A novel fibrous non-woven composite is provided that comprises as a first component substantially continuous coarse spun-bonded filaments of a thermoplastic polymer which exhibit molecular orientation, and as a second component fine discontinuous melt-blown microfibers of a thermoplastic polymer. The fibrous components are well admixed through their placement following their formation on the same equipment to form an integrated non-woven deposition in the absence of a discrete phase boundary between substantially homogeneous concentrations of the components, and are subsequently thermally bonded to form a unitary structure. The continuous coarse spun-bonded filaments provide good strength for a supporting function throughout the non-woven composite, and the fine discontinuous melt-blown microfibers perform an uninterrupted filtration and/or moisture transport function throughout the non-woven composite. The resulting product is useful in diaper, medical, and clothing applications.

BACKGROUND OF THE INVENTION 
Fibrous composites are known. They commonly consist of several preformed 
discrete layers of non-woven materials which are bonded or otherwise 
laminated together. 
Needle-felt floor coverings for example are conventionally manufactured 
from at least two non-woven sheets or layers that differ in fiber 
fineness, and color. Thereby combinations of properties can be attained 
that would be extremely difficult or even impossible to achieve in a 
single layer of a spun-bonded non-woven material. 
Non-woven goods that are employed as inserts in the clothing industry are 
also known to be manufactured in the form of composites, as are many 
specialized filters and medical dressings. The latter are often made from 
separate preformed non-wovens of continuous filaments and microfibers and 
are joined in surface-to-surface contact to form a composite. 
German Patent No. 2,356,720 and U.S. Pat. No. 4,041,203 to Brock et al. 
disclose such a two-layered composite. This structure comprises a 
non-woven layer of molecularly oriented continuous filaments of a 
thermoplastic polymer having a mean diameter of more than 12 .mu.m bonded 
in surface-to-surface contact to a previously thermally-bonded non-woven 
layer of short fibers of a thermoplastic polymer having a mean diameter of 
less than 10 .mu.m. The latter layer comprises a microfiber non-woven of 
discontinuous thermoplastic fibers having a softening temperature 
10.degree. to 40.degree. C. lower than that of the filaments in the former 
layer. The non-woven layer of molecularly oriented continuous filaments is 
point-bonded by the application of heat and pressure to the microfiber 
layer in laminar surface-to-surface contact. The resulting product 
exhibits a textile-like appearance and drape. The layer of continuous 
molecularly oriented filaments serves a supporting function for the 
adjoining microfiber layer. This known composite is manufactured by 
combining the as yet uncompacted continuous-filament non-woven layer with 
the previously compacted microfiber non-woven layer, which is obtained 
from a roll, upstream of the compacting calender as illustrated in FIG. 2 
of German Patent No. 2,356,720 and U.S. Pat. No. 4,041,203. The microfiber 
non-woven layer is accordingly already consolidated before being laminated 
and bonded to the continuous filament non-woven layer and has enough 
mechanical stability to withstand being stored in a roll and to withstand 
being unwound from the roll prior to being formed into a composite of the 
two discrete homogeneous layers. Thus the laminated composite is compacted 
with a calender to produce bonding once the loose and uncompacted 
continuous-filament non-woven layer and the already consolidated 
microfiber non-woven layer are placed in a side-by-side relationship. It 
is an essential characteristic of this known composite that the resulting 
laminated structure consists of individual discrete layers separated by a 
definite phase boundary between substantially homogeneous concentrations 
of the two components. The purpose of such multilayer composites with 
phase boundaries in their cross-section is to attempt to combine the 
properties and functions of the individual and discrete non-woven layers 
for particular applications. The molecularly oriented continuous-filament 
non-woven layer of the composite disclosed in German Patent No. 2,356,720 
and U.S. Pat. No. 4,041,203 is intended to act as a base, whereas the 
microfiber non-woven layer is intended to function primarily as an 
absorbent or filter. A composite is formed that is mechanically stable 
with the base of continuous filaments supporting the discrete layer of 
microfibers which can absorb moisture. 
