That is, the overall bonding point pattern is the same in the similarly prepared nonwoven fabric, except that the surface area of ​​the individual bonding points is larger, so that the overall percentage of bonding surface area of ​​the nonwoven fabric is higher, which also results in a decrease in bonding point compaction.In certain embodiments, the similarly prepared fabric is substantially identical (e.g., in terms of polymer chemistry, fiber structure, and extrusion conditions) to the fabric of the invention, except for the aforementioned bonding pattern in the comparison fabric, which has a compaction at the bonding point of less than 3.5 mm-1, as well as less than 4.0 mm-1. There may be some variations in the process conditions used in the similarly prepared nonwoven fabric, such as, for example, small variations in calender temperatures and pressures.

[00392] In certain embodiments, nonwoven fabrics, according to the embodiments of the present invention, may exhibit tensile strengths 10% higher compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1, such as, for example, Petition 870250088344, dated 09 / 29 / 2025, pages 134 / 234 115 / 165 example, less than 4.0 mm-1. In some embodiments, the nonwoven fabric may exhibit a tensile strength 10% to 50%, such as 12 to 30%, 12 to 25%, 12 to 24% or 12 to 20% greater than the tensile strength of a similarly prepared nonwoven fabric with a compaction at the bonding point less than 3.5 mm-1, such as less than 4.0 mm-1.

[00393] In certain embodiments, nonwoven fabrics according to the embodiments of the present invention may exhibit tensile strengths 10% higher compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%. In some embodiments, the nonwoven fabric may exhibit a tensile strength 10% to 30%, such as 12 to 20%, greater than the tensile strength of a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

[00394] In particular, the nonwoven fabrics according to the present invention may exhibit machine direction (MD) tensile strength increases of about 10 to 50% greater compared with a similarly prepared nonwoven fabric with a bonding point compaction of less than 3.5 mm-1, as well as less than 4.0 mm-1. In some embodiments, the nonwoven fabrics of the invention may exhibit a machine direction (MD) tensile strength increase ranging from about 10 to 30%, as well as from about 12 to 20%, or from about 12 to 15% compared with a similarly prepared nonwoven fabric with a bonding point compaction of less than 3.5 mm-1, as well as less than 4.0 mm-1. Petition 870250088344, dated 09 / 29 / 2025, pages 135 / 234 116 / 165

[00395] Furthermore, the nonwoven fabrics according to the present invention may exhibit increases in tensile strength in the transverse direction (CD) of about 10 to 50% greater compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1, such as less than 4.0 mm-1. In some embodiments, the nonwoven fabrics of the invention may exhibit an increase in tensile strength in the transverse direction (CD) ranging from about 10 to 30%, such as about 15 to 25%, about 18 to 24% or about 19 to 21% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1, such as less than 4.0 mm-1.

[00396] In certain embodiments, the nonwoven fabrics according to the present invention may exhibit increases in tensile strength in the machine direction (MD) that are about 10 to 50% greater compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%. In some embodiments, the inventive nonwoven fabrics may exhibit an increase in MD tensile strength ranging from about 10 to 30%, such as from about 12 to 20%, or from about 12 to 15% compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%.

[00397] Furthermore, the nonwoven fabrics according to the present invention may exhibit increases in tensile strength in the transverse direction (CD) of about 10 to 50% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%. In some embodiments, the nonwoven fabrics of the invention may Petition 870250088344, dated 09 / 29 / 2025, pages 136 / 234 117 / 165 exhibit an increase in tensile strength in the transverse direction (CD) ranging from about 10 to 30%, such as from about 15 to 25%, from about 18 to 24%, or from about 19 to 21% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

[00398] In some embodiments, the nonwoven fabrics according to the present invention may exhibit increases in elongation percentage of about 4 to 50% compared with a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1, such as, for example, less than 4.0 mm-1. In some embodiments, the nonwoven fabrics of the invention may exhibit an increase in elongation percentage of about 4 to 25%, such as, for example, about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1, such as, for example, less than 4.0 mm-1.

[00399] In some embodiments, the nonwoven fabrics according to the present invention may exhibit increases in elongation percentage of about 4 to 50% compared with a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%. In some embodiments, the nonwoven fabrics of the invention may exhibit an increase in elongation percentage of about 4 to 25%, such as about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

[00400] In certain embodiments, the nonwoven fabrics according to the present invention may exhibit an improvement in Petition 870250088344, dated 09 / 29 / 2025, pp. 137 / 234 118 / 165 abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a bonding point of less than 3.5 mm-1, as well as less than 4.0 mm-1. In some embodiments, the nonwoven fabrics of the invention may exhibit improved abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of about 10 to 25%, as well as about 12 to 24%, or about 18 to 22%, compared to a similarly prepared nonwoven fabric with a bonding point compaction of less than 3.5 mm-1, as well as less than 4.0 mm-1.

[00401] In certain embodiments, the nonwoven fabrics according to the present invention may exhibit improved abrasion resistance, as exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared with a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%. In some embodiments, the nonwoven fabrics of the invention may exhibit improved abrasion resistance, as exemplified by a percentage difference in the Martindale Abrasion Index of about 10 to 25%, such as about 12 to 24%, or about 18 to 22%, compared with a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

[00402] In some embodiments, the nonwoven fabrics, according to the embodiments of the invention, exhibited an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150% compared to a nonwoven fabric prepared in a different way. Petition 870250088344, dated 09 / 29 / 2025, pages 138 / 234 119 / 165 similar, with a compaction at the bonding point of less than 3.5 mm-1, as well as less than 4.0 mm-1. In certain embodiments, the nonwoven fabrics of the invention may exhibit an average percentage reduction in the weight of material removed during the abrasion test of 8 to 120%, as well as 9 to 95% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1, as well as less than 4.0 mm-1.

[00403] In some embodiments, the nonwoven fabrics, according to the embodiments of the invention, exhibited an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%. In certain embodiments, the nonwoven fabrics of the invention may exhibit an average percentage reduction in the weight of material removed during the abrasion test of 8 to 120%, such as 9 to 95%, compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

[00404] In some embodiments, the nonwoven fabrics, according to the embodiments of the invention, exhibited improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of about 5 to 20% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1, as well as less than 4.0 mm-1. In certain embodiments, the nonwoven fabrics of the invention may exhibit an average improvement in Handle-O-Meter values ​​of about 6 to 15%, as well as 8 to 10%, compared Petition 870250088344, dated 09 / 29 / 2025, pages 139 / 234 120 / 165 with a nonwoven fabric prepared in a similar manner, with a compaction at the bonding point of less than 3.5 mm-1, as well as less than 4.0 mm-1.

[00405] In some embodiments, the nonwoven fabrics according to the embodiments of the invention exhibited improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of about 5 to 20% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%. In certain embodiments, the nonwoven fabrics of the invention may exhibit an average improvement in Handle-O-Meter values ​​of about 6 to 15%, such as 8 to 10%, compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

[00406] In certain embodiments, the nonwoven fabrics, according to the embodiments of the invention, exhibited improvements in softness (measured with the Handle-O-Meter) of about 5 to 20% compared with a similarly prepared nonwoven fabric, with a compaction at the bonding point of less than 3.5 mm-1, as well as less than 4.0 mm-1. In certain embodiments, the nonwoven fabrics of the invention may exhibit an average improvement in softness of about 6 to 15%, as well as 8 to 10%, compared with a similarly prepared nonwoven fabric, with a compaction at the bonding point of less than 3.5 mm-1, as well as less than 4.0 mm-1.

[00407] In certain embodiments, the nonwoven fabrics according to the embodiments of the invention exhibited improvements in softness (measured with the Handle-O-Meter) of about 5 to 20% compared with a similarly prepared nonwoven fabric. Petition 870250088344, dated 09 / 29 / 2025, pp. 140 / 234 121 / 165 with a bonded surface area greater than 12%, such as 18.1%. In certain embodiments, the nonwoven fabrics of the invention may exhibit an average improvement in softness of about 6 to 15%, such as 8 to 10%, compared with a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

[00408] In certain embodiments, the nonwoven fabrics according to the embodiments of the invention may be characterized by having a bonded percentage area of ​​about 9.6 to 10.4%, an average surface area of ​​individual bonding points of about 0.15 to 2.0 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, a bonding point density of about 50 to 60 individual bonding points per square centimeter, a Martindale abrasion score of about 1.0 to 1.5 (e.g., 1.4 to 1.5), a transverse direction Handle-o-Meter of about 6.6 to 7.2 grams (for a nonwoven fabric with a base weight of 20 to 30 g / m2), a machine direction Handle-o-Meter of about 3.5 to 3.95 grams, and average abrasion resistance determined by the weight of material removed from 3.2 to 5.5 grams.

[00409] In certain embodiments, the nonwoven fabrics according to the embodiments of the invention may be characterized by having a bonded percentage area of ​​about 9.8 to 10%, an average surface area of ​​individual bonding points of about 0.16 to 0.19 mm2, an average compaction value at the bonding point of about 7.0 to 7.3 mm-1, a bonding point density of about 52 to 58 individual bonding points per square centimeter, a Martindale abrasion score of about 1.42 to 1.45, a Handle-o-Meter of Petition 870250088344, dated 09 / 29 / 2025, pp. 141 / 234 122 / 165 cross direction of approximately 6.7 to 7.0 grams (for a nonwoven fabric with a base weight of 20 to 30 g / m2), a machine direction Handle-O-Meter of approximately 3.6 to 3.9 grams and average abrasion resistance, as determined by the weight of material removed, of 3.4 to 3.6 grams.

[00410] In certain embodiments, the nonwoven fabrics according to the embodiments of the invention may be characterized by having a bonded area percentage of about 9.6 to 10.2%, an average individual bonding surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and an average increase in tensile strengths that are 10% greater, such as about 10 to 50%, about 12 to 24% or about 12 to 22%, compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1, such as less than 4.0 mm-1.

[00411] In certain embodiments, nonwoven fabrics according to the embodiments of the invention may be characterized by having a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and an average increase in tensile strengths that are 10% greater, such as about 10 to 50%, about 12 to 24%, or about 12 to 22%, compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%.

[00412] In certain embodiments, nonwoven fabrics according to the embodiments of the invention may be Petition 870250088344, dated 09 / 29 / 2025, pp. 142 / 234 123 / 165 characterized by having a bonded percentage area of ​​about 9.6 to 10.2%, an average individual bonding surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and an average increase in percentage elongation that is about 4 to 50%, such as about 4 to 20%, about 4 to 15%, or about 4 to 14%, compared with a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1, such as less than 4.0 mm-1.

[00413] In certain embodiments, nonwoven fabrics according to the embodiments of the invention may be characterized by having a bonded percentage area of ​​about 9.6 to 10.2%, an average individual bonding surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and an average increase in percentage elongation that is about 4 to 50%, such as about 4 to 20%, about 4 to 15%, or about 4 to 14%, compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%.

[00414] In certain embodiments, the nonwoven fabrics according to the embodiments of the invention may be characterized by having a bonded area percentage of about 9.6 to 10.2%, an average individual bonding surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and one or more of the following properties: i) an improvement in abrasion resistance, exemplified by a percentage difference in the Abrasion Index Petition 870250088344, dated 09 / 29 / 2025, pp. 143 / 234 124 / 165 Martindale results show a 10 to 30% reduction compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 1 mm-1; ii) an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, as of about 8 to 120% or 9 to 95% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 1 mm-1; and iii) improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of about 5 to 20%, as of about 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 1 mm-1.

