DE102006035361A1 - Shaped article, nonwoven fabric and its manufacture and use - Google Patents

Abstract

The invention relates to a shaped article, a nonwoven fabric and a method for forming a nonwoven fabric (1), wherein the nonwoven fabric (1) comprises a plurality of filaments (5), wherein the filaments (5) in at least a first outer layer (2), preferably a second outer layer (3) and an intermediate layer (4) of the nonwoven fabric (1) are arranged. The nonwoven fabric (1) forms in the intermediate layer (4), preferably in each one of the layers (2, 3, 4) a network of the filaments (5), wherein the individual filaments (5) touch other of the filaments (5) and thereby forming a plurality of contact points (7). The filaments (5) are connected to each other at at least many of the contact points (7) and the network of the intermediate layer (4) has a pressure-stable structure, which counteracts a pressure at least in the z-direction, so that the nonwoven fabric (1) and thus the Article (23) by a stabilization of at least one of the outer layers (2, 3) is rigid. Furthermore, a method for producing a shaped article (23) from a nonwoven fabric (1) having a plurality of filaments (5) is claimed, wherein the nonwoven fabric (1) is inserted as semifinished product into a mold (20), the mold (20 ) and the nonwoven fabric (1) is subjected to a predetermined deformation force at a predetermined temperature, and then the mold (20) is opened to remove the molded article (23). The temperature, ...

Description

The The present invention relates to a molded article comprising a Nonwoven fabric having a plurality of filaments and a Method for producing a shaped article from a nonwoven fabric with a plurality of filaments, wherein the nonwoven fabric as a semi-finished product is inserted in a mold, the mold gas-tight and closed hot Steam under a predetermined pressure for a predetermined time in the mold is introduced, then the steam from the mold dismissed and the mold is opened to remove the molded article. The present invention further relates to a nonwoven fabric a plurality of filaments having at least a first outer layer, preferably a second outer layer and an intermediate layer, wherein each of the filaments in at least two, preferably three of the layers and the nonwoven fabric is a extensive extension in the x and y directions and has a thickness in the z direction and a method of forming such a nonwoven fabric and its Application.

molded Articles made of nonwovens are finding increasing use for industrial applications Applications, especially in the automotive industry, as they are good acoustic and have pleasant haptic properties. In the automotive industry they usually become used for cladding in the engine, passenger or luggage compartment. They usually include lightweight fiber material for noise absorption, but need be stiffened to give sufficient structural strength. additionally These parts should have only a low weight and so on thin like possible be to take up little space and not increase the vehicle weight excessively. Around To achieve optimal properties of the product, the Requirements for noise absorption, dimensional stability and small thickness are matched, although they are each other often contradict.

From the US 6,756,332 B2 the structure for a headliner of a vehicle is known, which is a laminate of at least three individual layers. Between two outer layers, an intermediate layer is arranged, wherein the outer layers for the rigidity of the article and the inner layer for the noise absorption of the article are designed. In each layer is a mixture of different fibers, which are connected by binding fibers. Each of the three layers is independent of each other and therefore can be made with different fibers. The three layers are finally glued together with two adhesive layers to form a stiff and sound absorbing sandwich product. The disadvantage of this product is that it is expensive and therefore expensive to manufacture. In addition, adhesive is needed to make the sandwich structure in each case, which may cause difficulties in recycling the product.

From the US 5,591,289 Also known is a laminate for automotive applications and a method of making the same. The article described here is intended to replace fiberglass roof linings. On both sides of an intermediate layer fibers of an outer layer are applied and needled with the fibers of the intermediate layer. For the production of the article, different fibers and binders are used in the individual layers, whereby again a very complex product is produced here. By combining different layers, the manufacturing process becomes time-consuming and thus expensive. Also, the durability of the product, especially at high mechanical and thermal stresses, severely limited, since the individual layers can separate again. Likewise, there is also a problem with this product in recycling, since a variety of materials are used for the production of the article.

Instead of the connection of individual short fibers is in the WO 2004/088025 Among other things, the use of filaments proposed. In order to realize the various conflicting requirements of noise absorption and stiffness in the article, coarse fibers in a layer of the product are fused with fine fibers in the outer layer of the product. The resulting product already has many advantages, as it can be made recyclable and noise reduction and in particular noise reduction for technical products already well realized. However, it is also disadvantageous in this product that the production process is very cost-intensive, since different fibers have to be produced and connected to one another.

From the AT 207674 For example, a textile nonwoven fabric is known which has a top and bottom and a central zone. On the upper and lower sides, the fibers are confused, while in the middle zone of the web they are predominantly approximately perpendicular to the surfaces of the nonwoven fabric. The production of this textile nonwoven fabric is carried out with rotating screening drums, which loose fiber material is supplied. The fiber material fed to the screen rolls together with an air stream is separated from the air stream on the screen rolls and pressed together to form a nonwoven and subsequently solidified. To solidify the nonwoven binder are applied or applied after the web formation. This is done z. B. by spraying the web with powdered or liquid binders or by dipping. The provided with the binder fleece is finally solidified in a drying chamber or in a hot press after the production of the actual nonwoven fabric to the textile nonwoven fabric.

adversely in this nonwoven fabric and its manufacture, it is that the nonwoven fabric produced by short staple fibers. The fibers of the fleece in The middle zone is approximate perpendicular to the surfaces of the textile nonwoven fabric, but bring in the nonwoven fabric due to their loose arrangement in the middle position no essential Strength in the nonwoven fabric. Also, the strength is due to the Shortness of Fibers and their consequent involvement in the nonwoven strongly limited.

From the DE 100 84 561 T1 is also a nonwoven fabric and its production is known. There are described therein various types of fibers or filaments, such as spun-fleece fibers (spunlaying process), meltblown (meltblown), homofibers, bicomponent fibers, biconstituent fibers and various bonding processes for producing connection points of the filaments in the nonwoven, which also in can be used in the present invention. The Indian DE 100 84 561 T1 described nonwoven fabric has two parallel surfaces in which are continuous fibers that are bent out of this particular plane to form loops and then to be integrated into the other surface. The loops form according to the description of this document U-shaped waves with open channels between the waves. These open channels are intended to create a liquid absorbency which serves to apply the personal care absorbent article nonwoven fabric described therein. Due to this application, it is obvious that a particular rigidity of the product is not desired. It is trying to create a pliable fleece through the fiber loops and the open channels. Only for fixing the two surfaces, if necessary, a post-treatment of the nonwoven fabric is provided, which is to be achieved for example by Heißluftbonding after the formation of the nonwoven fabric or by admixture of binder. With such a nonwoven fabric is achieved, inter alia, by the open waves in the central region of the nonwoven fabric and the short integration of the fibers in the two parallel surfaces only a low tensile and compressive strength of the nonwoven fabric. For personal care absorbent articles this may be sufficient, but not for construction articles where high strength is required.

In the WO 2005/054558 A2 there is also described a nonwoven web having two parallel surface layers bonded to filaments which extend from one surface to the other surface of the nonwoven and are oriented in this intermediate layer substantially perpendicular to the surface layers. By a certain distribution of the filaments in the surface layers and the intermediate layer, a stiffness of the nonwoven fabric is achieved. Although such a nonwoven fabric is already more stable than the aforementioned nonwoven fabrics, a high rigidity, so that the material could be used as a construction material, but this is only possible in exceptional cases.

task Therefore, it is the above-mentioned disadvantages of the present invention to avoid and an article and a manufacturing process for one To create articles which is inexpensive and yet features like noise absorption and Has rigidity which makes it suitable as a technical component, especially in the automotive industry, to find use, as well To provide a nonwoven fabric, which has a high intrinsic stability and thus as a semi-finished product for the use of stable technical applications find use can.

The Task is solved with an article and a manufacturing process and a nonwoven fabric and a method according to the independent claims.