Such a composite nevertheless has been found to possess shortcomings. One 
particular disadvantage is that the function of each layer within the 
composite is confined to a single homogeneous layer and cannot be exerted 
as a whole throughout the cross-section of the composite. Assume, for 
example, that the microfiber non-woven layer of the composite is intended 
to absorb or transport moisture. Such microfiber non-woven layer is 
usually thinner than the filament non-woven layer, which acts as a base. 
To increase the filtering capacity of the microfiber non-woven layer it 
would be necessary to attempt to make it much thicker, which would 
introduce the drawback of slowing the filtration. Accordingly, the 
possible designs for satisfactory end uses are somewhat limited when 
following this technology. 
It is an object of the present invention to provide an improved fibrous 
non-woven composite article having a novel internal structure that was not 
available in the prior art. 
It is another object of the present invention to provide a novel non-woven 
composite article in which the support and absorptive properties of its 
components advantageously are manifest throughout its cross-section. 
These and other objects, as well as the scope, nature, and utilization of 
the claimed invention will be apparent to those skilled in the art from 
the following detailed description and appended claims. 
SUMMARY OF THE INVENTION 
It has been found that a fibrous non-woven composite comprises in 
admixture: 
(a) as a first component substantially continuous coarse spun-bonded 
filaments of a thermoplastic polymer which exhibit molecular orientation, 
and 
(b) as a second component fine discontinuous melt-blown microfibers of a 
thermoplastic polymer, 
wherein the first and second components of the fibrous non-woven composite 
were deposited following melt extrusion on the same equipment to produce 
an admixture of said components in the absence of a discrete phase 
boundary between substantially homogeneous concentrations of the 
components thereby creating an integrated non-woven deposition of the 
components, and the integrated non-woven deposition of the components 
subsequently was thermally bonded to form the non-woven composite which 
exhibits a unitary structure.

DESCRIPTION OF PREFERRED EMBODIMENTS 
The present invention provides a novel fibrous non-woven composite 
comprising substantially continuous coarse spun-bonded filaments of a 
thermoplastic polymer which exhibit molecular orientation in admixture 
with fine discontinuous melt-blown microfibers of a thermoplastic polymer 
wherein there is an absence of a discrete boundary between substantially 
homogeneous concentrations of the components. Since each fibrous component 
is melt extruded and is deposited with intimate commingling on the same 
equipment (e.g., layering machine), a more or less uniform mixture of 
coarse spun-bonded filaments and fine melt-blown microfibers is 
accomplished on an expeditious basis prior to thermal bonding to form the 
resulting composite article. 
Any thermoplastic polymer that is capable of melt extrusion to form fibers 
may be utilized to form the fibrous non-woven composite of the present 
invention. For instance, the thermoplastic polymer may be polyethylene, 
polypropylene, polyethylene terephthalate, polyamides, polyurethane, 
polystyrene, copolymers of the foregoing, etc. 
It is significant that the discontinuous melt-blown microfibers are mixed 
with the coarse continuous spun-bonded filaments without utilizing any 
intermediate compaction of the same. Accordingly, the layer of 
discontinuous melt-blown microfibers is not compacted prior to composite 
formation as is practiced in the prior art. This different formation 
technique has been found to lead to the formation of a novel product 
having advantageous overall properties. 
The product of the invention accordingly is a composite comprising at least 
two fibrous components (i.e., spun-bonded coarse continuous filaments and 
fine discontinuous melt-blown microfibers) whereby no individual 
homogeneous layers can be detected within the same and no discrete phase 
boundaries are present between substantially homogeneous concentrations of 
the components because the material is of an integrated unitary 
construction. 
The fibrous non-woven composite of the present invention can be 
distinguished from that of German Patent No. 2,202,955 and U.S. Pat. No. 
