Patent ID: 7645353
Filing Date: 2010-01-12
Classification: B32B,D04H,Y10T

Abstract:
1. A method for forming a multi-ply fabric, said method comprising: positioning at least one inner ply between a first outer ply and a second outer ply, said first outer ply and said second outer ply each comprising a nonwoven composite material that includes thermoplastic fibers and absorbent staple fibers, said absorbent staple fibers constituting greater than about 50 wt. % of said nonwoven composite material, wherein said absorbent staple fibers and said thermoplastic fibers of said nonwoven layer are hydraulically entangled, said inner ply comprising a nonwoven layer formed from approximately 100 wt. % thermoplastic polyolefin fibers comprising polypropylene, polyethylene, or combinations thereof; and ultrasonically laminating together said inner ply, said first outer ply, and said second outer ply, wherein the ultrasonically lamination forms bonded regions and imparts a patterned surface texture to at least one side of the multi-ply fabric, wherein pores are created at a surface of the fabric at the bonded regions and voids are created throughout a direction perpendicular to the surface of the fabric, the pores and voids allow liquids to enter the fabric at the surface of the bonded region and to travel laterally through the bonded region to the inner ply of the fabric between the bonded regions.