Method for producing a complex nonwoven fabric and resulting novel fabric

Abstract

The invention concerns a method for producing a complex nonwoven fabric which consists in continuously producing a complex wherein a first web of a cellulosic fibres (4) is continuously sandwiched between two webs of spunbonded filaments (2, 7), and which consists in: producing a first web of spunbonded filaments (2), the bundle of extruded and drawn filaments being received on a mobile conveyor belt (3) in the form of a non-bonded lap; depositing on said web 92) by airlaid process a second web of cellulosic fibres (4); depositing on the textile web (4) a second web (7) of non-bonded continuous filaments; transferring the resulting complex onto an installation (9) for water-jet bonding and hydro-entanglement consolidation; and in drying the nonwoven mixed product and then recuperating it, for example in the form of a cloth wind-up (18).

Description

[0001] For decades, it has been proposed to replace conventional textile webs (wovens and knits) with structures called "nonwovens".[0002] In general, such nonwoven structures can be classified in three broad categories, resulting from their actual manufacturing process, namely nonwovens produced by a so-called "dry process", these being formed by carding and / or the airlaid technique, nonwovens obtained by the "melt route", which technique is usually referred to by the expression "spunbond", and the technique called "wet process" derived from papermaking techniques.[0003] Moreover, it has been known for a very long time that it is possible to adapt the final properties of the product obtained by producing mixtures of materials, for example by combining together webs consisting of fibers of different type, for example natural, artificial or synthetic fibers.[0004] The invention provides a novel method making it possible to produce such a type of nonwoven article consisting of a mixtu...

AI Technical Summary

Benefits of technology

[0014] Such a problem is solved by combining, in a very precise way, techniques of the prior art used continuously and under very precise conditions, namely:

Problems solved by technology

the fact that the webs of continuous (spunbond) filaments have already been consolidated by a calendering heat treatment prevents intimate mixing of these filaments with the wood fibers of the airlaid web, which reduces the absorptivity of the complex and also results in the formation of a product which is rough and lacking in flexibility;

moreover, it is necessary, in order to ensure satisfactory cohesion between the plies and prevent delamination of the complex, to use, during the water-jet consolidation phase, very high fluid velocities, since the calendering points of the spunbond webs prevent any mobility of the synthetic filaments; these high water-jet velocities incur an extra energy consumption cost and a greater loss of cellulosic fiber;

finally, the fact that the continuous filaments of the webs cannot move makes the material very stiff, it losing its textile properties and being more like a paper than a true textile.

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