Claims
- 1. A process for making a two-ply nonwoven fabric laminate having a first ply of synthetic fibrous nonwoven material having an outer surface, an inner surface, and a thickness and a second ply of fibrous nonwoven material having an outer surface, an inner surface, and a thickness comprising:
- (a) coating said inner surface(s) of at least one of said first and second plies with a substantially continuous layer of an aqueous emulsion of a flexible, soft latex binder, said emulsion having a solids content of from about 45% to about 80% and a viscosity of from about 8,000 cp to about 25,000 cp, said latex binder having a glass transition temperature of from about 0.degree. C. to about -80.degree. C.;
- (b) forming said two-ply laminate by adhering said inner surfaces of said first ply and said second ply together under pressure, whereby said emulsion penetrates from said inner surface of said first ply to a depth of from about 20% to about 80% of said thickness of said first ply, and said emulsion penetrates from said inner surface of said second ply to a depth of from about 20% to about 80% of said thickness of said second ply; and
- (c) drying said emulsion.
- 2. The process of claim 1 wherein said second ply is tissue.
- 3. The process of claim 2 wherein said latex binder is an acrylic polymer binder.
- 4. The process of claim 3 wherein said first ply is a spunbond web.
- 5. The process of claim 4 wherein said spunbond web is no more than lightly bonded, and said emulsion penetrates from said inner surface of said first ply to a depth of from about 50% to about 80% of said thickness of said first ply.
- 6. The process of claim 3 wherein said first ply has a basis weight of from about 10 g/m.sup.2 to about 50 g/m.sup.2, said second ply has a basis weight of from about 10 g/m.sup.2 to about 50 g/m.sup.2, and said emulsion is coated on said inner surface(s) in an amount of from about 5 g/m.sup.2 to about 20 g/m.sup.2 (solids basis).
- 7. The process of claim 5 wherein said first ply has a basis weight of from about 10 g/m.sup.2 to about 50 g/m.sup.2, said second ply has a basis weight of from about 10 g/m.sup.2 to about 50 g/m.sup.2, and said emulsion is coated on said inner surface(s) in an amount of from about 7 g/m.sup.2 to about 15 g/m.sup.2 (solids basis).
- 8. The process of claim 6 wherein said emulsion penetrates from said inner surface of said second ply to a depth of from about 50% to about 80% of said thickness of said second ply.
- 9. The process of claim 7 wherein said emulsion penetrates from said inner surface of said second ply to a depth of from about 50% to about 80% of said thickness of said second ply.
- 10. The process of claim 8 wherein said emulsion has a solids content of from about 55% to about 70%.
- 11. The process of claim 9 wherein said emulsion has a solids content of from about 55% to about 70%.
- 12. The process of claim 10 wherein said emulsion has a viscosity of from about 12,000 cp to about 20,000 cp.
- 13. The process of claim 11 wherein said emulsion has a viscosity of from about 12,000 cp to about 20,000 cp.
- 14. The process of claim 12 wherein said binder has a glass transition temperature of from about -20.degree. C. to about -40.degree. C.
- 15. The process of claim 13 wherein said binder has a glass transition temperature of from about -20.degree. C. to about -40.degree. C.
- 16. The process of claim 15 wherein said emulsion has a viscosity of from about 14,000 cp to about 17,000 cp, and said emulsion is coated on said inner surface(s) in an amount of from about 8 g/m.sup.2 to about 12 g/m.sup.2 (solids basis).
- 17. The process of claim 15 wherein said process also comprises:
- (d) applying waterproofing chemicals to said two-ply laminate; and
- (e) drying said twoply laminate.
- 18. The process of claim 17 wherein an external binder system is applied at least to said outer surface of said second ply after step (c).
- 19. A process for making a two-ply nonwoven fabric laminate having a first ply of continuous-filament spunbond web having an outer surface and an inner surface, and a second ply of tissue having an outer surface and an inner surface comprising:
- (a) kiss-coating said inner surface(s) of at least one of said first and second piles with an aqueous emulsion of a flexible, soft acrylic polymer binder, said emulsion having a solids content of from about 45% to about 80% and a viscosity of from about 8,000 cp to about 25,000 cp, said latex binder having a glass transition temperature of from about 0.degree. C. to about -80.degree. C.;
- (b) forming said two-ply laminate by adhering said inner surfaces of said first ply and said second ply together under low pressure, whereby said latex binder penetrates from said inner surfaces of said first and second plies into said first and second plies but not to said outer surface of either said first ply or said second ply;
- (c) drying said emulsion;
- (d) applying waterproofing chemicals to said two-ply laminate; and
- (e) drying said two-ply laminate.
- 20. The process of claim 19 wherein said first ply has a basis weight of from about 10 g/m.sup.2 to about 50 g/m.sup.2, said second ply has a basis weight of from about 10 g/m.sup.2 to about 50 g/m.sup.2, and said emulsion is coated on said inner surface(s) in an amount of from about 5 g/m.sup.2 to about 20 g/m.sup.2 (solids basis).
- 21. The process of claim 19 wherein said first ply has a basis weight of from about 15 g/m.sup.2 to about 30 g/m.sup.2 ; said second ply has a basis weight of from about 15 g/m.sup.2 to about 30 g/m.sup.2 ; said emulsion has a solids content of from about 55% to about 70%, a viscosity of from about 12,000 cp to about 20,000 cp, and is coated on said inner surface(s) in an amount of from about 7 g/m.sup.2 to about 15 g/m.sup.2 (solids basis); and said latex binder has a glass transition temperature of from about -20.degree. C. to about -40.degree. C.
- 22. The process of claim 21 wherein an external binder system is applied at least to said outer surface of said second ply after step (c).
Parent Case Info
This is a division of application Ser. No. 474,417, filed on Mar. 11, 1983.
US Referenced Citations (28)
Foreign Referenced Citations (1)
Number |
Date |
Country |
1200235 |
Jul 1970 |
GBX |
Divisions (1)
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Number |
Date |
Country |
Parent |
474417 |
Mar 1983 |
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