[00415] In certain embodiments, the nonwoven fabrics according to the embodiments of the invention may be characterized by having a bonded area percentage of about 9.6 to 10.2%, an average individual bonding surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and one or more of the following properties: i) an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%; Petition 870250088344, dated 09 / 29 / 2025, pages 144 / 234 125 / 165 ii) an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, such as approximately 8 to 120% or 9 to 95% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%; and iii) improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of approximately 5 to 20%, such as approximately 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

[00416] In certain embodiments, the nonwoven fabrics according to the embodiments of the invention may be characterized by having a bonded area percentage of about 9.6 to 10.2%, an average individual bonding surface area of ​​about 0.10 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and one or more of the following properties: i) an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 1 mm-1; ii) an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, such as approximately 8 to 120% or 9 to 95% compared to a woven fabric Petition 870250088344, dated 09 / 29 / 2025, pages 145 / 234 126 / 165 nonwoven fabric prepared in a similar manner having a compaction at the bonding point of less than 3.5 mm-1, such as less than 4.0 mm-1; iii) improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of approximately 5 to 20%, as well as approximately 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1, as well as less than 4.0 mm-1; iv) an increase in tensile strengths in the machine direction (MD) that are about 10 to 50% greater, as of about 10 to 30%, as of about 12 to 20%, or about 12 to 15% greater, compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1, as of less than 4.0 mm-1; v) an increase in tensile strengths in the transverse direction (CD) that are about 10 to 50% greater, such as about 10 to 30%, such as about 15 to 25%, about 18 to 24%, or about 19 to 21%, compared with a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1, such as less than 4.0 mm-1; and vi) an increase in percent elongation that is about 4 to 50%, such as about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric having a compaction at the Petition 870250088344, dated 09 / 29 / 2025, pp. 146 / 234 127 / 165 bonding point smaller than 3.5 mm-1, such as smaller than 4.0 mm-1.

[00417] In certain embodiments, the nonwoven fabrics according to the embodiments of the invention may be characterized by having a bonded area percentage of about 9.6 to 10.2%, an average individual bonding surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and one or more of the following properties: i) an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%; ii) an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, such as approximately 8 to 120% or 9 to 95% compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%; iii) an improvement in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of approximately 5 to 20%, such as approximately 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%; iv) an increase in tensile strengths in the machine direction (MD) that are approximately 10 to 50% greater, such as Petition 870250088344, dated 09 / 29 / 2025, pp. 147 / 234 128 / 165 of about 10 to 30%, such as about 12 to 20%, or about 12 to 15% larger, compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%; v) an increase in tensile strengths in the transverse direction (CD) that are about 10 to 50% greater, such as about 10 to 30%, such as about 15 to 25%, about 18 to 24%, or about 19 to 21%, compared with a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%; and vi) an increase in percent elongation that is about 4 to 50%, such as about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%. System and method for preparing nonwoven fabric

[00418] Certain aspects of the invention provide systems and methods for preparing a bonded nonwoven fabric according to the embodiments described above.

[00419] With reference to FIG. 8, for example, a schematic diagram of a spunbond nonwoven fabric preparation system, according to certain embodiments of the invention, is illustrated and broadly designated by the reference character 100a. As shown in FIG. 8, a first polymer source (i.e., hopper) 102 is in fluid communication with the rotating beam 104 by means of the extruder 106. Petition 870250088344, dated 09 / 29 / 2025, pages 148 / 234 129 / 165

[00420] In certain embodiments, the first polymer source may provide a flow of a molten or semi-molten polymer resin. After extrusion, the extruded polymer flow is introduced into the spinning beam 104, at which point the flows enter a plurality of spinnerets (not shown) for spinning into filaments. After spinning, the spun filaments may then be stretched (i.e., attenuated) by means of a stretching unit (not shown) and randomized in a diffuser. The spinning beam 104 produces a curtain of filaments 108 which is deposited on the collecting surface 110 to produce a filament web. At this stage, the filaments may comprise a web 112 of filaments that are not bonded or are slightly bonded together.

[00421] A calender bonding unit 116, comprising a calender, is disposed downstream of the collection surface 110 and is configured and arranged to thermally direct adjacent filaments to each other and also impart a bonding pattern to the surface, according to embodiments of the invention, as discussed above. As discussed in greater detail below, the calender comprises a pair of cooperating rolls, wherein a first roll 116a comprises a roll with an engraved pattern, with a plurality of bonding points extending from a surface thereof, and the second roll 116b comprises a smooth or anvil-shaped surface. During bonding, the web 112 of filaments passes between the cooperating rolls, which are heated to a temperature sufficient to soften at least one polymeric component comprising the web filaments 112, producing a bonded nonwoven fabric 124.In certain embodiments, the glued nonwoven fabric 124 se. Petition 870250088344, dated 09 / 29 / 2025, pp. 149 / 234 130 / 165 moves to a bobbin winder 118, where the fabric is then wound onto rolls.

[00422] In some embodiments, an optional pair of cooperating rollers 120 (also referred to herein as a press roller) stabilizes the filament web by compressing it before its delivery to the calender 116 for bonding. In some embodiments, for example, the press roller may include a ceramic coating deposited on its surface. In certain embodiments, for example, one roller of the pair of cooperating rollers 120 may be positioned above the collection surface 110, and a second roller of the pair of cooperating rollers 120 may be positioned below the collection surface 110. In some embodiments, the system may also include a hot air blade (not shown) that exposes the web 112 to a flow of heated gas, such as air, to lightly bond and stabilize the web.

[00423] In some embodiments, the system 100a may further comprise a vacuum source 128 disposed below the collection surface 110. The vacuum source 128 provides a vacuum that helps to pull and drag the curtain of filaments 108 over the collection surface 110.

[00424] With reference to FIG. 9, a further aspect of a system and method for preparing a nonwoven fabric, according to at least one embodiment of the invention, is illustrated and broadly designated by the reference character 100b. In this embodiment, the system 100b can be configured and arranged to produce multicomponent filaments, as well as bicomponent filaments. Petition 870250088344, dated 09 / 29 / 2025, pages 150 / 234 131 / 165

[00425] System 100b includes a first polymer source (i.e., hopper) 130a that is in fluid communication with the spin beam 134 via extruder 136a. A second polymer source (i.e., hopper) 130b is also in fluid communication with the spin beam 134 via extruder 136b. In the preparation of multicomponent fabrics, the first polymer source may provide a flow of a first polymer resin, and the second polymer source may provide a flow of a second polymer resin. In melt spinning applications, the polymer flows are typically in a molten or semi-molten state. The first polymer resin and the second polymer resin may be different polymers or may be the same polymers, depending on the desired application and the desired properties of the nonwoven fabric.

[00426] After extrusion, the extruded polymer streams are introduced into the spinning beam 134, at which point the streams enter a plurality of spinnerets (not shown) for spinning into filaments. After spinning, the spun filaments may then be stretched (i.e., attenuated) by means of a stretching unit (not shown) and randomized in a diffuser. The spinning beam 134 produces a curtain of multicomponent filaments 138 which is deposited on the collection surface 110 to produce a web 140 of filaments. At this stage, the filaments may comprise a web 140 of multicomponent filaments that are either unbonded or slightly bonded together.

[00427] A calendering unit 116, comprising a calender, is disposed downstream of the collection surface 110 and is configured and arranged to thermally direct the Petition 870250088344, dated 09 / 29 / 2025, pp. 151 / 234 132 / 165 adjacent filaments and also impart a bonding pattern to the surface, according to the embodiments of the invention, as discussed above. As discussed in more detail below, the calender comprises a pair of cooperating rolls, wherein a first roll 116a comprises a roll with an engraved pattern, with a plurality of bonding points extending from a surface thereof, and the second roll 116b comprises a smooth or anvil-shaped surface. During bonding, the web 140 of filaments passes between the pairs of cooperating rolls, which are heated to a temperature sufficient to soften at least one polymeric component comprising the web filaments 140, so that the softened polymeric component melts and bonds to the adjacent filaments within the web to produce a bonded nonwoven fabric 142.In certain embodiments, the bonded nonwoven fabric 142 moves to a winder 118, where the fabric is then wound onto rolls.

[00428] As in the embodiment discussed previously, the 100b system may also include an optional pair of cooperating rollers 120, an optional hot air knife and a vacuum source 128.

[00429] Embodiments of the invention may also include multilayer nonwoven fabrics with 2 to 10 layers, such as 2 to 5 and, in particular, 2 to 3 layers.

[00430] Various layers of nonwoven fabric may include one or more spunbond layers, one or more carded layers, one or more air-laid layers, one or more melt-blown layers, and the like. Petition 870250088344, dated 09 / 29 / 2025, pp. 152 / 234 133 / 165

[00431] In certain embodiments, bonded nonwoven fabric may include a layer comprising single-component filaments and a second layer comprising multi-component filaments, such as two-component filaments.

[00432] In embodiments where the bonded nonwoven fabric includes multiple layers, the system may include additional fiber-forming devices as desired. For example, systems according to the embodiments of the invention may include one or more melt-blowing beams, one or more devices for preparing carded fabric layers, one or more devices for preparing airlaid fabric layers, and the like. Such additional devices may be from the same manufacturing line as the other fiber-forming devices to provide a continuous system. Alternatively, one or more additional layers may be provided from a feed roll onto which a previously prepared nonwoven fabric has been wound.

[00433] In certain embodiments, the bonded nonwoven fabric may include at least one spunbond layer comprising non-crimp or low-crimp filaments, and at least one layer comprising crimped filaments.

[00434] With reference to FIG. 10, a further aspect of a system and method for preparing a nonwoven fabric, according to at least one embodiment of the invention, is illustrated and broadly designated by the reference character 100c. In system 100c, the system includes at least two spinning beams and is configured and arranged to produce a bonded nonwoven fabric with at least two layers. Petition 870250088344, dated 09 / 29 / 2025, pp. 153 / 234 134 / 165

[00435] As shown, the system 100c includes a first spinning beam 150 in fluid communication with the extruder 152 and the first polymer source (hopper 154). After extrusion, the extruded polymer stream is introduced into the spinning beam 150, at which point the stream enters a plurality of spinnerets (not shown) for spinning into filaments. After spinning, the spun filaments can then be stretched (i.e., attenuated) by means of a stretching unit (not shown) and randomized in a diffuser. The spinning beam 150 produces a curtain of filaments 156 which is deposited on the collection surface 110 to produce a filament web. At this stage, the filaments may comprise a web 158 of filaments that are not bonded or are slightly bonded together.

[00436] A second rotation beam 160 is arranged downstream of the first rotation beam 150. The second rotation beam is in fluid communication with the second extruder 162a (which is in communication with the second polymer source (hopper 164a)) and the third extruder 162b (which is in communication with the third polymer source (hopper 164b)).

[00437] After extrusion, the polymer streams extruded from extruders 162a and 162b are introduced into the spinning beam 160, at which point the streams enter a plurality of spinnerets (not shown) for spinning into multicomponent filaments. After spinning, the spun filaments can then be stretched (i.e., attenuated) by means of a stretching unit (not shown) and randomized in a diffuser. The spinning beam 160 produces a curtain of multicomponent filaments 166 which is deposited onto the web 158, producing a composite web 168 comprising at least two layers. At this stage, the Petition 870250088344, dated 09 / 29 / 2025, pages 154 / 234 135 / 165 strands of weave 158 may be unglued or only slightly glued together.

