Nonwoven and apparatus for preparing nonwoven

Abstract

The invention relates to a nonwoven having at least one nonwoven web made of fibers. The nonwoven has an embossed pattern. The embossed pattern consists of a plurality of embossed parts which are preferably not connected to one another. Each of the imprint portions has an imprint surface of 0.05 to 0.3 mm2.

Description

Technical Field

[0001] The invention relates to a nonwoven having at least one nonwoven web of fibers, wherein the nonwoven has an embossed pattern, wherein the embossed pattern consists of a plurality of embossed portions that are preferably not connected to one another. In addition, the invention also relates to an apparatus and a method for producing such a nonwoven having at least one nonwoven web of fibers. Background Art

[0002] The nonwoven of the type described at the beginning and the equipment and method for preparing the nonwoven are known in principle with different embodiments in practice. The fibers produced are usually laid on a web laying device to form a nonwoven web and pre-consolidated subsequently, so as to ensure the transportability of the nonwoven web or the nonwoven, and to ensure that the nonwoven web is not moved or damaged when transported through the equipment. For further consolidation, the nonwoven is usually peeled off from the web laying device and for example delivered to a calender having at least one calender roller, especially having a calender roller pair. At this, a calender roller with an embossing element is usually used, and these embossing elements introduce the embossed pattern consisting of a plurality of embossing portions into the nonwoven during the consolidation process. By known calendering steps, satisfactory consolidation is achieved, and particularly the favorable mechanical stability of the nonwoven obtained is achieved. However, in the measures known in practice, a calender having at least one calender roller including an embossing element is used for consolidating the nonwoven, which has the disadvantage that the consolidation measures have an adverse effect on the thickness or volume of the nonwoven and that, in addition, a visually perceptible embossed pattern may appear in the nonwoven, in particular due to the size of the embossing. Although the embossed pattern is advantageous or necessary with regard to the mechanical properties of the nonwoven, it is disadvantageous from an aesthetic point of view, since the visual properties are adversely affected thereby. Furthermore, the embossed pattern or embossing produced by the known measures may be disadvantageous for further handling or processing of the nonwoven. Summary of the invention

[0003] In view of this, the technical problem to be solved by the present invention is to provide a nonwoven of the type mentioned at the beginning, in which the above-mentioned disadvantages can be effectively and functionally reliably avoided, and the nonwoven is distinguished by favorable mechanical properties, such as sufficient mechanical strength or surface resistance and satisfactory thickness or bulkiness, and in which the visual impairment caused by the embossed pattern formed by the embossed part can be reduced or avoided as much as possible. In addition, the technical problem underlying the present invention is to provide an apparatus and a method for producing such a nonwoven.

[0004] In order to solve the technical problem, the present invention teaches a nonwoven having at least one nonwoven fiber web made of fibers, wherein the nonwoven has an embossed pattern, wherein the embossed pattern consists of a plurality of embossed portions that are preferably not connected to each other, wherein the embossed portions each have a diameter of 0.05 to 0.3 mm. 2 , preferably 0.06 to 0.2 mm 2 , preferably 0.07 to 0.18 mm 2 , particularly preferably 0.08 to 0.15 mm 2 and very particularly preferably from 0.09 to 0.12 mm 2 In the context of the present invention, the embossing portions have a surface area of ​​less than 0.3 mm. 2 , preferably less than 0.2 mm 2 , preferably less than 0.18 mm 2 , particularly preferably less than 0.15 mm 2 , very particularly preferably less than 0.12 mm 2 , for example, less than 0.1 mm 2 The stamping surface.

[0005] In the context of the present invention, the term "embossed portion" refers in particular to a compacted location of a nonwoven at which the nonwoven has a smaller thickness than its non-embossed areas and at which the fibers of the nonwoven are at least partially connected or fused to one another, preferably by the action of pressure and / or temperature. The embossed portion of the embossed pattern according to the invention is preferably produced by at least one calender roller having a complementary embossed pattern consisting of embossed elements. This will be explained in more detail below.

[0006] In the scope of the present invention, the term "embossing pattern" refers in particular to a pattern formed by a plurality of embossing portions of a nonwoven. The embossing pattern can be a regular and / or irregular embossing pattern. Preferably, the embossing pattern is a regular embossing pattern. Then, each embossing portion is preferably distributed on the nonwoven at regular intervals, preferably at the same intervals. Further preferably, according to a preferred embodiment of the present invention, the embossing surface of each embossing portion of the embossing pattern is the same or substantially the same. It has been proven to be advantageous that the geometry of the embossing surface of each embossing portion is the same or substantially the same. Very particularly preferably, the embossing pattern has embossing portions of the same or the same size or embossing portions of the same or substantially the same size, wherein the embossing portions with the same geometry or substantially the same geometry are uniformly distributed. But in principle it is also possible that each embossing portion of the embossing pattern has sizes and / or geometries that are different from each other, and / or the embossing portion is arranged on the nonwoven with an irregular embossing pattern. Furthermore, the geometry of the embossing within the scope of the present invention refers in particular to the geometry of the embossing surface of the embossing in a plan view.

[0007] The embossing surface of the embossing part refers in particular to the embossed surface of the embossing part within the scope of the present invention, wherein when determining the size of the embossing surface, the material protrusions or material flanges that may be formed during the pressing or embossing process and at least partially surround the embossing part are in particular not part of the embossing surface of the embossing part. In the case where the embossing part or the embossing surface has a dot-shaped or circular geometry in a top view, the embossing surface of the embossing part corresponds, for example, to the area of ​​the dot-shaped or circular embossing part, wherein the material protrusions or material flanges that may surround the embossing part are not included in the embossing surface of the embossing part. The embossing part of the nonwoven of the present invention respectively has an embossing surface within the above range, which means in particular that at least 95%, preferably at least 97%, of all embossing parts of the nonwoven have an embossing surface within the above range. Particularly preferably, all embossing parts of the nonwoven have an embossing surface within the range. Within the scope of the present invention, the embossing surface of the embossing part can be determined in particular by an incident light or transmitted light 2D microscope, and / or by a scanning electron microscope (REM) and / or by micro-computed tomography (μCT). In a corresponding image evaluation, the embossing surface geometry or a geometry corresponding or substantially corresponding thereto is preferably used as the basis, and the evaluation is based on the respective visually imaged embossing surface of the embossing.

[0008] In the context of the present invention, a nonwoven having at least one nonwoven web made of fibers means in particular that the nonwoven has at least one nonwoven web or nonwoven ply consisting of produced and laid fibers. According to one embodiment, the nonwoven can have only one nonwoven web or nonwoven ply, or can also have a plurality of nonwoven webs or nonwoven plies stacked one above the other, which are combined to form a nonwoven laminate. This will be further described below.

[0009] The present invention recognizes that by means of an embossed portion according to the invention of a nonwoven having a special embossed surface size, a nonwoven can be provided for which visual impairment caused by the embossed pattern consisting of the embossed portion can be almost completely avoided due to the significantly reduced perceptibility of the embossed pattern at least to the human eye, and which nevertheless still stands out with favorable mechanical properties and a satisfactory thickness.

[0010] A particularly preferred embodiment of the present invention is characterized in that the embossed pattern is an invisible or substantially invisible embossed pattern, wherein the embossed portion is configured as an invisible or substantially invisible embossed portion. "Invisible" in this context particularly means that the embossed pattern of the nonwoven or the embossed portion of the nonwoven is not perceptible or substantially perceptible to the human eye.

