Patent Publication Number: US-2006019055-A1

Title: Hook and loop fastener device

Description:
FIELD OF INVENTION  
      The instant invention relates to a hook and loop fastener device.  
     BACKGROUND OF THE INVENTION  
      The use of hook and loop fastener devices in consumer and industrial applications is widely known. Examples of such applications include disposable hygiene absorbent articles such as diapers, disposable garments such as surgical gowns, and the like.  
      In general, a hook and loop fastener device comprises a hook component and a loop component. The hook component includes a plurality of hook-shaped members anchored to a base material. The loop component includes a plurality of upstanding loop members projecting outwardly from a backing material. The hook-shaped members are designed to engage the loop members in order to provide a strong mechanical bond therebetween. The hook members and the loop members can typically be engaged and disengaged repeatedly.  
      However, when the hook and loop fastener device is intended to be used in a disposable hygiene absorbent article or a disposable garment, a low cost loop component, which adequately functions to provide a resealable mechanical closure for a limited number of applications, is desirable. There is no need for the loop component of a disposable article to possess long term capability for repetitious engagements and disengagement with the hook component because such articles only have a short life span. However, the loop component used in conjunction with the hook component should provide a relatively high peel strength, and a relatively high shear strength, i.e. it should secure closure for a limited number of use cycles. The use of non-woven material to provide a low cost loop component, which adequately functions to provide a resealable mechanical closure for a limited number of applications, is well known.  
      U.S. Pat. No. 5,326,612 discloses a female loop component, which includes a non-woven secured to a backing, for engaging a complementary hook component in a refastenable fastening device.  
      U.S. Pat. No. 5,616,394 discloses a sheet of loops, which includes a sheet of longitudinally oriented fibers having anchor portions and arcuate portions projecting in one direction away from the anchor portions, and a thermoplastic backing material.  
      U.S. Pat. No. 5,773,120 discloses a loop material, which includes a bonded carded web that contains a binder, suitable for use in a hook and loop fastening system.  
      U.S. Pat. No. 5,786,060 discloses a female member, which includes a web having a heat-melt-adhering composite fiber body. The web has loops formed on its first surface while its second surface is densely heat-melt-adhered together.  
      U.S. Pat. No. 5,858,515 discloses a pattern-unbonded non-woven fabric having continuous bonded areas defining a plurality of discrete unbonded area, which is suitable for use as a loop fastening material for hook and loop fastening systems.  
      U.S. Pat. No. 5,888,607 discloses a non-woven fibrous loop material, which contains an open fibrous loop layer comprised predominately of polypropylene polymer, copolymer, or blend fibers, for use in hook and loop fastening systems.  
      U.S. Pat. No. 6,218,593 discloses an absorbent article, which includes a top sheet, a back sheet, and an absorbent member interposed between the top sheet and the back sheet. The absorbent article includes a fastening member, which is formed of a male sheet member designed to be brought into direct contact with the surface of the non-woven fabric constituting a back sheet to form a mechanical bond therebetween.  
      When a hook and loop fastener device is intended to be used in disposable articles such as a disposable garment or a disposable hygiene absorbent article, different factors, i.e. fastening performance, texture, and aesthetics, must be considered with regard to the loop component. Fastening performance factors include peel strength as well as shear strength. A relatively high peel strength and shear strength is desired to secure closure for at least a limited number of use cycles without excessive fiber fuzz formation. Fuzz formation can occur when fibers break or pull free from the loop component upon disengagement with the hook component. Loop component texture factors include softness, flexibility, and resiliency, i.e. compression resistance. Softness and flexibility are important to avoid discomfort to the wearer, as well as providing a comfortable form-fitting garment or article. A relatively high degree of compression resistance, resolves problems, i.e. compression of the loop fibers, caused during the transportation and storage of loop materials. A high compression resistance is desirable because compression of the loop fibers impairs the optimum engagement between the hook members and the loop fibers; thus, the hook and loop fastening device fails to provide a secured closure. Finally, an aesthetic factor includes the visibility of printed graphics of the loop component to enhance the physical appearance of a hook and loop fastening device.  
      Despite the extensive levels of activity and research efforts in developing non-woven loop materials suitable for a limited number of application cycles, there is a still a need for a light weight, low cost, high performance loop material, which is relatively easy to manufacture, and possesses a relatively high degree of softness, compression resistance, and visibility of printed graphics, with additionally having the ability to be bonded to a further layer. Such loop material is suitable for a hook and loop fastener device, particularly as such as are used in disposable hygiene absorbent articles, e.g. diapers.  