[00438] As in the embodiments discussed previously, a calender bonding unit 116, comprising a calender, is disposed downstream of the collection surface 110 and is configured and arranged to thermally direct adjacent filaments toward each other and also to impart a bonding pattern to the surface, according to the embodiments of the invention, as discussed previously. During bonding, the web 168 of filaments passes between cooperating pair rolls, which are heated to a temperature sufficient to soften at least one polymeric component comprising the web filaments 168 to produce a bonded nonwoven fabric 170. In certain embodiments, the bonded nonwoven fabric 170 moves to a winder 118, where the fabric is then wound onto rolls.

[00439] As in the embodiment discussed earlier, the 100c system may also include an optional pair of cooperating rollers 120 and a vacuum source 128.

[00440] In certain embodiments, the nonwoven fabric can be air-bonded before heat spot bonding by means of a calender bonding unit.

[00441] According to certain embodiments, for example, bonding the web to form the bonded nonwoven fabric comprises thermal spot bonding of the web with heat and pressure by means of a calender with a pair of cooperating rolls, including a patterned roll. The patterned roll imprints a three-dimensional geometric bonding pattern onto the nonwoven fabric. Petition 870250088344, dated 09 / 29 / 2025, pages 155 / 234 136 / 165

[00442] FIG. 11 illustrates a calender gluing unit 116 that conforms to at least one embodiment of the present description. In certain embodiments, the calender gluing unit comprises a pair of cylindrical rolls 116a and 116b positioned in an opposite and cooperative relationship to receive a nonwoven fabric between them. In the illustrated embodiment, the patterned roll 116a includes a plurality of individual raised gluing points 200 that extend radially outward from a surface 202 of the patterned roll 116a and are arranged to define one or more patterns on the surface 202 of the patterned roll 116a.

[00443] Roller 116b (also called anvil roller) has a generally smooth surface 204. However, in some embodiments, both rollers 116a and 116b may be patterned to include a plurality of individual raised gluing points 200 extending radially outward from surfaces 202 and 204.

[00444] Rollers 116a and 116b include a central shaft 210 and 212, respectively, which extends laterally in the CD direction. The central shafts 210 and 212 of rollers 116a and 116b are substantially perpendicular to the MD direction of the system for manufacturing the nonwoven fabric of the invention (see Figures 8 to 10, systems 106a to 106c). Rollers 116a and 116b also include radial shafts rl and r2, which extend radially outward from the central shafts 210 and 212.

[00445] The glue dots are arranged and distributed collectively across the surface of the pattern roll to define a first pattern that is transmitted to the nonwoven sheet when Petition 870250088344, dated 09 / 29 / 2025, pp. 156 / 234 137 / 165 subjected to thermal bonding when passed between rollers 116a, 116b of the calender bonding unit 116.

[00446] In certain embodiments, the standardized roll 116a comprises a plurality of dies, wherein each die comprises a plurality of individually spaced bonding points extending across the surface of the standardized roll 116a. The bonding point dies on the surface of the standardized roll 116a are configured and arranged to impart a plurality of thermal bonding point dies in the machine direction, in the transverse direction and in the diagonal direction of a nonwoven fabric subjected to thermal dot bonding by means of the calender bonding unit 116.

[00447] Returning now to FIG. 12, to provide a plurality of bonding point arrays extending in the direction of the nonwoven fabric machine, the standard roll 116a includes a plurality of annular array pairs AA1, AA2, wherein each annular array AA1, AA2 of the pair 214 comprises a plurality of spaced bonding points 200 that are arranged radially around the circumference of the standard roll 116a. Typically, the individual bonding points of each annular array are arranged in the same plane defined by a radial axis r1. The annular arrays comprise a plurality of array pairs 214 wherein each array pair comprises a first annular array AA1 defining a first member of the annular array pair 214 and a second annular array AA2 defining a second member of the annular array pair 214.The plurality of ring matrix pairs 214 defines a pattern in which the first ring matrix AA1 and the second ring matrix. Petition 870250088344, dated 09 / 29 / 2025, pp. 157 / 234 138 / 165 AA2 alternate in a repetitive pattern on the surface of the patterned roll 116a in the transverse direction of the roll.

[00448] In certain embodiments, the individual bonding points 200 of the second annular die AA2 are radially displaced relative to the adjacent bonding points of the first annular dies AA1. In other words, the adjacent bonding points of the first and second annular dies are not aligned with each other on the surface of the patterned roll in the transverse direction of the roll, while the bonding points of all other annular dies are substantially aligned in the transverse direction of the roll. For example, in Figure 12, bonding points 200a and 200c, both on separate annular dies AA2, are aligned with each other in the transverse direction, while bonding points 200b and 200d, which are on the first annular dies AA1, are not aligned with bonding points 200a and 200c in the transverse direction of the patterned roll 116a.

[00449] In certain embodiments, the standardized roll 116a also includes matrices of individual gluing points spaced 200 that extend in the transverse direction of the standardized roll 116a. Furthermore, the matrices extending in the transverse direction of the standardized roll 116a comprise a plurality of pairs of transverse direction matrices 216, in which each pair of matrices comprises a first transverse direction matrix CDA1, which defines a first member of the pair of transverse direction matrices 216, and a second transverse direction matrix CDA2, which defines a second member of the pair of matrices. The plurality of pairs of transverse direction matrices 216 defines a pattern in which the first transverse direction matrix Petition 870250088344, dated 09 / 29 / 2025, pp. 158 / 234 139 / 165 CDA1 and the second transverse direction matrix CDA2 alternate radially around the circumference of the patterned roll in a repetitive pattern. In certain embodiments, the first transverse direction matrix CDA1 and the second transverse direction matrix CDA2 extend across the surface 202 of the roll in a direction substantially parallel to the central axis 210 of the roll.

[00450] In certain embodiments, the individual 200 bonding points of the first cross-direction matrix CDA1 are offset in the cross direction relative to the adjacent bonding points of the second cross-direction matrix CDA2. In other words, the adjacent bonding points of the first and second cross-direction matrices are not radially aligned with each other on the surface of the patterned roll, while the bonding points of all other cross-direction matrices are substantially radially aligned along the surface of the patterned roll. For example, in Figure 12, bonding points 200a and 200e, both on separate cross-direction matrices CDA2, are radially aligned with each other, while bonding points 200b and 200f, which are on the first cross-direction matrices CDA1, are not radially aligned with bonding points 200a and 200e of patterned roll 116a.

[00451] In certain embodiments, the standardized roll 116a also includes a plurality of spiral matrices comprising a plurality of spaced, configured, and arranged gluing points in a spiral pattern that extends circumferentially around the outer surface of the standardized roll 116a. In this sense, Figure 12 illustrates pairs of spiral matrices 218, having a first spiral matrix SPA1 and Petition 870250088344, dated 09 / 29 / 2025, pp. 159 / 234 140 / 165 a second spiral matrix SPA2, in which the pairs of spiral matrices are spaced along the surface of the patterned roll 116a. The spiral matrices give a pattern to the nonwoven sheet, comprising a plurality of arrangements that extend diagonally along the surface of the bonded nonwoven fabric (see, for example, Figure 1, arrangements A5 and A6).

[00452] With reference to FIG. 13A, the gluing points 200 generally have an oblong shape, such as oval-elliptical, rectangular, rod-shaped or bar-shaped, or similar. In some embodiments, the patterned roll 116a may comprise a combination of oblong gluing points and circular / square / diamond-shaped gluing points, such as a patterned roll used to form the gluing pattern shown in FIGS. 7A-7D.

[00453] In an oblong-shaped gluing point, gluing point 200 includes a primary gluing point axis 230 and a secondary gluing point axis 232, wherein the primary gluing point axis has a greater length than the secondary gluing point axis.

[00454] In certain embodiments, the principal axis of the gluing points in the same array (e.g., first annular array AA1) is oriented / aligned in the same direction, while the principal axis of the individual gluing points in the array forming the second member (e.g., second annular array AA2) of the array pair is oriented / aligned in an alignment that is oriented approximately 85° to 95° relative to the alignment of the principal axis of the gluing points in the first annular array AA1. In certain embodiments, the individual gluing points in the first annular array are oriented / aligned in a Petition 870250088344, dated 09 / 29 / 2025, pp. 160 / 234 141 / 165 alignment that is oriented at approximately 86° to 94°, as well as at approximately 87° to 93°, 88° to 92°, 86° to 94°, 89° to 91° or 90° in relation to the alignment of the main axis of the 200 bonding points in the second annular matrix AA2.

[00455] In certain embodiments, the dot density (number of individual dots per square centimeter on the surface of the standardized roll) is about 50 to 65 cm2,

[00456] Returning to FIG. 13A, a perspective view of a raised bonding point 200 is illustrated, according to at least one embodiment of the invention. As shown, the raised bonding point 200 includes a base 220, a raised surface 222, and a continuous side wall 224 extending between the base 220 and the raised surface 222. The raised surface is configured and arranged to fit into discrete regions of the nonwoven fabric surface and apply sufficient pressure and heat to cause the fibers coupled to the bonding point to soften and fuse, forming an individual bonding point on the nonwoven fabric surface.

[00457] In certain embodiments, the average length of the main gluing point axis 230 is about 0.65 mm to 1.25 mm, and in particular, about 0.70 to 1.20 mm, and more particularly, about 1.15 to 0.72 mm, and even more particularly, about 0.74 to 1.10 mm.

[00458] In a preferred embodiment, the average length of the main gluing point axis 230 is about 0.74 to 0.78 mm, with an average length of about 0.76 mm being somewhat more preferred. Petition 870250088344, dated 09 / 29 / 2025, pp. 161 / 234 142 / 165

[00459] In certain embodiments, the average shaft length of 1.24 mm point, main bonding 230 is less than 1.22 mm, 1.25 mm, mm, less than 1.21 mm, less than 1.23 mm, less than 1.14 mm, 1.11 mm, mm, less than 1.01 mm, 0.98 mm, mm, less than 0.88 mm, 0.85 mm, mm, less than 0.75 mm, 0.73 mm, mm, less than 1.20 mm, 1.17 mm, mm, less than 1.07 mm, 1.04 mm, mm, less than 0.94 mm, 0.91 mm, mm, less than 0.81 mm, 0.78 mm, mm, less than 0.68 mm, less than 1.19 mm, less than 1.16 mm, less than 1.13 mm, less than 1.10 mm, less than 1.09 mm, less than 1.06 mm, less than 1.03 mm, less than 1.00 mm, less than 0.97 mm, less than 0.96 mm, less than 0.93 mm, less than 0.90 mm, less than 0.87 mm, less than 0.84 mm, less than 0.83 mm, less than 0.80 mm, less than 0.77 mm, less than 0.74 mm, less than 0.71 mm, less than 0.70 mm, less than 0.67 mm or less than 1.15 mm, 1.12 mm, mm, less than less than 1.02 mm, 0.99 mm, mm, less than less than 0.89 mm, 0.86 mm, mm, less than less than 0.76 mm, 0.73 mm, mm,less than 1.18 mm, mm, less than 1.08 mm, 1.05 mm, mm, less than 0.95 mm, 0.92 mm, mm, less than 0.82 mm, 0.79 mm, mm, less than 0.69 mm.

