Laminate Fabrics

Abstract

The present invention provides laminate fabrics comprising two or more spunlaced fabric layers.

1 . A laminate fabric, comprising:
 a first nonwoven, spunlaced fabric layer comprising a front surface and a back surface opposite the front surface, said front surface comprising a first three-dimensional pattern; and   a second nonwoven, spunlaced fabric layer comprising a front surface and a back surface opposite the front surface, said front surface comprising a second three-dimensional pattern,   wherein the first and second nonwoven, spunlaced fabric layers are laminated together such that the back surface of the first nonwoven, spunlaced fabric layer is coupled to the back surface of the second nonwoven, spunlaced fabric layer.   
     
     
         2 . The laminate fabric of  claim 1 , wherein the first three-dimensional pattern and the second three-dimensional pattern are substantially the same. 
     
     
         3 . The laminate fabric of  claim 1 , wherein the first three-dimensional pattern and the second three-dimensional pattern are aligned such that the laminate fabric appears to comprise one consistent pattern throughout the depth of the fabric. 
     
     
         4 . The laminate fabric of  claim 1 , wherein the first nonwoven, spunlaced fabric layer comprises one or more fibers selected from the group consisting of cellulose, viscose and lyocell. 
     
     
         5 . The laminate fabric of  claim 1 , wherein the first nonwoven, spunlaced fabric layer comprises one or more fibers selected from the group consisting of polyester, polyethylene and polypropylene. 
     
     
         6 . The laminate fabric of  claim 1 , wherein the second nonwoven, spunlaced fabric layer comprises one or more fibers selected from the group consisting of cellulose, viscose and lyocell. 
     
     
         7 . The laminate fabric of  claim 1 , wherein the second nonwoven, spunlaced fabric layer comprises one or more fibers selected from the group consisting of polyester, polyethylene and polypropylene. 
     
     
         8 . The laminate fabric of  claim 1 , wherein the first and second nonwoven, spunlaced fabric layers are laminated together using an adhesive. 
     
     
         9 . The laminate fabric of  claim 1 , wherein the first three-dimensional pattern is generated by the spunlacing process used to form the first nonwoven, spunlaced fabric. 
     
     
         10 . The laminate fabric of  claim 1 , wherein the second three-dimensional pattern is generated by the spunlacing process used to form the second nonwoven, spunlaced fabric. 
     
     
         11 . The laminate fabric of  claim 1 , wherein the laminated fabric is a towel. 
     
     
         12 . The laminate fabric of  claim 1 , wherein at least one of the first and second nonwoven, spunlaced fabric layers has been treated with a finish comprising an antimicrobial agent, an antistat, a flame retardant, a surfactant, a wetting agent, a binder, a cross-linker, and/or a blocked isocyanate. 
     
     
         13 . The laminate fabric of  claim 1 , wherein the average surface roughness of the front surface of the first nonwoven, spunlaced fabric layer is at least about 50 microns. 
     
     
         14 . The laminate fabric of  claim 1 , wherein the average surface roughness of the front surface of the first nonwoven, spunlaced fabric layer is about 100 to about 250 microns. 
     
     
         15 . The laminate fabric of  claim 1 , wherein the average surface roughness of the front surface of the second nonwoven, spunlaced fabric layer is at least about 50 microns. 
     
     
         16 . The laminate fabric of  claim 1 , wherein the average surface roughness of the front surface of the second nonwoven, spunlaced fabric layer is about 100 to about 250 microns. 
     
     
         17 . A laminate fabric, comprising:
 a first nonwoven, spunlaced fabric layer comprising a front surface and a back surface opposite the front surface, said front surface comprising a first three-dimensional pattern; and   a second nonwoven, spunlaced fabric layer comprising a front surface and a back surface opposite the front surface, said front surface comprising a second three-dimensional pattern,   wherein the first and second nonwoven, spunlaced fabric layers are laminated together such that the back surface of the first nonwoven, spunlaced fabric layer is coupled to the back surface of the second nonwoven, spunlaced fabric layer,   wherein the first and second three-dimensional patterns resulted from the spunlacing process(es) used to form the first and second nonwoven, spunlaced fabric layers.   
     
     
         18 . The laminate fabric of  claim 17 , wherein the first nonwoven, spunlaced fabric layer comprises cellulose, viscose and/or lyocell fibers, as well as polyester, polyethylene and/or polypropylene fibers. 
     
     
         19 . The laminate fabric of  claim 17 , wherein the second nonwoven, spunlaced fabric layer comprises cellulose, viscose and/or lyocell fibers, as well as polyester, polyethylene and/or polypropylene fibers. 
     
     
         20 . The laminate fabric of  claim 17 , wherein the first and second nonwoven, spunlaced fabric layers are laminated together using an adhesive.