Composite nonwoven web

A process for producing a composite sheet, said process comprising the steps of:

• (a) forming a first stratum by fourdrinier casting and drying an aqueous slurry containing a distribution of glass fiber, thermoplastic fibrous materials and hydrophilic polymer, said glass fiber and said thermoplastic fibrous material in said first stratum being bonded by said hydrophilic polymer;
• (b) forming a second stratum by carding a distribution of a textile polymer fiber and a thermoplastic fibrous material, said polymer fiber and said thermoplastic fiber in said second stratum being bonded by matting;
• (c) said thermoplastic fibrous material of said first startum and thermoplastic fibrous material of said second stratum being compatible;
• (d) calendering said first stratum and said second stratum in superposition under heat and pressure to fuse said thermoplastic fibrous materialer of said first stratum and said thermoplastic fibrous material of said second stratum;
• (e) said first stratum, by total weight, containing a glass fiber to textile polymer fiber ratio of (from 40 to 94%) divided by (from 5 to 50%);
• (f) said second stratum, by total weight, containing from 10 to 90% textile polymer fiber and from 10 to 90% thermoplastic fibrous material;
• (g) said textile polymer fiber being composed of a material selected from the class consisting of polyesters, polyamides, polyvinyls, polyolefins, polyacrylics, and cellulosics;
• (h) said thermoplastic fibrous material having a fusion point within the range of 200.degree. to 450.degree. F.;
• (i) said textile polymer fiber and said glass fibers having fusion points distinctly above the fusion point of said thermoplastic fibrous material.

A composite sheet structure comprising:

• (a) a first cohesive stratum and a second cohesive stratum;
• (b) said first cohesive stratum containing a discrete distribution of nonwoven glass fiber and a discrete distribution of a hydrophilic polymer;
• (c) said second cohesive stratum being composed of a plurality of layers, each containing a discrete distribution of nonwoven textile polymer fiber and being cohesive by the temporary matting of said fibers;
• (d) said first cohesive stratum and said second cohesive stratum containing a distribution of nonwoven thermoplastic fibrous material, of which part is interspersed with said glass fiber and part is interspersed with said textile polymer fiber;
• (e) said discrete distribution of said hydrophilic polymer binding said nonwoven glass fiber and said nonwoven thermoplastic fibrous material into said first cohesive stratum;
• (f) said glass fiber, said textile polymer fiber, and said thermoplastic fibrous material being locked in position within said composite sheet structure between said first and second cohesive stratums and also within each of said first and second cohesive stratums primarily by fusion of said thermoplastic fibrous material to said glass fiber and to said textile polymer of said first and second cohesive stratums;
• (g) said first stratum, by total weight, containing a glass fiber to textile polymer fiber ratio of (from 40 to 94%) divided by (from 5 to 50%);
• (h) said second stratum, by total weight, containing from 10 to 90% textile polymer fiber and from 10 to 90% thermoplastic fibrous material;
• (i) said textile polymer fiber being composed of a material selected from the class consisting of polyesters, polyamides, polyvinyls, polyolefins, polyacrylics, and cellulosics;
• (j) said thermoplastic fibrous materials having fusion points within the range of 200.degree. to 450.degree. F.;
• (k) said textile polymer fiber and said glass fibers having fusion points distinctly higher than said thermoplastic fibrous material.