[00460] In certain embodiments, the main gluing point 230 is the average shaft length greater than 0.65 mm, greater than, 0.66 mm, greater than 0.67 mm, greater than 0.68 mm, greater than 0.69 mm, greater than 0.70 mm, greater than 0.71 mm, greater than 0.72 mm, greater than 0.73 mm, greater than 0.74 mm, greater than 0.75 mm, greater than 0.76 mm, greater than 0.77 mm, greater than 0.78 mm, greater than 0.79 mm, greater than 0.80 mm, greater than 0.81 mm, greater than 0.82 mm, greater than 0.83 mm, greater than 0.84 mm, greater than 0.85 mm, greater than 0.86 mm, greater than 0.87 mm, greater than 0.88 mm, greater Petition 870250088344, dated 09 / 29 / 2025, pp. 162 / 234 143 / 165 greater than 0.89 mm, greater than 0.90 mm, greater than 0.91 mm, greater than 0.92 mm, greater than 0.93 mm, greater than 0.94 mm, greater than 0.95 mm, greater than 0.96 mm, greater than 0.97 mm, greater than 0.98 mm, greater than 0.99 mm, greater than 1.0 mm, greater than 1.01 mm, greater than 1.02 mm, greater than 1.03 mm, greater than 1.04 mm, greater than 1.05 mm, greater than 1.06 mm, greater than 1.07 mm, greater than 1.08 mm, greater than 1.09 mm, greater than 1.1 mm, greater than 1.11 mm, greater than 1.12 mm, greater than 1.13 mm, greater than 1.14 mm, greater than 1.15 mm, greater than 1.16 mm, greater than 1.17 mm, greater than 1.18 mm, greater than 1.19 mm, greater than 1.20 mm, greater than 1.21 mm, greater than 1.22 mm, greater than 1.23 mm, greater than 1.24 mm.

[00461] In certain embodiments, the average width of the axis of the minor 232 bonding point is about 0.24 mm to 0.60 mm, and in particular, about 0.25 to 0.55 mm, and more particularly, about 0.27 to 0.50 mm, and even more particularly, about 0.28 to 0.48 mm.

[00462] In preferred embodiments, the average width of the axis of the smaller gluing point 232 is about 0.24 to 0.36 mm, and in particular, about 0.26 to 0.32 mm, and more particularly, about 0.28 to 0.31 mm. In a slightly more preferred embodiment, the individual gluing points have an average width of about 0.30 mm.

[00463] In certain embodiments, the average width of the axis of the minor 232 gluing point is less than 0.6 mm, less than 0.59 mm, less than 0.58 mm, less than 0.57 mm, less than 0.56 mm, less than 0.55 mm, less than 0.54 mm, less than 0.53 mm, less than 0.52 mm, less than 0.51 mm, less than 0.50 mm, less than 0.49 mm, less than 0.48 mm, less than 0.47 mm, less than 0.46 mm, less than 0.45 mm, less than 0.44 mm, less than 0.43 mm, Petition 870250088344, dated 09 / 29 / 2025, pp. 163 / 234 144 / 165 less than 0.42 mm, less than 0.41 mm, less than 0.40 mm, less than 0.39 mm, less than 0.38 mm, less than 0.37 mm, less than 0.36 mm, less than 0.35 mm, less than 0.34 mm, less than 0.33 mm, less than 0.32 mm, less than 0.31 mm, less than 0.30 mm, less than 0.29 mm, less than 0.28 mm, less than 0.27 mm, less than 0.26 mm or less than 0.25 mm.

[00464] In certain embodiments, the average width of the axis of the minor 232 bonding point is greater than 0.24 mm, greater than 0.25 mm, greater than 0.26 mm, greater than 0.27 mm, greater than 0.28 mm, greater than 0.29 mm, greater than 0.30 mm, greater than 0.31 mm, greater than 0.32 mm, greater than 0.33 mm, greater than 0.34 mm, greater than 0.35 mm, greater than 0.36 mm, greater than 0.37 mm, greater than 0.38 mm, greater than 0.39 mm, greater than 0.40 mm, greater than 0.41 mm, greater than 0.42 mm, greater than 0.43 mm, greater than 0.44 mm, greater than 0.45 mm, greater than 0.46 mm, greater than 0.47 mm, greater than 0.48 mm, greater than 0.49 mm, greater than 0.50 mm, greater than 0.51 mm, greater than 0.52 mm, greater than 0.53 mm, greater than 0.54 mm, greater than 0.55 mm, greater than 0.56 mm, greater than 0.57 mm, greater than 0.58 mm, or greater than 0.59 mm.

[00465] In the preparation of the nonwoven fabric of Figures 8A to 8C, the main axis of the bonding point 230 varies from about 1.0 to 1.2 mm, and in particular, from about 1.2 to 1.18 mm, and more particularly, from about 1.12 to 1.06 mm. In a slightly more preferred embodiment for the preparation of the nonwoven fabrics of Figures 8A to 8C, the individual bonding points have an average length of about 1.09 mm.

[00466] In the preparation of the nonwoven fabric of Figures 8A to 8C, the axis of the minor bonding point 232 varies from about 0.35 to 0.6 mm, and in particular, from about 0.4 to 0.5 mm, and more Petition 870250088344, dated 09 / 29 / 2025, pp. 164 / 234 145 / 165 in particular, from about 0.42 to 0.52 mm. In a slightly more preferred embodiment for the preparation of nonwoven fabrics of Figures 8A to 8C, the individual bonding points have an average width of about 0.47 mm.

[00467] In certain embodiments, the surface area of ​​the raised surface 222 is about 0.15 to 0.75 mm2, and in particular, about 0.18 to 0.55 mm2, and more particularly, about 0.20 to 0.35 mm2. In a preferred embodiment, the surface area of ​​the raised surface 222 is about 0.20 to 0.30 mm2, and somewhat more preferably, about 0.21 to 0.25 mm2.

[00468] In the preparation of the nonwoven fabric of FIGS. 8A-8C, the surface area of ​​the raised surface 222 is about 0.25 to 0.55 mm2, and in particular, about 0.30 to 0.50 mm2, and more particularly, about 0.35 to 0.45 mm2. In a preferred embodiment, the surface area of ​​the raised surface 222 is about 0.38 to 0.42 mm2, and somewhat more preferably, about 0.4 mm2.

[00469] FIGS. 13B and 13C are side views of a gluing point 200, taken along the major axis 230 and the minor axis 232 of the gluing point, respectively. In certain embodiments, the gluing points 200 may have an average height h (distance between the base 220 and the raised surface 222) of about 0.5 to 1.25 mm, and in particular, about 0.85 to 1.15 mm, and more particularly, about 0.9 to 1.1 mm, a height of about 0.95 to 1.05 mm being somewhat more preferred, and a height of about 1.0 mm being even more preferred. Petition 870250088344, dated 09 / 29 / 2025, pp. 165 / 234 146 / 165

[00470] In certain realizations, the average height of the points of The adhesive thickness of 200 mm is less than 1.20 mm, less than 1.19 mm, less than 1.18 mm, less than 1.17 mm, less than 1.16 mm, less than 1.15 mm, less than 1.14 mm, less than 1.13 mm, less than 1.12 mm, less than 1.11 mm, less than 1.10 mm, less than 1.09 mm, less than 1.08 mm, less than 1.07 mm, less than 1.06 mm, less than 1.05 mm, less than 1.04 mm, less than 1.03 mm, less than 1.02 mm, less than 1.01 mm, less than 1.00 mm, less than 0.99 mm, less than 0.98 mm, less than 0.97 mm, less than 0.96 mm, less than 0.95 mm, less than 0.94 mm, less than 0.93 mm, less than 0.92 mm, less than 0.91 mm, less than 0.90 mm, less than 0.89 mm, less than 0.88 mm, less than 0.87 mm, less than 0.86 mm, less than 0.85 mm, less than 0.84 mm, less than 0.83 mm, less than 0.82 mm, less than 0.81mm, less than 0.80mm, less than 0.79mm, less than 0.78mm, less than 0.77mm, less than 0.76mm, less than 0.75mm, less than 0.74mm, less than 0.73mm, less than 0.72mm, less than 0.71mm, less than 0.70mm, less than 0.69mm,less than 0.68 mm, less than 0.67 mm, less than 0.66 mm, less than 0.65 mm, less than 0.64 mm, less than 0.63 mm, less than 0.62 mm, less than 0.61 mm, less than 0.60 mm, less than 0.59 mm, less than 0.58 mm, less than 0.57 mm, less than 0.56 mm, less than 0.55 mm, less than 0.54 mm, less than 0.53 mm, less than 0.52 mm or less than 0.51 mm.

[00471] In certain embodiments, the average height of the 200 bonding points is greater than 0.5 mm, greater than 0.51 mm, greater than, 0.52 mm, greater than 0.53 mm, greater than 0.54 mm, greater than 0.55 mm, greater than 0.56 mm, greater than 0.57 mm, greater than 0.58 mm, greater than 0.59 mm, greater than 0.60 mm, greater than 0.61 mm, greater than 0.62 mm, greater than 0.63 mm, greater than 0.64 mm, greater than Petition 870250088344, dated 09 / 29 / 2025, pp. 166 / 234 147 / 165 0.65 mm, greater than 0.66 mm, greater than 0.67 mm, greater than 0.68 mm, greater than 0.69 mm, greater than 0.70 mm, greater than 0.71 mm, greater than 0.72 mm, greater than 0.73 mm, greater than 0.74 mm, greater than 0.75 mm, greater than 0.76 mm, greater than 0.77 mm, greater than 0.78 mm, greater than 0.79 mm, greater than 0.80 mm, greater than 0.81 mm, greater than 0.82 mm, greater than 0.83 mm, greater than 0.84 mm, greater than 0.85 mm, greater than 0.86 mm, greater than 0.87 mm, greater than 0.88 mm, greater than 0.89 mm, greater than 0.90 mm, greater than 0.91 mm, greater than 0.92 mm, greater than 0.93 mm, greater than 0.94 mm, greater than 0.95 mm, greater than 0.96 mm, greater than 0.97 mm, greater than 0.98 mm, greater than 0.99 mm, greater than 1.0 mm, greater than 1.01 mm, greater than 1.02 mm, greater than 1.03 mm, greater than 1.04 mm, greater than 1.05 mm, greater than 1.06 mm, greater than 1.07 mm, greater than 1.08 mm, greater than 1.09 mm, greater than 1.1 mm, greater than 1.11 mm, greater than 1.12 mm, greater than 1.13 mm, greater than 1.14 mm, greater than 1.15 mm, greater than 1.16 mm, greater than 1.17 mmgreater than 1.18 mm, greater than 1.19 mm, or greater than 1.20 mm.

[00472] In certain embodiments for the preparation of nonwoven fabrics of FIGS. 8A-8C, the bonding points 200 may have an average height h (distance between the base 220 and the raised surface 222) which is about 0.5 to 0.85 mm, and in particular about 0.55 to 0.8 mm, and more particularly about 0.6 to 0.75 mm, with a height of about 0.65 to 0.7 mm being somewhat more preferred, and a height of about 0.68 mm being even more preferred.

[00473] In certain embodiments, the continuous side wall 224 of the gluing point 200 may be perpendicular to the surface 202 of the standardized roll. In other embodiments, the continuous side wall 224 of the gluing point 200 may be inclined at Petition 870250088344, dated 09 / 29 / 2025, pp. 167 / 234 148 / 165 in relation to the surface of the standardized roll. As shown in Figures 13B and 13C, the angle a7 between the surface 202 and the continuous side wall 224 can be from about 90° to 120°, with an angle a7 of about 90° to 120° and, in particular, of about 105° to 115°.

[00474] In certain other embodiments, the cross-direction matrices (e.g., CDA1, CDA2) extending on the CD of the standardized roll 116a may be angled relative to the central axis 210. That is, instead of being parallel to the central axis, the cross-direction matrices may extend at an angle of inclination greater than 0° and less than 6° relative to a horizontal line (the horizontal line being parallel to the central axis 210) drawn laterally on the surface of the standardized roll. In particular, the angle of inclination may vary from greater than 0° to less than 6°. In a preferred embodiment, the angle of inclination is from about 0.5° to 4° and, in particular, from about 1° to 3°, with an angle of about 2° being preferred.

