Continuous fiber nonwoven fabric manufacturing method and associated fiber nonwoven fabric manufacturing apparatus and fiber nonwoven fabric sheet

Abstract

This invention relates to a method for manufacturing a continuous fiber nonwoven fabric from a fiber mixture of carrier fibers and bonding fibers, comprising the following steps: a. feeding fibers; b. dispersing / carding and opening the fibers; c. mixing the fibers; d. drawing the fibers between two air-permeable conveyor belts running at the same speed and opposite to each other, i.e., drawing air from the outside at the front of the conveyor belts, such that the airflow is always drawn out parallel to the conveyor belts through the laid nonwoven material by air suction that varies over time and varies in width and position, thereby causing the fibers to accumulate perpendicular to the surface of the conveyor belts; e. thermally curing the resulting fiber nonwoven fabric by heating and cooling with the aid of hot air or shortwave radiation. Furthermore, this invention relates to a fiber nonwoven fabric manufacturing apparatus.

Description

Technical Field

[0001] The present invention relates to a continuous method for manufacturing nonwoven fabrics and an associated nonwoven fabric manufacturing apparatus, as well as a nonwoven fabric blank made of a fiber mixture of carrier fibers and adhesive fibers. Background Technology

[0002] Nonwoven fabrics are structures made of fibers, filaments, or chopped yarns of finite length. Because nonwoven fabrics can use a wide variety of raw materials and have numerous manufacturing methods, they can be specifically adapted to a broad range of application requirements.

[0003] Thus, there are fiber nonwoven fabrics weighing several kilograms per square meter used for insulation, as well as nonwoven fabrics weighing less than one gram per square meter, the so-called nano nonwoven fabrics.

[0004] The structures of these nonwoven fabrics vary depending on the requirements.

[0005] Highly absorbent fiber nonwovens are, for example, dense, have high flow resistance, and consist of thin or very thin fibers. A particular implementation of fiber nonwovens is meltblown fiber nonwovens. In the meltblown method, polymer filaments exiting a nozzle are stretched directly by hot air flowing in the direction of filament emergence. The fibers, swirled by the airflow, are laid on a screen belt. This laying process produces a fine nonwoven fabric made of entangled polymer fibers.

[0006] Electrostatically formed nonwoven fabrics are produced by forming and depositing fibers from a polymer solution or polymer melt under the influence of an electric field.

[0007] Conversely, nonwoven fabrics used for thermal insulation have a larger volume. It is also known to couple meltblown nonwoven fabrics with short fibers to produce large-volume structures.

[0008] If the nonwoven fabric is subjected to mechanical stress and has elastic properties, it preferably has fibers oriented in the direction of stress. Such nonwoven insulation is used, for example, under carpets or behind bulkheads in vehicles, or in the manufacture of breathable mattresses.

[0009] Fibers can have different orientations in nonwoven fabrics. Fibers are generally more or less parallel to the surface. Distinguishing between oriented nonwoven fabrics, cross-laid nonwoven fabrics, and random-laid nonwoven fabrics is important. In oriented nonwoven fabrics, the fibers are strongly oriented in one direction. In cross-laid nonwoven fabrics, the fibers are preferably oriented in two directions by stacking individual fiber webs or nonwoven fabrics with longitudinally oriented fibers onto a single nonwoven fabric using a cross-laying machine. In random-laid nonwoven fabrics, the fibers or filaments can take any orientation.

[0010] In the prior art, various manufacturing methods are distinguished when producing nonwoven fabrics from short fibers. Mechanically formed nonwoven fabrics are those manufactured using napping or carding machines or air-laid methods. Napping or carding is a dry manufacturing method in which multiple layers of nonwoven fabric are laid up and down. The fibers are mostly flat and parallel to the surface. Depending on the way the nonwoven fabric is laid, oriented nonwoven fabrics or cross-laid nonwoven fabrics are produced. Randomly laid nonwoven fabrics can also be formed if a dedicated carding machine is used.