[0011] In the scope of the present invention, the minimum spacing d of the two embossing parts of the embossed pattern is respectively 0.6 to 2.5 mm, preferably 0.8 to 2.0 mm, preferably 0.9 to 1.8 mm, particularly preferably 0.95 to 1.6 mm and very particularly preferably 1.0 to 1.5 mm. Suitably, the minimum spacing d of the two embossing parts of the embossed pattern is respectively at least 0.6 mm, especially at least 0.8 mm, preferably at least 1.0 mm, particularly preferably at least 1.4 mm and fully particularly preferably at least 2.0 mm. The minimum spacing d of the two embossing parts of the embossed pattern refers in particular to the minimum spacing d of the two directly adjacent embossing parts of the embossed pattern, that is, the minimum spacing of an embossing part of the preferred embossed pattern to the embossing part closest to it. In addition, the minimum spacing d of the two embossing parts of the embossed pattern refers in particular to the minimum spacing between the embossing boundaries of the two embossing parts, i.e. the minimum spacing of the two embossing parts along the non-embossed surface of the non-woven fabric located therebetween. This embodiment is based on the recognition that the visual perceptibility of the embossed pattern from the embossed portion can be further reduced thereby, wherein advantageous mechanical properties and sufficient thickness of the nonwoven are nevertheless ensured. The above-mentioned minimum spacing of two embossed portions of the embossed pattern is preferably at least 95%, preferably at least 97%, of all embossed portions of the nonwoven. Particularly preferably, the above-mentioned minimum spacing of two embossed portions relates to all embossed portions of the nonwoven.

[0012] According to the particularly preferred embodiment of nonwoven of the present invention, the total embossing area of ​​embossed pattern accounts for the ratio of the total surface area of ​​the nonwoven of 2 to 12%, preferably 2.5 to 8%, preferably 3 to 6%, particularly preferably 3.5 to 5.5% and very particularly preferably 4 to 5%. Within the scope of the present invention, the total embossing area of ​​embossed pattern accounts for the ratio of the total surface of nonwoven less than 10%, preferably less than 8%, more preferably less than 6.5%, particularly preferably less than 5.5% and very particularly preferably less than 5%. The visual perceptibility of the embossed pattern composed of the embossed portion can be further reduced by the total embossing area of ​​the embossed pattern. Nevertheless, the nonwoven with satisfactory mechanical properties is still obtained. The total embossing area of ​​embossed pattern refers especially to the summation of all embossed faces of embossed pattern in this article. The total surface area of ​​nonwoven refers especially to the whole nonwoven surface area including embossed and non-embossed regions within the scope of the present invention.

[0013] It is recommended that the embossing surface of the embossing part has at least one geometric shape selected from the following group in a top view: "point or circle, ellipse, square, rectangle, rhombus, polygon, line, wave". As mentioned above, the embossing surface of the embossing part refers in particular to the embossed surface of the embossing part, excluding material protrusions or material flanges that may surround the embossing surface. Preferably, the embossing surfaces or embossing parts of the embossing pattern have the same or essentially the same geometric shapes. However, in principle, it is also within the scope of the present invention that the embossing pattern has embossing surfaces or embossing parts with different geometric shapes. A very particularly preferred embodiment of the present invention is characterized in that the embossing part or the embossing surfaces of all embossing parts are point-shaped or circular in a top view.

[0014] Furthermore, within the scope of the present invention, the aspect ratio of the embossing surface of the embossing portion is respectively less than 4, preferably less than 3, particularly preferably less than 2, for example equal to 1. In this regard, the aspect ratio of the embossing surface refers in particular to the ratio of the maximum length or the maximum longitudinal extension of the embossing surface of the embossing portion to the maximum width or the maximum width extension of the embossing surface of the embossing portion, and for example to the ratio of the lengths of the axes of symmetry. When the embossing surface of the embossing portion has a point-shaped or circular geometry in a top view, the aspect ratio is, for example, equal to 1. When the embossing surface of the embossing portion has an elliptical geometry in a top view, the aspect ratio corresponds, for example, to the ratio of the length of the major axis or the major semi-axis to the length of the minor axis or the minor semi-axis of the ellipse. When the embossing surface of the embossing portion has a rectangular geometry in a top view, the aspect ratio corresponds, for example, to the ratio of the length of the rectangle to the width of the rectangle. When the embossing surface of the embossing portion has a rhombus geometry in a top view, the aspect ratio corresponds, for example, to the ratio of the length of the longer diagonal to the length of the shorter diagonal of the rhombus. When the embossing surface of the embossing portion has a square geometric shape in a plan view, the aspect ratio is equal to 1. If it is a curved shape, the aspect ratio of the embossing surface is preferably described by the aspect ratio of the surrounding rectangle.

[0015] In principle, within the scope of the present invention, the fiber of at least one nonwoven web is staple fibers or at least one nonwoven web comprises staple fibers. According to a preferred embodiment, the fiber of at least one nonwoven web is continuous filaments. Particularly preferably, the fibers of all nonwoven webs of nonwovens are continuous filaments. Continuous filaments are distinguished from staple fibers due to their almost unlimited length, and the staple fibers have significantly smaller lengths, for example 1 mm to 60 mm.

[0016] As described above, according to a particularly preferred embodiment of the present invention, the fibers of the at least one nonwoven web are configured as continuous filaments. Preferably, the fibers of the at least one nonwoven web or at least one nonwoven web of a nonwoven are made into continuous filaments consisting of at least one thermoplastic, preferably at least one polyolefin. It is recommended that the at least one polyolefin is polypropylene and / or polyethylene. In principle, the continuous filaments can also be made of other thermoplastics, such as polyesters, such as polyethylene terephthalate (PET) and / or polylactic acid (PLA), and mixtures of the above-mentioned thermoplastics. According to one embodiment, copolymers of the thermoplastics are used. Conventional additives, such as plasticizers, fillers, colorants, etc., can be metered into the thermoplastics. Within the scope of the present invention, the continuous filaments of the at least one nonwoven web or at least one nonwoven web of a nonwoven are made into spunbonded continuous filaments. In principle, the continuous filaments of the at least one nonwoven web or a nonwoven web of a nonwoven can also be made into meltblown continuous filaments.

[0017] According to a particularly preferred embodiment of the present invention, the fibers of at least one nonwoven web are configured as crimped continuous filaments, wherein the crimped continuous filaments are preferably multicomponent filaments, particularly preferably bicomponent filaments.

[0018] In this context, it has proven particularly advantageous that the multicomponent filaments or bicomponent filaments have a first component which consists of or essentially consists of at least one thermoplastic, in particular at least one polyolefin, preferably polyethylene and / or polypropylene, and / or that the multicomponent filaments or bicomponent filaments have a second or further component which consists of or essentially consists of at least one thermoplastic, in particular at least one polyester and / or polypropylene. In particular, polyethylene terephthalate (PET) and / or polylactic acid (PLA) are suitable as polyesters. According to one embodiment, copolymers of these plastics are used. If, here or hereinafter, reference is made to a component of a multicomponent filament or bicomponent filament and in particular to a plastic or polymer, "essentially consisting of ..." means in particular that the component or polymer is present in at least 95% by weight, preferably in at least 97% by weight, and more preferably in at least 98% by weight. The remaining % by weight may in particular consist of additives such as plasticizers, fillers, colorants, etc.

[0019] According to a preferred embodiment of the present invention, the first component of the multicomponent filaments or bicomponent filaments is based on polyethylene, and preferably consists of polyethylene or essentially consists of polyethylene. According to another preferred embodiment, the first component of the multicomponent filaments or bicomponent filaments is based on polypropylene, and preferably consists of polypropylene or essentially consists of polypropylene. Instead of polypropylene or in addition to polypropylene, at least one polypropylene copolymer can also be used within the scope of the present invention.

[0020] According to a preferred embodiment of the present invention, the second or other components of the multi-component filaments or bi-component filaments are based on at least one polyester and / or on polypropylene. Particularly preferably, the second or other components of the multi-component filaments or bi-component filaments are composed of at least one polyester and / or polypropylene. For the second or other components, instead of polypropylene or in addition to polypropylene, at least one polypropylene copolymer can also be used, and preferably, instead of polyester or in addition to polyester, at least one polyester copolymer can also be used. Suitably, polyethylene terephthalate (PET) and / or polylactic acid (PLA) are particularly suitable as polyesters, and PET copolymers (Co-PET) are particularly suitable as polyester copolymers. It is also within the scope of the present invention to use polylactic acid copolymers (Co-PLA) as the first component and polylactic acid (PLA) as the second or other components.