Of the molded according to the invention Article has a nonwoven fabric with a variety of filaments on. The filaments are in at least a first outer layer, preferably also in a second outer layer, as well as in an intermediate layer of the nonwoven fabric arranged. The nonwoven fabric forms at least in the Intermediate layer, preferably also in one or both outer layers, a network of filaments, with the individual filaments other touch the filaments and doing a variety of points of contact form. The filaments are interconnected at many of the points of contact, so that the network of the intermediate layer a pressure-stable structure which counteracts a pressure at least in the z-direction, so that the nonwoven fabric and thus the article by stabilizing at least one of the outer layers is rigid. The shaped article according to the invention becomes particularly special stiff, since the filaments are in the form of a network or a Support each other's matrix and so that also the area stabilize extending shaped article substantially orthogonal in its z-direction. The connected contact points become common also called bonding sites. Among other things, they are essential for education of the networks and the through these networks in the semi-finished and properties introduced into the final article.

In particular, the liner of the molded The article may have different thicknesses and thus be adapted according to the requirements of the shape of the article. The article is made of a homogeneous material since the same filaments are used both in the outer layers and in the intermediate layer. By a variation of the network, in particular in the intermediate layer, different properties can be introduced into the molded article. Thus, the design of the network, for example, with different thickness, density or filament cross sections to influence the different requirements of the product. The article can thus be adapted to the specific requirements, without a material mix would be required. This results in significant advantages, both in terms of production, since the article is not composed of different layers separately prepared, but is homogeneous with respect to its material. In addition, there are significant advantages in terms of. The recycling of the article, since only one uniform material can be used. Due to the fact that the filaments pass through all the layers of the article, a special connection of the individual layers is not required. The product properties are influenced by the design of the networks and the filaments used. The filaments in the individual layers are, however, identical in each case, ie the filaments used differ only within the scope of their production inaccuracies.

The Properties of the article according to the invention are at least partially already through the semifinished product, i. by the nonwoven in itself, intended. The resulting Features and benefits are detailed described in connection with the nonwoven fabric and its preparation. It should not be discussed separately at this point. Yet apply the advantages of the corresponding characteristics of the nonwoven fabric also for the article itself.

During the Nonwoven fabric as a semi-finished product largely homogeneous along its planar Extension is formed in the x-y direction, has the nonwoven fabric in the article advantageously areas of different characteristics regarding airflow resistance, Porosity, Poisson Number, Modulus of elasticity, thickness, Density, strength and thus matched acoustic properties on. It can thus be created an article, which accordingly the individual requirements receives individual areas. These Areas are formed by the deformation of the nonwoven fabric into the mold of the final article. It can thus be created an article which areas higher Strength, for example, to attach the article to others Components, or to better withstand a wind of the vehicle and other areas with better sound insulation and / or sound absorption. About that In addition, the Properties even by the arrangement of appropriate functional layers on the outer layers of the nonwoven fabric become.

influence On the properties of the article can advantageously thereby done that in the article areas of different density of Connections of the contact points and / or thickness of the respective layers are present. The density of Connections of the contact points corresponds to the number of connection points per room element. Both changes influence the strength and the acoustic properties of the article and can be customized. The density of the compounds becomes, for example changed by that the compounds present in the semifinished product are dissolved and in more or less big Number, size or Form be recreated again. The thickness of the article is thereby varied that the semi-finished product is more or less compressed and the connections be fixed in this compressed position.

Especially It is advantageous if the thickness of the article substantially through a change in the Thickness of the intermediate layer changeable is. The intermediate layer of the nonwoven fabric is characterized by the position of the filaments, which have a clearer z-component here than in the outer layers, rather the possibility on top of that they favor by reducing this z component the x or y component of the orientation of the filaments is a smaller one Thickness of the article causes.

advantageously, the thickness of the article is between 2 and 30 mm, preferably between 2 and 15 mm. Is the nonwoven fabric from which the article is made is, especially compressed, it results, for example a thickness of 2 mm. In this area, the article is particularly suitable good for an attachment to other components, since here the strength of the Article is particularly high. In areas where more acoustic Characteristics of the article are required are thicker areas, in particular until to 30 mm, particularly advantageous because this creates pores, in which the sound can be absorbed very well. Even if starting Substantially, the nonwoven fabric is reduced in thickness However, there is also an increase in the thickness of the article compared to the nonwoven fabric of the semifinished product possible by the filaments pulled apart and fixed in this position.

In particular, for applications in the automotive sector, it is advantageous if the article has a basis weight between 500 and 2,500 g / m ² , preferably 500-1800 g / m ² . With such a basis weight is a good compromise between the properties in terms of strength and the akus to find performance without the article becoming overly difficult. Of course, the basis weight may be increased beyond this specified level if correspondingly heavy materials are additionally applied to the nonwoven fabric.

Especially It is advantageous if the density of the connections of the contact points lower in the intermediate layer in the nonwoven fabric of the starting material as in the outer layers is. For the article of the final product can these connections of the contact points at least in a single area except for the density of the outer layers elevated be. This means that the article in this area largely Completely is compressed. A distinction of the individual external situations and the liner will be in this highly compressed state of the final product be very difficult to detect. The ex Liner can disappear completely in such an area or at best as a thin one approaching similar Line be visible. A highly compressed area of the article can be singular or multiple, in the same or different Extensions may be present in the article, but it can also be the complete articles, depending on the required properties of the article, be compressed like that.

Of the inventive article is suitable due to its dimensional stability and acoustic properties especially for Applications in the automotive industry. The article is not on such Applications limited. For example, an application in other areas, in which, for example, sound absorption and / or sound insulation required is, make sense. Especially if an effective sound absorption on a small space or with a relatively low basis weight is required, the article of the invention is advantageously used. So can also buildings, Ships or aircraft very advantageously equipped with this material become.

Especially Advantageous application finds the article in the automotive industry as a headliner, Engine encapsulation, heat shield, underbody, wheel arch, engine compartment, interior or trunk lining. In all these areas is a certain Structural strength required by the material, without requiring a large thickness or a heavy weight is allowed.

Especially compared to articles of the prior art with, for example same dimensions, such as the thickness and / or the same basis weight the article according to the invention has better acoustic and / or mechanical properties. There can be measuring methods for this be used, as described for example in DIN 53455, DIN EN63, DIN 53453, DIN 52215, DIN 29053, DIN EN ISO 10534-1, EN 20527-1 / 2, DIN EN ISO 157 or ASTM C-384. Also the so-called Alpha cabin and the ISOKELL according to the worldwide Recognized Rieter standard can be used to determine comparative values be used. By an appropriate design of the nonwoven fabric as starting material and reshaping of the article can appropriate desired Properties are achieved.

advantageously, are the acoustic properties of the article about thickness, density, modulus, Poisson's number, porosity and / or airflow resistance, the filaments, the nonwoven fabric and / or the networks of the individual Determined locations. The filaments can different cross sections or different materials which cause different acoustic properties by they influence the absorption or reflection of the sound.

Of the inventive article advantageously has different insulation, absorption and / or Reflection properties in the individual layers. While in a denser outer layer rather an insulation of the sound will be the looser liner and the second, in this case then defined porous outer layer rather for absorption used for the sound. By a design of the individual layers depending on the individual task of the article or individual areas within the article can these different insulation, Absorption and / or reflection properties are influenced.

The Dämmungs-, Absorption and reflection properties of the individual layers, starting from the nonwoven used, and according to the requirements of Articles are in the making of the article by change the networks of the individual layers influenced. It will be here the joints as well as the location of the filaments in comparison newly fixed to the nonwoven fabric used and thereby produce modified Dämmungs-, Absorption and reflection properties.

The mechanical properties of the article according to the invention are determined by modulus of elasticity, area moment of inertia, tensile strength, flexural strength, impact strength of the filaments and / or the networks of the layers. All of these parameters can be influenced in the article according to the invention by the corresponding design of the nonwoven fabric and the deformation of the nonwoven fabric in the final article. They may be varied completely or partially in the article depending on the requirements in the article. The nonwoven fabric already contains the basic properties of the end article, which are used in the manufacture of the end article then be brought to the required size.