[0011] Aerodynamically formed nonwoven fabrics are those formed by fibers on a breathable padding material using airflow. If the nonwoven fabric is manufactured using an air-laid facility, the fibers are drawn onto a breathable belt and oriented onto the surface. Depending on the laying and conveyor belt speed, the fibers can be at angles up to 70° to 80° with the surface, and are not perfectly perpendicular in the process. In this case, the fibers on the two surfaces take opposite angles, resulting in a strong curvature of the fibers.

[0012] In the case of hydrodynamically formed nonwoven fabrics, fibers are suspended in water and laid on a permeable liner. This method is also known as the wet method.

[0013] Fibers perpendicular to the surface can be obtained using the Struto method, also known as the Wavemacker method or V-Lap method. This is a method for producing a planar nonwoven fabric with vertical pleats from a carded nonwoven fabric with horizontal fiber layers.

[0014] As a method for subsequently reinforcing the nonwoven fabric produced in the manner described above, various possibilities are known, such as the possibility of friction bonding, or the possibility of a mechanical combination of friction bonding and form-fit bonding, or the possibility of material bonding, which can be achieved chemically by adding an adhesive or thermally by using thermoplastics. The most commonly used reinforcement method is to use thermoplastics in the form of low-melting-point plastics, preferably fibers. These so-called bonding fibers have a melting range of 100-200°C and are preferably present as compact fibers or bicomponent fibers.

[0015] Document DE 10 2010 034 159 A1 discloses a discontinuous solution for manufacturing nonwoven components having fibers oriented perpendicular to the surface, wherein fibers are transported by airflow into a mold having a flow-through opening, wherein the mold is separately constructed and moves separately before filling, the fiber material is compressed by closing the mold after filling, and then the fiber material is heated by hot air until the fibers connect with each other, wherein the fibers in the mold are oriented perpendicular to the transport direction and in the direction of the air flowing out of the mold before compression.

[0016] Furthermore, a fabric laying machine with inclined combs is known from document WO 2006092029 A1. These inclined combs lay vertically falling fiber material webs onto a screen belt of a continuous conveyor passing through an oven. Reciprocating pushers press the folds formed by the combs into shark units extending across the width of the web belt. These units have toothed plates that initially slow down the folding of the web and longitudinal fingers located above the conveyor, forming a flat overlapping area. A textile raising machine conveys the fiber web to a grinding zone, where the oven fuses all the low-melting-point synthetic fibers in the web with the surrounding fibers to produce a density of 80-2000 g / m³. 2 The non-woven fabric. The comb path direction remains constant, while the push rod and shark unit move towards and away from the comb. The actuators for the comb and push rod are independent.

[0017] A method, an apparatus, and a preform are described in US 20040097155 A1, in which rod-shaped fibers crimped during the manufacturing process are directly incorporated into meltblown fibers. By spreading the nonwoven fabric in two porous shafts with the aid of air, a fabric with two surfaces and a thinned central region is produced, in which the fibers lie flat and in which the fibers take a C-shaped orientation.

[0018] An aerodynamic method is described in document WO 2009056745 A1, in which fibers are transported between at least one moving porous wall by means of airflow and air is drawn out from the outside. In this document, long fibers are preferably laid along the porous wall, while short fibers are laid mainly perpendicular to the airflow.

[0019] Cormatex has disclosed a facility that lays fibers in a channel and also draws the fibers out from the side.

[0020] The problem with the prior art is that all methods for manufacturing fiber nonwoven fabric blanks from short fibers with fibers oriented perpendicular to the surface have the same density along the longitudinal and transverse directions of the blank within a dispersion range.

[0021] The technology disclosed in document WO 2006092029 A1 also has another drawback: because the density is the same along the longitudinal and transverse directions of the slab, only two-dimensional deformation can be achieved by forming folds. This leads to the nonwoven fabric cracking.