[0021] Within the scope of the present invention, the continuous filaments, preferably the crimped continuous filaments, are constructed as multicomponent filaments or bicomponent filaments with a side-by-side configuration and / or with a sheath-core configuration, in particular with an eccentric sheath-core configuration, and wherein preferably the first component mentioned above is the sheath component and suitably the second or other component mentioned above is the core component. If the continuous filaments are constructed as multicomponent filaments or bicomponent filaments with a sheath-core configuration, it is also possible within the scope of the present invention that it is a central sheath-core configuration.

[0022] If the continuous filament or the curled continuous filament is constructed as a multi-component filament or a bi-component filament with an eccentric sheath-core configuration according to a preferred embodiment, then within the scope of the present invention, the sheath of the filament and the core of the filament are both constructed as a circle when observed in the cross section of the filament. According to another preferred embodiment of the present invention, the multi-component filament or the bi-component filament is constructed as a multi-component filament or a bi-component filament with an eccentric sheath-core configuration, and the core of these filaments is constructed as a fan-shaped when observed in the cross section of the filament, and with respect to its periphery, it has an arc-shaped peripheral segment and a linear peripheral segment, so that a D-shaped core appears to be obtained when observed in the cross section of the filament.

[0023] If continuous filament or crimped continuous filament is multicomponent filament or bicomponent filament with at least one above-mentioned first component and at least one above-mentioned second or other component in the scope of the present invention, then preferably, the first component is a component with a lower melting point compared with the second component. The first or lower melting point component is preferably polyethylene and / or polypropylene, especially polyethylene. According to a preferred embodiment, the ratio of the first component with a lower melting point of the multicomponent filament or bicomponent filament of at least one nonwoven web of nonwoven is 20 to 80% by weight, preferably 25 to 65% by weight, more preferably 30 to 50% by weight (based on the components of multicomponent filament or bicomponent filament). Within the scope of the present invention, the lower melting point component of multicomponent filament or bicomponent filament or the first component with a lower melting point is particularly used as a bonding component for multicomponent filament or bicomponent filament.

[0024] According to a particularly preferred embodiment of the nonwoven of the present invention, the fiber titer of the nonwoven, in particular the titer of the continuous filaments or crimped continuous filaments, is 0.5 to 6.0 denier, preferably 0.8 to 5.0 denier, particularly preferably 1.0 to 2.5 denier.

[0025] A recommended embodiment of the invention is characterized in that the nonwoven has a density of less than 200 g / m 2 , especially less than 150 g / m 2 , preferably less than 100 g / m 2 , more preferably less than 75 g / m 2 , particularly preferably less than 50 g / m 2 and very particularly preferably less than 30 g / m2 Particularly preferably, the nonwoven fabric has a weight per unit area of ​​10 g / m 2 Up to 80 g / m 2 , preferably 15 g / m 2 Up to 60 g / m 2 , more preferably 15 g / m 2 Up to 30 g / m 2 .

[0026] Very preferably, the nonwoven has a thickness h of 0.1 to 0.85 mm, preferably 0.15 to 0.75 mm, preferably 0.2 to 0.65 mm, particularly preferably 0.25 to 0.55 mm. Within the scope of the present invention, the nonwoven has a thickness h of at least 0.4 mm, in particular at least 0.5 mm, preferably at least 0.55 mm, more preferably at least 0.6 mm, particularly preferably at least 0.625 mm. The thickness h refers to the maximum thickness or total thickness of the nonwoven transversely, in particular perpendicularly or substantially perpendicularly to its planar extension in the non-embossed area of ​​the nonwoven. The thickness or total thickness h of the nonwoven is measured according to method WRT 120.6 (05) option A.

[0027] A very advantageous embodiment of the invention is characterized in that the nonwoven has an abrasion resistance of at least 2 grades according to the Martindale standard, preferably an abrasion resistance of 1 grade according to the Martindale standard, and / or the nonwoven has a maximum bending stiffness of a cantilever of a maximum of 100 mm, preferably a maximum of 90 mm, preferably a maximum of 80 mm, particularly preferably a maximum of 75 mm and very particularly preferably a maximum of 70 mm. This embodiment is based on the recognition that the nonwoven is therefore characterized by a very satisfactory abrasion resistance, and / or the nonwoven has an advantageously low bending stiffness and in particular also has an improved drapability compared to known measures or nonwovens. In the nonwoven according to the invention, these properties are advantageously combined with a satisfactory mechanical strength and at least a significantly reduced visual perceptibility of the embossed pattern formed by the embossing. The abrasion resistance of the nonwoven is determined within the scope of the invention in particular using a Martindale abrasion test device according to the following test method:

[0028] In particular, the device "SDL Atlas M235 Martindale Tester" is used as the test device. The procedure for determining the wear resistance is preferably based on WSP20.5 (05), wherein in particular the following deviations from WSP20.5 (05) are made: the surfaces (top / bottom) are tested individually; at least 10, preferably at least 20 tests are carried out for each sample and surface, wherein the test pieces are taken uniformly from the sample surface, and the final result is the arithmetic mean. The test specimen should be taken from a representative position, i.e. not just from the edge, for example, because the test or result deviations should not be influenced by macroscopic deviations (e.g. poor process control), but only by typical (local) fluctuations; the test specimen is tensioned on a standard felt and mounted in the lower fixture; this workpiece is fixed together with a PU foam patch (e.g. from SDL Atlas) using the same nonwoven as the moving upper friction surface, the test surfaces resting against each other; the contact pressure is 9 kPa; 32 cycles, i.e. two complete cycles of the Lissajous figure; the counterparts (test specimen and upper friction surface) are replaced after each test;

[0029] The samples are rated on a scale of 1 to 5, with 1 being the highest score. For example, if the average value for the top surface is 1 and the average value for the bottom surface is 3, the sample is rated 1 overall. Only changes in the nonwoven are evaluated, and if the nonwoven has previously had similar defects, this is disregarded. In this context, for example, a fiber strand means a group or bundle of fibers on the surface. If a test specimen clearly has such a defect from the outset, the test specimen in question must be excluded.

[0030] 1 point: Almost no changes can be observed from above. Slight looseness of the surface is allowed, in which case only the filaments are allowed to loosen, but no larger or longer agglomerations are allowed. When observed from the side, the height of the loose filaments should not exceed 5 mm. Single filaments or multiple filaments are allowed to gather into small balls with a diameter of less than 2 mm.

[0031] 2 points: In addition to the above damage mode (1 point): The filaments are loose and entangled with adjacent filaments to form elongated agglomerates. These groups of filaments are called "strands" or "threads or bundles". These strands are 5 to 40 mm long and are connected to the substrate at least every 10 mm of their length. The maximum height of a strand is 5 mm (5 mm above the surface) and the maximum width is 2 mm.

[0032] 3 points: The "strands" are no longer connected to the substrate along their length, possible connections are >10 mm apart from each other, or the strands are only connected to the sample at the start and end points. It is possible to lift and move these strands, for example with a needle.

[0033] 4 points: The strands connect to each other to form a network. A "spider web".

[0034] 5 points: The sample is further damaged and holes are formed for the first time.

[0035] The flexural stiffness of a nonwoven is determined within the scope of the present invention, in particular, in accordance with the method “WSP 90.1 (05) Standard Test Method for Stiffness of Nonwoven Fabrics Using Cantilever Test”.