     SUMMARY OF THE INVENTION  
      The instant invention is a hook and loop fastener device. According to the instant invention, the hook and loop fastener device includes a loop component. The loop component includes a binder-free non-woven material having a bottom layer and a top layer. The bottom layer includes a first bicomponent fiber and a first monocomponent fiber. The first bicomponent fiber comprises the majority of the bottom layer based on total weight of the bottom layer, and the first monocomponent fiber comprises the balance thereof. The top layer includes a second bicomponent fiber, and a second monocomponent fiber. The second monocomponent fiber comprises the majority of the top layer based on total weight of the top layer, and the second bicomponent layer comprises the balance thereof. The bottom layer and the top layer may further include interfiber bonding to form the binder-free non-woven material. The non-woven material may further be island bonded via hot-roll calendering thereby forming a bonded area and a non-bonded area. Additionally, the loop component may include a backing layer bonded to the non-woven material. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      For the purpose of illustrating the invention, there is shown in the drawings a form that is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.  
       FIG. 1  is a perspective view of a loop component of the instant invention;  
       FIG. 2  is an enlarged sectional view of the loop component shown in  FIG. 1 ;  
       FIG. 3  is an enlarged sectional view of the bottom layer of the loop component shown in  FIG. 1 ;  
       FIG. 4  is an enlarged sectional view of the top layer of the loop component shown in  FIG. 1 ;  
       FIGS. 5   a, b , and  c  are schematic illustrations of different shapes of non-bonded area of the loop component (MD is top to bottom);  
       FIG. 6  is a cross-sectional view of a hook and loop fastener device;  
       FIGS. 7   a  and  b  are schematic illustrations of different hook shapes;  
       FIG. 8  is a perspective view of a disposable diaper including the loop component of the instant invention; and  
       FIG. 9  is an schematic illustration of a manufacturing scheme for the loop component of the instant invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring to the drawings wherein like numerals indicate like elements, there is shown, in  FIG. 1 , a preferred embodiment of a loop component  10 . Loop component  10  includes a binder-free non-woven  12 , and preferably, a backing layer  14 . Non-woven  12  is a multi-layer carded non-woven. Preferably, non-woven  12  has at least two layers, a bottom layer  16  and a top layer  18 , as shown in  FIG. 2 , but is not so limited. The instant invention will be discussed as having two layers herein.  
      Non-woven  12  may have a basis weight of 20 to 50 g/m 2 , and preferably, non-woven  12  has a basis weight of 30 to 35 g/m 2 . Non-woven  12  may have any thickness, and preferably, non-woven  12  has a thickness in the range of 40 to 90 mils (1.0 to 2.3 mm). Most preferably, non-woven  12  has a thickness of about 60 mils (1.5 mm). Furthermore, non-woven  12  may have any machine direction tensile strength. Preferably, non-woven  12  has a machine direction tensile strength of more than 450 g/2.54 cm. Most preferably, non-woven  12  has a machine direction tensile strength of 980 g/2.54 cm. In addition, non-woven  12  may have any cross-machine direction tensile strength. Preferably, non-woven  12  has a cross-machine direction tensile strength of at least 50 g/2.54 cm. Most preferably, non-woven  12  has a cross-machine direction tensile strength of 120 g/2.54 cm. Finally, non-woven  12  may have any density, and more preferably, non-woven  12  has a low density. Most preferably, the bottom layer  16  of the non-woven  12  has a greater density than the top layer  18  of non-woven  12 .  
      Backing layer  14  may be positioned beneath the non-woven  12  to provide a foundation for the non-woven  12 , and to provide dimensional stability. Backing layer serves as a surface to which the non-woven  12  can be affixed, and a surface on which graphics can be printed. Many types of materials are suitable for use as backing layer  14 . The backing layer  14  preferably should be some type of material that the hook members of a hook component will not penetrate. The backing layer  14  may be a film, a non-woven web, or a woven fabric. Preferably, backing layer  14  is a film, as shown in  FIG. 1 . The backing layer  14  may be made of polyester, polyethylene, polypropylene, blends thereof, layers thereof, or any other suitable material. More preferably, the backing layer is made of any material, which is similar in chemistry to the first bicomponent fiber in order to provide stronger bonding therebetween. Furthermore, the backing layer  14  may have any thickness. Preferably, backing layer  14  has a thickness in the range of 9 to 28 μ. In addition, the backing layer  14  may have any basis weight, and preferably, the backing layer  14  has a basis weight in the range of 10 to 30 g/m 2 . Most preferably, the backing layer  14  has a basis weight in the range of 14 to 24 g/m The backing layer  14  may be bonded to non-woven  12 , as discussed below in further detail.  