[0022] Nonwoven fabrics with varying densities and fiber orientations in thickness are disclosed in the publications of WO 2009056745 A1 and US 20040097155 A1, as well as in the method described by Comatex. These nonwoven fabrics have planes parallel to each other in the surface region and are largely perpendicular to the central region, which makes the nonwoven fabric more difficult to deform into three-dimensional parts.

[0023] The method of manufacturing fiber nonwoven fabric blanks based on the principle of airflow web formation (WO 2009056745 A1, US20040097155A1 and Comatex – with fibers oriented perpendicular to the surface) can only achieve very small density differences along the longitudinal and transverse directions of the blank.

[0024] The drawback of all these methods that achieve the same density across width and length is that, when molded to varying thicknesses, the density in the thinner regions is significantly higher than that in the raw material. This leads to increased weight, makes the thinner regions harder, and generally reduces acoustic properties.

[0025] Nonwoven fabrics manufactured using known air-laid methods (WO 2009056745 A1, US 20040097155 A1 and Comatex) always have fibers parallel to the surface due to limitations in the manufacturing process, which negatively impacts three-dimensional deformation. Summary of the Invention

[0026] The objective of this invention is to provide a simple, effective, economical, continuous, and aerodynamic method for producing nonwoven fabrics and an apparatus for producing fiber nonwoven fabrics having fibers oriented perpendicular to the surface and a defined fiber orientation, and preferably also having a density distribution along the length and width of the fiber nonwoven fabric, as well as a corresponding nonwoven fabric.

[0027] This task is accomplished by the method for manufacturing a continuous fiber nonwoven fabric from a fiber mixture of carrier fibers and bonding fibers according to the main claim, and by the associated fiber nonwoven fabric manufacturing apparatus and fiber nonwoven fabric blank according to the parallel claims. Further advantageous designs can be obtained in the dependent claims.

[0028] A method for manufacturing a continuous fiber nonwoven fabric from a fiber mixture of carrier fibers and bonding fibers includes the following steps:

[0029] a. Feeding fibers;

[0030] b. Disperse / comb and open the fibers;

[0031] c. Mix the fibers;

[0032] d. The fibers are drawn into the space between two breathable conveyor belts that are opposite each other and running at the same speed, i.e., air is drawn out from the outside at the front of the conveyor belts, such that the airflow is always drawn out parallel to the conveyor belts through the laid nonwoven material by air suction that varies with time and with width and position, thereby causing the nonwoven fiber to accumulate perpendicular to the surface of the conveyor belts.

[0033] e. The resulting nonwoven fabric is thermally hardened by heating and cooling with the aid of hot air or shortwave radiation.

[0034] By using air guidance, the orientation of fibers in the front region of a conveyor belt running parallel to each other can be controlled. When fibers are drawn out directly at the beginning of the conveyor belt, the fibers preferably accumulate and form layers parallel to the conveyor belt. The ratio of parallel fibers to perpendicular fibers can be controlled by the amount of air drawn out.

[0035] Air can be drawn out from the beginning of the conveyor belt in the front region, pushing the fibers along the belt. This changes the fiber orientation from parallel to the conveyor belt to a direction perpendicular to the conveyor belt.

[0036] If the suction area along the conveyor belt is different on both sides, a slab with fiber layers parallel to the conveyor belt can be produced.

[0037] To prevent fibers from spreading out on the conveyor belt, the filling amount and conveyor belt speed are controlled so that fiber agglomeration always occurs directly at the beginning of the conveyor belt.

[0038] By controlling the process during startup, parallel fiber deposition on the conveyor belt can be prevented, which offers a significant advantage when deforming nonwoven fabrics.

[0039] During startup, the nonwoven fabric construction is halted until the conveyor belt is full, after which the process continues (see also: [link to other documentation]). Figures 9 to 11 ).

[0040] The density along the length of the nonwoven fabric can be varied by changing the suction force over time. This density, and consequently the properties of the resulting fibrous nonwoven fabric, can be adjusted by the belt speed of the conveyor belt. Combining suction force and belt speed enhances the achievable effect of varying the desired density and properties. Density distribution across the width of the fibrous nonwoven fabric can also be achieved by varying the suction intensity along the position and over time. This allows the manufacture of nonwoven fabrics with limited positional density differences in both the longitudinal and transverse directions within the blank.