The Networks of the individual layers in the article cause an inherent stability of the article, so that a particularly required in the automotive industry low sagging of the article, often sagging called, even at higher Temperatures, for example, obtained at temperatures between 80 ° C and 100 ° C. becomes. Furthermore, the behavior of the article by choice the polymers are influenced.

in the Compared to articles of the prior art, for example with the same thickness and / or the same basis weight, the article of the invention a higher one Drawability on. In particular, when the nonwoven fabric in the outer layers long areas of Filaments, e.g. Loops, these can be when heating against each other warped and refastened. Forgiven by the opposite, which in the one outer layer stronger than in the other outer layer The article can be given a shape which is far from the original Position of the semi-finished product deviates and thus, for example, cup-shaped bulges receives which is suitable for fastening the article to a substructure or geometric specifications of other components for better use of space can follow.

are in the article stiffening areas, in particular beads, ribs or eyes, arranged, so the article can be attached particularly well, i.e. be screwed on. Furthermore becomes the intrinsic stability of the article, by the ribs are formed accordingly. It's through the eyes allows to set the distance of the article from a substructure. This Distance may be important for the acoustic properties of the article when installed to have.

advantageously, are at least individual areas of the article, in particular the Solidification areas of the article more compressed than areas with better acoustic properties. By the stronger compression a defined attachment of the article is made possible. There are fewer free spaces between the individual fibers or filaments for example, when screwing the article to a substructure changed indefinitely would become. Compressed areas can also specifically used as areas with better insulation properties become. In areas with better absorbent properties is a bulkier Material advantageous to reduce the sound level better.

Of the Article can be more or less compressed to the required meet requirements to be able to. It changes in particular the orientation of the filaments in the intermediate layer. It may happen that in heavily compressed areas of the Article the filaments in the intermediate layer similar to the filaments in the outer layers a pronounced Having orientation in the x-y direction of the nonwoven fabric. In the Normally, however, the different layers are more accurate Analysis still recognizable. It is possible that in the liner For example, the orientation of the filaments is preferably in the y-direction, while the Filaments in the outer layers preferably aligned in the x direction are.

at the method according to the invention for producing a molded article from a nonwoven fabric with a variety of filaments, the nonwoven fabric as a semi-finished in a mold inserted, the mold closed, and the nonwoven under a predetermined temperature of a predetermined deformation force or a predetermined deformation pressure is exposed. Subsequently, will opened the mold for removal of the molded article. The filaments of the nonwoven fabric are in at least a first outer layer, preferably in one second outer layer and arranged in an intermediate layer of the nonwoven fabric. The nonwoven fabric forms in the intermediate position, preferably in each one of the Layers, a network of filaments, with individual filaments touch others of the filaments and doing a variety of points of contact form. The filaments are interconnected at many of the points of contact. The network of the intermediate layer has a pressure-stable structure, which counteracts a pressure at least in the z-direction, so that the nonwoven fabric by stabilizing at least one of the outer layers is rigid.

As a result of the influence of the temperature and the deformation force or the deformation pressure at the contact points, compounds are reshaped and the nonwoven fabric is fixed in the form predetermined by the shape. With the aid of a predefined semifinished product in the form of a nonwoven fabric with an intermediate layer and one or two outer layers, the method according to the invention creates a shaped article with particularly high stability and design freedom. The semifinished product assumes the shape given by the shape. The resulting article is fixed in this form by the connection points of the semifinished product are more or less solved by the temperature and acting on the joints deformation pressures and the deformation forces and fixed again in the new form after cooling. Due to the temperature and the deformation pressures acting on the connection points or deformation forces, the joints are soft or completely dissolved. By forming the semi-finished produce new or different contact points, which after cooling the Ar cure again and thus keep the article in the new form. Depending on how much the semifinished product is compressed in the mold, starting from the nonwoven fabric, a more or less thick product with different properties is produced. While at the more compressed locations, for example, it is suitable to be bolted to a substructure, the product may be designed at the less compressed locations to include particularly good mechanical or acoustic properties. It is thus an article to produce, which produces starting from a simple and uniform semi-finished product with different properties in different areas of the product. Even in the areas which are essentially responsible for acoustic concerns, the network-like structure of the intermediate layer provides a very high stability, which opens up a multitude of new uses for the article.

Especially It is advantageous if in the manufacturing process, a nonwoven fabric with bicomponent filaments or biconstituent filaments, in particular from thermoplastic material combinations, for example PET, PBT, PP, PE or PA as a structural component and CoPET, CoPBT, PP or PE used as an adhesive component of the filaments becomes. The structural component and the adhesive component preferably have different melting temperatures and can be targeted by the setting of a certain steam temperature are softened. So Is it possible, that the PET used, for example, is still relatively strong, while the corresponding co-PET already begins to melt. Are the contact points connected to the Co-PET, so can they are dissolved at the corresponding melting temperature of the Co-PET and be moved to a new position. After cooling under the melting temperature, the co-PET solidifies again and fixed the point of contact in her new position. The new connection of the contact points may be a different size, strength and / or have a different angle of the interconnected filaments. Also, it is possible the Number of connections of the contact points to enlarge or to shrink, depending on the requirements of the final product.

advantageously, the temperature and / or the deformation pressure or the deformation force acts less than 60 s on the nonwoven fabric. This ensures a fast Deforming the nonwoven fabric and thereby a cost-effective Manufacturing process.

To the Melting at least one of the polymers of the filament it is advantageous when the applied temperature is in the range of the melting temperature comprising this polymer. At least the temperature should be below the melting temperature of the second polymer of the filament to the fundamental Maintain structure of the nonwoven fabric. Of course it is it also possible instead of filaments with different materials too To use monofilament, which is connected with fusible adhesives is. The temperature is then adjusted so that the glue and does not melt the monofilament.

advantageously, the temperature is introduced by that hot steam is introduced into the mold after it has been closed and is released from this before it is opened. The required Temperature is thereby produced quickly and inexpensively.

Becomes the mold is sealed gas-tight, so is a uniform heating of the semi-finished product and the steam can be in the mold at least temporarily while held uniformly the forming process become.

Around To achieve a particularly fast production of the article is the mold immediately after the release of the steam from the mold opened and the article immediately after opening the mold from the mold taken.

By the compression of the semifinished product is in particular the network of Liner compressed. This originally compared to the backsheet looser network is more or less compressed by the shape and thus determines the outer contour of the article, while still stabilizing the outer layers and thus leads to an overall stable article.

Around especially quickly melt one of the components of the semifinished product to be able to It is advantageous if the mold before inserting the nonwoven fabric is preheated in the mold. This results in a faster heat transfer effected in the nonwoven fabric, whereby the forming process is carried out even faster. additional Materials can before the forming process and / or after the forming process or by additional subsequent Process steps are applied. You can as well on the still Semi-finished nonwoven fabric can be applied as well as during the forming process. The nonwoven fabric can be used inside the mold or before inserting in the mold is brought to the required forming temperature.

The following descriptions of the nonwoven fabric according to the invention and its advantages, as well as the advantageous embodiments of the nonwoven fabric, can also be applied to the finished end product produced with this nonwoven fabric. The out molded articles made of the nonwoven largely still have the advantages of the semifinished product. It is therefore quite advantageous to introduce at least some of the product properties required later in the finished article during the production of the semi-finished product. In the manufacture of the article, these properties can then be further modified, for example reinforced or attenuated.

Of the Nonwoven fabric according to the invention consists of a multitude of filaments with a first outer layer, a second outer layer and an intermediate layer, wherein each of the filaments in at least two, preferably all three of the layers and the nonwoven fabric a plane Extension in the x and y direction and a thickness in the z direction having. Forms according to the invention the nonwoven fabric in the intermediate layer, preferably in each individual the layers form a network of filaments, with the individual filaments touch others of the filaments and doing a variety of points of contact form. The filaments are interconnected at many of the points of contact. The network of the intermediate layer has a pressure-stable structure at least in the z direction. The structure is designed such that it at least counteracts a pressure in the z direction, so that the nonwoven fabric by stabilizing at least one of the outer layers is rigid. The outer layer is so stable that they are bent only with comparatively large forces or even be kinked. It is through the structure of the liner especially stabilized against kinking. This will be a nonwoven fabric obtained, even at larger Abstützabständen than is inherently stable in comparable nonwovens of the prior art and less flexes or even buckles.