      Backing layer  14  may be printed with a wide variety of printing inks using a wide variety of printing processes. Both the printing inks and printing processes may themselves be conventional. Furthermore, a wide variety of graphics may be printed on the backing layer  14 , examples include, but are not limited to, patterns, designs, photographs, drawings, barcodes, words, ideas, concepts, logos, brands, trademarks, slogans, advertisings, instructions, cartoon characters and combinations thereof. In the alternative, where no backing layer is present, non-woven  12  may be printed with a wide variety of printing inks using a wide variety of printing processes. Both the printing inks and printing processes may themselves be conventional, as mentioned hereinabove. Furthermore, a wide variety of graphics may be printed on the non-woven  12 , examples, as mentioned hereinabove, include, but are not limited to, patterns, designs, photographs, drawings, barcodes, words, ideas, concepts, logos, brands, trademarks, slogans, advertisings, instructions, cartoon characters and combinations thereof.  
      When the backing layer is present, the total basis weight of the non-woven  12  together with the backing layer  14  may be any basis weight. Preferably, the total basis weight of the non-woven  12  and backing layer  14  is in a range of 30 to 80 g/m 2 . More preferably, the total basis weight of the non-woven  12  and backing layer  14  is in a range of 44 to 59 g/m 2 .  
      Non-woven  12  may be translucent. Preferably, non-woven  12  is relatively highly translucent. Translucency of the non-woven  12  is important because a relatively high degree of translucency would ensure visibility of the printed graphics. However, translucency is inversely related to the basis weight of the non-woven  12 , i.e. the lower the basis weight of the non-woven  12 , the higher degree of translucency; therefore, both translucency of non-woven  12  and basis weight of non-woven  12  must be considered in tandem.  
      Referring to  FIGS. 2 and 3 , bottom layer  16 , a non-woven strength layer, comprises a first fiber blend  24 . Bottom layer  16  provides strength and a foundation to which the top layer  18  is bonded. First fiber blend  24  includes a first monocomponent fiber  26  and a first bicomponent fiber  28 . Preferably, first fiber blend  24  includes a plurality of the first monocomponent fibers  26  and a plurality of the first bicomponent fibers  28 . First bicomponent fibers  28  may comprise the majority of the first fiber blend  24  based on the total weight of the first fiber blend  24 , and first. monocomponent fiber  26  comprises the balance thereof. Preferably, first bicomponent fibers  28  comprise from about 60 to 99 percent by weight of the first fiber blend  24 , and first monocomponent fiber  26  comprises the balance thereof, i.e. 1 to 40 percent by weight of the first fiber blend  24 . More preferably, first bicomponent fibers  28  comprise from about 60 to 85 percent by weight of the first fiber blend  24 , and first monocomponent fiber  26  comprises the balance thereof, i.e. 15 to 40 percent by weight of the first fiber blend  24 . Most preferably, first bicomponent fibers  28  comprise about 75 percent by weight of the first fiber blend  24 , and first monocomponent fiber  26  comprises the balance thereof, i.e. 25 percent by weight of the first fiber blend  24 .  
      Referring to  FIGS. 2 and 4 , top layer  18 , a non-woven loop fastener layer, comprises a second fiber blend  30 . Second fiber blend  30  includes a second monocomponent fiber  32  and a second bicomponent fiber  34 . Preferably, second fiber blend  30  includes a plurality of the second monocomponent fibers  32  and a plurality of the second bicomponent fibers  34 . Second monocomponent fibers  32  may comprise the majority of the second fiber blend  30  based on the total weight of the second fiber blend  30 , and second bicomponent fiber  34  comprises the balance thereof. Preferably, second monocomponent fibers  32  comprise from about 60 to 99 percent by weight of the second fiber blend  30 , and second bicomponent fiber  34  comprises the balance thereof, i.e. 1 to 40 percent by weight of the second blend  30 . More preferably, second monocomponent fibers  32  comprise from about 60 to 85 percent by weight of the second fiber blend  30 , and second bicomponent fiber  34  comprises the balance thereof, i.e. 15 to 40 percent by weight of the second blend  30 . Most preferably, second monocomponent fibers  32  comprise 75 percent by weight of the second fiber blend  30 , and second bicomponent fiber  34  comprises the balance thereof, i.e. 25 percent by weight of the second blend  30 .  
