US4636418A
Expired / Lapsed
US
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Cloth-like composite laminate and a method of making
Assignee: Fort James Corp
•
Filing: 1984-05-17
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Granted: 1987-01-13
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Expires: 2004-05-17
Abstract
Abstract A method of making a cloth-like composite laminate is provided. The method includes the steps of air laying a continuous layer of three-dimensional cellulosic fibers one side of a layer of nonwoven material; applying to the continuous layer of three-dimensional cellulosic fibers and the nonwoven material layer a latex adhesive containing a wetting agent; and drying the latex adhesive and wetting agent to bind the layer of cellulosic fibers to the nonwoven material layer to form a cloth-like composite laminate having a continuous layer of three-dimensional cellulosic fibers bound to one side of the nonwoven material layer.
Inventors
- 👤 Gregory J. Kennard
- 👤 II Cedric A. Dunkerly
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 22:38
CPC Classifications
D; D04; D04H; D04H1/00; D04H1/70; D04H1/72; D04H1/732; D04H1/40; D04H1/42; D04H1/425; D04H1/58; D04H1/593; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24074; Y10T428/24091; Y10T428/24099; Y10T428/25; Y10T428/253; Y10T428/27; Y10T428/273; Y10T428/277; Y10T442/00; Y10T442/10; Y10T442/184; Y10T442/198; Y10T442/60; Y10T442/695
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
100 words
A method of making a cloth-like composite laminate comprising the steps of: (a) air laying a continuous layer of three-dimensional cellulosic fibers onto one side of a layer of nonwoven material; (b) applying to the continuous layer of three-dimensional cellulosic fibers and the nonwoven material layer a latex adhesive containing a wetting agent; and (c) drying the latex adhesive and wetting agent to bond the layer of cellulosic fiber to the non-woven material layer to form a cloth-like composite laminate having substantially all of a continuous layer of three-dimensional cellulosic fibers bound to one side of the nonwoven material layer.
Claim 2
Independent Claim
100 words
A method of making a cloth-like composite laminate comprising the steps of: (a) air laying a continuous layer of three-dimensional cellulosic fibers onto one side of a layer of nonwoven material; (b) applying to the continuous layer of three-dimensional cellulosic fibers and the nonwoven material layer a latex adhesive containing a wetting agent; and (c) drying the latex adhesive and wetting agent to bond the layer of cellulosic fiber to the non-woven material layer to form a cloth-like composite laminate having substantially all of a continuous layer of three-dimensional cellulosic fibers bound to one side of the nonwoven material layer.
Claim 3
Dependent Claim
13 words
The method of claim 1, wherein the cellulosic fibers are wood pulp fibers.
Claim 4
Dependent Claim
20 words
The method of claim 2, wherein the wood pulp fibers are selected from mechanical pulp fibers and chemical pulp fibers.
Claim 5
Dependent Claim
27 words
The method of claim 2, wherein the wood pulp fibers are selected from the group consisting of cedar fibers, southern pine fibers, spruce fibers, and hemlock fibers.
Claim 6
Dependent Claim
12 words
The material of claim 2, wherein the wood pulp fibers are twisted.
Claim 7
Dependent Claim
33 words
The method of claim 1, wherein the weight of the cellulosic fibers air laid onto the nonwoven material layer is within the range of 5 pound per ream to 50 pounds per ream.
Claim 8
Dependent Claim
33 words
The method of claim 1, wherein the weight of the cellulosic fibers air laid onto the nonwoven material layer is within the range of 15 pounds per ream to 40 pounds per ream.
Claim 9
Dependent Claim
23 words
The method of claim 1, wherein the nonwoven material is selected from the group consisting of nylon, rayon, polyester, polypropylene, glass, and aramids.
Claim 10
Dependent Claim
28 words
The method of claim 1, wherein the weight of the nonwoven material is within the range of 0.2 ounces per square yard to 3 ounces per square yard.
Claim 11
Dependent Claim
28 words
The method of claim 1, wherein the weight of the nonwoven material is within the range of 0.3 ounces per square yard to 1 ounce per square yard.
Claim 12
Dependent Claim
28 words
The method of claim 1, wherein the latex application step is performed by spraying the latex adhesive and the wetting agent on the continuous layer of cellulosic fibers.
Claim 13
Dependent Claim
28 words
The method of claim 1, wherein the latex application step is performed by foaming the latex adhesive and the wetting agent on the continuous layer of cellulosic fibers.
Claim 14
Dependent Claim
25 words
The method of claim 1, wherein the latex adhesive is selected from the group consisting of acrylate emulsions, butadiene-styrene emulsions, acetate-ethylene emulsions, and acrylonitrile-butadiene emulsions.
Claim 15
Dependent Claim
18 words
The method of claim 1, wherein the three-dimensional cellulosic fibers in the continuous layer are interfiber bound together.