[0041] The thickness of the nonwoven fabric can be adjusted from 5mm to 100mm by using a defined, adjustable distance between the conveyor belts. The nonwoven fabric can be pre-compressed by changing the belt spacing.

[0042] The nonwoven fabric is preferably heated using hot air. In one variation, the nonwoven fabric can be heated using short-wave radiation.

[0043] Depending on the further application of the nonwoven fabric, the heat penetration and cooling processes will vary.

[0044] In the first embodiment, the nonwoven fabric is heated through, activating all the bonding fibers and achieving maximum mechanical properties in a cooled state. Optimal parameters can be determined through pre-testing. The nonwoven fabric is then air-cooled and cut to suitable sizes for subsequent applications. Figure 8 Upsetting hardness was demonstrated for a 50mm thick nonwoven fabric. Relationship with heating time.

[0045] In another embodiment, the nonwoven fabric is heated only briefly, and then its strength is adjusted so that it can be transported and stacked. Figure 3 In this process, the initial heating time is sufficient for the nonwoven fabric. The nonwoven fabric is then cooled and cut to the appropriate size for its subsequent use.

[0046] In another specific embodiment, the nonwoven fabric is fully heated and laid directly into the final mold in a thoroughly heated state for deformation and cooling, thereby producing the finished part.

[0047] The nonwoven fabric manufacturing apparatus comprises a feeding device for carrier fibers, a feeding device for bonding fibers, at least one dispersing / carding device or fiber opener for carding, separating, loosening and dispersing carrier fibers and / or bonding fibers, at least one mixing system for mixing the dispersed fibers, and a transport system. At the front of the transport system is an air extraction device consisting of air ducts and pressure-controlled nozzles for aligning and laying the fibers, and at the rear of the transport system is a heat source and a subsequent cooling source for heat curing the resulting nonwoven fabric. The front of the transport system with the air extraction device consists of breathable conveyor belts running at the same speed opposite each other, drawing the dispersed and mixed fibers between the opposing conveyor belts. The fibers are arranged perpendicular to the conveyor belts due to air being drawn from the outside onto the conveyor belts at different densities across the width and length of the nonwoven fabric. The belt spacing can be changed by automatic or manual control.

[0048] Downstream of the transport system, which has an air extraction device and a heat source, a conveyor belt can be arranged to transport the nonwoven fabric.

[0049] Furthermore, cutting equipment for longitudinal and transverse cutting can be coupled to the conveyor belt.

[0050] Furthermore, tools with three-dimensional contours for manufacturing molded parts can be arranged downstream of the conveyor belt and the cutting equipment.

[0051] Preferably, the two conveyor belts run in parallel. The distance between the breathable conveyor belts can be adjusted to regulate the thickness of the nonwoven fabric.

[0052] In another embodiment, the distance between the conveyor belts can be reduced along the length of the conveyor belts and thus the nonwoven fabric can be pre-compressed.

[0053] The suction area is divided into separately operable zones in width. This control can be achieved by changing the cross-section while maintaining the same suction pressure, or by varying the suction pressure itself.

[0054] By combining belt speed and central suction pressure, nonwoven fabrics with defined densities that vary depending on location can be obtained.

[0055] In the first embodiment, the nonwoven fabric leaves the conveyor belt in a cooled state without being transferred to another transport system.

[0056] In another embodiment, heated nonwoven fabric is cut into blank portions and laid into the lower half of a 3D molding tool. The lower half moves along the bottom, and the upper half of the tool closes the tool, pressing the product into the final mold and cooling it to produce a three-dimensional product.

[0057] Furthermore, the cooling source for thermosetting can be arranged in a cooling manner downstream of the heat source at the rear of the transport system or downstream of the contents of the three-dimensional mold component.

[0058] Various options can be selected as the cooling and heat sources for thermosetting. For example, the heat source can be configured as a hot airflow. In one particular embodiment, the nonwoven fabric is heated by means of short-wave radiation.

