Abstract Improvements in producing a bonded non-woven fabric matting where the bonding agent is located in discontinuous areas of the matting or is present in differing and varying proportions in different areas of the matting. Such a product is made by substantially uniformly impregnating the matting with a heat sensitive coagulatable binder latex, non-uniformly heating the impregnated matting to the coagulation temperature of the latex only in predetermined areas of the matting whereby coagulating the binder from the latex only in the preselected areas which have been subjected to heating to a temperature sufficient to coagulate binder from the latex, and then removing that portion of the latex from which the binder was not coagulated by the nonuniform heating.
Process as claimed in claim 1, including passing said substantially uniformly impregnated batting through the nip of a pair of heated toothed rollers, each of which has protuberances which alternate with respect to each other, wherein said protuberances force said impregnated latex into the area of said batting between said protuberances, and coagulating said latex in said areas.
Claim 2
Dependent Claim
32 words
Process as claimed in claim 1 wherein said steps C & D are carried out simultaneously with a contact time of about 1 second at a temperature of about 120 to 420*C.
Claim 3
Dependent Claim
43 words
Process as claimed in claim 1 including the additional step of applying a polymeric film form coating comprising vinyl chloride or polyurethane to at least one surface of said spot bonded non-woven fabric which was contacted by said heated depth contoured surface means.
Claim 4
Dependent Claim
14 words
Process aS claimed in claim 1 including needling the batting produced in step A.
Claim 5
Dependent Claim
14 words
Process as claimed in claim 1 including profiling both major surfaces of said batting.
Claim 6
Dependent Claim
18 words
Process as claimed in claim 6 including longitudinally splitting said profiled, spot-bonded batting between the major surfaces thereof.
Claim 7
Dependent Claim
19 words
Process as claimed in claim 7 including applying a polymer coating to the profiled surfaces of said split batting.