Patent ID: 7045030

Claim:
A method for forming a nonwoven laminate fabric, comprising the steps of: a. providing a first polyolefin polymer, b. providing a second polyolefin polymer, wherein said second polyolefin polymer is dissimilar to said first polyolefin polymer, c. forming said first polyolefin polymer into a first continuous filament precursor web having a basis weight of no more than about 12 grams per square meter, d. forming said second polyolefin polymer into a second continuous filament precursor web having a basis weight of no more than about 12 grams per square meter, wherein said second continuous filament precursor web is formed on the surface of said first continuous filament precursor web, and e. consolidating said first and said second continuous filament precursor web by application of elevated temperature and pressure to form a nonwoven laminate fabric; including providing a thermoplastic polymer, in the form of meltblown fibers, exhibiting a melt temperature profile that is compatible with the thermoplastic composition of the first and second polyolefin polymers, and applying said thermoplastic polymer onto said first continuous filament precursor web at a component basis weight level of no more than about 3 grams per square meter to form a thermoplastic adhesion layer.