Stitchbonded fabric with a substrate having diverse regional properties

Abstract

A stitchbonded fabric has a regionally segmented base layer in which one or more physical properties in at least one region is substantially different from those of another region. Typical physical properties that can differ among substrate regions include density, basis weight, chemical composition, thickness, porosity, permeability, elongation, elasticity, tensile strength, barrier properties, dyeability, abrasion resistance, and texture. The stitchbonded fabric thus has an improved combination of properties. In one aspect the base layer is discontinuous such that at least one region is devoid of all substrate material. The base layer is stitched continuously over its full extent such that all regions including open areas devoid of substrate material are stitched. The stitchbonded fabric with a discontinuous base layer advantageously can provide enhanced stretch capability to the overall fabric, especially in the cross direction and is particularly useful for stretchable skirts of mattress covers. A process for making a stitchbonded fabric includes continuously feeding substrate webs of diverse properties to a stitchbonding machine. Optionally, the webs are laterally separated or partially excised to create regions devoid of substrate material.