      The first monocomponent fiber  26  of the bottom layer may be a thermoplastic polymer. Thermoplastic polymer, as used herein, refers to a polymer that melts when exposed to heat and returns to its original condition when cooled to room temperature. Examples of thermoplastic polymers include, by way of illustration only, end-capped polyacetals, such as poly(oxymethylene) or polyformaldehyde, poly(trichloroacetaldehyde), poly(n-valeraldehyde), poly(acetaldehyde), and poly(propionaldehyde); acrylic polymers, such as polyacrylamide, poly(acrylic acid), poly(methacrylic acid), poly(ethyl acrylate), and poly(methyl methacrylate); fluorocarbon polymers, such as poly(tetrafluoroethylene), perfluorinated ethylene-propylene copolymers, ethylene-tetrafluoroethylene copolymers, poly(chlorotrifluoroethylene), ethylene-chlorotrifluoroethylene copolymers, poly(vinylidene fluoride), and poly(vinyl fluoride); polyamides, such as poly(6-aminocaproic acid) or poly(e-caprolactam), poly(hexamethylene adipamide), poly(hexamethylene sebacamide), and poly(1 1-aminoundecanoic acid); polyaramides, such as poly(imino-1,3-phenyleneiminoisophthaloyl) or poly(m-phenylene isophthalamide); parylenes, such as poly-p-xylylene and poly(chloro-p-xylylene); polyaryl ethers, such as poly(oxy-2,6-dimethyl-1,4-phenylene) or poly(p-phenylene oxide); polyaryl sulfones, such as poly(oxy-1,4-phenylenesulfonyl-1,4-phenyleneoxy-1,4-phenylene-isopropylidene-1,4-phenylene) and poly(sulfonyl-1,4-phenyleneoxy-1,4-phenylenesulfonyl-4,4′-biphenylene); polycarbonates, such as poly(bisphenol A) or poly(carbonyldioxy-1,4-phenyleneisopropylidene-1,4-phenylene); polyesters, such as poly(ethylene terephthalate), poly(tetramethylene terephthalate), and poly(cyclohexylene-1,4-dimethylene terephthalate) or poly(oxymethylene-1,4-cyclohexylenemethyleneoxyterephthaloyl); polyaryl sulfides, such as poly(phenylene sulfide) or poly(thio-1,4-phenylene); polyimides, such as poly(pyromellitimido-1,4-phenylene); polyolefins, such as polyethylene, polypropylene, poly(1-butene), poly(2-butene), poly(1-pentene), poly(2-pentene), poly(3-methyl-1-pentene), and poly(4-methyl-1-pentene); vinyl polymers, such as poly(vinyl acetate), poly(vinylidene chloride), and poly(vinyl chloride); diene polymers, such as 1,2-poly-1,3-butadiene, 1,4-poly-1,3-butadiene, polyisoprene, and polychloroprene; polystryrenes; copolymers of the foregoing, such as acrylonitrile-butadiene-styrene (ABS) copolymers; and the like. Preferably, first monocomponent fiber  26  is polyester, and most preferably, first monocomponent fiber  26  is poly(ethylene terephthalate) (PET). First monocomponent fiber  26  is important for the tensile strength of non-woven  12 . Such fibers are commercially available from Wellman of Charlotte, N.C.  
      Denier, as used herein, refers to a weight-per-unit-length measure of a fiber, and it is a direct numbering system in which the lower numbers represent the finer sizes and the higher numbers represent the coarser sizes. Fibers of finer deniers feel softer, are more flexible and have more surface area, however, they are weaker in tensile strength than fibers of higher denier. Furthermore, fibers of lower denier yield a higher density, thinner non-woven. Conversely, higher fiber denier yields a coarser, lower density non-woven having a high loft.  
      The first monocomponent fiber  26  of the bottom layer may have any denier; and preferably, first monocomponent fiber  26  has a denier in the range of 2 to 10 denier per filament (dpf). Most preferably, first monocomponent fiber  26  has a denier in the range of 2.25 to 6 dpf to provide adequate strength while maintaining softness and flexibility, as well as high surface area for bonding.  
      The first monocomponent fiber  26  may have any cross section. Monocomponent fiber  26  may be a solid fiber, a hollow fiber, or a combination thereof.  
      The first monocomponent fiber  26  may have any orientation, i.e. machine direction (MD), or cross-machine direction (CD). Machine direction, as used herein, refers to the length of the non-woven in the direction in which it is produced, and the cross-machine direction is the width of the non-woven, i.e. a direction generally perpendicular to the machine direction orientation. Preferably, first monocomponent fiber  26  has a MD orientation.  
      The second monocomponent fiber  32  of the top layer may be a thermoplastic polymer, as described hereinabove. Preferably, second monocomponent fiber  32  is polyester, and most preferably, second monocomponent fiber  32  is poly(ethylene terephthalate) (PET). Second monocomponent fiber  32  is important for the tensile strength of the loops of the loop component so that they withstand hook retraction. Such fibers are commercially available from Invista of Wichita, Kans.  
