COFORMED DISPERSIBLE NONWOVEN FABRIC BONDED WITH A HYBRID SYSTEM AND METHOD OF MAKING SAME

A water-dispersible coformed fibrous nonwoven fabric structure comprising a primary reinforcing polymer material, preferably capable of being meltspun; a secondary reinforcing polymer material having an average fiber length less than or equal to about 15 mm and preferably having a softening point at least about 30 DEG C. lower than the softening point of the primary reinforcing polymer; and, an absorbent material, such as pulp or a superabsorbent. The fabric structure maintains desired tensile strength and softness while being water-dispersible and flushable. The fabric produced can be incorporated into an article and can be flushed down a commode. The fabric is flushable when placed in water, with agitation, if necessary, and will disperse into unrecognizable pieces without clogging conventional plumbing or piping. A method of producing the fabric structure comprises mixing the secondary reinforcing material and absorbent material and injecting this coform blend into a stream of meltspun primary reinforcing fibers. After a web structure has been established, the structure is exposed to thermal or ultrasonic energy sufficient to soften and bond the secondary reinforcing material fibers, but not to soften the primary reinforcing material fibers. An embossed pattern can be printed on the structure.