Nonwoven fabric having improved performance

Abstract

The present invention relates generally to nonwoven materials, and specifically, to a nonwoven fabric comprised of at least three continuous filament precursor webs, each precursor web being of a thermoplastic polymer dissimilar from the other precursor webs, wherein the resulting durable nonwoven laminate fabric exhibits improved tactile and ductile qualities, as well as improved tensile strength, the nonwoven fabric being eminently suitable for application in improving the comfort and use of hygiene, medical and industrial products.

1 - 8 . (canceled)  
     
     
         9 . A method for forming a soft, durable 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. extruding said first and second polymers from separate orifices of the same spinneret,    d. collecting said first and second polymers forming a first continuous filament precursor web,    e. collecting said first and second polymers forming a second continuous filament precursor web, wherein said second continuous filament precursor web is formed directly onto the surface of said first continuous filament precursor web, and    f. consolidating said first and said second continuous filament precursor webs by application of elevated temperature and pressure to form a nonwoven laminate fabric.    
     
     
         10 . A method for forming a 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. extruding said first and second polymers from separate orifices of the same spinneret,    d. collecting said first and second polymers forming a first continuous filament precursor web,    e. collecting said first and second polymers forming a second continuous filament precursor web,    f. juxtaposing said first continuous filament precursor web and said second continuous filament precursor web in face to face relationship, and    g. consolidating said first and said second continuous filament precursor web by application of elevated temperature and pressure to form a nonwoven laminate fabric.