      Higher fiber denier, as mentioned hereinabove, yields a coarser non-woven loop material having a high loft. Loft, as described above, is important because a high loft non-woven is more open for hook component engagement and provides better resistance against loop compression. Therefore, optimum fiber denier, with regard to the second monocomponent fiber  32 , is important in order to provide sufficient loop tensile strength, resistance to compression, adequate spacing among the loop fibers into which the hooks can enter and engage the loop fibers, and adequate softness and flexibility. The second monocomponent fiber  32  may have any denier; and preferably, second monocomponent fiber  26  has a denier in the range of 2 to 10 dpf. Most preferably, second monocomponent fiber  32  has a denier in the range of 2 to 9 dpf.  
      In the alternative, the second monocomponent fiber  32  may comprise a blend of two or more different monocomponent fibers. Preferably, 40 to 60 weight percent of the second monocomponent fiber  32  has a fiber denier in the range of 2 to 4 dpf, and the remaining balance thereof has a fiber denier in the range of 5 to 9 dpf.  
      The second monocomponent fiber  32  may have any cross section. Monocomponent fiber  32  may be a solid fiber, a hollow fiber, or a multi-lobal fiber (e.g. trilobal fiber). Preferably, 40 to 60 weight percent of the second monocomponent fibers  32  are solid fibers or hollow fibers, and the remaining balance thereof are multi-lobal fibers (e.g. trilobal fibers).  
      The second monocomponent fiber  32  may have any orientation, i.e. machine direction (MD), or cross-machine direction (CD), as described hereinabove. Preferably, the second monocomponent fibers  32  have a MD orientation.  
      The first bicomponent fiber  28  of the bottom layer may be a bicomponent thermoplastic polymer fiber. Bicomponent thermoplastic polymer fibers, as used herein, refers to fibers which have been formed from at least two of the abovementioned thermoplastic polymers extruded from separate extruders but spun together to form one fiber. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the bicomponent fibers and extend continuously along the length of the bicomponent fibers. The component polymers may be present in any desired ratio. The configuration of such a bicomponent fiber may be, for example, a core/sheath arrangement wherein one polymer is surrounded by another or a side-by-side arrangement. Preferably, the bicomponent thermoplastic polymer fibers have a core/sheath arrangement. The core and sheath components of the bicomponent thermoplastic polymer fiber may have any melting point temperatures. Preferably, sheath component of the bicomponent thermoplastic polymer has a lower melting point temperature than the core component of the bicomponent thermoplastic polymer. Most preferably, sheath component of the bicomponent thermoplastic polymer has a melting point temperature, which is 25 to 50° C. lower than the melting point temperature of the core component of the bicomponent thermoplastic polymer. Preferred examples of core/sheath arrangement bicomponent thermoplastic polymer fibers include polyolefin filaments, such as polyethylene terephthalate (PET)/polyethylene (PE), polyethylene terephthalate (PET)/copolymers of polyethylene terephthalate (CO-PET), polypropylene (PP)/polyethylene (PE), polyethylene terephthalate (PET)/polypropylene (PP), and polypropylene (PP)/polypropylene (PP). Most preferably, the bicomponent thermoplastic polymer, core/sheath arrangement, includes polyethylene terephthalate (PET)/polyethylene (PE), polyethylene terephthalate (PET)/polypropylene (PP), and polyethylene terephthalate (PET)/ copolymers of polyethylene terephthalate (CO-PET).  
      The first bicomponent fiber  28  may have any denier. Preferably, first bicomponent fiber  28  has a denier in the range of 2 to 10 dpf in order to provide the optimum bonding surface necessary for strong interfiber bonding. Most preferably, first bicomponent fiber  28  has a denier in the range of 3 to 6 dpf.  
      The first bicomponent fiber  28  of the top layer may have any orientation, i.e. machine direction (MD), or cross-machine direction (CD), as described hereinabove. Preferably, the first bicomponent fiber  28  has a MD orientation.  