[00475] Nonwoven fabrics, according to the embodiments of the present invention, can be used in a wide variety of applications, such as absorbent and personal hygiene applications, medical applications such as clothing, aprons, face masks, wound dressings and the like. Other applications include industrial applications such as residential construction, filtration, furniture and the like. Other possible applications may include agricultural applications such as soil coverings, root wraps, plant covers, protective bags and the like. In one embodiment, the nonwoven fabric can be combined with one or more additional layers to form a laminate. In particular, a laminate comprising the fabrics Petition 870250088344, dated 09 / 29 / 2025, pp. 168 / 234 149 / 165 nonwovens of the invention discussed above can be adapted for use in a disposable absorbent article, such as a diaper, panties, an adult incontinence product, a sanitary napkin or any other article that may benefit from the desirable properties provided by nonwoven fabrics, according to the embodiments of the present invention.

[00476] Nonwoven fabrics, according to embodiments of the invention, can be used to prepare a variety of different structures. For example, in some embodiments, the bonded nonwoven fabric of the invention may comprise from 1 to 10 layers and, in particular, from 2 to 8 layers, as well as from 3 to 6 layers.

[00477] In this regard, FIG. 14A is a cross-sectional side view of a single-layer bonded nonwoven fabric 300, according to at least one embodiment of the invention. The nonwoven fabric 300 comprises a plurality of fibers bonded together by means of a plurality of individual bonding points spaced to form a coherent weave. The nonwoven fabric 300 comprises a first surface 302 and a second surface 304, wherein at least one of the surfaces includes a bonding pattern according to one or more of the bonding patterns discussed above. In certain embodiments, the first surface 302 includes a bonding pattern according to at least one embodiment of the invention, and the second surface does not include a bonding pattern on its surface. In other words, during bonding, only surface 302 is brought into contact by a patterned roll with a plurality of individual bonding points. Petition 870250088344, dated 09 / 29 / 2025, pp. 169 / 234 150 / 165

[00478] With reference to FIG. 14B, a cross-sectional side view of a two-layer composite nonwoven fabric, according to at least one embodiment of the invention, is illustrated and broadly designated by the reference character 320. The composite nonwoven fabric 320 comprises a first layer 322 and a second layer 324, bonded together at the interface 326. The first layer 322 comprises a surface 328 with a bonding pattern 330 disposed thereon, according to at least one embodiment of the description, as discussed above. The second nonwoven fabric 324 comprises the outer surface 332. In certain embodiments, the outer surface 332 of the second layer of nonwoven fabric 324 may comprise a substantially smooth surface that has not been subjected to spot bonding by means of a calender roll.In other embodiments, the outer surface 332 may include a bonding pattern imposed upon it, according to at least one embodiment of the description, as discussed previously.

[00479] The second layer of nonwoven fabric may comprise the same type of nonwoven fabric as the first layer of nonwoven fabric. In certain embodiments, the second layer of nonwoven fabric may comprise the same type of nonwoven fabric as the first layer of nonwoven fabric. For example, the second layer of nonwoven fabric may be a melt-blown fabric, a spunbond fabric, a carded fabric, an air-laid fabric, a resin-bonded fabric, a spunlace fabric, or similar.

[00480] In some embodiments, both the first nonwoven fabric and the second nonwoven fabric may each comprise a spunbond nonwoven fabric. Petition 870250088344, dated 09 / 29 / 2025, pp. 170 / 234 151 / 165

[00481] In certain embodiments, bonded nonwoven fabric can be combined with one or more additional layers to prepare a composite or laminated material.

[00482] Examples of such composites / laminates may include a spunbond composite, such as a spunbond-meltblown (SM) composite, a spunbond-meltblown-spunbond (SMS) composite, or a spunbond-meltblown-meltblown-spunbond (SMMS) composite. In some embodiments, the composites may be prepared comprising a layer of bonded nonwoven fabric and one or more layers of film. It should be recognized that other configurations are also within the scope of the invention.

[00483] In these multilayer structures, the base weight of the spunbond nonwoven fabric layer can vary from 5 g / m2 to 150 g / m2. In some embodiments comprising a multilayer structure (e.g., SM, SMS and SMMS), the amount of meltblown material in the composite structure can vary from about 5 to 30% by weight and, in particular, from about 5 to 15% by weight of the structure as a percentage by weight of the structure as a whole.

[00484] Multilayer structures, according to the embodiments, can be prepared in various ways, including continuous in-line processes, in which each layer is prepared in successive order on the same line, or by depositing a second layer of nonwoven fabric onto a previously formed spunbond layer. The layers of the multilayer structure can be thermally bonded to form a multilayer composite sheet material, providing a composite sheet material with the bonding patterns described in this document. Furthermore, composite sheet materials, according to certain Petition 870250088344, dated 09 / 29 / 2025, pp. 171 / 234 152 / 165 embodiments of the invention may also be subjected to other bonding techniques, such as dry thermal bonding, mechanical bonding, adhesive bonding, hydroentanglement or combinations thereof. In certain embodiments, the layers are thermally joined by points, passing the multilayer structure through a bonding unit composed of a pair of calender rolls, in which the standardized calender roll has an engraved surface containing the inventive bonding pattern.

[00485] As noted above, fabrics prepared according to the embodiments of the invention can be used in a wide variety of articles and applications. For example, the embodiments of the invention can be used in personal care applications, such as baby care products (diapers, wipes), feminine care (sanitary napkins, sanitary pads, tampons), adult care (incontinence products) or cosmetic applications (sanitary napkins), agricultural applications, such as root bandages, seed bags, crop protectors, industrial applications, such as work overalls, airplane pillows, car trunk liners, sound insulation, and household products, such as mattress covers and scratch protectors for furniture.

[00486] The following examples are provided to illustrate one or more embodiments of the present invention and should not be construed as limiting the invention. EXAMPLES

[00487] The spunbond nonwoven fabrics in the following examples were prepared with a Reicofil 4S spunbond spinning yarn. Petition 870250088344, dated 09 / 29 / 2025, pp. 172 / 234 153 / 165 produced by Reifenhaeuser. Unless otherwise indicated, all percentages are percentages by weight. The materials and test methods used in the examples are identified below. Testing methods:

[00488] The base weight was measured in accordance with NWSP 130.1.

[00489] The MD and CD tensile strengths were measured according to NWSP 110.4B (modified: gauge length was 100 mm, sample width was 50 mm and speed was 100 mm / min.).

[00490] MD and CD elongations were measured according to NWSP 110.4B (modified: gauge length was 100 mm, sample width was 50 mm and speed was 100 mm / min.).

[00491] The caliper was measured according to NWSP 120.6.

[00492] Air permeability was measured in accordance with the standard. ASTM 90.3.

[00493] The hydraulic head was measured according to WSP80.6.

[00494] The Handle-O-Meter was measured in accordance with NWSP 90.3.

[00495] Smooth bending was measured according to WSP90.1.

[00496] Abrasion resistance was measured according to the standard. NWSP 20.5: The surface of each nonwoven fabric test sample was subjected to 32 rubs at a pressure of 9 kPa with a white eraser. The test sample was weighed before rubbing. After rubbing, the sample was scraped and weighed again.

[00497] Martindale Abrasion Test Method Rating Scale (Martindale Abrasion Index). In this method, the Petition 870250088344, dated 09 / 29 / 2025, pp. 173 / 234 154 / 165 The surface of each nonwoven fabric test sample was subjected to 32 rubs at a pressure of 9 kPa with a white eraser. The surface of the samples was then evaluated under a microscope for defects and subsequently rated on a scale of 1 to 5, with a score of 1 to 2 considered acceptable to the consumer and a score of 3 to 5 considered unacceptable. The lower the score, the better the abrasion resistance of the fabric. The scores are determined based on the following criteria: Score between 1 and 2: the samples show few or no visible defects (the sample may present fluff (short fibers lifted from the fabric) and micropills (smaller than 2 mm in diameter); Score between 2 and 3: the samples contain pills (the fibers are coiled into balls measuring less than 2 mm in diameter), small cords (less than 2 mm wide), and the pills and cords are not connected to a network of individual fibers; Scores of 3 or higher: samples will exhibit cords (long fibers that twist to form a braided rope), loft, cobwebs (networks of interconnected cords and pills that increase the fabric's loft and sharp cobwebs), holes in the fabric's surface, and increased loft.

[00498] Materials:

[00499] “PP-1” refers to a homopolymer polypropylene with an MFR of 34 g / 10 min available from Braskem under product number CP360H. Petition 870250088344, dated 09 / 29 / 2025, pp. 174 / 234 155 / 165

[00500] PP-2 refers to a homopolymer polypropylene with an MFR of 1284 g / 10 min available from Braskem under product number H155.

[00501] PP-3 refers to a metallocene-catalyzed polypropylene with an MFR of 35 g / 10 min available at Basell under product number HM 562S.

[00502] PP-4 refers to a homopolymer polypropylene with an MFR of 35 g / 10 min available from IRPC under product code 1105SC.

[00503] CoPP refers to a polypropylene copolymer with an MFR of 4 8 g / 10 min available from Exxon Mobil under the trade name VISTAMAXX™7050FL.

[00504] L-MODU refers to a low isotacticity polypropylene copolymer available from Idemitsu under the product name L-MODU™.

[00505] TiO2 refers to Remafin White PPF2K002G titanium dioxide available from Clariant / Avient under product code PP0N420701.

[00506] SA refers to a slip agent available from Evonik Industries under the trade name ACCUREL® SF 617. Comparative example 1:

[00507] In Comparative Example 1, a two-layer spunbond nonwoven fabric was prepared, in which the first layer was composed of non-corrugated filaments made of PP-1, and the second layer was composed of bicomponent filaments with a side-by-side configuration (70:30), in which one side was composed of PP-1 and the other of a mixture of PP-1 and PP-2. The amount Petition 870250088344, dated 09 / 29 / 2025, pages 175 / 234 The amount of PP-1 in the mixture was 98.65% by weight, and the amount of PP2 was 1.35% by weight, based on the total weight of the mixture.

[00508] The resulting two-layer spunbond fabric was thermally spot-bonded with a calender bonding unit consisting of a plain anvil roll and a patterned roll, with a bonding pattern similar to that shown in Figure 1, except for the size of the individual bonding dots, the density of the bonding dots, and the total % of the bonded surface area of ​​the bonded nonwoven fabric. The patterned roll was heated to a temperature of approximately 152 °C. The percentage of the nonwoven fabric surface bonded in Comparative Example 1 was 18.1%, and the bonding density was 49.9 bonding dots per cm2.

[00509] Inventive Example 1 was identical to the nonwoven fabric of Comparative Example 1, except that the nonwoven fabric sample was thermally bonded by spots with a calender bonding unit having a standardized roll with a bonding pattern according to the pattern shown in FIG. 1. In addition, the standardized roll had a transverse inclination of approximately 2°. The calender bonding unit was operated at a temperature of approximately 155°C. The percentage of the nonwoven fabric surface bonded in Inventive Example 1 was 9.92%, and the bonding density was 55.2 bonding spots per cm2.