3,768,118 wherein a method is disclosed for manufacturing a tangled 
non-woven web of two different discontinuous fibers. The fibers in this 
prior art method are first broken down into separate fibers by two intake 
grids and are supplied by two high-speed converging streams of air to a 
mixing point. The individual fibers intersect and penetrate one another in 
the mixing zone, and the mixture is layered into a tangled non-woven 
composite on an air-permeable support, such as a layering belt. These 
short fibers (e.g., wood pulp) are accordingly initially mixed together in 
a mixing zone before the non-woven composite of exclusively discontinuous 
fibers is constructed on the air-permeable support. This method utilizes 
staple fibers, which are discontinuous and short enough to mix at the 
mixing zone before being layered. See Col. 3, lines 13 to 27 of German 
Patent No. 2,202,955 and Col. 1, lines 14 to 23 of U.S. Pat. No. 3,768,118 
with respect to the lengths of the fibers involved. The "long fibers" 
there discussed are generally between 1/2 and 21/2 inches, and the "short 
fibers" have a length less than about one-fourth inch. 
The substantially continuous coarse spun-bonded filaments of a 
thermoplastic polymer utilized in the present invention exhibit a diameter 
greater than 15 .mu.m, and typically exhibit a diameter of approximately 
15 to 25 .mu.m, and most preferably a diameter of approximately 18 to 22 
.mu.m. Such coarse continuous filaments can be formed using conventional 
technology for forming the fibers of a spun-bonded non-woven product. 
Molecular orientation can be imparted to such coarse continuous filaments 
immediately following their melt extrusion while utilizing conventional 
techniques, such as aerodynamic drawing. 
The fine discontinuous melt-blown microfibers of a thermoplastic polymer 
utilized in the present invention exhibit a diameter less than 10 .mu.m, 
and typically exhibit a diameter of approximately 0.5 to 10 .mu.m, and 
most preferably a diameter of 2 to 8 .mu.m. The discontinuous microfibers 
can be formed by conventional technology for forming melt-blown 
microfibers, such as melt-extrusion followed by subjection to aerodynamic 
forces which act upon the resulting spinline to create periodic filament 
breakage and the formation of fine discontinuous melt-blown microfibers. 
Melt extrusion conditions can be selected for such component which 
inherently impart no substantial molecular orientation to the resulting 
melt-blown microfibers, or alternatively conditions which impart molecular 
orientation can be utilized as will be apparent to those skilled in the 
formation of melt-blown microfibers. 
Depending on the desired end use, the fibrous non-woven composite of the 
present invention commonly comprises 20 to 97 percent by weight of the 
substantially continuous coarse spun-bonded filaments of thermoplastic 
polymer, and 3 to 80 percent by weight for the fine discontinuous 
melt-blown microfibers. For many end uses, it has been determined that the 
preferred concentrations can range from 40 to 97 percent by weight for the 
substantially continuous coarse spun-bonded filaments, and from 3 to 60 
percent by weight for the fine discontinuous melt-blown microfibers. The 
percent by weight for each component is based upon the total weight of the 
fibrous non-woven composite of the present invention. 
The difference in properties between the continuous coarse spun-bonded 
filaments as employed in the present invention versus both the "short" and 
"long" discontinuous fibers of the prior art as previously discussed is 
self-evident. However, even the fibers of the second component employed in 
the present invention and referred to as "microfibers" are not comparable 
in length to the "long" or "short" fibers of the prior art previously 
discussed. More specifically, the discontinuous melt-blown microfibers 
utilized in the present invention can be several 100 mm. in length. 