      The second bicomponent fiber  34  may be a bicomponent thermoplastic polymer fiber. Bicomponent thermoplastic polymer fibers, as used herein, refers to fibers which have been formed from at least two of the abovementioned thermoplastic polymers extruded from separate extruders but spun together to form one fiber. The polymers are arranged in substantially constantly positioned distinct zones across the cross-section of the bicomponent fibers and extend continuously along the length of the bicomponent fibers. The component polymers may be present in any desired ratio. The configuration of such a bicomponent fiber may be, for example, a core/sheath arrangement wherein one polymer is surrounded by another or a side-by-side arrangement. Preferably, the bicomponent thermoplastic polymer fibers have a core/sheath arrangement. The core and sheath components of the bicomponent thermoplastic polymer fiber may have any melting point temperatures. Preferably, sheath component of the bicomponent thermoplastic polymer has a lower melting point temperature than the core component of the bicomponent thermoplastic polymer. Most preferably, sheath component of the bicomponent thermoplastic polymer has a melting point temperature, which is 25 to 50° C. lower than the melting point temperature of the core component of the bicomponent thermoplastic polymer. Preferred examples of core/sheath arrangement bicomponent thermoplastic polymer fibers include polyolefin filaments, such as polyethylene terephthalate (PET)/polyethylene (PE), polyethylene terephthalate (PET)/copolymers of polyethylene terephthalate (CO-PET), polypropylene (PP)/polyethylene (PE), polyethylene terephthalate (PET)/polypropylene (PP), and polypropylene (PP)/polypropylene (PP). Most preferably, the bicomponent thermoplastic polymer, core/sheath arrangement, includes polyethylene terephthalate (PET)/polyethylene (PE), polyethylene terephthalate (PET)/polypropylene (PP), and polyethylene terephthalate (PET)/copolymers of polyethylene terephthalate (CO-PET).  
      The second bicomponent fibers  34  may have any denier. Preferably, second bicomponent fiber  34  has a denier in the range of 2 to 10 dpf. Most preferably, second bicomponent fiber  34  has a denier in the range of 3 to 6 dpf.  
      The second bicomponent fiber  34  may have any orientation, i.e. machine direction (MD), or cross-machine direction (CD), as described hereinabove. Preferably, the second bicomponent fiber  34  has a MD orientation.  
      Referring to  FIGS. 2-4 , in either bottom layer  16  or the top layer  18 , the monocomponent fibers  26  and  32  do not bond to themselves and each other, but the bicomponent fibers  28  and  34  do bond to themselves as well as to monocomponent fibers  26  and  32 ; thus, there is no need for any binders. Binder, as used herein, refers to any polymeric material, which may be used to bind the fibers of a non-woven web.  
      In the manufacturing of non-woven  12 , bottom layer  16  or top layer  18  may be formed separately via a carding process, as illustrated in  FIG. 9 . Preferably, bottom layer  16  and top layer  18  are formed simultaneously via the carding process. In the alternative, bottom layer  16  or top layer  18  may be formed via airlaying.  
      In the carding process, staple fibers, which are usually purchased in bales, are separated via a picker. Next, the fibers are sent through a combing or carding unit, which further breaks apart and aligns the staple fibers in the machine direction to form a fibrous non-woven web of loose fibers. Once the web has been formed, it is then thermally interfiber bonded in a conventional manner to form interfiber bonded bottom layer  16  or interfiber bonded top layer  18 . Conventional thermal bonding methods include, for example, infrared heat bonding  37  or hot-through-air bonding. Interfiber bonded bottom layer  16  and interfiber bonded top layer  18  may be formed separately as described above via carding process in two different steps. Preferably, interfiber bonded bottom layer  16  and interfiber bonded top layer  18  are formed simultaneously via two cards in a single step, as illustrated schematically in  FIG. 9 . First card  31  forms the non-woven web for the bottom layer  16 , as described above, while second card  33  simultaneously forms non-woven web for top layer  18 . Next, the non-woven web for top layer  18  is placed atop the non-woven web for bottom layer  16  to form a multilayer non-woven web  35 , and then, the multi-layer non-woven web  35  is treated with infrared heat bonding  37  or hot-through-air bonding to form interfiber bonded bottom layer  16  and interfiber bonded top layer  18  simultaneously, and thereby forming non-woven  12 . In the alternative, the webs for bottom layer  16  and top layer  18  may individually be treated with infrared heat bonding  37  or hot-through-air bonding to form interfiber bonded bottom layer  16 , and interfiber bonded top layer  18 . Subsequently, top layer  18  is placed atop bottom layer  16 , and thereby forming non-woven  12 .  
      The non-woven  12  may then be island bonded to itself thereby forming bonded area  20  and non-bonded area  22 . In the alternative, non-woven  12  may be island bonded to a backing layer  14  thereby forming bonded area  20  and non-bonded area  22 . The island bonding of non-woven  12 , i.e. island bonding between interfiber bonded bottom layer  16  and interfiber bonded top layer  18 , may be accomplished by different methods. Preferably, the island bonding of non-woven  12  is accomplished via thermal bonding. More preferably, the island bonding of non-woven  12  is accomplished via hot-roll calendering  39 . Island bonding patterns and spacing will be discussed in greater detail below.  
