Patent ID: 7195685

Claim:
A method for forming a soft, durable nonwoven laminate fabric comprising the steps of: a. providing a first thermoplastic polymer, b. providing a second thermoplastic polymer, wherein said second thermoplastic polymer is dissimilar to said first thermoplastic polymer, c. providing a third thermoplastic polymer, wherein said third thermoplastic polymer is dissimilar to said first thermoplastic polymer, d. forming said first thermoplastic polymer into a first continuous filament precursor web, e. forming said second thermoplastic polymer into a second continuous filament precursor web, f. forming said third thermoplastic polymer into a third continuous filament precursor web, wherein all fabric material of the third continuous filament precursor web consists of thermoplastic filaments, wherein said third continuous filament precursor web is positioned between said first and second continuous filament precursor webs, and g. consolidating said first, second, and third continuous filament precursor webs by application of elevated temperature and pressure to form a nonwoven laminate fabric, wherein said third continuous filament precursor web alone acts as a bonding agent for said consolidating step.