Claim 16
Independent Claim
160 words
A method of making a cloth-like composite laminate comprising the steps of: (a) pre-treating a nonwoven material layer with a latex adhesive and wetting agent; (b) air laying a continuous layer of three-dimensional cellulosic fibers onto one side of the nonwoven material layer; (c) drying the latex adhesive and wetting agent to bond substantially all of the layer cellulosic fibers to one side of the nonwoven material layer; (d) air laying a second continuous layer of cellulosic fibers to a second side of the nonwoven material layer; (e) applying to the second continuous layer of three-dimensional cellulosic fibers and the nonwoven material layer a latex adhesive containing a wetting agent; and (f) drying the latex adhesive and wetting agent to bind substantially all of the second continuous layer to the second side of the non-woven material layer to form a cloth-like composite laminate having two continuous layers of three-dimensional cellulosic fibers bound to opposite sides of the nonwoven material layer.
Claim 17
Independent Claim
160 words
A method of making a cloth-like composite laminate comprising the steps of: (a) pre-treating a nonwoven material layer with a latex adhesive and wetting agent; (b) air laying a continuous layer of three-dimensional cellulosic fibers onto one side of the nonwoven material layer; (c) drying the latex adhesive and wetting agent to bond substantially all of the layer cellulosic fibers to one side of the nonwoven material layer; (d) air laying a second continuous layer of cellulosic fibers to a second side of the nonwoven material layer; (e) applying to the second continuous layer of three-dimensional cellulosic fibers and the nonwoven material layer a latex adhesive containing a wetting agent; and (f) drying the latex adhesive and wetting agent to bind substantially all of the second continuous layer to the second side of the non-woven material layer to form a cloth-like composite laminate having two continuous layers of three-dimensional cellulosic fibers bound to opposite sides of the nonwoven material layer.
Claim 18
Dependent Claim
22 words
The method of claim 15, wherein the nonwoven material is a scrim having a plurality of holes for receiving the cellulosic fibers.
Claim 19
Dependent Claim
52 words
A cloth-like composite laminate comprising: (a) a nonwoven material layer; (b) an air laid continuous layer of three-dimensional cellulosic fibers positioned on one side of the nonwoven material layer; and (c) a latex adhesive containing a wetting agent binding substantially all of the air laid continuous layer to the nonwoven material layer.
Claim 20
Dependent Claim
52 words
A cloth-like composite laminate comprising: (a) a nonwoven material layer; (b) an air laid continuous layer of three-dimensional cellulosic fibers positioned on one side of the nonwoven material layer; and (c) a latex adhesive containing a wetting agent binding substantially all of the air laid continuous layer to the nonwoven material layer.
Claim 21
Dependent Claim
15 words
The cloth-like composite laminate of claim 17, wherein the cellulosic fibers are wood pulp fibers.
Claim 22
Dependent Claim
22 words
The cloth-like composite laminate of claim 18, wherein the wood pulp fibers are selected from mechanical pulp fibers and chemical pulp fibers.
Claim 23
Dependent Claim
29 words
The cloth-like composite laminate of claim 18, wherein the wood pulp fibers are selected from the group consisting of cedar fibers, southern pine fibers, spruce fibers and hemlock fibers.
Claim 24
Dependent Claim
14 words
The cloth-like composite laminate of claim 18, wherein the wood pulp fibers are twisted.
Claim 25
Dependent Claim
25 words
The cloth-like composite laminate of claim 17, wherein the nonwoven material is selected from the group consisting of nylon, rayon, polyester, polypropylene, glass, and aramids.
Claim 26
Dependent Claim
28 words
The cloth-like composite laminate of claim 17, wherein the weight of the cellulosic fibers is within the range of 15 pounds per ream to 40 pounds per ream.
Claim 27
Dependent Claim
31 words
The cloth-like composite laminate of claim 17, wherein the weight of the nonwoven material layer is within the range of 0.2 ounce per square yard to 3 ounces per square yard.
Claim 28
Dependent Claim
31 words
The cloth-like composite laminate of claim 17, wherein the weight of the nonwoven material layer is within the range of 0.3 ounces per square yard to 1 ounce per square yard.
Claim 29
Dependent Claim
15 words
The cloth-like composite laminate of claim 17, wherein the cellulosic fibers are interfiber bound together.
Claim 30
Dependent Claim
27 words
The cloth-like composite laminate of claim 17, wherein the latex adhesive is selected from the group consisting of acrylate emulsions, butadiene-styrene emulsions, acetate-ethylene emulsions, and acrylonitrile-butadiene emulsions.
Claim 31
Dependent Claim
20 words
The cloth-like composite laminate of claim 17, wherein the nonwoven material layer and the cellulosic fiber layer have diverse properties.
Claim 32
Dependent Claim
52 words
The cloth-like composite laminate of claim 17, further comprising: a second air laid continuous layer of three-dimensional cellulosic fibers positioned on a second side of the nonwoven material layer; and a latex adhesive containing a wetting agent binding substantially all of the second air laid continuous layer to the nonwoven material layer.
Claim 33
Dependent Claim
15 words
The cloth-like composite laminate of claim 17, wherein the nonwoven material layer is a scrim.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1990-01-12 | 1990-07-14 | 1991-01-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1994-01-12 | 1994-07-14 | 1995-01-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1998-01-12 | 1998-07-14 | 1999-01-13 | $7700.00 | Window Closed / Lapsed |