      In infrared heat bonding, the non-woven web is subjected to infrared heat while in hot-through-air bonding, hot air is passed through the non-woven web. In either method, sufficient heat is applied to soften or melt the sheath of the bicomponent fibers of the non-woven web enabling interfiber bonding between adjacent fibers.  
      Airlaying is a well know process by which fibrous non-woven webs can be formed. In airlaying process, bundles of small fibers are separated and entrained in an air supply and then deposited onto a forming screen, usually with the assistance of a vacuum supply. The randomly deposited fibers then can be bonded to one another using a conventional manner, as described above.  
      Hot-roll calendering refers to a bonding process via application of heat and pressure wherein non-woven  12  is passed between a heated embossed roll and a smooth roll under pressure thereby forming a bonded area  20  therebetween, as shown in  FIG. 2 . In the alternative, non-woven  12  and backing layer  14  are co-fed through a calender having at least two rolls, i.e. a smooth roll and a heated embossed roll with desired non-bonding patterns thereby forming a bonded area  20 .  
      Island bonding patterns and spacing will be discussed hereinafter. The bonded area  20  may cover any portion of the non-woven  12 . Preferably, the bonded area  20  covers an area in the range of 25 to 60 percent based on the total area of the non-woven  12 . Most preferably, the bonded area  20  covers an area in the range of 33 to 55 percent based on the total area of the non-woven  12 . Bonded area  20  is important because sufficient bonding area provides for a strongly bonded non-woven material  12 . Furthermore, the bonded area  20  secures the loop fibers to the non-woven  12  structure, so that the loop fibers do not easily pull free from the non-woven structure  12  upon the retraction of the hooks therefrom.  
      Referring to  FIGS. 5   a, b , and  c , the non-bonded area  22  is defined by the bonded area  20 , and as used herein, refers to the regions available for hook engagement, i.e. loop fibers. The non-bonded area  22  may cover any portion of the non-woven  12 . Preferably, the non-bonded area  22  covers an area in the range of 45 to 67 percent based on the total area of the non-woven  12 . The non-bonded area  22  comprises a plurality of non-bonded islands  36 . Non-bonded islands, as used herein, refers to isolated non-bonded regions surrounded entirely by the bonded area  20 . Each non-bonded island  36  has a non-bonding pattern selected from the group consisting of slots, bars, squares, circles, diamonds, combinations thereof, and the like. Non-bonded islands  36  may have any orientation, i.e. machine direction or cross-machine direction. Preferably, non-bonded islands  36  have a machine direction orientation. Each non-bonded island  36  may have any MD width  38 . The MD width  38  of each non-bonded island  36  is important because the MD width  38  of the non-bonded islands  36  determines the length of each individual loop fibers. The length of each individual loop fiber is important because it directly affects the fastening performance, i.e. peel strength, and shear strength, of the loop component  10 , as shown in Table I. The greater the MD width  38  of each non-bonded island  36 , the greater the number of hooks capable of engaging the loop fibers; consequently, there is a greater possibility that loop fibers break and/or pull free from bonded area  20 , and generate fuzz. In addition, if an excessive amount of loop fibers break and/or pull free from bonded area  20 , then the peel performance will be negatively affected. Preferably, each non-bonded island  36  has a MD width  38  in the range about 1.5 to 3 mm.  
      Non-bonded islands  36  may be spaced apart from each other in any direction. Preferably, non-bonded islands  36  are spaced apart from each other in a machine direction. Non-bonded islands  36  may be spaced apart from each other any distance  40  in MD. Preferably, the distance  40  is in the range of 1 to 2 mm. The distance  40  is important because it ensures strong bonding foundation for a loop component  10 .  
      Referring to  FIG. 6 , there is shown a preferred embodiment of a hook and loop fastener device  42 , which includes the loop component  10  of the instant invention. The fastener device  42  includes a loop component  10 , as described hereinabove, and a hook component  44 . Referring to  FIG. 7 , the hook component  44  comprises a base  46 , a plurality of upstanding engaging elements  48  extending from one surface of the base  46 . Each upstanding engaging element includes a stem  50  and a hook member  52 . Upstanding engaging elements  48  may have any shape. Preferably, upstanding engaging elements  48  have a shape selected from the group consisting of J-shape, T-shape, mushroom shape, and combinations thereof.  
      In operation, referring to  FIGS. 6 and 7 , the hook component  44  and the loop component  10  are pressed face-to-face against each other. Thus, the hook members  52  are entangled by the loop fibers of the non-woven  12 . The non-woven  12  provides space for the upstanding engaging elements  48 , and particularly, for hook members  52  to occupy when the fastener device  42  is closed. The engagement therebetween the hook component  44  and the loop component  10  provides a connection which resists the forces that may be exerted on the fastener device  42 .  