[0036] In the context of the present invention, the strength of the nonwoven in the machine direction (MD) is at least 8 N / 5 cm, in particular at least 10 N / 5 cm, preferably at least 15 N / 5 cm, more preferably at least 17.5 N / 5 cm, particularly preferably at least 20 N / 5 cm, very particularly preferably at least 22.5 N / 5 cm. In the context of the present invention, the machine direction (MD) is in particular the conveying direction F of the nonwoven on the laying device. In the context of the present invention, the strength of the nonwoven in the machine direction is determined in particular according to the following method: "Determination of tensile strength (based on Edana 20.2-89)": unit N / 5 cm; sample width 50 mm; tension length 100 mm; test speed 200 mm / min.

[0037] According to a particularly preferred embodiment of the present invention, the depth t of the embossing portion is respectively 0.1 to 0.8 mm, preferably 0.15 to 0.7 mm, particularly preferably 0.2 to 0.6 mm, and very particularly preferably 0.25 to 0.5 mm. The depth t of the embossing portion here refers in particular to the thickness of the nonwoven or the total thickness h and the thickness difference between the thickness of the nonwoven in the region of the embossing surface of the embossing portion. The total thickness h of the nonwoven is determined in particular according to the above method. Within the scope of the present invention, the thickness of the nonwoven in the region of the embossing surface of the embossing portion can be obtained, for example, by visual analysis or microscopic analysis of the cross section of the nonwoven. This can be achieved, for example, by casting a sample with a cross section passing through the embossing point and polishing the cross section. Then in this cross section, a common microscope can be used to determine the thickness of the embossing surface from the side. In the case of a light weight per unit area, the embossing surface can be porous, so it is preferred to determine only the thickness in the constructed component here. In addition or alternatively, micro-computed tomography (μCT) scanning is suitable, which allows the average thickness of the embossing surface to be determined.

[0038] Within the scope of the present invention, nonwoven has only one nonwoven web or only one nonwoven ply.Nonwoven web or nonwoven ply can be for example by continuous filaments, particularly by the nonwoven web made of the continuous filaments of crimping.According to a preferred embodiment, nonwoven is configured as a nonwoven laminate composed of at least two, particularly by at least two above-mentioned nonwoven webs or nonwoven plies.Preferably, the fiber of the at least two nonwoven webs or nonwoven plies, especially all nonwoven webs or nonwoven plies of nonwoven, is continuous filament or crimped continuous filament.But in principle, nonwoven can also have nonwoven web or nonwoven plies with the fiber made of non-crimped continuous filaments or staple fibers.It has been proved advantageous that at least one nonwoven web or the fiber of the nonwoven plies of the outer surface of nonwoven that is assigned to is crimped continuous filament and / or staple fibers. Thus, in particular, the softness of the nonwoven can be improved and the bending stiffness can be reduced. In addition, it is possible that the properties of the fibers or continuous filaments of different nonwoven webs or nonwoven plies of the nonwoven are different. For example, the continuous filaments of the first nonwoven web can have a lower average fineness than the continuous filaments of the second nonwoven web, so that a fineness gradient is produced.

[0039] According to a preferred embodiment of the present invention, nonwoven is a spunbond nonwoven with at least one spunbond nonwoven web or with at least one spunbond nonwoven ply. It is possible that the nonwoven is configured as a nonwoven laminate composed of at least two spunbond nonwoven webs or at least two spunbond nonwoven plies. But it is also possible that the nonwoven laminate has at least one meltblown nonwoven ply or meltblown nonwoven web. In addition, within the scope of the present invention, nonwoven is configured as a nonwoven laminate composed of at least three, for example, at least four nonwoven webs or nonwoven plies. Each nonwoven web or nonwoven ply can be configured as a spunbond nonwoven web or a nonwoven ply respectively. But in principle, the nonwoven laminate can also have at least one meltblown nonwoven web or meltblown nonwoven ply. The spunbond nonwoven web or spunbond nonwoven ply, respectively, preferably consists of continuous filaments or crimped continuous filaments.

[0040] A proven advantageous embodiment of the invention is characterized in that the nonwoven is consolidated with at least one calender roller for producing an embossed pattern and preferably with at least one hot fluid primary consolidation device, in particular with at least one hot air primary consolidation device. The at least one calender roller is preferably part of a calender, which preferably comprises at least two calender rollers or at least one calender roller pair. If the nonwoven is consolidated according to a preferred embodiment with at least one calender roller for producing an embossed pattern and with at least one hot fluid primary consolidation device, a nonwoven is produced in particular that is characterized by advantageous visual properties, particularly advantageous mechanical strength, and at the same time advantageous low bending stiffness and satisfactory wear resistance.

[0041] The term "thermal fluid" within the scope of the present invention refers to a temperature-controlled or heated fluid. Preferably, the thermal fluid is a temperature-controlled or heated gas and particularly preferably hot air. In principle, however, the thermal fluid can also be a temperature-controlled or heated liquid, for example water.

[0042] The invention also relates to the use of the nonwoven described above for at least one hygiene product or in at least one hygiene article.

[0043] In order to solve this technical problem, the present invention also teaches a device for preparing a nonwoven, in particular a device for preparing the nonwoven according to the above nonwoven, wherein the nonwoven has at least one nonwoven fiber web made of fibers, wherein the device has at least one fiber generating device, in particular at least one spinning beam and at least one laying device, in particular at least one laying screen belt, for laying the fibers into a nonwoven fiber web, wherein at least one calendering roller is also provided for introducing an embossing pattern consisting of a plurality of embossing portions into the nonwoven, wherein the calendering roller has a complementary embossing pattern consisting of embossing elements for this purpose, wherein the embossing elements each have a diameter of 0.05 to 0.3 mm. 2 , preferably 0.06 to 0.2 mm 2 , preferably 0.07 to 0.18 mm 2 , particularly preferably 0.08 to 0.15 mm 2 and very particularly preferably from 0.09 to 0.12 mm 2 The pressed surface.

[0044] In the context of the invention, the embossing elements of the complementary embossing pattern of at least one calender roller each have an embossing height in the range of 0.3 to 1.2 mm, preferably 0.4 to 0.9 mm, particularly preferably 0.5 to 0.8 mm. The embossing height here refers in particular to the height difference between the pressing surface of the embossing element and the bottom of the calender roller. This embodiment is based on the recognition that during the calendering process with such a calender roller, the compaction of the nonwoven can be at least substantially minimized.

[0045] Suitably, the mesh-laying screen belt of the device according to the present invention is a mesh-laying screen belt that is continuously surrounded. Within the scope of the present invention, the calender roller is a part of a calender. The calender is preferably connected to the downstream of the mesh-laying device or the mesh-laying screen belt in the conveying direction F of the nonwoven. According to a particularly preferred embodiment, the calender has at least one calender roller pair, and at least one of the two calender rollers of the calender or calender roller pair, in particular one calender roller is the above-mentioned calender roller for introducing the embossed pattern consisting of the embossing portion into the nonwoven. Another or additional roller of the calender or calender roller pair is suitably a smoothing roller with a smooth outer surface. Therefore, within the scope of the present invention, the nonwoven is preferably consolidated using a calender, which has at least one aforementioned calender roller and at least one smoothing roller for introducing the embossed pattern consisting of a plurality of embossing portions into the nonwoven. Then, the embossed pattern is preferably introduced into the nonwoven only from one side of the nonwoven. Nevertheless, the embossing pattern is preferably still present in the resulting nonwoven on both nonwoven sides, wherein in particular the embossing depth is distributed differently on the two nonwoven sides.

[0046] The pressing surface in the context of the present invention refers in particular to the surface of the embossing element of the calender roller that is provided for producing the embossing surface of the embossing portion. If the embossing element of the calender roller is, for example, constructed as a cylindrical embossing element for producing an embossing surface with a dot-shaped or circular geometry in a top view, the pressing surface of the embossing element corresponds in particular to the surface on the upper side of the cylinder. If the embossing element of the calender roller is constructed with an embossing surface with a dot-shaped or circular geometry in a top view, for example a truncated cone shape, i.e., with a side angle, the pressing surface of the embossing element corresponds in particular to the top surface of the truncated cone in order to produce the embossing portion. One embodiment of the present invention uses a plurality of side angles for the embossing element, wherein the embossing element preferably has a smaller side angle in the area provided for contact with the nonwoven than further in the direction of the bottom of the calender roller. The side angle gradient can be step-by-step or continuous here.