[00510] The dimensions and physical properties of the recording reels used in Comparative Example 1 and Inventive Example 1 are summarized in Tables 1 and 2 below. Petition 870250088344, dated 09 / 29 / 2025, pp. 176 / 234 157 / 165 Table 1: Dimensions of the gluing points of the Comparative Example and the Inventive Example 1 Example No. Bonding point length* (mm) Bonding point width** (mm) Bonding point surface area (mm2) Bonding point density (bonding points / cm2) Comparative Example 1 0.882 0.524 0.36 49.9 Inventive Example 1 0.76 0.30 0.18 55.2 *Measurement of the main axis of the gluing point. ** Measurement of the main axis of the gluing point. Table 2: Dimensions of the recording roll of the Comparative Example and the Inventive Example 1 Example No. Distance between midpoints of oval bonding in CD* (mm) Distance between midpoints of oval bonding in MD* (mm) Distance between midpoints of bonding in DD* (mm) Bonded surface area (%) Angle between matrix DD and matrix CD (°) Petition 870250088344, dated 09 / 29 / 2025, pp. 177 / 234 158 / 165 Comparative Example 1 2.634 1.521 1.521 18.1 30 o Inventive Example 1 1.9 1.9 1.34 9.92 45 o *Measurements between adjacent bonding points on the same matrix.

[00511] Ten samples of Comparative Example 1 and Inventive Example 1 were prepared and evaluated. The average results are presented in Tables 3 to 5 below. Table 3: Bonding properties of nonwoven fabrics Example No. Average collective distance between adjacent bonding points (mm) Average surface area of ​​bonding points (mm2) Average compaction at the bonding point (mm-1) Percentage of bonded surface area Comparative Example 1 1.19 0.36 3.30 18.1 Inventive Example 1 1.28 0.18 7.11 9.92 Table 4: Physical / mechanical properties of Comparative Example 1 and Inventive Example 1 Petition 870250088344, dated 09 / 29 / 2025, pp. 178 / 234 159 / 165 Example No. Base weight (g / m2) Caliper (mm) Tensile strength MD (N / cm) Tensile strength of CD (N / cm) Elongation MD (%) Elongation CD (%) Air permeability (m3 / m2 / min) Comparative Example 1 25.32 0.26 7.21 3.86 65.44 76.04 153.73 Inventive Example 1 24.7 0.27 8.13 4.16 68.46 86.60 150.77 Percentage increase n / an / a 12.76 20.37 4.62 13.89 -1.93

[00512] In Table 4, it can be observed that the inventive nonwoven fabrics showed increases in both tensile strength and percentage elongation compared to Comparative Example 1. The increases in tensile strength were particularly surprising, as increases in % bonding area would normally also increase the tensile strength of the nonwoven fabric compared to a nonwoven fabric with less % bonding area.

[00513] In particular, the nonwoven fabric of Inventive Example 1 exhibited an increase in tensile strength in the machine direction of more than 10%, and in particular, more than 12%, compared to the nonwoven fabric of Comparative Example 1. Furthermore, the nonwoven fabric of Inventive Example 1 exhibited an increase in tensile strength in the transverse direction of more Petition 870250088344, dated 09 / 29 / 2025, pp. 179 / 234 160 / 165 of 15% and, in particular, of more than 20%, compared to the nonwoven fabric of Comparative Example 1.

[00514] The percentage elongations in the machine direction and transverse direction were also improved in the nonwoven fabric of Inventive Example 1 compared to the nonwoven fabric of Comparative Example 1. For example, the nonwoven fabric of Inventive Example 1 showed an increase of 4.6% and 13.9% in the percentage elongations in the machine direction and transverse direction, respectively, compared to the nonwoven fabric of Comparative Example 1.

[00515] The air permeability between the tissues of Comparative Example 1 and Inventive Example 1 was comparable, with Inventive Example 1 showing an insignificant decrease of less than 2%. TABLE 5: Abrasion and softness for the Comparative Example and the Example Inventive 1 Example No. Martindale Abrasion (Index) Mild Abrasion (mg) Embossed Abrasion (mg) Medium Abrasion (mg) HOM CD (g) HOM MD (g) HOM Medium (g) Comparative Example 1 1.75 20.50 3.1 11.8 7.38 4.06 5.72 Inventive Example 1 1.43 5.30 3.4 4.35 6.81 3.75 5.28 Increase (%) -18.23 -74.15 9.68 -63.14 -7.72 -7.64 -8.65 Petition 870250088344, dated 09 / 29 / 2025, pages 180 / 234 161 / 165 Percentage difference (%) 20.1 118 9.2 92 8 8 8

[00516] Surprisingly, the inventive nonwoven fabric also demonstrated improvements in abrasion resistance and softness compared to Comparative Example 1. In particular, a fabric with a higher % bonded area would have reduced abrasion resistance compared to the nonwoven fabric of Comparative Example 1, which had a % bonded area that was approximately half that of the nonwoven fabric of Comparative Example 1. The smooth side of Inventive Example 1 (the side in contact with the smooth anvil roller surface) showed a decrease of approximately 74% in material removed during the abrasion test compared to the nonwoven fabric of Comparative Example 1. The surface of the nonwoven fabric of Inventive Example 1 in contact with the pattern roller showed a slight percentage increase in material removed during the abrasion test (approximately 9.7%) compared to the nonwoven fabric of Comparative Example 1; however, the average abrasion resistance of the two sides of the nonwoven fabric showed a decrease of approximately 63% of the material removed during abrasion resistance compared to the nonwoven fabric of Comparative Example 1. Consequently, the results show that the inventive fabrics, containing a reduction in the percentage of bonded area compared to the comparative nonwoven fabrics (containing a higher percentage of bonded area), showed improvements in abrasion resistance. Petition 870250088344, dated 09 / 29 / 2025, pp. 181 / 234 162 / 165

[00517] Evaluation using the Martindale Index Method also demonstrated that the inventive fabrics exhibited improved abrasion resistance compared to the nonwoven fabric of Comparative Example 1. In particular, Inventive Example 1 showed a percentage reduction in the Martindale Index of 18.2%, reflecting an improvement of almost 20% in abrasion resistance. Again, this is surprising, given that the bonded surface area in Inventive Example 1 is almost half that of Comparative Example 1.

[00518] Furthermore, the inventive fabrics also showed improvements in softness compared to the nonwoven fabrics of Comparative Example 1, as evidenced by the reduction in Handle-O-Meter (HOM) values.

[00519] Based on the previous results, it is evident that the nonwoven fabrics of the invention exhibit superior mechanical properties combined with greater abrasion resistance and greater softness. Such improvements are not expected in tandem, as a reduction in both tensile strength and abrasion resistance would be expected as the % of bonded area of ​​the nonwoven fabric is reduced compared to Comparative Example 1. Inventive Examples 2 and 3

[00520] In Inventive Examples 2 and 3, a three-layer spunbond nonwoven fabric was prepared, in which each layer comprised the same polymer blend. The nonwoven fabric was thermally spot-bonded with a calender bonding unit operated at a temperature of approximately 150 °C. Petition 870250088344, dated 09 / 29 / 2025, pages 182 / 234 163 / 165 The calendering unit had the same engraving pattern as Inventive Example 1. The percentage of the nonwoven fabric surface bonded in Inventive Examples 2 and 3 was 9.92%, and the bonding density was 55.2 bonding points per cm². The nonwoven fabric of Inventive Example 2 was prepared at a polymer flow rate of 180 kg / m² / h and a cabin pressure of 5100 Pa. The nonwoven fabric of Inventive Example 3 was prepared at a polymer flow rate of 160 kg / m² / h and a cabin pressure of 5300 Pa.

[00521] The fibers of Inventive Examples 2 and 3 comprised a mixture of 92.2% PP-3, 7.0% CoPP and 0.8% TiO2 and SA.

[00522] Inventive Example 4

[00523] In Inventive Example 4 below, a three-layer spunbond nonwoven fabric was prepared with a calender bonding unit consisting of a smooth anvil roll and a pattern roll engraved with a bonding pattern configured to produce a bonding pattern similar to that shown in FIG. 8A. The die chamber pressure was operated at pressures above 5,100 Pa with a polymer flow rate of 200 kg / m² / hour.

[00524] The fibers of Inventive Example 4 comprised a mixture of 81.4% PP-4, 18.0% L-MODU and 0.8% TiO2e SA. The calender bonding unit was operated at a temperature of approximately 150 °C. The percentage of the nonwoven fabric surface bonded in Inventive Example 4 was 13.4%, and the bonding density was 33.4 bonding points per cm2.

[00525] The average height of the individual gluing points on the recording roll was 68 mm, the average width was 0.47 mm, and the average length of each gluing point was 1.09 mm. A Petition 870250088344, dated 09 / 29 / 2025, pp. 183 / 234 164 / 165 The average surface area of ​​the bonding points was 0.4 mm2, with an average collective bonding distance of 1.6 mm and a bonding compaction density of 4 mm-1.

[00526] The properties of nonwoven fabric from the Examples Inventive statements 2-4 are provided in Table 6 below. TABLE 6: MECHANICAL PROPERTIES OF INVENTIVE EXAMPLES 2-4 Example No. Base weight (gsm) Filament size (Dtex) Tensile strength MD (N / 25.4 mm) Tensile strength CD (N / 25.4 mm) Elongation MD (%) Elongation CD (%) Air permeability (m3 / m2 / s) Inventive Example 2 15 1.26 17.3 7.2 58.4 76.7 83.3 Inventive Example 3 15.1 0.9 19.3 9.1 60.4 77.4 78.1 Inventive Example 4 15 1.1 1.3 15.2 8.6 79.9 93.5 86 TABLE 7: BENDING SOFTNESS AND HYDRAULIC LOAD OF THE EXAMPLES INVENTIVES 2-4 Example Base weight Size of the bend MD Bend CD Average bend Hydraulic load No. (g / m2) filament (Dtex) (mm) (mm) (mm) (mmH2c) Petition 870250088344, dated 09 / 29 / 2025, pages 184 / 234 165 / 165 Inventive Example 2 15 1.26 45.5 20.2 32.8 107.2 Inventive Example 3 0.1 0.9 43.4 20.2 31.8 110.7 Inventive Example 4 15 1.1 1.3 42.1 27.9 35.0 99.9

[00527] Interestingly, it was observed that the reduction in flow rate and the increase in cabin pressure resulted in finer fibers, as can be seen in the comparison of Inventive Examples 2 and 3. In particular, the fibers from Inventive Example 2 had an average filament size of 1.26 Dtex, while the fibers from Inventive Example 3 had an average filament size of 0.9 Dtex. This represents a 28.6% reduction in fiber fineness.

Claims

1. Nonwoven fabric characterized by comprising a plurality of fibers bonded together in a spliced ​​pattern on a surface to form a coherent weave, the nonwoven fabric having a vertical axis extending in a machine direction and a horizontal axis extending in a transverse direction, the spliced ​​pattern comprising a plurality of spaced pairs of matrices extending in the machine, transverse and diagonal directions of the nonwoven fabric, wherein each matrix comprises a plurality of spaced spliced ​​points having an oblong shape, and wherein the nonwoven fabric has a spliced ​​surface area percentage of less than about 12% and an average spliced ​​point compaction value of about 6.5 to 8.0 mm-1.

2. Nonwoven fabric according to claim 1, characterized in that the nonwoven fabric has an average surface area of ​​about 0.15 to 0.25 mm2.

3. Nonwoven fabric according to any one of claims 1 to 2, characterized in that the nonwoven fabric has a bonding point density of about 50 to 60 individual bonding points per square centimeter.

4. Nonwoven fabric according to any one of claims 1 to 3, characterized in that the nonwoven fabric has a Martindale abrasion score of about 1.0 to 1.5, a Handle-o-Meter in the transverse direction of about 6.6 to 7.2 grams, a Handle-o-Meter in the machine direction of about 3.5 to 3.95 grams and an average abrasion resistance, Petition 870250088344, dated 09 / 29 / 2025, page 186 / 234 2 / 24 as determined by the weight of the material removed, of 3.2 to 5.5 grams.