By the different layers of the nonwoven, which through the filaments are already connected to each other, already a certain basic strength produced of the nonwoven fabric. A separation of the individual layers becomes by the extension of the filaments into the individual layers and avoided by the thus created connection of the three layers. To increase this strength is now still provided that the filaments in the individual layers point or line touch and at many of these points of contact connected to each other. This will create a stable network, one can also call it a matrix, formed, in which very short filament sections between the individual contact points arise. Characterized in that the filament sections thus mutually on relatively short lengths will support a stable network, in the manner of a space framework obtained, which overall results in a stable nonwoven fabric. The nonwoven fabric works through the stable network, in particular the intermediate layer of a deformation contrary to a given condition, as the individual free Filament sections are very short and the filaments in the individual Layers support each other. The bending required for a deformation of the nonwoven fabric the individual filament sections is thus only under greater effort and bending a plurality of filament sections possible. The Matrix of the intermediate layer has a pressure-stable structure at least in the z direction and supports so that the two outer layers. These outer layers are held in position by the stable intermediate layer and result in a sturdy nonwoven fabric as a whole because it prevents them will buckle at a corresponding load. It will to obtain a nonwoven which is particularly good for technical Applications is suitable because it already has a great inherent stability. The nonwoven fabric can therefore also over larger areas be used self-supporting.

advantageously, is the nonwoven fabric according to the invention a semi-finished, which is weiterverarbeitbar to a final product. By a targeted shaping of the nonwoven fabric, for example, by edges or crimping the load capacity of the nonwoven further increased become. It can also additional Connections at the points of contact be created. The many connected contact points of the semi-finished product serve as a good starting point for the stability of the end product. The Further processing of the semifinished product can also take place in that the nonwoven fabric is pressed in some places and joints in this state in new form and / or other number permanent be created. The end product thus has different thicknesses and strengths on. The nonwoven fabric can be used in a variety of ways and gives a stable product, which, among other things, heat or sound insulating properties having. The surfaces The end product can thus also be produced with high strength become.

advantageously, have the networks of the outside layers at least in the x / y direction a tensile and pressure stable structure. This structure supports the possibility a semi-finished product and later to produce a final product that has high intrinsic stability and over size surfaces self-supporting can be used. Be the outer layers tensile and pressure stable "tailored", so they produce together with the pressure stable intermediate layer a very stable fleece.

A great advantage of the present invention is that the networks of the individual layers can be formed depending on the requirements of the semifinished product or of the end product. They can also be formed largely independently of each other, so that created a semi-finished product which optimally meets the individual requirements of the finished product.

Act the individual networks of a deformation of the nonwoven fabric from the given condition contrary, so they are designed such that the individual matrices depending on the expected force just To be able to withstand this expected force, a product is created that optimum material strength with minimal use of material.

Of the Nonwoven receives already by an increased stability and strength that the Filaments in the intermediate layer to each other to a network or connected to a matrix. This strength can be increased again if the filaments are also in one or each of the outer layers connected to a network. Thus support themselves the filaments mutually ingesting on the nonwoven fabric acting forces. This will be the case for most nonwovens of the invention. But it is also possible that one or both outside situation (s) already treated, processed or manufactured in the nonwoven fabric are that they cover the network of the liner like a film.

advantageously, the nonwoven fabric extends flat. This is the ideal shape when the nonwoven fabric as a semi-finished for the further technical application should be used. The area can just or simply bent one or more times. It already can in the production of the nonwoven fabric a certain basic shape in the Cross section of the nonwoven web are introduced. From the flat semi-finished product the nonwoven fabric according to the invention results in a variety of applications and processing options, as they are known in technical applications. Of course, the use concludes Non-technical applications of nonwoven fabric, if the corresponding rigid material properties of the nonwoven fabric for these other applications do not bother or even helpful.

All it is particularly advantageous if the nonwoven fabric is formed in this way is that the filaments in the outer layers substantially in x and y direction of the nonwoven fabric are oriented. The filaments in the intermediate position, in comparison to the filaments in the outer layers a stronger one pronounced orientation in the z-direction of the nonwoven fabric. Through the interaction of along- and transverse oriented filaments in the individual matrices becomes a already stable basic structure of the nonwoven obtained, which by the compound of the invention the filaments at their points of contact a particularly stable formation of the nonwoven fabric causes. By aligning the filaments in the matrix of the outer layers becomes a stability of the nonwoven fabric in the x and / or y direction. The more in z-direction aligned filaments of the matrix of the intermediate layer take care of a stability of the nonwoven fabric orthogonal, ie in the z direction to the surface of the Nonwoven. Furthermore Hold the Matrix of the liner the matrices of the outer layers in the form. The nonwoven fabric is thus very stable compared Tensile, compressive and / or shear forces, which act on the nonwoven fabric from different directions. By the connection of the filaments at their points of contact is beyond causes a shifting of the individual filaments against each other Cause of shear, which act on the nonwoven fabric is made difficult, so that thereby a particularly high stability of the nonwoven fabric is achieved. The orientations of the filaments in the outer layers and Of course, the interlayer gradually merge, so that the orientation in the z-direction of the filaments in the intermediate layer most pronounced in the middle of the liner will appear.

If the filaments in the outer layers in x direction at least 3 times the thickness of the nonwoven fabric, preferably a multiple of this, for example, 10 or 20 times the thickness of the Nonwoven extend, so is particularly advantageous Way causes a high strength of the nonwoven produced becomes. The filaments form in the networks of the outer layers Loops, their lengths have the stated minimum values. This creates connected contact points the filaments in the network, which is a particularly good cohesion create the filaments. Also formed from such a nonwoven fabric Article has a big one Strength and deformability due to the filaments in the outer layers even with a deformation of the nonwoven fabric, for example, during deep drawing of the nonwoven fabric still stick together well and overlap exhibit. In strong in the z direction deformed areas of the article may be the extension of the filaments in the outer layers due to the high distortion also less than 3 times the thickness of the Be nonwoven fabric.

advantageously, support filament sections of a layer of filament sections of a adjacent location. Will they also be at such points of contact connected to each other is a shift of the two outer layers effective against each other. The individual layers adhere thus firmly together, creating a very resistant nonwoven fabric is obtained. Due to the better cohesion of the individual layers This way not only avoids the two outer layers but can be pulled apart also the overall stability of the nonwoven fabric is increased.

Around personnel from all directions, the network is three-dimensional educated. The individual filament sections are thereby supported by all Directions and cause a uniform resistance of the nonwoven fabric or the article made from it.

The individual filament sections resist deformation of the nonwoven fabric due to the reinforcement by the associated with them other filament sections in all directions. The nonwoven will thus resistant to compressive and tensile loads and receives a size Inherent stability.

Especially is with the nonwoven fabric according to the invention ensures that filament sections of a deflection due the reinforcement oppose through the other filament sections connected to them. The filament sections are usually supported short, so that particularly kink-resistant bars be achieved in the form of filament sections. Also because of that not just punctual connections, but also linear Connections of the filament sections arise at their points of contact are reinforcements the individual filament sections with respect to their total cross section receive. This also serves the resistance to deformation or Deflection of the entire nonwoven fabric and the article.

advantageously, the nonwoven fabric is formed such that the network of a local Linear expansion at least one outer layer, which at the deflection of the nonwoven fabric from the vorgebebenen Condition would have to occur counteracts. The one or both outer layers thus act as stiffening Element of the nonwoven fabric. The area moment of inertia is due to the structure of the invention across from a conventional nonwoven fabric elevated. The article produced therefrom thus has a high intrinsic stability and will be great too Abutment distances and no or few reinforcements meet the permissible for example in the automotive industry and given sag.