[0059] Nonwoven fabrics can be cooled by cold air or by contact, preferably in 3D molding tools.

[0060] In particular, when a fiber nonwoven fabric is manufactured accordingly (by means of the method and / or the apparatus according to the invention), the fiber nonwoven fabric has a density distribution defined in length and width. Attached Figure Description

[0061] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings, which should be used to explain the invention and not as a necessary limitation thereof:

[0062] Figure 1 A schematic diagram showing an embodiment in which the fibers are vertically oriented between two parallel, breathable conveyor belts is illustrated.

[0063] Figure 2 A schematic diagram of an embodiment of a fiber nonwoven fabric preform is shown;

[0064] Figure 3A schematic diagram of an embodiment of a fiber nonwoven fabric manufacturing apparatus is shown, which has separate feeding devices for carrier fibers and adhesive fibers, a common mixing system, and parallel extending breathable conveyor belts.

[0065] Figure 4 A schematic diagram showing different air guidance and air suction forces across different widths is provided.

[0066] Figure 5 A schematic diagram of an embodiment of a fiber nonwoven fabric manufacturing apparatus having a rear section with a parallel-extending breathable conveyor belt, a heat source, a cooling source, and a cutting device is shown.

[0067] Figure 6 A schematic diagram of an embodiment of a fiber nonwoven fabric manufacturing apparatus having a rear section with a parallel-extending breathable conveyor belt, a heat source, a cutting device, and a three-dimensional mold component is shown.

[0068] Figure 7 The possible density distribution of the floor insulation layer in passenger vehicles is shown;

[0069] Figure 8 The upsetting hardness is shown as dependent on the heat penetration time;

[0070] Figure 9 The diagram illustrates the intake of fibers between two conveyor belts running at the same speed, with the fibers being drawn in parallel to the conveyor belts.

[0071] Figure 10 This illustrates the control of fiber filling at the start of production;

[0072] Figure 11 The fiber arrangement in the conveyor belt during continuous production is shown; and

[0073] Figure 12 The fiber arrangement in the conveyor belt is shown, wherein there is fiber suction along the conveyor belt in the front region that varies with position.

[0074] It should be noted that components with the same function have uniform reference numerals. Detailed Implementation

[0075] Figure 1 A schematic diagram of an embodiment showing vertically oriented fibers 3 between two parallel extending breathable conveyor belts 4, 4' is shown.

[0076] Figure 2 A schematic diagram of an embodiment of a fiber nonwoven fabric blank 2 having vertically oriented fibers 3 is shown.

[0077] Figure 3A schematic diagram of an embodiment of a fiber nonwoven fabric manufacturing apparatus 1 is shown. This apparatus includes separate feeders 5, 5' for carrier fibers and bonding fibers, separate fiber openers 6, 6', a common mixing system 7, and breathable conveyor belts 4, 4' extending parallel above and below. Fibers are guided from the feeders 5, 5' into the fiber openers 6, 6', respectively. Following the fiber openers 6, 6' is the common mixing system 7 for mixing the fibers to achieve a uniform distribution.

[0078] Figure 4 The previous view shows a schematic diagram of an embodiment of a fiber nonwoven fabric manufacturing apparatus 1, which has separate feeders 5, 5' for carrier fibers and adhesive fibers, separate fiber openers 6, 6', a common mixing system 7, and breathable conveyor belts 4, 4' extending parallel above and below. Fibers are guided from the feeders 5, 5' to the fiber openers 6, 6', respectively. Following the fiber openers 6, 6' is the common mixing system 7 for mixing the fibers to achieve a uniform distribution.

[0079] The airflow and fiber flow are guided through the deflection channel 16 into two parallel breathable conveyor belts 4 and 4' by a system consisting of multiple ventilators 15-1 to 15-4.

