Patent ID: 6881375

Claim:
A method of forming fibers into a web, comprising the steps of: a) co-extruding a first and a second component, said first component having a recovery percentage R 1 and said second component having a recovery percentage R 2 , wherein R 1 is higher than R 2 ; b) directing said first and second components through a spin pack to form a plurality of continuous molten fibers each having a predetermined diameter; c) routing said plurality of molten fibers through a quench chamber to form a plurality of cooled fibers; d) routing said plurality of cooled fibers through a draw unit to form a plurality of solid fibers each having a smaller diameter than said molten fibers; e) stretching each of said cooled and solid fibers by at least 50 percent; f) allowing said stretched fibers to relax thereby forming coiled fibers, said coiled fibers having about 50 to about 500 coils per inch, and said first component of each of said coiled fibers adhering to said second component; and g) depositing said coiled fibers onto a moving support to form a web.