[0047] Within the scope of the present invention, the at least one calendering roller for introducing an embossing pattern consisting of a plurality of embossing parts into the non-woven is preferably constructed in a standard manner so that the above-mentioned characteristics of the embossing parts can be achieved, in particular with regard to the embossing surface and / or with regard to the minimum spacing d between two embossing parts and / or with regard to the depth t of the embossing parts and / or with regard to the ratio of the total embossing area of ​​the embossing pattern to the total surface area of ​​the non-woven and / or with regard to the aspect ratio of the embossing surface of the embossing part.

[0048] Within the scope of the present invention, the at least one fiber generating device or the at least one spinning manifold is configured to generate a spunbonded nonwoven web from continuous filaments, especially from crimped continuous filaments. If the nonwoven is configured as a nonwoven laminate consisting of at least two nonwoven plies or nonwoven webs according to one embodiment of the present invention, then within the scope of the present invention, there are at least two fiber generating devices, especially at least two spinning manifolds, and preferably all fiber generating devices or spinning manifolds are designed to generate a spunbonded nonwoven web consisting of continuous filaments, especially crimped continuous filaments. Very particularly preferably, at least one fiber generating device or at least one spinning manifold, preferably all fiber generating devices or all spinning manifolds of the device according to the present invention are arranged to generate multi-component filaments or bicomponent filaments. In addition, within the scope of the present invention, the device is configured to prepare at least one nonwoven web from crimped continuous filaments. Preferably, at least one fiber generating device or at least one spinning manifold is arranged to generate crimped continuous filaments. When a plurality of spinning beams are used for the apparatus according to the invention, at least one spinning beam or at least two spinning beams or all spinning beams are arranged to produce crimped continuous filaments.

[0049] A very suitable design of the invention is characterized in that, for the fibers or continuous filaments spun by at least one fiber generating device or by at least one spinning manifold, at least one cooling device for cooling the fibers or filaments and at least one stretching device connected to the cooling device for stretching the fibers or filaments are provided. Advantageously, at least one diffuser is connected to the stretching device along the flow direction of the fibers or filaments. A very recommended embodiment of the invention is characterized in that the unit consisting of the cooling device and the stretching device is constructed as a closed unit and no other air is supplied to the unit from the outside except for the cooling air supplied to the cooling device. Advantageously, the fibers or filaments leaving the diffuser are laid directly on the laying device or the laying screen belt.

[0050] A particularly preferred embodiment of the device of the present invention is characterized in that the device has at least one hot fluid main consolidation device, in particular a hot air main consolidation device, wherein the hot fluid main consolidation device is preferably arranged downstream of the calender roller in the conveying direction F of the nonwoven. Therefore, according to a preferred embodiment, at least one hot fluid main consolidation device is arranged downstream of the calender roller according to the present invention for introducing the embossing pattern composed of the embossing portion into the nonwoven in the conveying direction F of the nonwoven, and in particular is arranged downstream of the calender having the calender roller. The hot fluid main consolidation device or the hot air main consolidation device can in particular be a hot air furnace for consolidating or main consolidating nonwovens.

[0051] It has proven to be particularly effective within the scope of the present invention that at least one hot fluid main consolidation device or at least one hot air main consolidation device is configured as a hot air furnace, particularly preferably in the form of an omega furnace and / or a multi-drum furnace and / or a single-belt furnace and / or a double-belt furnace. Suitably, consolidation or main consolidation using at least one hot fluid main consolidation device is carried out by applying at least one hot fluid to the nonwoven on one side or both sides in the at least one hot fluid main consolidation device. If the hot fluid main consolidation device, in particular the hot air main consolidation device, is a hot air furnace according to a preferred embodiment, the fluid temperature furthermore corresponds within the scope of the present invention in particular to the hot air temperature during hot air consolidation in the hot air furnace. In principle, at least one hot fluid main consolidation device can also be arranged upstream of a calender roller or a calender having a calender roller in the conveying direction F of the nonwoven.

[0052] It has proven to be advantageous if the device has at least one pre-consolidation device, in particular at least one hot fluid pre-consolidation device, preferably at least one hot air pre-consolidation device, wherein the pre-consolidation device is particularly preferably arranged upstream of the calender rollers in the conveying direction F of the nonwoven, in particular upstream of a calender having calender rollers or a calender roller pair, and very particularly preferably connected downstream of the at least one fiber generating device or the at least one spinning beam or directly downstream thereof. Preferably, the at least one pre-consolidation device is then also arranged upstream of the preferably provided hot fluid main consolidation device in the conveying direction F of the nonwoven.

[0053] Within the scope of the present invention, the pre-consolidation device or the hot fluid pre-consolidation device is arranged above the laying device or the laying screen belt. In addition, within the scope of the present invention, the at least one hot air pre-consolidation device is configured in the form of at least one hot air knife and / or in the form of at least one hot air field. However, in principle, the pre-consolidation device can also be at least one roller or a leveling roller, especially a roller pair or a leveling roller pair. If the device according to the present invention has at least two fiber generating devices or at least two spinning manifolds, then within the scope of the present invention, at least one pre-consolidation device, especially at least one hot fluid pre-consolidation device or a hot air pre-consolidation device is connected or directly connected to the downstream of each fiber generating device or each spinning manifold in the conveying direction F of the nonwoven, and the hot air pre-consolidation device is suitably configured in the form of a hot air knife and / or in the form of a hot air field. If the nonwoven is prepared with only one nonwoven fiber web according to one embodiment, it is preferred that a hot air knife is used as the pre-consolidation device. If the nonwoven is produced according to a preferred embodiment with multiple nonwoven fiber webs or nonwoven material layers, the hot air knife is preferably used as a pre-consolidation device for the topmost or last laid nonwoven fiber web or nonwoven material layer, and in particular the hot air knife and the hot air field are used as pre-consolidation devices for the remaining nonwoven fiber webs or nonwoven material layers.

[0054] In order to solve the technical problem, the present invention also teaches a method for preparing a nonwoven, in particular for preparing the above-mentioned nonwoven and / or using the above-mentioned device, wherein the nonwoven has at least one nonwoven fiber web made of fibers, wherein the fibers are produced by at least one fiber generating device, in particular by at least one spinning beam, and then the fibers are laid on at least one laying device, in particular at least one laying screen belt, to form a nonwoven fiber web, wherein the nonwoven fiber web or nonwoven is subsequently consolidated by at least one calender roller, and wherein an embossing pattern consisting of a plurality of embossing portions is introduced into the nonwoven by means of the calender roller, wherein the embossing portions each have a diameter of 0.05 to 0.3 mm 2 , preferably 0.06 to 0.2 mm 2 , preferably 0.07 to 0.18 mm 2 , particularly preferably 0.08 to 0.15 mm 2 and very particularly preferably from 0.09 to 0.12 mm 2 The stamping surface.

[0055] Within the scope of the method according to the invention, the nonwoven is preferably consolidated, in particular mainly consolidated, by means of at least one hot fluid main consolidation device, in particular by means of at least one hot air main consolidation device, after being consolidated by means of at least one calender roller, in particular by means of at least one calender machine or calender roller pair having said calender roller.

[0056] According to a preferred embodiment of the method of the present invention, after the nonwoven is laid on the web laying device, in particular on the web laying screen belt, it is first pre-consolidated with at least one pre-consolidation device, in particular with at least one hot fluid pre-consolidation device, preferably with at least one hot air pre-consolidation device, preferably subsequently consolidated with the at least one calender roller of the present invention, and subsequently consolidated, in particular mainly consolidated, with a hot fluid main consolidation device or a hot air main consolidation device. It is also possible that the nonwoven is first consolidated or pre-consolidated with a hot fluid main consolidation device after pre-consolidation, and then consolidated with at least one calender roller of the present invention. Pre-consolidation in the scope of the present invention refers in particular to the consolidation of the nonwoven or nonwoven fiber web, which ensures transportability, but preferably results in a lower degree of consolidation of the nonwoven than the degree of consolidation of the consolidation or main consolidation.