[0080] Air is drawn from the outside onto the breathable conveyor belts 4 and 4' using air extraction devices 8, 8', 81-8.10, with varying intensities over time across the width of the nonwoven fabric, causing fibers to condense perpendicularly to the conveyor belt surface at different densities. The air extraction devices 81-8.10 are initiated at the beginning of the conveyor belts, while the end devices 82 are located directly before the area designated for heat curing. A heat source 9 and a cold source 10 are connected in series for heat curing. The finished nonwoven fabric is then further processed in subsequent production steps.

[0081] exist Figure 5 The diagram shows the rear of an embodiment of a nonwoven fabric manufacturing apparatus 1, which includes breathable conveyor belts 4 and 4' extending parallel above and below, a heat source 9, a cooling source 10, and a subsequent conveyor belt 11 with a cutting device 12. The manufactured nonwoven fabric blanks 2 are collected in a product collection container 13. The end 82 of the air extraction device is located directly before the area for heat curing, which includes the heat source 9 and the cooling source 10.

[0082] Figure 6A schematic diagram of the rear of an embodiment of a nonwoven fabric manufacturing apparatus 1 is shown, which has breathable conveyor belts 4, 4' extending parallel above and below, a heat source 9, a subsequent conveyor belt 11 with a cutting device 12, and a three-dimensional mold component 14. The lower half of the three-dimensional mold component 14 moves along beneath a warm and therefore easily moldable nonwoven fabric blank 2. As the conveyor belt 11 ends, these portions are individually laid on the lower half of the three-dimensional mold component. Then, the upper half of the mold component presses against the lower half of the mold component with a set pressure, and these lower halves are respectively filled with the nonwoven fabric blank 2, thus shaping the nonwoven fabric blank 2. The heated nonwoven fabric blanks shaped in the three-dimensional mold component 14 are cooled in the lower half of the three-dimensional mold component 14 before being transferred to the product collection container 13. A finished nonwoven fabric product is obtained.

[0083] Figure 7 The possible density distribution of floor insulation panels for passenger vehicles is shown. In this example, the density is higher in the footrest area, at 70 kg / m³. 3 The density inside the passageway and under the seats is 30 kg / m³. 3 .

[0084] Figure 8 The upsetting hardness is shown as a function of the heat penetration time.

[0085] Figure 9 The diagram illustrates the intake of fibers between two conveyor belts running at the same speed, with the fibers being drawn in parallel to the conveyor belts.

[0086] also, Figure 10 This demonstrates the control of fiber filling at the start of production, while Figure 11 The fiber arrangement in the conveyor belt during continuous production is shown. Figure 12 The arrangement of suction along the conveyor belt at different positions on the upper and lower sides is shown, as well as the fiber arrangement in the conveyor belt.

[0087] List of reference numerals

[0088] 1. Fiber Nonwoven Fabric Manufacturing Equipment

[0089] 2. Fiber nonwoven fabric blank

[0090] 3. Vertically oriented fibers

[0091] 4. 4' breathable conveyor belt

[0092] 5.5' Feeding device

[0093] 6. 6' Fiber Opener

[0094] 7, 7' hybrid system

[0095] 8. 8' Air extraction device 8-1 to 8-10

[0096] 81. Start of the air extraction device

[0097] 82. End of air extraction device

[0098] 9. Heat source

[0099] 10 Cooling source

[0100] 11 Conveyor Belt

[0101] 12 Cutting equipment

[0102] 13 Product collection containers

[0103] 14 Three-dimensional mold components

[0104] 15-1 to 15-4 Ventilators used for air control

[0105] 16 deflection channels

Claims

1. A method for manufacturing a continuous fiber nonwoven fabric from a fiber mixture of carrier fibers and bonding fibers. Includes the following steps: a. Feeding fibers; b. Disperse / comb and open the fibers; c. Mix the fibers; d. Air is drawn out from the outside at the front of two breathable conveyor belts that are opposite each other and running at the same speed, thereby drawing the fibers into the space between the two breathable conveyor belts. Under the action of air suction force that varies with time and width and position, the airflow is always drawn out parallel to the breathable conveyor belts through the laid non-woven material, thereby causing the fibers to accumulate perpendicular to the surface of the breathable conveyor belts. e. The resulting nonwoven fabric is thermally hardened by heating and cooling with the aid of hot air or shortwave radiation.