Typically, such melt-blown microfibers have lengths of approximately 200 
to 1000 mm., or more, with the exact length of such discontinuous 
microfibers not being critical to the achievement of the desired 
properties discussed herein. As will be apparent to those skilled in fiber 
technology, if the lengths of the melt-blown discontinuous microfibers are 
too short, their movement may be difficult to control and they may be 
blown away from the contemplated area for admixture during composite 
formation thereby having a deleterious impact upon the overall 
productivity. Accordingly, extremely short melt-blown microfiber lengths 
are avoided in preferred embodiments. 
The fibrous non-woven composite product of the present invention could not 
be formed while utilizing the teachings of U.S. Pat. No. 3,768,118 or its 
equivalent, German Patent No. 2,202,955, to Ruffo et al. It would not be 
possible to deposit the continuous coarse filaments utilized herein by 
employing the fiber laying device as described in this prior art. If such 
continuous coarse filaments were transported on rotating feed rolls as 
described in the prior art, the continuous filaments would tend to stick 
to these rolls, and would roll up. Accordingly, they would not be 
forwarded to the collector screen as desired in such prior technology. See 
Col. 18, lines 3 to 43, of U.S. Pat. No. 3,768,118 where the rayon 
fiberizing system shown on right side of FIG. 1 of that patent is 
described. The rayon is provided in the form of a carded batt of staple 
fibers (335). If one chose to utilize continuous filaments which is not 
even remotely suggested, they would have to be introduced in the form of a 
flat sheet which would be the only form having some geometrical similarity 
to the carded batt used in the reference. Such flat sheet would be 
positively directed to the clothing of the rayon lickerin (338). The 
continuous filaments would be positively maintained in position relative 
to the feed roll (337) until the fibers would contact the teeth (339) of 
the rayon lickerin (338). However, due to their continuous nature, the 
continuous filaments could never be effectively combed from the surface of 
the flat sheet which served as their source. Instead, they would simply be 
broken or caused to disintegrate as the rayon teeth of the lickerin are 
rotated on shaft (341) at a high speed (e.g., 3,000 rpm as stated at Col. 
18, line 28). The resulting fibrous product would always consist of 
irregular and short fibers (i.e., staple fibers) and would be forwarded to 
the forming area. It could not reasonably be expected that a process 
involving disintegration of the continuous filaments by means of the rayon 
lickerin (338) could possibly lead to fibrous non-woven composite of the 
present invention. A portion of the continuous filaments would always 
stick to the teeth (339) of the rayon lickerin (338). These would remain 
caught in the teeth and would cause a continuous build-up of a non-uniform 
layer on its surface thereby necessitating mandatory stoppage of the 
equipment which would have to be frequently serviced by cleaning. However, 
the essential difference relative to the present invention would reside in 
the fact that the resulting prior art product, if ever capable of being 
manufactured while utilizing continuous filaments as a starting material, 
would always be formed from staple fibers rather than from coarse 
spun-bonded continuous filaments and fine melt-blown microfibers as 
presently claimed. 
The use of the molecularly oriented coarse spun-bonded continuous filaments 
as one of two fiber components within the composite of the present 
invention has been found to provide important advantages. For instance, 
the final non-woven fabric is provided with excellent strength 
characteristics in all directions throughout its structure which would not 
be possible if all discontinuous fibers were utilized. The use of any 
combination of "short" and "long" fibers, as defined in the prior art, 
could never yield such an advantageous strength characteristic as that of 
the present invention. 
The aerodynamic conditions that are created by flowing air that accompanies 
continuous filaments while they are being extruded under pressure from a 
liquid melt make it impossible to fully mix diverse fiber types together 
before they are deposited. However, the fine melt-blown discontinuous 
microfibers utilized in the present invention also enter into and 
penetrate void areas within the web comprising the continuous coarse 
spun-bonded filaments. Cavities between the continuous coarse filaments 
are thereby filled by the melt-blown microfibers that enter at high 
velocity. 
Again in contrast to the prior art, the filaments utilized to form the 
product of the present invention are not separated into individual fibers 
by intake grids and then mixed together in a mixing zone or chamber before 
being layered. Intake grids would also tend to break the continuous 
filaments down into short fibers, which would be contrary to the present 
invention. 