      The hook and loop fastener device  42  is especially useful as a fastening device for disposable articles, particularly, disposable absorbent articles such as diapers. Preferably, the hook and loop fastener device  42  is utilized as a fastening device in disposable diapers  54 , as shown in  FIG. 8 .  
      A disposable diaper  54  includes a body liner  56 , an outer cover  58 , an absorbent structure (not shown) disposed therebetween the bodyside liner  56  and the outer cover  58 , and a fastening device. Preferably, the fastening device is a hook and loop fastener device  42 , and more preferably, the fastening device  42  includes loop component  10 , as described hereinabove. The loop component  10  may be affixed to the outer cover  58  via glue bonding process or ultrasonic bonding process.  
      The present invention further provides a method of preparing a loop component  10  suitable for use in a hook and loop device  42 . First, bottom layer  16 , as described hereinabove, is provided, and then, top layer  18 , as described hereinabove, is provided. Top layer  18  is placed atop of bottom a layer  16 , thereby forming binder-free non-woven  12 . Backing layer  14  may be provided. Backing layer  14  may then be thermally island bonded to non-woven  12  to form bonded area  20  and non-bonded area  22 . In the alternative, where backing layer  14  is not provided, non-woven  12  may be thermally island bonded to itself to form bonded area  20  and non-bonded area  22 .  
     EXAMPLES  
      Ten different loop component samples, as described hereinbelow in detail, were prepared, and tested for fastening performance, i.e. peel strength. The results of the aforementioned test are shown below in Table I. Each of the ten loop component samples comprised a non-woven with total basis weight of 35.6 g/m 2 , and each said non-woven had a top layer and bottom layer. Each top layer had a total basis weight of 26 g/m 2 , and furthermore, each said top layer further comprised 4 denier per filament (dpf) CoPET/PET concentric core bicomponent fibers with a basis weight of 5.25 g/m 2 ; 3 dpf round PET staple fibers with a basis weight of 10.5 g/m 2 ; and 6 dpf trilobal PET staple fiber with a basis weight of 10.5 g/m 2 . Each bottom layer had a total basis weight of 9.6 g/m 2 , and furthermore, each said bottom layer comprised a 4 dpf CoPET/PET concentric core bicomponent fiber with a basis weight of 7.2 g/m 2 ; and 2.25 dpf round PET staple fiber with a basis weight of 2.4 g/m 2 . Each said non-woven sample was island bonded at the same temperature and pressure thereby forming bar patterns. MD width  38  ranged from 1.5 to 3.5 mm while the MD distance  40  ranged from 1 to 2 mm. Said samples were tested using a commercially available hook known as CS600 from 3M Company. CS600 has 1700 hooks per inch 2 , and has a width of 15 mm.  
      The peel strength, as described hereinbelow, was determined, and subsequently, samples were observed for the amount fuzz formation.  
      The 180° peel strength test involves attaching a hook component to a loop component of a hook and loop fastening system and then peeling the hook component from the loop component at a 180° angle. The maximum load needed to disengage the two components is recorded in newtons. As shown in Table I, peel strength results indicate that such peel strength results greater than 3 newtons are considered acceptable; however, higher peel strength is preferred. While the peel strength results and the amount of fuzz formation of the samples Nos. 1 to 8 are preferred, the peel strength results and the amount of fuzz formation of the samples Nos. 1 to 6 are most preferred. Furthermore, the peel strength results, as shown in Table I, indicate that a non-woven having a total non-bonded area of 46 to 67 percent based on the total area of the non-woven  12 , a MD distance  40  in the range of 1 to 2 mm, and a MD width  38  in the range of 1.5 to 3 mm would yield the most preferred peel performance and fuzz formation.  
                                   TABLE I                                       180° Peel,                   MD   % Non-   Peek Force       Sample   MD Width   Distance   bonded   newtons       No.   38, mm   40, mm   Area   (average)   Results                                                        1   1.5   1.75   46.2%   3.5   low fuzz       2   1.5   1   60.0%   3.5   low fuzz       3   2   2   50.0%   4.2   low fuzz       4   2   1.5   57.1%   4.5   low fuzz       5   2   1   66.7%   4.6   low fuzz       6   2.25   1.75   56.3%   4.6   low fuzz       7   3   2   60.0%   4.9   low fuzz       8   3   1.5   66.7%   5.8   low to medium                           fuzz       9   3   1   75.0%   6.0   high fuzz       10   3.5   1   77.8%   6.0   high fuzz                  
 
      The present invention may be embodied in other forms without departing from the spirit and the essential attributes thereof, and, accordingly, reference should be made to the appended claims, rather than to the foregoing specification, as indicating the scope of the invention.