5. Nonwoven fabric according to any one of claims 1 to 4, characterized in that the percentage of bonded surface area of ​​the nonwoven fabric is about 9.8 to 10%, the average surface area of ​​the bonding point is about 0.16 to 0.2 mm2, the average compaction value at the bonding point is about 6.75 to 7.25 mm-1, and the density of the bonding point of the nonwoven fabric is about 52 to 58 individual bonding points per square centimeter.

6. Nonwoven fabric according to any one of claims 1 to 5, characterized in that the nonwoven fabric has a Martindale abrasion score of 1 to 2, a Handle-o-Meter in the transverse direction of about 6.7 to 7.0 grams, a Handle-o-Meter in the machine direction of about 3.6 to 3.9 grams, and an average abrasion resistance, as determined by the weight of the material removed, of 3.4 to 3.6 grams.

7. Nonwoven fabric according to any one of claims 1 to 6, characterized in that the bonding pattern comprises alternating first and second arrays of individual bonding points extending in the transverse direction of the nonwoven fabric, wherein the individual bonding points of the first array and the second array each have a length and a width, and wherein the lengths of the individual bonding points of the first array are aligned substantially in the same direction and at an angle that is about 43 to 47 degrees relative to the horizontal axis of the nonwoven fabric, and the lengths of the individual bonding points of the second array are rotated about 88 to 92 degrees relative to Petition 870250088344, dated 09 / 29 / 2025, p.187 / 234 3 / 24 to the alignment of the lengths of the individual gluing points of the first matrix, and in which the individual gluing points of the second matrix are offset in the transverse direction of the adjacent individual gluing points of the first matrix.

8. Nonwoven fabric according to any one of claims 1 to 7, characterized in that the number of individual bonding points per cm2 is about 45 to 60, and in particular, about 50 to 58, and more particularly, about 54 to 56.

9. Nonwoven fabric according to any one of claims 1 to 8, characterized in that the percentage of bonded area of ​​the nonwoven fabric is about 9 to 10.5%, and in particular, about 9.8 to 10.2%, and more particularly, about 9.9 to 10%.

10. Nonwoven fabric according to any one of claims 1 to 9, characterized in that the distance between adjacent bonds in the transverse direction is about 1.4 to 1.6 mm, and in particular, about 1.45 to 1.55 mm, and more particularly, about 1.48 to 1.52 mm.

11. Nonwoven fabric according to any one of claims 1 to 10, characterized in that the distance between adjacent bonding points on the same matrix in a diagonal direction of the nonwoven fabric is about 0.7 to 0.95 mm, and in particular, about 0.75 to 0.90 mm, and more particularly, about 0.80 to 0.85 mm.

12. Nonwoven fabric according to any one of claims 1 to 11, characterized in that the bonding points have an oval-elliptical shape, a rectangular shape, a rod shape, or a combination thereof.

13. Nonwoven fabric according to claim 7, characterized in that the bonding pattern further defines a plurality of alternating and repeated third and fourth matrices of individual bonding points extending in the machine direction of the nonwoven fabric, and wherein the individual bonding points of the third matrix are displaced in the machine direction from the adjacent individual bonding points of the fourth matrix.

14. Nonwoven fabric according to claim 13, characterized in that the bonding pattern further defines a plurality of alternating fifth and sixth matrices of individual bonding points extending in a direction that is diagonal to the direction of the nonwoven fabric machine.

15. Nonwoven fabric according to claim 14, characterized in that the adjacent bonding points in each of the fifth and sixth dies are directionally aligned at an angle that is about 88 to 92 degrees relative to a directional alignment of an adjacent individual bonding point in the same die.

16. Nonwoven fabric according to any one of claims 1 to 15, characterized in that three adjacent matrices of individual bonds further define a plurality of bonding patterns in both the machine direction and the cross direction, having a quincunx-type bonding pattern in which four individual bonding points that define the corners of the quincunx-type bonding pattern share a directional orientation that is substantially the same with respect to the cross or machine directions of the nonwoven fabric, and in which an individual bonding point that defines a central point of the quincunx-type bonding pattern has a directional orientation that is rotated from about 88 to 92 degrees relative to the directional orientation of the individual bonding points that define the corners of the quincunx-type bonding pattern.

17. Nonwoven fabric according to any one of claims 1 to 16, characterized in that an angle formed by a matrix extending in the diagonal direction and a matrix extending in the transverse direction is about 43 to 47 degrees, and in particular, about 45 degrees.

18. Nonwoven fabric according to any one of claims 1 to 17, characterized in that the nonwoven fabric exhibits a Martindale abrasion score of less than 1.5 and, in particular, of 1.2 to 1.5, and more particularly, of about 1.40 to 1.

45.

19. Nonwoven fabric according to any one of claims 1 to 18, characterized in that the nonwoven fabric has a base weight of about 20 to 30 g / m2 and exhibits a softness, as demonstrated by a cross-direction gauge, of less than 7.0 grams (g), such as less than 7.9 grams or less than 7.5 grams.

20. Nonwoven fabric according to any one of claims 1 to 19, characterized in that the nonwoven fabric has a base weight of about 20 to 30 g / m2 and exhibits a softness, as demonstrated by a machine-driven measuring tool, of less than 3.9 grams (g), such as less than 3.8 grams or less than 3.78 grams.

21. Nonwoven fabric according to any one of claims 1 to 20, characterized in that the nonwoven fabric exhibits an increase in tensile strength, percent elongation, abrasion resistance and softness compared to a similarly prepared nonwoven fabric, except that the similar fabric was joined by stitches with a stitching pattern having a compaction at the stitching point of less than 3.5 mm-1.

22. Nonwoven fabric according to any one of claims 1 to 21, characterized in that the nonwoven fabric exhibits a tensile strength that is 10% or greater compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1, such as an increase in tensile strength that is 10% to 50%, such as 12 to 30%, 12 to 25%, 12 to 24% or 12 to 20% greater than the tensile strength of a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

23. Nonwoven fabric according to any one of claims 1 to 22, characterized in that the nonwoven fabric exhibits an increase in tensile strength of 10% or more compared with a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

24. Nonwoven fabric according to any one of claims 1 to 23, characterized in that the nonwoven fabric exhibits an increase in tensile strength that is 10% to 30%, such as 12% to 20%, greater than the tensile strength of a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

25. Nonwoven fabric according to any one of claims 1 to 24, characterized in that the nonwoven fabric exhibits an increase in tensile strength in the machine direction that is about 10 to 50% greater compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

26. Nonwoven fabric according to any one of claims 1 to 25, characterized in that the nonwoven fabric exhibits an increase in tensile strength in the machine direction of about 10 to 30%, such as about 12 to 20%, or about 12 to 15% compared with a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

27. Nonwoven fabric according to any one of claims 1 to 26, characterized in that the nonwoven fabric exhibits an increase in tensile strength in the transverse direction that is about 10 to 50% greater compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm -1.

28. Nonwoven fabric according to any one of claims 1 to 27, characterized in that the nonwoven fabric exhibits an increase in tensile strength in the transverse direction of about 10 to 30%, such as about 15 to 25%, about 18 to 24%, or about 19 to 21% in Petition 870250088344, dated 09 / 29 / 2025, page 192 / 234 8 / 24 compared with a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

29. Nonwoven fabric according to any one of claims 1 to 28, characterized in that the nonwoven fabric exhibits an increase in tensile strength in the machine direction that is about 10 to 50% greater compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

30. Nonwoven fabric according to any one of claims 1 to 29, characterized in that the nonwoven fabric exhibits an increase in tensile strength in the machine direction of about 10 to 30%, such as about 12 to 20%, or about 12 to 15% compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

31. Nonwoven fabric according to any one of claims 1 to 30, characterized in that the nonwoven fabric exhibits an increase in tensile strength in the transverse direction that is about 10 to 50% greater compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

32. Nonwoven fabric according to any one of claims 1 to 31, characterized in that the nonwoven fabric exhibits an increase in tensile strength in the transverse direction of about 10 to 30%, such as about 15 to 25%, about 18 to 24%, or about 19 to 21% compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%. Petition 870250088344, dated 09 / 29 / 2025, pp. 193 / 234 9 / 24 33. Nonwoven fabric according to any one of claims 1 to 32, characterized in that the nonwoven fabric exhibits an increase in percentage elongation of about 4 to 50% compared with a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

34. Nonwoven fabric according to any one of claims 1 to 33, characterized in that the nonwoven fabric exhibits a percentage increase in elongation of about 4 to 25%, such as about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

35. Nonwoven fabric according to any one of claims 1 to 34, characterized in that the nonwoven fabric exhibits an increase in percentage elongation of about 4 to 50% compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

36. Nonwoven fabric according to any one of claims 1 to 35, characterized in that the nonwoven fabric exhibits an increase in percentage elongation of about 4 to 25%, such as about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

37. Nonwoven fabric according to any one of claims 1 to 36, characterized in that the nonwoven fabric exhibits an increase in abrasion resistance, as exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

38. Nonwoven fabric according to any one of claims 1 to 37, characterized in that the nonwoven fabric exhibits an increase in abrasion resistance, as exemplified by a percentage difference in the Martindale Abrasion Index of about 10 to 25%, such as about 12 to 24%, or about 18 to 22%, compared with a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

39. Nonwoven fabric according to any one of claims 1 to 38, characterized in that the nonwoven fabric exhibits an increase in abrasion resistance exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

40. Nonwoven fabric according to any one of claims 1 to 39, characterized in that the nonwoven fabric exhibits an increase in abrasion resistance, as exemplified by a percentage difference in the Martindale Abrasion Index of about 10 to 25%, such as about 12 to 24%, or about 18 to 22%, compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%. Petition 870250088344, dated 09 / 29 / 2025, pp. 195 / 234 11 / 24 41. Nonwoven fabric according to any one of claims 1 to 40, characterized in that the nonwoven fabric exhibits an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150% compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

42. Nonwoven fabric according to any one of claims 1 to 41, characterized in that the nonwoven fabric exhibits an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 8 to 120%, such as 9 to 95% compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

43. Nonwoven fabric according to any one of claims 1 to 42, characterized in that the nonwoven fabric exhibits an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%.

44. Nonwoven fabric according to any one of claims 1 to 43, characterized in that the nonwoven fabric exhibits an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 8 to 120%, such as 9 to 95%, compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%. Petition 870250088344, dated 09 / 29 / 2025, pp. 196 / 234 12 / 24 45. Nonwoven fabric according to any one of claims 1 to 6, characterized in that the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 5 to 20% compared to a similarly prepared nonwoven fabric having a compaction point of less than 3.5 mm-1.

46. ​​Nonwoven fabric according to any one of claims 1 to 45, characterized in that the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 6 to 15%, as well as 8 to 10%, compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

47. Nonwoven fabric according to any one of claims 1 to 46, characterized in that the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 5 to 20% compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

48. Nonwoven fabric according to any one of claims 1 to 47, characterized in that the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 6 to 15%, such as 8 to 10%, compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%.

49. Nonwoven fabric according to any one of claims 1 to 48, characterized in that the nonwoven fabric exhibits an increase in softness, as demonstrated by an average difference in Handle-O-Meter values ​​of about 5 to 20% compared to a similarly prepared nonwoven fabric having a compaction at the bonding point of less than 3.5 mm-1.