Similar distinctions between the presently claimed invention and that of 
U.S. Pat. No. 4,751,134 to Chenovet apply. The stated object of this prior 
art patent is to form a "non-woven matrix of glass and synthetic fibers." 
The two fiber components utilized are defined at Col. 3, lines 35 to 46, 
and at lines 47 to 53, respectively. The first fiber component of this 
prior art is fiberized glass fibers having a diameter of 3 to 10 microns 
and widely varying lengths of one-half to 3 inches. The second synthetic 
fiber component has fiber lengths of one quarter to 4 inches. Even here, 
in comparison to the present invention, the fibers employed are relatively 
short and could not yield a product having the desirable strength 
characteristic which is achieved by the present invention in view of the 
presence of the coarse continuous filaments in combination with the fine 
discontinuous microfibers. 
One essential characteristic of the product of the present invention is 
that, due to the resultant good admixture of the diverse spun-bonded and 
melt-blown components, there is hardly any nonuniformity in the fibrous 
blend throughout the cross-section of the resulting fibrous non-woven 
composite. The new fibrous composite accordingly effectively combines the 
different functions of both types of fiber throughout a cross-section of 
the product. It should be noted that the good admixture of the two 
components over the cross-section of the composite serves to extend the 
operability and function of each component over the total thickness of the 
resulting fibrous non-woven composite. 
Accordingly, the function of the fine discontinuous melt-blown microfibers 
is substantially distributed over the entire cross-section of the 
composite, as is the supporting function of the relatively coarse 
continuous spun-bonded filaments of the thermoplastic polymer which 
exhibit molecular orientation. The prescribed mixture of the individual 
components well facilitates the function of each component at all areas of 
the resulting fibrous non-woven composite and, in contrast to the prior 
art, there are no phase boundaries between layered components that are 
present in substantially homogeneous concentrations. 
The new composite article of the present invention makes it possible for 
the first time to render each function ascribed to the diverse components 
more or less homogeneously over the total cross-section of the fibrous 
composite whereas in the prior art, the functions ascribed to the 
individual components are limited to each separate layer. 
Since the individual components are intermixed throughout the cross-section 
in accordance with the invention, the components can now also carry out 
the particular functions assigned to them throughout a substantially 
thicker are. For example, one function of the fine discontinuous 
microfibers is to filter or transport moisture. Since the intermixed 
discontinuous microfibers are distributed throughout the thickness of the 
fibrous composite, the filtration area is expanded and filtration will be 
more rapid. Also, the transport of moisture is not interrupted. 
The present invention provides a further advantage. The mixing of the two 
components together, makes it possible to preliminarily compact to some 
degree the composite-forming components during the integrated non-woven 
deposition of the components on a support (e.g., a continuous belt) on the 
same equipment immediately following melt extrusion. This preliminary 
compaction that inherently occurs well facilitates the conveying of the 
mixture in a preferred embodiment to a bonding calender for thermal 
pattern or point-bonding through the simultaneous application of heat and 
pressure. Accordingly, it is no longer necessary to take steps to achieve 
a desired level of compactness before the composite can be forwarded to 
the calender where bonding is accomplished. 
Turning now in detail to the drawings, the schematic sectional view of FIG. 
1 represents a fibrous non-woven composite 10 comprising a mixture of the 
coarse continuous spun-bonded filaments of thermoplastic polymer 12 and 
the fine discontinuous melt-blown microfibers of thermoplastic polymer 14. 