2. The method for manufacturing continuous fiber nonwoven fabric according to claim 1, characterized in that, The suction forces on the opposing breathable conveyor belts (4, 4') are the same.

3. The method for manufacturing continuous fiber nonwoven fabric according to claim 1, characterized in that, The suction along the breathable conveyor belts (4, 4') that are opposite each other is different.

4. The method for manufacturing continuous fiber nonwoven fabric according to any one of claims 1 to 3, characterized in that, During the production cycle, the suction force and / or the belt speed of the breathable conveyor belt (4, 4') are adjusted according to a pre-given system, wherein variations with position and time are possible.

5. The method for manufacturing continuous fiber nonwoven fabric according to any one of claims 1 to 3, characterized in that, The belt speed of the breathable conveyor belt (4, 4') is combined with the suction force of the air being drawn out.

6. The method for manufacturing continuous fiber nonwoven fabric according to any one of claims 1 to 3, characterized in that, The distance between the breathable conveyor belts (4, 4') is adjustable.

7. The method for manufacturing continuous fiber nonwoven fabric according to any one of claims 1 to 3, characterized in that, The nonwoven fabric is heated by hot air and / or shortwave radiation.

8. A nonwoven fabric manufacturing apparatus (1) comprising: - Feeding device for carrier fibers (5, 5'); - Feeding device for bonding fibers (5, 5'); - At least one dispersion / carding device or fiber opener (6, 6') for carding, separating, loosening and dispersing carrier fibers and / or adhesive fibers; - At least one mixing system (7, 7') for mixing dispersed fibers; -Transportation system, - An air extraction device (8, 8') consisting of an air duct and pressure-controlled nozzles (15-1 to 15-4) is located at the front of the transport system for aligning and laying fibers, and -The rear of the transport system has a heat source (9) and a subsequent cooling source (10) for heat curing the resulting nonwoven fabric. The front of the transport system with air extraction devices (8, 8') consists of two opposing breathable conveyor belts (4, 4') running at the same speed. The air extraction devices (8, 8') extract air at the front of the opposing breathable conveyor belts (4, 4') to draw the dispersed and mixed fibers into the space between the two breathable conveyor belts (4, 4'). Under the action of air suction force that varies with time and with position in width, the airflow is always parallel to the breathable conveyor belts (4, 4') and is drawn out through the laid non-woven fabric material, thereby causing the fibers to accumulate perpendicular to the breathable conveyor belts (4, 4').

9. The fiber nonwoven fabric manufacturing apparatus (1) according to claim 8, characterized in that, Downstream of the transport system, which has air extraction devices (8, 8') and a heat source (9), a conveyor belt (11) is arranged for transporting the nonwoven fabric.

10. The fiber nonwoven fabric manufacturing apparatus (1) according to claim 9, characterized in that, The conveyor belt (11) has a cutting device (12) for cutting the fiber nonwoven fabric into partial / fiber nonwoven fabric blanks.

11. The fiber nonwoven fabric manufacturing apparatus (1) according to claim 10, characterized in that, A three-dimensional mold component (14) is arranged downstream of the conveyor belt (11) and the cutting device (12).

12. The fiber nonwoven fabric manufacturing apparatus (1) according to any one of claims 8 to 11, characterized in that, The cooling source (10) for heat curing is arranged in - Downstream of the heat source (9) at the rear of the transport system, or -The contents downstream of the cooled three-dimensional mold component (14).

13. A fiber nonwoven fabric blank, manufactured by means of the method for manufacturing continuous fiber nonwoven fabric according to any one of claims 1 to 7 or by means of the fiber nonwoven fabric manufacturing apparatus (1) according to any one of claims 8 to 12. Its features are, The fiber nonwoven fabric blank has a density distribution defined in length and width.

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