Patent ID: 7928024

Claim:
A three-layer porous composite pad with enhanced resistance to delamination comprising; an upper portion, a porous adhesive web and a bottom portion, said upper portion comprising a first plurality of fibers, said first plurality of fibers comprising low denier bicomponent fibers, said low denier bicomponent fibers being cohesively bonded at inter-fiber crossover points, said upper portion being prepared by providing said first plurality of fibers, carding said first plurality of fibers into a uniform first carded web, subjecting said first carded web to a first heating step, said first heating step being accomplished by placing said first carded web, in a stress-free state, into an oven, at a temperature in the range of 280° F. to 350° F. for a duration of 10 to 15 minutes, thereby allowing the constituent fibers of said upper portion to shrink in a stress-free state, and hot pressing, using spacer bars placed between heated press platens to a desired thickness in the range of 0.020″ to 0.050″, said first carded and shrunk web in a heated press at a temperature at least equal to the melting point of the low melting point component but not exceeding the melting point of the high melting point component of said low denier bicomponent fibers, said bottom portion comprising a second plurality of fibers, said second plurality of fibers comprising coarser bicomponent fibers, said coarser bicomponent fibers being, on the average, coarser than said low denier bicomponent fibers of said first plurality of fibers by at least 2 denier, said coarser bicomponent fibers being cohesively bonded at interfiber crossover points, said bottom portion being prepared by providing said second plurality of fibers, carding said second plurality of fibers into a uniform second carded web, subjecting said second carded web to a first heating step, said first heating step being accomplished by placing said second carded web, in a stress-free state, into an oven, at a temperature in the range of 280° F. to 350° F. for a duration of 10 to 15 minutes, thereby allowing the constituent fibers of said bottom portion to shrink in a stress-free state, and hot pressing, using spacer bars placed between heated press platens to a desired thickness, said second carded and shrunk web in a heated press at a temperature at least equal to the melting point of the low melting point component but not exceeding the melting point of the high melting point component of said coarser bicomponent fibers, and said porous adhesive web being made of a low melting point thermoplastic polymeric material, said adhesive web being positioned between said top portion and said bottom portion and joining said top portion to said bottom portion, thus forming a three-layer porous composite pad and thereby providing a delamination resistant composite pad having a high fluid-holding capacity bottom portion reservoir and an upper portion having a smooth surface.