Patent ID: 7611594

Claim:
A method of making a fiber laminate, the method comprising the steps of sequentially: forming a nonwoven spunbond filament layer of predetermined characteristics; initially bonding the nonwoven spunbond filament layer in a calender comprising calender rolls by varying contact pressure and/or surface temperature of the calender rolls to obtain a nonwoven spunbond filament layer having varying degrees of bonding, measuring tensile strength of the nonwoven spunbond filament layer having varying degrees of bonding to obtain varying tensile strengths, and determining highest tensile strength from the varying tensile strengths, the nonwoven spunbond filament layer having the highest tensile strength being the nonwoven spunbond filament layer at maximum bonding; thereafter prebonding the nonwoven spunbond filament layer to a tensile strength of at least 50% of the tensile strength thereof at maximum bonding under conditions that are otherwise the same as in the step of initially bonding the nonwoven spunbond filament layer by adjusting the contact pressure and/or the surface temperature of the calender rolls to form a prebonded nonwoven spunbond filament layer; treating the prebonded nonwoven spunbond filament layer with at least one wetting agent; applying at least one layer of hydrophilic fibers onto the prebonded nonwoven spunbond filament layer treated with the wetting agent; and hydrodynamically bonding the layer of hydrophilic fibers to the spunbond filament layer to create a two-layer laminate forming an absorbent cloth.