Especially It is advantageous if the network is designed such that it is a tensile force and / or a shearing force and thus a local longitudinal expansion counteracts in any direction. It will be a tear resistant Nonwoven produced, which over it out only under relatively large Force is deformable. In particular, it causes the Nonwoven fabric at least its own weight over a larger area without significant Bending or deformation contributes. This is due to the one hand loose structure in particular the Intermediate layer and the low basis weight achievable thereby obtained with simultaneous inner stiffening of the nonwoven fabric. The nonwoven fabric is thereby also stable against a compressive force, which to a big one Part is taken up by the networked intermediate layer.

Around to increase the absorption of a compressive force, it is advantageous if in the intermediate position and / or in at least one outer layer, but depending on the compressive strength in the intermediate layer, the ratio of Length too Diameter of a plurality of filament sections is selected such that the individual filament sections in the sense of a stable buckling bar also relatively large compressive forces be able to record, without them buckling.

Preferably is the network of liner regarding its ability the pressure absorption substantially uniform, so that no Partial weak points of the nonwoven fabric arise at which the Nonwoven fabric could collapse. In particular, it is advantageous if no linearly extending There are weak points, which are a kinking along this Enable vulnerabilities would.

For some Applications of the final product, it is advantageous if the nonwoven fabric in the x-z or y-z cross section, in particular with respect to the two outer layers is formed asymmetrically. Thus, on the respective outer layer acting different tensile and compressive forces are absorbed. ever After installation of the end article can thus under the lowest possible Weight and minimal material use created a nonwoven fabric which can be optimally adapted to the requirements. Thus, depending on the load direction, the matrix or the network an outer layer For example, much thicker than the other outer layer be created, which is due to the different intake of Tensile and compressive forces Consideration can be taken. For example, the matrix of the outer layer, which is more loaded on pressure, made thicker than the matrix of the tensioned outer layer. By the lesser Material use is also reduced its own weight, what more Advantages in terms of carrying capacity and the weight when installed in the technical object causes.

Around the carrying capacity to use the nonwoven optimally, can be advantageously provided be that the density of the nonwoven fabric in the matrices or the Networking the outside layers higher than in the matrix or the network of the intermediate layer. Especially if the nonwoven fabric is to be subjected to deflection, is this is advantageous because it increases the area moment of inertia of the nonwoven fabric, if more material in the outer layers of the Nonwoven fabric is arranged. The intermediate layer then serves as a stable Spacer for the two outer layers.

advantageously, For example, the filaments of the nonwoven web are bicomponent filaments or biconstituent filaments. They are made of different materials that are different Properties, for example, have different melting temperatures. In one execution such filaments is the only melting at a higher temperature Core of the filament of a melting at a lower temperature Coat surrounded. This may be effected by probing the nonwoven fabric be that the points of contact permanently connect and power transmission Serve by the outer component of the Bicomponent filament melted briefly and then again is solidified. Of course the invention is not limited to such bicomponent filaments or limited to biconstituent filaments. Such are, for example It is also possible to use monocomponent filaments which form the compound themselves melted or bonded with adhesives. The adhesives can dissolved for further processing of the nonwoven fabric according to the invention and again be fixed or it will be for the finishing adhesives added to the nonwoven fabric in stabilize its new shape. Also are different cross sections the filaments possible, to different properties, such as stability or thermal or acoustic insulation of the Nonwoven fabric to produce.

Preferably the filaments are spunbond fibers or meltblown fibers. The Production of the nonwoven fabric is very fast with these known fibers and cost-effective possible.

are the filaments of thermoplastic material combinations, for example PET, PBT, PP, PE or PA as a structural component and CoPET, CoPBT, PP or PE produced as an adhesive component of the filaments (5), and they have different melting temperatures, so can Fusion of the filaments are particularly targeted. By a more or less high temperature in the range of the component with the lower melting temperature, the type and amount of Affected joints without reducing the strength of the other component. The lower melting component serves as an adhesive, so to speak for the Compound of higher melting Component. By relationship of materials of components is a good recyclability nevertheless available.

Point the filaments used depending on the requirement profile of a to be manufactured article and the manufacturing process a thickness with a value of less than 40 microns or 20 dtex, preferably between 7 and 38 μm or 0.5 and 15 dtex, they are on the one hand well processable and on the other hand give a particularly stable and sound-absorbing Product. The filaments all have the same thickness in the nonwoven fabric on. Different filaments are not used, even though Naturally other filaments additionally applied in particular embodiments can be. The choice of the filament diameter used may be dependent of the required mechanical and acoustic properties of the Article to be made from the nonwoven fabric.

Around a particularly strong fleece with low basis weight it is advantageous if in a spatial element of the intermediate layer the number of points of contact, which are interconnected, less than in the outer layers. This creates more stable outer layers which are on these outer layers acting forces, which are aligned in particular in the x-y direction, counteract. If, however, a nonwoven fabric is expected, which is particularly pressure-resistant is, so will be tried in a space element of the liner to increase the number of interconnected points of contact, and their number may be equal to or greater than in the outer layers create.

Around to influence the features of the article, for example to the stability of the nonwoven further increase or the appearance of the nonwoven fabric to required conditions of Endartikels adapt, it is advantageous if at least one the two outer layers with other materials, such as fibers, nonwovens, textiles, Leather, paper or foils is occupied. The connection can be, for example by gluing, bonding, laminating or laminating done. hereby can create a visually appealing visible side of the nonwoven fabric become. Also can Properties of the nonwoven fabric such as sound or odor absorption, haptics, Water repellency or similar to be obtained. Often But it is not necessary the surface of the article with additional To prove materials, since the surface quality of the nonwoven fabric according to the invention and the article produced therefrom is already sufficient by the orientation of the outer layers, the entanglement of the filaments and the good bonding achieved a very good surface finish becomes.

In particular, for reasons of cost-effective recycling of the nonwoven fabric, it is particularly advantageous if the nonwoven fabric and / or the material with which the nonwoven fabric is coated is made of a uniform material. The connection of the individual filament sections at the contact points is thereby created not with foreign materials, but advantageously by the filament material itself or by materials which are at least related to the material of the filament are. Thus, in the case of a bicomponent filament, a polyester may be used as the core and a co-polyester may be used as the sheath.

is the nonwoven fabric and / or the material with which the nonwoven fabric occupies is, for example, with additives for improving the product properties Flammability, abrasion resistance, media resistance, eg. B. regarding oil or water or acoustics provided, so can the produced from the nonwoven fabric Items are applied very individually. As additives can to For example, colorants or flame retardants may be added which are particular Permit purposes of the nonwoven fabric. The fire resistance of the Article may, for example, according to FMVSS 302 are detected.

advantageously, are the connections of the contact points for the Further processing of the nonwoven fabric solvable and then in same or changed Number, size, strength and / or angle of the interconnected filaments recoverable. The connections can while in the semis in numbers low be alone to ensure the basic strength of the nonwoven fabric. In the processed end product can then the number of connections elevated become a higher one To produce strength of the nonwoven fabric. The release of the compounds, for example done by steam. In the course of further processing can also the size of the joint changed become. From one or two smaller joints can one larger connection point be generated. Also, the crossing angle of two filaments during the Further processing changed Become by putting the connection under stress and in the new position is fixed again.

advantageously, the thickness of the nonwoven fabric has a value between 5 and 40 mm, preferably between 8 and 30 mm. Making it a nonwoven fabric, the diverse can be further processed.