In order to demonstrate that the fibrous non-woven composite 10 has no 
discrete layers of individual components separated by phase boundaries and 
is actually a substantially homogeneous mixture of the two components, 
coarse continuous spun-bonded filaments 12 are represented in the drawing 
by continuous hatching and the fine discontinuous melt-blown microfibers 
14 are represented by broken hatching. Both the molecularly oriented and 
substantially continuous coarse spun-bonded filaments 12 and the fine 
discontinuous melt-blown microfibers 14 extend substantially throughout 
the total thickness of the fibrous non-woven composite 10 which exhibits a 
unitary construction in the absence of phase boundaries created by the 
lamination of diverse components. The continuous coarse spun-bonded 
filaments 12 serve as a reliable strong support and the fine discontinuous 
melt-blown microfibers 14 serve a filtering and moisture transport 
function throughout the cross-section of the fibrous non-woven composite. 
The filtration and moisture transport component in the form of fine 
discontinuous melt-blown microfibers 14 is accordingly distributed 
throughout the total cross-section thereby making it possible to attain 
more extensive and more rapid filtration than would be possible with one 
or more thin discrete homogeneous filtration layers of such melt-blown 
microfibers. The supporting function of the continuous coarse spun-bonded 
filaments 12 also extends throughout the cross-section of the fibrous 
non-woven composite 10. 
The fibrous non-woven composite 10 is produced following the melt extrusion 
of its components in an integrated non-woven production process on the 
same equipment (i.e., a non-woven laying machine) in a non-woven spinning 
plant (not shown). Continuous coarse spun-bonded filaments 12 and fine 
discontinuous melt-blown microfibers 14 are layered together in good 
admixture in a single sheet following melt extrusion from separate 
extrusion orifices in the absence of the preliminary formation of two 
discrete substantially homogeneous concentrations of the components 
thereby creating an integrated non-woven deposition of the components that 
is subsequently bonded through the simultaneous application of heat and 
pressure. 
As will be apparent from the enlarged schematic simplified illustration in 
FIG. 2, continuous coarse spun-bonded filaments 12 and the fine 
discontinuous melt-blown microfibers 14 are blended into a substantially 
homogeneous admixture. The fine discontinuous melt-blown microfibers 14 
extensively fill and occupy the spaces between the comparatively thicker 
coarse continuous spun-bonded filaments 12 thereby forming a substantially 
homogeneous unitary mass of the diverse fibrous components. The good 
admixture of diverse fiber components that constitutes the fibrous 
non-woven composite 10 is created through melt extrusion and disposition 
on a common support without previously subjecting the individual 
components (i.e., the continuous coarse spun-bonded filaments 12 and/or 
the fine discontinuous melt-blown microfibers 14) to a preliminary 
compaction. 
The substantially continuous coarse spun-bonded filaments of thermoplastic 
polymer which exhibit molecular orientation that constitute the supporting 
matrix of the fibrous non-woven composite 10 can be conventionally spun 
via melt extrusion. As previously indicated, the fine discontinuous 
microfibers 14 can be advantageously produced by the use of conventional 
procedures used to form fine melt-blown discontinuous fibers. The exertion 
of aerodynamic forces on the extrudate preferably is adjusted so as to 
decrease the frequency of fiber breakage and to thereby form longer 
lengths of the resulting discontinuous microfibers than otherwise would be 
formed during such melt-blowing. 
The following Example is presented as a specific illustration of the 
present invention. It should be understood, however, that the invention is 
not limited to the specific details set forth in the Example. 
EXAMPLE 
The thermoplastic polymer used to form each of the components of the 
fibrous non-woven composite is primarily isotactic polypropylene. The 
polypropylene used to form the continuous coarse spun-bond filaments has a 
melt flow index of approximately 25 at 230.degree. C. and 2.16 Kg. 
pressure. The polypropylene used to form fine discontinuous microfibers 
has a melt flow index immediately prior to extrusion of 800 at 230.degree. 