[0057] If a nonwoven with at least two nonwoven webs or nonwoven plies is produced according to a preferred embodiment, or if an apparatus with at least two fiber production devices or with at least two spinning beams is provided, a first nonwoven web is first preferably produced by the at least one first spinning beam and laid on a web laying device, in particular a web laying screen belt, and in particular preconsolidated with a first preconsolidation device or a hot fluid preconsolidation device. Preferably, a second nonwoven web produced by a second fiber production device or a second spinning beam is then laid on the first nonwoven web, and the second nonwoven web or the assembly consisting of the first nonwoven web and the second nonwoven web is then preconsolidated with the aid of at least one further preconsolidation device or a hot fluid preconsolidation device. Preferably, the nonwoven is then removed from the web laying device and conveyed to a calender having the at least one calender roller according to the invention or as described above. By means of the calender rollers of the calender, an embossing pattern consisting of a plurality of embossing portions is suitably introduced into the nonwoven, and the nonwoven is preferably consolidated here. Suitably, the nonwoven is then consolidated or mainly consolidated using a hot fluid main consolidation device or a hot air main consolidation device.

[0058] In the context of the present invention, the surface temperature of the at least one calender roller, in particular a calender or a calender roller pair having the calender roller, is higher than the temperature of the hot fluid of the at least one hot-fluid main consolidation device, in particular by 1° C. to 15° C., preferably by 1° C. to 5° C., or lower than the temperature of the hot fluid of the at least one hot-fluid main consolidation device, or is identical or essentially identical to the temperature of the hot fluid of the at least one hot-fluid main consolidation device. In the context of the present invention, at least one calender roller, in particular at least one calender or a calender roller pair having the calender roller, is preferably a heated calender roller or a heated calender.

[0059] It is also possible within the scope of the present invention that the fluid temperature of at least one hot fluid main consolidation device is in the range of Tm-5°C to Tm+10°C with respect to the melting point Tm of the above-mentioned lower melting point first component of the multi-component filaments or bi-component filaments, wherein the melting temperature Tm of the lower melting point first component is determined in particular by means of dynamic differential scanning calorimetry (DSC) according to ISO11357-3:2011 standard.

[0060] The present invention is based on the following understanding, that is, the outstanding feature of the nonwoven according to the present invention is the embossed pattern consisting of the embossed portion, and the visual damage of the nonwoven can be almost completely avoided by this embossed pattern. Due to the characteristics of this specially designed embossed portion and the nonwoven, at least the visual perceptibility of the embossed pattern can be significantly reduced by the human eye, thereby obtaining an almost invisible embossed pattern consisting of the embossed portion. According to the present invention, this is especially realized by the relatively small embossed area of ​​the embossed portion. The minimum spacing of the preferred arrangement of every two embossed portions of the embossed pattern and the ratio of the total embossed area of ​​the embossed pattern to the total surface area of ​​the nonwoven also advantageously contribute to at least significantly reducing the perceptibility of the embossed pattern by the human eye. Nevertheless, the nonwoven still has favorable mechanical properties and satisfactory thickness. According to a preferred embodiment of the present invention, the nonwoven also has very high wear resistance and low bending stiffness. It must be emphasized in addition that the above-mentioned characteristics of the nonwoven can be realized with less laborious measures within the scope of the present invention. This is also particularly applicable to the device according to the present invention and the method according to the present invention.

[0061] The invention is explained in more detail below with reference to the drawing, which shows only one exemplary embodiment. BRIEF DESCRIPTION OF THE DRAWINGS

[0062] In a schematic way:

[0063] Figure 1 A top view of a nonwoven according to the invention is shown,

[0064] Figure 2 Shown along Figure 1 The cross section of line AA in

[0065] Figure 3 shows a vertical section through a device according to the invention,

[0066] Figure 4 Shown by Figure 3 A vertical cross-sectional view of a portion of a device. DETAILED DESCRIPTION

[0067] Figure 1 and Figure 2A nonwoven 1 according to the invention is shown, which has at least one nonwoven web 2 consisting of fibers. In the embodiment according to the drawings, the nonwoven 1 has two nonwoven webs 2, 2' consisting of continuous filaments 6, and is in particular configured as a nonwoven laminate. The continuous filaments 6 can preferably and in this embodiment be crimped continuous filaments 6. Preferably and in this embodiment, the nonwoven 1 is a spunbond nonwoven, which has two spunbond nonwoven webs 2, 2' consisting of crimped continuous filaments 6. The crimped continuous filaments 6 can be bicomponent filaments with an eccentric sheath-core configuration in this embodiment, wherein the sheath of the continuous filaments 6 is preferably composed of polyethylene or essentially composed of it, and wherein the core of the continuous filaments 6 is especially composed of at least one polyester and / or composed of polypropylene or essentially composed of it.

[0068] Figure 1 and Figure 2 It is also shown that the nonwoven 1 has an embossed pattern 3, wherein the embossed pattern 3 is composed of a plurality of embossed portions 4 that are not connected to one another. The embossed portions 4 are here particularly compacted locations of the nonwoven 1, at which the nonwoven 1 has a smaller thickness than its unembossed areas, and at which the crimped continuous filaments 6 of the nonwoven 1 are preferably at least partially connected or fused to one another by the action of pressure and / or temperature. Preferably and in this embodiment, the embossed pattern 3 is a regular embossed pattern 3, whose individual embossed portions 4 are preferably and in this embodiment distributedly arranged at regular intervals on the nonwoven 1.

[0069] According to the present invention, the embossing portions 4 have a diameter of 0.05 to 0.3 mm. 2 The embossing surface 5 of the embossing part 4 is within the scope of the present invention and in this embodiment refers in particular to the embossed surface of the embossing part 4, wherein when determining the size of the embossing surface 5, material protrusions or material flanges that may be formed during the pressing or embossing process and at least partially surround the embossing part 4 are not part of the embossing surface 5 of the embossing part 4. This is particularly true in Figure 2 . It is further preferred and in this embodiment that the embossing surfaces 5 of the individual embossing portions 4 of the embossing pattern 3 are of the same size or substantially of the same size. Preferably and in the embodiment according to the figures, the embossing surfaces 5 of the embossing portions 4 have a dot-shaped or circular geometry in a top view. Very particularly preferably and in this embodiment, the embossing pattern 3 has embossing portions 4 of the same or the same size or embossing portions 4 of substantially the same or substantially the same size, wherein the embossing portions 4 of the same or substantially the same geometry are uniformly distributed.

[0070] Within the scope of the present invention, the minimum spacing d between two embossed portions 4 of the embossed pattern 3 is respectively 0.6 to 2.5 mm. The minimum spacing d between two embossed portions 4 here refers in particular to the minimum spacing d between two directly adjacent embossed portions 4 of the embossed pattern 5, that is, preferably the minimum spacing d from one embossed portion 4 of the embossed pattern 3 to the embossed portion 4 closest to it. In addition, the minimum spacing d between two embossed portions 4 refers in particular to the minimum spacing d between the embossed boundaries of the two embossed portions 4, that is, the minimum spacing between the two embossed portions 4 along the non-embossed surface of the nonwoven 1 located therebetween.

[0071] It has proven to be advantageous if the total embossed area of ​​the embossed pattern 3 accounts for 2 to 12% of the total surface area of ​​the nonwoven 1. The total embossed area of ​​the embossed pattern 3 in this context refers in particular to the sum of the embossed areas 5 of the embossed pattern 3. The total surface area of ​​the nonwoven 1 in the context of the present invention refers in particular to the entire nonwoven surface area including embossed and non-embossed areas.