If the nonwoven fabric has a surface weight of between 400 and 2500 g / m ² , preferably 400-1800 g / m ² , then it can be used particularly well in vehicle construction, in which low weights are required.

at a method according to the invention for forming a nonwoven fabric with at least one, advantageously two outer layers and an intermediate layer in which the filaments are in at least two, preferably three of the layers are, the filament is on filed a storage field. The liner of the nonwoven fabric is by depositing parts of the filaments in a central region of the Filing field and outer layers of the nonwoven fabric by depositing other parts of the filaments formed in respective side areas of the storage field. The way deposited filaments are withdrawn through the central area, wherein the deposited in the side portions of the filaments with respect to the in the central area deposited parts of the filaments are folded, so that in the or the outer layer / n located portions of the filaments substantially in the x-y direction of the nonwoven fabric and the parts in the intermediate layer the filaments compared to the filaments in the outer layers a stronger one pronounced Have orientation in the z-direction of the nonwoven fabric. In the liner, preferably in each of the individual layers, a network is created formed the filaments, wherein the individual filaments other of the Touch filaments and doing a variety of points of contact form. The filaments are joined together at many of the points of contact and thereby form the network of filaments, wherein at least the network of the intermediate layer at least a pressure-stable structure in the z direction. The network of the liner is formed so that it has a structure which at least in the z-direction one Counteracts pressure so that the nonwoven fabric by stabilizing at least one of the outer layers rigid and stabilized against kinking. The nonwoven receives thereby a greater inherent stability with respect to his Deflection and its tendency to buckle than comparable nonwovens The prior art is the case. Comparable nonwovens For example, nonwovens with the same basis weight, the same thickness or the same filaments.

Of the Nonwoven fabric is formed by peeling from the storage field, wherein the deposited in the side areas of the filaments opposite to the Central area deposited parts of the filaments are folded. This causes the parts located in the outer layers the filaments in the z-direction substantially parallel to each other and for the big one Part substantially orthogonal to those in the intermediate layers Filament sections stand. The further the parts of the filaments, the later be folded away from the central area, the longer it gets in the x-direction the longitudinal extent the parts of the filaments which are arranged in the outer layers.

Of the Nonwoven fabric can be made of a uniform material and thereby ideally recycled. Also is through the ensures appropriate production, that the touching ones Filament sections at many points of contact connect. Only through this very frequent connection, creating knots by crossing filaments and reinforcing sections by parallel stacking or structures which are reminiscent of a ladder, a very inherently stable fleece is produced.

The individual filaments can Endlosfilamente be or from essentially continuous pieces exist, which is a length of, for example, more than 15 cm or more than one meter or a length which passes through the entire nonwoven fabric produced. Important Anyway, the filaments are not just in one of the three Layers but from one layer at least to the neighboring, better even in all three layers rich and thus a certain basic stability of the nonwoven fabric produce. By the above In addition, crosslinking eventually becomes the strength of the nonwoven fabric generated. The formation of the network of each layer of the nonwoven fabric by targeted storage of the parts of the filaments in the individual layers causes, together with the connection of many points of contact of the filaments a targeted and predeterminable strength of the nonwoven fabric. Of the Nonwoven fabric can thus be tailored to the respective requirement of the final product.

Of the The nonwoven fabric produced in this way can subsequently be cut to size and its intended use supplied become. In addition to the cut is also possible that the nonwoven fabric is subjected to a further shaping and thus on the special requirements of the final product, for which the nonwoven fabric according to the invention is used as a semi-finished product is received.

Especially It is advantageous if the filaments oscillate on the storage field be filed. As a result, the parts of the filaments on the side areas and the central area of the storage field reciprocally distributed. The filaments are thus fed to the storage field and form so successively the material supply for the outer layers and the intermediate layer later Nonwoven. To the flat extending nonwoven fabric are a variety of filaments side by side in the manner of a curtain supplied to the storage field. The area, up which impinge the filaments on the storage field corresponds essentially one oval each, which can overlap. This will also be a Networking adjacent filaments generated, resulting in another stability of the nonwoven contributes.

advantageously, becomes the thickness potential of the nonwoven fabric, the outer layers and the liner inter alia by the width and shape of the central area and the respective page areas of the storage field. The means that dependent can be set by central area and page areas which Thickness can receive the semi-finished product and thus the final product. The filing field determines in which way the filaments hit and when deducting and be deflected. Through a wide Central area in relation to the side areas becomes a nonwoven fabric be produced, which has relatively thin outer layers and a wide intermediate layer receives. By in relation to the central area wider side areas of the Deposits field become thicker outer layers generated in comparison to the liner. In essence, it can be stated that incident in the central area or near the central area Parts of the filaments are more likely to be fed to the intermediate layer of the nonwoven fabric and the parts impinging in the side areas of the storage area the filaments rather folded and orthogonal to the parts of the filaments of the Liner to the outer layers be assigned.

advantageously, The production of the nonwoven fabric is also determined by the amplitude of determined oscillating filament storage. Swing the tray the filament sections over the central area of the filing field, so is a thicker backsheet produced of the nonwoven fabric. In contrast, receives the nonwoven fabric a thinner one Outer layer, if the Filamentablage only slightly above the central area out swinging. Also the longitudinal extension the filaments in the outer layers becomes relevant determined by the amplitude. The further the filaments in the side area swing in, the longer becomes the loop of the filament, which is folded into the outer layer.

The Amplitude is partly due to the delivery speed of the Filaments and the take-off speed of the nonwoven fabric determined. The slower the nonwoven fabric is pulled off, the more and longer it will become Parts of the filament are placed in the side area.

The Filaments can Applied to the storage field after the meltblown, the spunlaying process become. These application methods are known per se. In which Meltblown processes become the endless filaments through a stream of air swirled together and then applied to the storage field. The filaments can do this be torn into pieces. When spunlaying procedure maintaining the endless filaments in their endless form and continuously on the filing field is fed up. Each of these application methods generates a more or less different character of the nonwoven fabric. at however, each of these methods is characterized by the subsequent probing, this means the fixing of contact points the filaments produces a stable nonwoven, which is a strong has crosslinked and mutually supporting structure.

A particularly good cross-linking of the filament sections with each other is achieved when the storage of the filament on the storage field is such that the probability of dropping a Tei les of the filament in the side area of the filing field is smaller than the probability of depositing in the central area or in its vicinity. As a result, a particularly large number of filament sections are supplied to the central region and thus to the intermediate layer of the nonwoven fabric. In the nonwoven fabric, this has the effect that, even with a greater thickness of the intermediate layer, a sufficient number of filament parts is contained, which is ensured for crosslinking and thus the support of the individual filament sections over short lengths.

Around the nonwoven fabric for the further processing in particular to the requirements of the final product is adapted, it is advantageously provided that the nonwoven fabric following the production of the outer layers and the intermediate layer associated with at least one further material layer, in particular glued, bonded or laminated. This can, for example the visual appearance of the nonwoven fabric to the respective Requirements of the construction of the final product can be adjusted.

A possibility the application of the further layer is that the fleece for example, occupied by the meltblown process with other fibers becomes. This is a very economical process for producing a suitable composite nonwoven fabric.

When more location can Also fibers by other methods, textile, nonwovens, leather, paper or Foil materials, in particular by gluing, bonding or Laminate be applied to the visual appearance or to meet other requirements of the final product.

Of the produced according to the invention Nonwoven fabric essentially serves as semi-finished product for the production of end products. Accordingly, the nonwoven fabric following manufacture the outer layers and the liner are deformed. Due to the deformation can an additional stability of the nonwoven fabric.

Especially It is advantageous if the deformation of the network of the nonwoven fabric is changed. The deformation can inter alia on the existing connections at the points of contact of the Filament sections act by repealing these compounds, this means solved again will be created and / or new connections. So it is possible that Nonwoven fabric in the new shape in turn, an inherent stability already by the inner network structure of the outer layers and to give the liner. The release of the compounds, for example done by steam. By changing the number of connections can the strength of the nonwoven fabric in particular for the respective Purpose of the final product compared to the nonwoven fabric as a semi-finished product changed become. Also, the deformation can make the network permanent changed be that existing angles of each other in one connection crossing filaments and / or the sizes of the compounds are changed. The crossing angles can For example, be reduced to the thickness of the nonwoven fabric to reduce.

