Patent ID: 7025914
Filing Date: 2006-04-11
Classification: B32B,D04H,Y10T

Abstract:
1. A method of making a lofty nonwoven fabric laminate in a single, in-line process, comprising steps in the order of: a) depositing a first layer of filaments onto a wire; b) bonding the first layer to an integrity sufficient to withstand high speed web transfer; c) depositing a second layer of crimped homofilament fibers connected to the first layer while the first layer remains on the wire; d) traversing the second layer of crimped homofilament fibers through a flow of heated air at a temperature, flow rate, and traversal rate sufficient to set the crimps of the fibers without substantial melt bonding or relaxation of the fibers and to provide an integrity sufficient to withstand high speed web transfer; and e) bonding the heat set second layer and the first nonwoven layer in a manner having sufficient integrity to withstand high speed web transfer.