50. Nonwoven fabric according to any one of claims 1 to 49, characterized in that the nonwoven fabric has a bonded area percentage of about 9.6 to 10.4%, an average surface area of ​​individual bonding points of about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, a bonding point density of about 50 to 60 individual bonding points per square centimeter, a Martindale abrasion score of about 1.0 to 1.5, a transverse direction Handle-o-Meter of about 6.6 to 7.2 grams, a machine direction Handle-o-Meter of about 3.5 to 3.95 grams, and an average abrasion resistance, as determined by the weight of the material removed, of 3.2 to 5.5 grams.

51. Nonwoven fabric according to any one of claims 1 to 50, characterized in that the nonwoven fabric has a spliced ​​percentage area of ​​about 9.8 to 10%, an average surface area of ​​individual splicing points of about 0.15 to 0.2 mm2, an average compaction value at the splicing point of about 7 to 7.2 mm-1, a splicing point density of about 52 to 58 individual splicing points per square centimeter, a Martindale abrasion score of about 1.42 to 1.45, a transverse direction Handle-o-Meter of about 6.7 to 7.0 grams, a machine direction Handle-o-Meter of about 3.6 to 3.9 grams and an abrasion resistance Petition 870250088344, dated 09 / 29 / 2025, p. 198 / 234 14 / 24 average, as determined by the weight of the material removed, from 3.4 to 3.6 grams.

52. Nonwoven fabric according to any one of claims 1 to 51, characterized in that the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonding surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1 and an average increase in tensile strengths that are 10% greater, such as about 10 to 50%, about 12 to 24% or about 12 to 22%, compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1.

53. Nonwoven fabric according to any one of claims 1 to 52, characterized in that the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and an average increase in tensile strengths that are 10% greater, such as about 10 to 50%, about 12 to 24%, or about 12 to 22%, compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%.

54. Nonwoven fabric according to any one of claims 1 to 53, characterized in that the nonwoven fabric has a spliced ​​percentage area of ​​about 9.6 to 10.2%, an average individual spliced ​​surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the splicing point of about 6.75 to 7.25 mm-1, and an average increase in percentage elongation that is about 4 to 50%, such as about 4 to 20%, about 4 to 15%, or about 4 to 14%, compared to a similarly prepared nonwoven fabric having a compaction at the splicing point of less than 3.5 mm-1.

55. Nonwoven fabric according to any one of claims 1 to 54, characterized in that the nonwoven fabric has a spliced ​​percentage area of ​​about 9.6 to 10.2%, an average individual spliced ​​surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the splicing point of about 6.5 to 7.5 mm-1, and an average increase in percentage elongation that is about 4 to 50%, such as about 4 to 20%, about 4 to 15%, or about 4 to 14%, compared with a similarly prepared nonwoven fabric having a spliced ​​surface area greater than 12%, such as 18.1%.

56. Nonwoven fabric according to any one of claims 1 to 55, characterized in that the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and one or more of the following properties: i) an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1; Petition 870250088344, dated 09 / 29 / 2025, p. 200 / 234 16 / 24 ii) an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of about 5 to 20%, as of about 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1; and iii) improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of about 5 to 20%, as of about 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1.

57. Nonwoven fabric according to any one of claims 1 to 56, characterized in that the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and one or more of the following properties: i) an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%; ii) an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, as of approximately 8 to 120% or 9 to 95% compared to a non-Petition 870250088344, dated 09 / 29 / 2025, p.201 / 234 17 / 24 similarly prepared fabric with a bonded surface area greater than 12%, such as 18.1%; and iii) improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of about 5 to 20%, such as about 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%.

58. Nonwoven fabric according to any one of claims 1 to 57, characterized in that the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1, and one or more of the following properties: i) an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1; ii) an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, or of approximately 8 to 120% or 9 to 95% compared to a similarly prepared nonwoven fabric with a compaction at the bonding point of less than 3.5 mm-1;iii) improvements in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of approximately 5 to 20%, as of approximately 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric with a bonding point compaction of less than 3.5 mm-1; iv) an increase in tensile strengths in the machine direction (MD) that are approximately 10 to 50% higher, as of approximately 10 to 30%, as of approximately 12 to 20%, or approximately 12 to 15% higher, compared to a similarly prepared nonwoven fabric having a bonding point compaction of less than 3.5 mm-1;v) an increase in tensile strengths in the transverse direction (CD) that are about 10 to 50% greater, such as about 10 to 30%, about 15 to 25%, about 18 to 24%, or about 19 to 21%, compared with a similarly prepared nonwoven fabric with a bonding point compaction of less than 3.5 mm⁻¹; and vi) an increase in percent elongation that is about 4 to 50%, such as about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric having a bonding point compaction of less than 3.5 mm⁻¹.

59. Nonwoven fabric according to any one of claims 1 to 58, characterized in that the nonwoven fabric has a bonded area percentage of about 9.6 to 10.2%, an average individual bonded surface area of ​​about 0.15 to 0.25 mm2, an average compaction value at the bonding point of about 6.75 to 7.25 mm-1 and one or more of the following properties: i) an improvement in abrasion resistance, exemplified by a percentage difference in the Martindale Abrasion Index of 10 to 30% compared to a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%;ii) an average percentage reduction in the weight of material removed during the abrasion test (according to Test Method NWSP 20.5) of 5 to 150%, such as approximately 8 to 120% or 9 to 95% compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%; iii) an improvement in softness, as demonstrated by an average improvement in Handle-O-Meter values ​​of approximately 5 to 20%, such as approximately 6 to 15% or 8 to 10%, compared to a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%; iv) an increase in tensile strengths in the machine direction (MD) that are about 10 to 50% greater, such as about 10 to 30%, or about 12 to 20%, or about 12 to 15% greater, compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%;v) an increase in tensile strengths in the transverse direction (CD) that are about 10 to 50% greater, such as about 10 to 30%, or about 15 to 25%, Petition 870250088344, dated 29 / 09 / 2025, page 204 / 234 20 / 24, or about 18 to 24% or about 19 to 21%, compared with a similarly prepared nonwoven fabric with a bonded surface area greater than 12%, such as 18.1%; and vi) an increase in percent elongation that is about 4 to 50%, such as about 5 to 20%, or about 5 to 15%, compared with a similarly prepared nonwoven fabric having a bonded surface area greater than 12%, such as 18.1%.

60. Nonwoven fabric according to any one of claims 1 to 59, characterized in that the nonwoven fabric comprises a spunbond layer.

61. Nonwoven fabric according to any one of claims 1 to 60, characterized in that the nonwoven fabric comprises a first spunbond layer with low or no crimp filaments and a second layer comprising crimp filaments.

62. Nonwoven fabric according to any one of claims 1 to 61, characterized in that the nonwoven fabric comprises at least two layers wherein one of the layers is selected from the group of meltblown material layer; carded fabric layer, spunbond layer, resin-bonded layer, airlaid fabric layer and a spunlace layer.

63. Use of nonwoven fabric as defined in one or more of claims 1 to 62, characterized in that the nonwoven fabric is in an absorbent article. Petition 870250088344, dated 09 / 29 / 2025, pp. 205 / 234 21 / 24 64. Nonwoven article characterized in that it comprises nonwoven fabric as defined in any one or more of claims 1 to 62.

65. Sheet composite material characterized in that it comprises nonwoven fabric as defined in any one or more of claims 1 to 62.

66. Sheet composite material according to claim 65, characterized in that the sheet material comprises a layer of blow-molded material.

67. Sheet composite material according to claim 26, characterized in that the melt-blown material layer is sandwiched between two spunbond layers, and wherein at least one of the spunbond layers conforms to the nonwoven fabric layer as defined in one or more of claims 1 to 61.

68. Absorbent article characterized in that it comprises nonwoven fabric as defined in one or more of claims 1 to 62.

69. Calender sizing unit for spot sizing of a sheet material, characterized in that the calender sizing unit comprises a pair of cooperating cylindrical rolls in which at least one of the rolls includes an engraved pattern thereon, the engraved pattern comprising a plurality of individual and spaced sizing points extending radially outward from a roll surface, the plurality of sizing points defining a pattern comprising a plurality of spaced matrices extending in the transverse and radial direction of the roll, and are configured and arranged to thermally spot-size a nonwoven fabric in which a percentage of the sized surface area of ​​the nonwoven fabric is less than about 12% and an average compaction value at the sizing point of the nonwoven fabric is about 6.5 to 8 mm -1.

70. Calendering unit according to claim 69, characterized in that the engraved pattern further comprises a plurality of spaced pairs of dies extending circumferentially around the roll in a spiral-like shape.

71. Calender gluing unit according to claim 69 or 70, characterized in that the gluing points have a continuous side wall and a raised surface, the raised surfaces having an average surface area of ​​about 0.15 to 0.25 mm2.

72. Calender gluing unit according to one or more of claims 69 to 71, characterized in that the number of gluing points is about 50 to 60 individual gluing points per square centimeter.

73. Calender gluing unit according to one or more of claims 69 to 72, characterized in that the average length of the gluing points is about 0.74 to 0.78 mm, and the average width of the gluing points is about 0.24 to 0.36 mm.

74. System for preparing a nonwoven fabric characterized by comprising, a first source of polymer; Petition 870250088344, dated 09 / 29 / 2025, page 207 / 234 23 / 24 a spinning beam in communication with the first source of polymer, the spinning beam configured and arranged to produce a plurality of polymer fibers; a collection surface disposed below the spinning beam to deposit the plurality of polymer fibers onto it to form a fiber web;a thermal bonding unit disposed downstream of the yarn bundle, the thermal bonding unit comprising a pair of cooperating cylindrical rolls in which at least one of the rolls includes an engraved pattern thereon, the engraved pattern comprising a plurality of individual and spaced bonding points extending radially outward from a roll surface, the plurality of bonding points defining a pattern comprising a plurality of spaced matrices extending in the transverse and radial direction of the roll, and are configured and arranged to thermally bond by points the fiber weft to form a nonwoven fabric in which a percentage of bonded surface area of ​​the nonwoven fabric is less than about 12% and an average compaction value at the bonding point of the nonwoven fabric is about 6.5 to 8 mm-1.; 75. Method for preparing a bonded nonwoven fabric characterized by comprising: providing a nonwoven web comprising a plurality of fibers; introducing the nonwoven web into a thermal bonding unit comprising a pair of cooperating cylindrical rollers wherein at least one of the rollers includes an engraved pattern thereon, the engraved pattern comprising a plurality of points. Petition 870250088344, dated 09 / 29 / 2025, p. 208 / 234 24 / 24 individual and spaced bonding points extending radially outward from a roll surface, a plurality of bonding points defining a pattern comprising a plurality of spaced matrices extending in the transverse and radial direction of the roll, and thermal point bonding of the fiber weft to form a nonwoven fabric in which a percentage of the bonded surface area of ​​the nonwoven fabric is less than about 12% and an average compaction value at the bonding point of the nonwoven fabric is about 6.5 to 8 mm-1.

76. Nonwoven fabric characterized by comprising a plurality of fibers bonded with a bonding pattern on a surface to form a coherent weave, the nonwoven fabric containing a vertical axis extending in a machine direction and a horizontal axis extending in a transverse direction, the bonding pattern comprising a plurality of spaced pairs of matrices extending in the machine, transverse and diagonal directions of the nonwoven fabric, wherein each matrix comprises a plurality of spaced bonding points having an oblong shape, and wherein the nonwoven fabric has a percentage bonded surface area of ​​less than about 14%, a collective average bonding distance of about 1.5 to 1.7 mm, and an average compaction value at the bonding point of about 3.0 to 5.0 mm-1.

77. Nonwoven fabric according to claim 76, characterized in that the fibers comprise a mixture of a polypropylene resin and less than 20% by weight of a polypropylene copolymer.

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