Patent ID: 7191501

Claim:
A method for making a nonwoven fabric, comprising; providing a single homogenous fibrous batt comprising carded and cross-lapped fibers oriented at an angle relative to a machine direction of the batt, and wherein said homogeneous fibrous batt being formed of fibers selected from the group consisting of: (1) carded cotton fibers; and (2) a carded blend of cotton fibers and synthetic fibers, impinging a fluidic stream upon said fibrous batt comprising applying hydraulic energy to opposite expansive surfaces of said fibrous batt to form a nonwoven fabric, said nonwoven fabric having highly entangled, opposite outer surface regions and a lightly entangled inner core region positioned between said highly entangled outer surface regions formed by application of hydraulic energy in the range of about 0.027 to 0.046 hp-hr/lb, and applying hydraulic fluid to said nonwoven fabric upon a three-dimensional image transfer device having a movable imaging surface to effect imaging and patterning of the nonwoven fabric.