To the It can also get the new shape of the nonwoven fabric for the final product be advantageous if, following the surface preparation of the outer layers and the intermediate layer, the density of the respective layer is changed. By compression or by expansion, for example, the Interlayer becomes the characteristic and shape of the nonwoven fabric changed. This form can also be resolved by resolution and / or regeneration of connections of the contact points are supported or even be generated. The shaping by changing the layers can be uniform over the Entire nonwoven fabric done or locally to different To produce forms of the nonwoven fabric.

Of the newly created nonwoven fabric is particularly suitable for use as a semi-finished product for technical Components. Thus, the nonwoven offers itself especially for use in the isolation of objects because the nonwoven fabric has a plurality of cavities which provide both heat and sound insulation to care. Of course is also the use of the nonwoven fabric for shaping or reinforcement in Vehicle construction suitable. So can the nonwovens, for example, as a headliner, but also as laminations of linings of interior trim parts to particularly good to create haptic properties of the panels, use Find. Due to the inherent stability of the nonwoven fabric according to the invention also great self-supporting surfaces produced. The nonwoven fabric according to the invention is also suitable, for example, for use in high and low Depth construction. It can be used for the production of intermediate layers in road construction or be used in landfill construction. Also it can be suitable for reinforcement of Concrete structures. About that In addition, the use of the nonwoven fabric in medical technology conceivable. Here he can, for example, for the stabilization of components or also of associations or tubes be used. The description of possible uses described here the nonwoven fabric according to the invention is not exhaustive. This results in many more applications for this new stable nonwoven fabric.

Further advantages of the invention are in the subsequent embodiments described. It shows:

1 a cross section through a nonwoven fabric according to the invention,

2 a section of the nonwoven fabric with indicated joints,

3 a detail on a plan view of the nonwoven fabric with indicated filament loops,

4a -c various changes in the joints

5 the process for the production of the nonwoven fabric according to the invention with a schematically illustrated deposition surface,

6 the preparation according to 4 with a modified storage area,

7 a top view of a storage area with multiple filaments,

8th a cross section through a nonwoven fabric according to the invention during the probing,

9a c details of a nonwoven fabric according to the invention in the intermediate region,

10a c further details of a nonwoven fabric in a border area,

11a -c details of a nonwoven fabric in a further edge region,

12 Details of another nonwoven fabric according to the invention,

13 Details of another nonwoven fabric according to the invention,

14a an open mold with a nonwoven fabric,

14b a closed mold with a molded article,

14c the finished molded article,

15 Details of an article according to the invention and

16 a vehicle with applications for the article according to the invention.

In 1 is a cross-section in a schematic representation through a nonwoven fabric 1 shown. It can be seen that the nonwoven fabric 1 from a first outer layer 2 and another outer layer 3 which consists of an intermediate layer 4 spaced apart from each other. In the outer layer 2 and the outer layer 3 as well as in the intermediate layer 4 are a variety of filaments 5 arranged, which is composed of a substantially horizontal position in the outer layer 2 in a tendency to vertical position in the intermediate layer 4 and then again in a horizontal position in the outer layer 3 move. Each one of the filaments 5 This embodiment is thus in both outer layers 2 . 3 and in the liner 4 involved. The nonwoven fabric 1 extends flat in the x- / y-direction with a thickness d _V in the z-direction, which consists of the two individual thicknesses d _{A of} the outer layers 2 . 3 and the thickness d _{Z of} the intermediate layer 4 composed. Due to the often occurring gradual transition of the filaments 5 from an outer layer 2 in the liner 5 and back to the other outer layer 3 the thickness d _A or d _{Z of} the individual layers is not always exactly to determine, but it is in the nonwoven fabric 1 the tendency orientation of the filaments 5 in the outer layers 2 . 3 in the x / y direction and in the intermediate position 4 usually very easy to recognize in the z-direction.

The individual filaments 5 are in the outer layers 2 . 3 and the liner 4 each interconnected. Every situation 2 . 3 . 4 forms a network in itself, it can also be called a matrix, which has a predetermined property in terms of its ability to absorb power. The networking arises because of the fact that the individual filaments 5 at a variety of points of contact 7 meet where they are connected. Through this connection creates a stronger cohesion in the individual layers 2 . 3 . 4 , The nonwoven fabric 1 is thus very resistant to a compressive force D or a tensile force Z, which at the surface of the nonwoven fabric 1 attack. At a compressive force D on the surface of the nonwoven fabric 1 is the free kink length of the single filament 5 through the multitude of connected points of contact 7 reduced. Every filament 5 becomes, so to speak, through adjacent filaments 5 supported, so that thereby a space structure of individual filaments 5 is formed. The matrix of the liner 4 supports the outer layers, so to speak 2 . 3 from. A similar effect occurs when a tensile force Z on the surface of the nonwoven fabric 1 acts. Here is the extension of the single filament 5 , especially in the intermediate layer 4 , by the retention of adjacent filaments 5 which at the points of contact 7 attack, enlarged.

The variety of touch points 7 reinforce the nonwoven fabric 1 not only with respect to a compressive force D and a tensile force Z, but also with respect to a shear force S, which the individual layers 2 . 3 . 4 want to move against each other. Here too the cross-linking of the individual filaments acts 5 in the networks of the layers 2 . 3 . 4 to the effect that the individual filaments 5 assist in the absorption of force and thus a firmer fleece 1 form. The networks are in each of the locations 2 . 3 . 4 present, so that an optimal power consumption is guaranteed. In addition, the individual layers are based 2 . 3 . 4 through the connected contact points 7 also from each other, so that in this way a stable construction of the nonwoven fabric 1 arises.

A special feature of the invention is that the filaments 5 far in the outer layers 2 . 3 protrude into it. They form as in 1 . 2 and 3 schematically illustrated, loops FS with a length I, which is usually a multiple of the thickness d _V advantageously more than 3 times, often even 20 times this thickness d _{V of} the nonwoven fabric 1 equivalent. The loops FS arise because of the filaments 5 from the matrix of the liner 4 into the matrix of the outer layer 2 or 3 enter, in this substantially along the surface of the nonwoven fabric 1 run, within the outer layer 2 or 3 describe a kind of bow and extend in the opposite direction. For example, in the area of entry into the outer layer 2 or 3 leaves the filament 5 finally the outside situation again 2 or 3 and step back into the matrix of the liner 4 and then into the opposite outer layer 3 or 2 one to take about the same course there. Through these filament loops FS becomes in connection with the connected contact points 7 a solid filament composite in the matrices of the outer layers 2 . 3 created.

In 2 is schematically an enlarged section of the nonwoven fabric 1 shown. In this illustration is the course of the individual filaments 5 can be seen, which is essentially in the representation of the left in the outer layer 2 starting to the right within the outer layer 2 extend, then bent down the liner 4 go through and turn essentially right-angled to the left into the outer layer 3 into it. The individual filaments 5 can take this course multiple times if they have a corresponding length. For short filaments 5 but it is also conceivable that the filaments 5 only from the one outer layer 2 about the liner 4 in the other outer layer 3 run.

In the presentation of the 2 is also the different networked structure of the individual layers 2 . 3 and 4 of the nonwoven fabric 1 shown. The individual filaments 5 form a variety of filament sections 6 , which are between two points of contact 7 extend. The contact points 7 denote the places where filaments are 5 touch and connect with each other. The contact points 7 can be almost punctiform, but also extend flat, as with the point of contact 7 ' is indicated. In this way arise next to the nodes at the points of contact 7 also reinforced filament sections 6 which also contributes to the stability of the nonwoven fabric 1 contribute.