[0072] It is further preferred that the aspect ratio of the embossing surface 5 of the embossing part 4 is respectively less than 3, preferably less than 2. The aspect ratio of the embossing surface 5 in this context refers in particular to the ratio of the maximum length or maximum longitudinal extension of the embossing surface 5 of the embossing part 4 to the maximum width or maximum width extension of the embossing surface 5 of the embossing part 4. In the exemplary embodiment according to the figures, the embossing surface 5 of the embossing part 4 has a dot-shaped or circular geometry in top view, so that the aspect ratio is equal to 1.

[0073] The thickness h of the nonwoven 1 is preferably 0.15 to 0.75 mm. In the embodiment according to the figures, the thickness h of the nonwoven 1 can be about 0.4 mm. The thickness h here refers to the maximum thickness or total thickness of the nonwoven 1 transversely, in particular perpendicularly or substantially perpendicularly to its planar extension in the non-embossed area of ​​the nonwoven 1. This can be seen in particular from Figure 2 see.

[0074] Within the scope of the present invention, the embossed pattern 3 of the nonwoven having a plurality of embossed portions 4 is characterized in particular in that, due to this special design of the embossed portions 4 and the properties of the nonwoven 1, the visual perceptibility of the embossed pattern 3 to the human eye is at least significantly reduced, resulting in an almost invisible embossed pattern 3 consisting of the embossed portions 4.

[0075] Figure 3A device 9 according to the invention is shown for preparing the aforementioned nonwoven 1 having two nonwoven webs 2, 2' made of crimped continuous filaments 6. The device preferably and in this embodiment has two spinning beams 10, 10', which are preferably and in this embodiment arranged to produce spunbond nonwoven webs 2, 2', respectively, which are composed of crimped continuous filaments 6 in the form of bicomponent filaments. In addition, corresponding to the preferred embodiment, there is a continuously circulating laying screen belt 11 for laying the continuous filaments 6 into nonwoven webs 2, 2'. According to the invention, the device 9 has a calender roller 7 for introducing an embossed pattern 3 into the nonwoven 1. Preferably and in the present embodiment, the calender roller 7 is part of a calender 16 composed of a calender roller pair 7, 17. Preferably and in this embodiment, the calender roller 7 of the calender 16 has a complementary embossed pattern 12 composed of embossing elements 13, each of which has a diameter of 0.05 to 0.3 mm. 2 The pressing surface 14 is in particular the surface of the embossing element 13 of the calender roller 7 which is provided for producing the embossing surface 5 of the embossed portion 4 of the nonwoven 1. Figure 3 In the embodiment of the present invention, the embossing element 13 of the calender roller 7 is configured as a truncated cone, and the pressing surface 14 corresponds to the top surface of the truncated cone. Another or other calender roller 17 of the calender 16 is preferably and in this embodiment configured as a smoothing roller 17 with a smooth outer surface.

[0076] According to a particularly preferred embodiment and in this embodiment, the device 9 has a hot air main consolidation device 8, which is preferably arranged downstream of the calender roller 7 or downstream of the calender 16 in the conveying direction F of the nonwoven 1. Preferably, the hot air main consolidation device 8 is configured as a hot air furnace. Suitably and in this embodiment, the device 9 also has two pre-consolidation devices in the form of hot air pre-consolidation devices 15, 15'. The hot air pre-consolidation devices 15, 15' are preferably and in this embodiment respectively arranged upstream of the calender roller 7 or upstream of the calender 16 in the conveying direction F of the nonwoven 1. Preferably and according to Figure 3 In the embodiment of the present invention, the hot air pre-consolidation devices 15, 15' are respectively directly connected to the downstream of the spinning beams 10, 10' for pre-consolidating the laid nonwoven fiber webs 2, 2'. The first hot air pre-consolidation device 15 is preferably directly connected to the downstream of the first spinning beam 10 in the conveying direction F of the nonwoven 1, followed by the second spinning beam 10', and the second hot air pre-consolidation device 15' is directly connected to the downstream of the second spinning beam. The hot air pre-consolidation devices 15, 15' are preferably arranged as hot air knives and / or hot air fields.

[0077] Within the scope of the present invention and in accordance with Figure 3In the embodiment of the present invention, a nonwoven web 2 composed of crimped continuous filaments 6 is first produced by the first spinning beam 10 and laid on the laying screen belt 11. Subsequently, the nonwoven web 2 is preferably and in this embodiment pre-consolidated by means of a hot air pre-consolidation device 15. Then, a second nonwoven web 2' made of crimped continuous filaments 6 is suitably produced by the second spinning beam 10' and laid on the first nonwoven web 2. The second nonwoven web 2' or the aggregate composed of the first nonwoven web 2 and the second nonwoven web 2' is then recommended to be pre-consolidated with a second hot air pre-consolidation device 15', and then preferably peeled off from the laying screen belt 11 and conveyed to a calender 16 with a calender roller 7. With the help of the calender roller 7 of the calender 16, an embossed pattern 3 composed of a plurality of embossing portions 4 is introduced into the nonwoven 1 and the nonwoven 1 is suitably consolidated therein. Subsequently, a consolidation or main consolidation of the nonwoven 1 preferably takes place by means of at least one hot air main consolidation device 8 .

[0078] Figure 4 The basic structure of a part of a device 9 for producing a nonwoven fiber web 2 according to the present invention by a spunbond method is shown, which device comprises a spinning nozzle or a spinning beam 10 for spinning continuous filaments 6 and thus for forming a spunbond nonwoven fiber web 2 from the continuous filaments 6. The continuous filaments 6 spun by the spinning nozzle or the spinning beam 10 are introduced into a cooling device 18 having a cooling chamber 19. Preferably and in this embodiment, air supply cabins 20, 21 are arranged one above the other on two opposite sides of the cooling chamber 19. Preferably, air of different temperatures is introduced into the cooling chamber 19 from the air supply cabins 20, 21 that are arranged one above the other.

[0079] Recommendedly and in this embodiment, a stretching device 22 for stretching the continuous filaments 6 is connected downstream of the cooling device 18 in the filament flow direction. Suitably and in this embodiment, the stretching device 22 has an intermediate channel 23, which connects the cooling device 18 with a stretching shaft 24 of the stretching device 22. Preferably and in this embodiment, the unit consisting of the cooling device 18, the intermediate channel 23 and the stretching shaft 24 is constructed as a closed unit, and except for the cooling air supplied to the cooling device 18, no other air is supplied to the unit from the outside.

[0080] Suitably and in this embodiment, a diffuser 25 is connected to the stretching device 22 in the direction of the filament flow, through which the continuous filament 6 is guided. After passing through the diffuser 25, the continuous filament 6 is preferably and in this embodiment laid on a laying device configured as a laying screen belt 11. The laying screen belt 11 is preferably and in this embodiment implemented as a continuously circulating laying screen belt 11. Within the scope of the invention, the laying screen belt 11 is air-permeable, so that process air can be sucked from below through the laying screen belt.

Claims

1. A nonwoven material comprising at least one nonwoven web (2) made of fibers, wherein the nonwoven material (1) has an embossed pattern (3), wherein the embossed pattern (3) consists of a plurality of embossed portions (4) which are preferably not connected to one another, wherein the embossed portions (4) each have a diameter of 0.05 to 0.3 mm. 2 , preferably 0.06 to 0.2 mm 2 , more preferably 0.07 to 0.18 mm 2 , particularly preferably 0.08 to 0.15 mm 2 and very particularly preferably from 0.09 to 0.12 mm 2 The stamping surface (5) of the embodiment of the present invention is as follows.

2. The nonwoven according to claim 1, wherein the minimum distance d between two embossing portions (4) of the embossing pattern (3) is respectively 0.6 to 2.5 mm, preferably 0.8 to 2.0 mm, more preferably 0.9 to 1.8 mm, particularly preferably 0.95 to 1.6 mm and very particularly preferably 1.0 to 1.5 mm.