C. and 2.16 Kg. pressure. As illustrated in FIG. 3, the melt extrusion 
spinning equipment 20 for forming continuous coarse spun-bonded filaments 
22 is located over a moving foraminous conveyor belt 24 so that the 
filaments following extrusion from the melt are forwarded perpendicularly 
to the conveyor. Air is continuously withdrawn from the underside of the 
conveyor belt 24 by gaseous withdrawal means which produce a zone of 
reduced pressure (not shown). Approximately 2,500 extrusion orifices are 
provided for the continuous coarse spun-bonded filaments per meter of 
production. Immediately following melt extrusion the resulting continuous 
spun-bonded filaments are substantially molecularly oriented at 26 by 
aerodynamic drawing at a draw ratio in excess of 200:1. The resulting 
continuous coarse spun-bonded filaments 22 which exhibit molecular 
orientation have a diameter of approximately 20 .mu.m. as they are 
deposited on conveyor 24. The spinning equipment 28 for the fine 
discontinuous melt-blown microfibers is positioned immediately following 
spinning equipment 20 and also is directed perpendicularly towards the 
same conveyor 24. The fine melt-blown microfibers enter into and penetrate 
void areas of the previously deposited web comprising continuous coarse 
spun-bonded filaments. Cavities between the continuous coarse spun-bonded 
filaments are thereby filled by the melt-blown microfibers that enter at 
high velocity. Approximately 1,000 extrusion orifices are provided for the 
microfibers per meter of production and the resulting extrudate 
periodically is broken to form discontinuous microfibers through the 
adjustment of the aerodynamic velocity of the hot air stream flowing 
therewith. The fine discontinuous melt-blown microfibers have a diameter 
of approximately 2 to 6 .mu.m. with some variation among microfibers, and 
lengths within the range of approximately 200 to 1,000 mm. as they are 
deposited. The area of the conveyor belt 24 immediately below spinning 
equipment 20 and 28 constitutes a web-forming area. In this manner a 
unitary substantially homogeneous sheet of the composite material 30 is 
formed on a single support having a weight of approximately 25 g./sq. 
meter. This sheet is next transported by means of the conveyor 24 to a 
location (not shown) where thermal point-bonding is accomplished by 
conventional means through the simultaneous application of heat and 
pressure. The resulting fibrous non-woven composite following thermal 
point-bonding consists of 50 percent by weight of the continuous coarse 
spun-bonded filaments and 50 percent by weight of the fine discontinuous 
melt-blown microfibers. 
A representative internal structure of the resulting non-woven composite is 
shown in FIGS. 5 and 6 as previously discussed. Thus, the resulting 
composite is a thermally bonded non-woven sheet material produced 
following sequential or simultaneous melt extrusion (as described) using 
an integrated non-woven formation technique on the same deposition device 
of a non-woven spinning system. 
The invention is not restricted to the two-component embodiment described 
by way of this Example and the resulting non-woven composite optionally 
can be formed while utilizing more than two components in a directly 
analogous manner. Additionally, for special end uses a substantially 
homogeneous concentration of either component or a different component can 
be provided or otherwise placed upon the surface of the fibrous non-woven 
composite of the present invention when such presence would be 
advantageous. For instance, a substantially homogeneous concentration of 
the substantially continuous coarse spun-bonded filaments can be provided 
when only the upper portion of the web formed from the same is penetrated 
by the fine melt-blown microfibers to form the fibrous non-woven composite 
described herein and a portion of the substantially coarse filaments 
remains below as a homogeneous area. Alternatively, a discrete layer of 
either component can be deposited upon the surface of the composite 
article of the present invention via melt extrusion. 
The fields of use for the new composite vary depending upon the particular 
materials and their relative concentrations employed, and include medical 
and clothing applications in particular. The fibrous non-woven composite 
formed in this Example is particularly suited for use as a barrier leg 
cuff or for use in a diaper, etc. 
Although the invention has been described with a preferred embodiment, it 
is to be understood that variations and modifications may be resorted to 
as will be apparent to those skilled in the art. Such variations and 
modifications are to be considered within the purview and scope of the 
claims appended hereto.