Patent ID: 7036197

Claim:
A method for preparing a stretchable nonwoven fabric which comprises the steps of: providing a substantially nonbonded nonwoven web comprising multiple-component fibers, the multiple-component fibers being capable of developing three-dimensional spiral crimp upon heating; conveying the substantially nonbonded nonwoven web on a first conveying surface having a first conveying speed; transferring the substantially nonbonded nonwoven web from the first conveying surface through a transfer zone to a second conveying surface, the second conveying surface having a second conveying speed; the substantially nonbonded nonwoven web being conveyed through the transfer zone in such a way that the substantially nonbonded nonwoven web does not contact a conveying surface in the transfer zone; heating the substantially nonbonded nonwoven web in the transfer zone to a temperature sufficient to cause the multiple-component fibers to develop three-dimensional spiral crimp resulting in an area shrinkage of the substantially nonbonded nonwoven web and a decrease in the speed of the web as it is conveyed through the transfer zone, the heating temperature being selected such that the nonwoven web remains substantially nonbonded during the heating step; transferring the heat-treated substantially nonbonded nonwoven web to the second conveying surface as the web exits the transfer zone, the second conveying speed being less than the first conveying speed and the second conveying speed being selected to be approximately equal to the speed of the heat-treated substantially nonbonded nonwoven web as the web contacts the second conveying surface upon exiting the transfer zone; and bonding the heat-treated substantially nonbonded nonwoven web with an array of discrete bonds to form the stretchable multiple-component bonded nonwoven fabric.