3. The nonwoven according to claim 1 or 2, wherein the total embossed area of ​​the embossed pattern (3) accounts for 2 to 12%, preferably 2.5 to 8%, more preferably 3 to 6%, particularly preferably 3.5 to 5.5% and very particularly preferably 4 to 5% of the total surface area of ​​the nonwoven (1).

4. The nonwoven material according to any one of claims 1 to 3, wherein the embossing surface (5) of the embossing portion (4) has at least one geometric shape selected from the following group in a top view: "dot or circle, ellipse, square, rectangle, rhombus, polygon, line, wave". 5 . The nonwoven according to claim 1 , wherein the aspect ratio of the embossing surface ( 5 ) of the embossing portion ( 4 ) is respectively less than 4, preferably less than 3, particularly preferably less than 2, for example equal to 1.

6. The nonwoven material according to any one of claims 1 to 5, wherein the fibers of the at least one nonwoven fiber web (2) are configured as continuous filaments (6), preferably crimped continuous filaments (6), wherein the crimped continuous filaments (6) are preferably multicomponent filaments, particularly preferably bicomponent filaments.

7. A nonwoven according to claim 6, wherein the multicomponent filaments or bicomponent filaments have a first component, which consists of or essentially consists of at least one thermoplastic, in particular at least one polyolefin, preferably polyethylene and / or polypropylene, and / or wherein the multicomponent filaments or bicomponent filaments have a second or further component, which consists of or essentially consists of at least one thermoplastic, in particular at least one polyester and / or polypropylene.

8. A nonwoven fabric according to claim 6 or 7, wherein the continuous filaments (6), preferably the curled continuous filaments (6), are constructed as multi-component filaments or bi-component filaments having a side-by-side configuration and / or having a sheath-core configuration, in particular having an eccentric sheath-core configuration, and wherein preferably the first component is the sheath component and the second component is the core component.

9. The nonwoven according to any one of claims 1 to 8, wherein the nonwoven (1) has a density of less than 200 g / m 2 , especially less than 150 g / m 2 , preferably less than 100 g / m 2 , more preferably less than 75 g / m 2 , particularly preferably less than 50 g / m 2 and very particularly preferably less than 30 g / m 2 Weight per unit area. 10 . The nonwoven according to claim 1 , wherein the nonwoven ( 1 ) has a thickness h of 0.1 to 0.85 mm, preferably 0.15 to 0.75 mm, more preferably 0.2 to 0.65 mm, particularly preferably 0.25 to 0.55 mm.

11. The nonwoven according to claim 1 , wherein the nonwoven ( 1 ) has an abrasion resistance of at least class 2 according to the Martindale scale, preferably an abrasion resistance of class 1 according to the Martindale scale, and / or wherein the nonwoven ( 1 ) has a maximum bending stiffness of a cantilever of at most 100 mm, preferably at most 90 mm, more preferably at most 80 mm, particularly preferably at most 75 mm and very particularly preferably at most 70 mm.

12. The nonwoven according to any one of claims 1 to 11, wherein the nonwoven (1) has a strength in the machine direction (MD direction) of at least 8 N / 5 cm, in particular at least 10 N / 5 cm, preferably at least 15 N / 5 cm, more preferably at least 17.5 N / 5 cm, particularly preferably at least 20 N / 5 cm, very particularly preferably at least 22.5 N / 5 cm. 13 . The nonwoven according to claim 1 , wherein the depth t of the embossing ( 4 ) is in each case 0.1 to 0.8 mm, preferably 0.15 to 0.7 mm, particularly preferably 0.2 to 0.6 mm, very particularly preferably 0.25 to 0.5 mm. 14 . The nonwoven according to claim 1 , wherein the nonwoven ( 1 ) is formed as a nonwoven laminate composed of at least two nonwoven fiber webs ( 2 , 2 ′) or nonwoven plies.

15. The nonwoven according to any one of claims 1 to 14, wherein the nonwoven (1) is consolidated using at least one calender roller (7) for producing an embossed pattern (3) and preferably using at least one hot fluid main consolidation device, in particular at least one hot air main consolidation device (8).

16. A device for producing a nonwoven (1), in particular for producing a nonwoven (1) according to any one of claims 1 to 15, the nonwoven having at least one nonwoven web (2) made of fibers, wherein the device (9) has at least one fiber producing device, in particular at least one spinning beam (10) and at least one laying device, in particular at least one laying screen belt (11), for laying the fibers into the nonwoven web (2), wherein at least one calender roller (7) is also provided for introducing an embossing pattern (3) consisting of a plurality of embossing portions (4) into the nonwoven (1), wherein the calender roller (7) has for this purpose a complementary embossing pattern (12) consisting of embossing elements (13), wherein the embossing elements (13) each have a diameter of 0.05 to 0.3 mm 2 , preferably 0.06 to 0.2 mm 2 , more preferably 0.07 to 0.18 mm 2 , particularly preferably 0.08 to 0.15 mm 2 and very particularly preferably from 0.09 to 0.12 mm 2 The pressed surface (14) is provided.

17. An apparatus according to claim 16, wherein the apparatus (9) has at least one hot fluid main consolidation device, in particular at least one hot air main consolidation device (8), wherein the hot fluid main consolidation device is preferably arranged downstream of the calender roller (7) in the conveying direction F of the nonwoven (1).

18. An apparatus according to claim 16 or 17, wherein the apparatus has at least one pre-consolidation device, in particular at least one hot fluid pre-consolidation device, preferably at least one hot air pre-consolidation device (15), wherein the pre-consolidation device is particularly preferably arranged upstream of the calender roller (7) in the conveying direction F of the non-woven (1), and is very particularly preferably connected downstream of the at least one fiber generating device or the at least one spinning beam (10) or directly connected downstream thereof.

19. A method for producing a nonwoven (1), in particular for producing a nonwoven (1) according to any one of claims 1 to 15 and / or using an apparatus (9) according to any one of claims 16 to 18, the nonwoven having at least one nonwoven web (2) made of fibers, wherein the fibers are produced using at least one fiber production device, in particular using at least one spinning beam (10), wherein the fibers are subsequently laid on at least one laying device, in particular at least one laying screen belt (11), to form a nonwoven web (2), wherein the nonwoven web (2) or the nonwoven (1) is subsequently consolidated using at least one calender roller (7), and wherein an embossing pattern (3) consisting of a plurality of embossing portions (4) is introduced into the nonwoven (1) by means of at least one calender roller (7), wherein the embossing portions (4) each have a diameter of 0.05 to 0.3 mm. 2 , preferably 0.06 to 0.2 mm 2 , preferably 0.07 to 0.18 mm 2 , particularly preferably 0.08 to 0.15 mm 2 and very particularly preferably from 0.09 to 0.12 mm 2 The stamping surface (5) of the embodiment of the present invention is as follows.

20. The method according to claim 19, wherein the nonwoven (1), preferably after consolidation by means of at least one calender roller (7), is consolidated, in particular mainly consolidated, by means of at least one hot fluid main consolidation device, in particular by means of at least one hot air main consolidation device (8).

21. A method according to any one of claims 19 or 20, wherein the nonwoven (1), after being laid on the laying device, in particular on the laying screen belt (11), is first pre-consolidated with at least one pre-consolidation device, in particular with at least one hot fluid pre-consolidation device, preferably with at least one hot air pre-consolidation device (15), preferably subsequently consolidated with the at least one calender roller (7), and then preferably consolidated, in particular main consolidated, with a hot fluid main consolidation device or a hot air main consolidation device (8).

22. The method according to any one of claims 19 to 21, wherein the surface temperature of the at least one calendering roller (7) is higher than the temperature of the hot fluid of the at least one hot fluid main consolidation device, in particular 1°C to 15°C higher, preferably 1°C to 5°C higher, or lower than the temperature of the hot fluid of the at least one hot fluid main consolidation device, or is the same or substantially the same as the temperature of the hot fluid of the at least one hot fluid main consolidation device.

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