Patent ID: 8317977

Claim:
A method of forming a layered precipitated nonwoven product comprising: a) forming a nonwoven base sheet of at least non-cellulose fibersby depositing thermoplastic filaments on a moving forming surface to form a spunlaid batt of filaments, and bonding the thus deposited thermoplastic filaments by thermal point bonding or by air bonding to form the base sheet, b) applying a material sensitive to a gelatinizing agent on the base sheet, c) associating the base sheet and the material together to form a composite sheet, d) forming a gelatinized sheet by treating before or during step c) one of (i) the base sheet on which the material sensitive to the gelatinizing agent is applied, (ii) the material sensitive to the gelatinizing agent, and (iii) the composite sheet with a gelatinizing agent to partially dissolve the material sensitive to the gelatinizing agent, e) washing the gelatinized sheet to remove gelatinizing agent and to regenerate and to precipitate the material dissolved/gelatinized in step d), and f) drying the product.