As can be seen from the illustration, the individual filament sections 6 significantly shorter than, for example, the distance between the two outer layers 2 and 3 , Without the formation of these connected contact points 7 would be the free kink length of a filament 5 according to the thickness d _{Z of} the intermediate layer 4 , This inevitably leads to a very soft product, which may also have advantages depending on the application, but for the present nonwoven fabric 1 not desired. The contact points 7 are not only in the liner 4 but also in the outer layers 2 and 3 so that also the outer layers 2 and 3 become much more stable than when the individual filaments 5 only without connected contact points 7 would lie together. In this case, only frictional forces of the individual filaments 5 for the cohesion, so is the nonwoven fabric 1 but consolidated by a mechanical connection of the individual filaments.

The nonwoven fabric according to the invention is essentially a semi-finished product intended for further processing. During further processing is on the connections of the contact points 7 Influence. The 4a to 4c show different points of contact 7 of filaments 5 how they can be changed starting from the semi-finished product to the final product. In 4a becomes the crossing angle between two filaments 5 changed. While in the case of the semi-finished product in the left-hand illustration the crossing angle α is relatively large, the point of contact became 7 put under stress in the processing and the smaller angle α 'generated. According to 4b became the connection of the contact point 7 after further processing to a larger contact point 7 ' , Out 4c it can be seen that at some points of contact 7 also a merger to a point of contact 7 ' can be done. Of course, it is also possible that connections are completely dissolved or newly formed.

In 5 is schematically the production of the nonwoven fabric according to the invention 1 shown. A variety of filaments 5 falls accordingly on a filing field 8th , The storage box 8th consists of a central area 9 and two side panels 10 , The filaments 5 meet in the central area 9 or the page areas 10 on and through the central area 9 pulled down through it. This will make the areas of the filaments 5 which are in the side areas 10 have hit in the direction of arrow P bent backwards. This creates the result Loops FS, which are essentially in the outer layers 2 . 3 lay down largely parallel and relatively tightly compressed. Through these later connected contact points 7 The solid nonwoven fabric is created 1 in or behind the intermediate area 9 , The filament pieces, which are on the side area 10 have formed, essentially form the outer layer 2 of the later nonwoven fabric 1 , Accordingly, by choosing the shape and size of the side areas 10 and the central area 9 and by the width of filing the filaments 5 on the storage box 8th the thickness d _{A of} the outer layer 2 respectively. 3 and the length I of the filament loops FS are affected.

As in the example of 6 is shown, the side area 10 on both sides of the central area 9 be formed differently. This will make more filament 5 from the larger side area 10 in the central area 9 inserted, so that the larger side area 10 associated outer layer becomes thicker and the loops FS longer than in the smaller side area 10 assigned outer layer of the nonwoven fabric 1 ,

The ones with the filaments 5 supplied air can either through the storage box 8th be removed through, for example, if this is partially perforated. The air can also be on the side of the storage area 8th be sucked off.

According to 7 is a plan view of a schematically illustrated storage box 8th outlined. Most filaments 5 become oscillating and usually largely random on the filing field 8th stored. The result is a substantially elliptical surface on which the filaments 5 each on the filing field 8th incident. Statistically speaking, the largest amount of filaments per unit time is in the central area 9 on. This filament is then distributed largely uniformly on the intermediate layer 4 , The on the side areas 10 incident filament pieces are essentially in the outer layers 2 and 3 incorporated. The ellipses of filing filing 5 overlap partially, allowing also a networking of adjacent filaments 5 with each other. This also contributes to a stiffness and strength of the nonwoven fabric 1 at.

The width of the central region largely determines the thickness d _{V of} the later nonwoven fabric 1 , The supplied filaments 5 be in the central area 9 summarized and moved out of this down. The nonwoven fabric 1 is then already used as a solid semi-finished product.

In 8th is schematically the probing, that is the connection or bonding of the contact points 7 shown. Before a bonding device 11 lie the filaments 5 at their points of contact 7 only together. The contact points 7 are shown as white dots. The nonwoven fabric 1 goes through the bonding device 11 in the direction of the arrow. This can be horizontal as shown, but also vertical, immediately after the drop box 8th or spaced therefrom. In the bonding device 11 The filaments are heated, causing them at the contact points 7 partially melt and be firmly connected with the cooling. The firmly connected contact points 7 '' are marked here with a black dot.

The 9a - 9c . 10a - 10c and 11a - 11c each show scanning electron micrographs of an article according to the invention 23 , In 9a is a liner 4 represented with a relatively loose filament composite. The individual filaments 5 are, as in the photographs of the 9b and 9c becomes clear, at points of contact 7 firmly connected. The connection takes place, for example, by melting the individual filaments together 5 especially if these consist of bicomponent filaments. From the various illustrations, it can be seen that there are simple points of contact 7 There are two filaments 5 cross. On the other hand, there are also points of contact 7 ' , on which several filaments 5 connected to each other and thus produce a relatively thick node.

10a shows an outer layer 2 , It can be seen that in the outer layer 2 the individual filaments 5 are much closer together. But here, too, there are, as in the pictures of 10b and 10c you can see contact points 7 , on which several filaments 5 are firmly connected to each other. In particular from 9c is a structure recognizable, which reminds of a ladder and which gives a particularly strong bond.

Finally, in 11a an outer layer 3 shown. This outer layer 3 is less dense than the outer layer 2 packed. But here is how from the 11b and 11c it can be seen, a connection of the individual filaments 5 at the points of contact 7 he follows.

The 12 and 13 show details of two nonwovens of the invention 1 in comparison to the article 23 , It clearly shows the different orientation and the connections of the individual filaments 5 with each other in different situations 2 . 3 and 4 of the nonwoven fabric 1 seen. The nonwovens 1 These figures have relatively few joints. It is therefore more a semi-finished product, which is further processed by further process steps and then receives more joints as needed. It is clear in these Recordings also recognize the network structure. The special stability of the nonwoven fabric 1 is determined both by the network and by the orientation of the filaments 5 generated. The small, arranged below image of 12 shows weakly bonded bonding points, as with the nonwoven fabric 1 This embodiment is typical.

14a shows a sketched open form 20 with a shell 21 and a lower part 22 , On the mutually facing sides of the upper part 21 and lower part 22 is a desired outer contour for one with the shape 20 manufactured article 23 incorporated. In the area of the corresponding contour is the nonwoven fabric 1 positioned as the semi-finished product to be processed. The nonwoven fabric 1 consists of one outer layer each 2 . 3 and a liner 4 , It has a thickness D _V which is sufficient for the production of the article 23 , The thickness D _V can be either about the later maximum thickness of the article 23 correspond. But it can also be thicker to the article 23 compared to the nonwoven fabric 1 to have compressed more in the area of its thick places than the original nonwoven fabric 1 , top 21 and lower part 22 can be preheated to the subsequent deformation process with the mold closed 20 to accelerate. But it can also be the nonwoven fabric 1 outside the mold 20 brought to the appropriate temperature and then in a relatively cold form 20 be inserted for forming.

In 14b is the shape 20 shown in closed condition. top 21 and lower part 22 partially contact. In the between shell 21 and lower part 22 remaining free space extends the now deformed fleece 1 and make the article 23 , It is apparent from the sketched illustration that the article 23 may have different thicknesses, which on the one hand substantially to the thickness of the nonwoven fabric 1 or that it can also be compressed so far that all fibers have intimate contact with each other.

In the form outlined outlined 20 there is a system 24 for introducing steam into the cavity between the upper part 21 and lower part 22 , The hot steam makes the connections of the networks in the outer layers 2 and 3 and the liner 4 solved or at least softened so that they can be changed. At a lower temperature of the steam or a shorter exposure time less joints are dissolved or deformed than at a higher temperature of the steam or a longer exposure time. After a predetermined time, usually when the connections have consolidated, the article becomes 23 cooled and the compounds solidify in the new location and shape. The item 23 this keeps the one through the form 20 introduced shape. The nonwoven fabric 1 is thus largely arbitrarily malleable. Also, the article can 23 be prepared so that it receives a different sound transmission, by more or less dense layers in the layers 2 . 3 or 4 be created.

The finished article 23 according to 14c can then be out of shape 20 be removed and optionally further processed. It can be provided with other attachments, can be punched or drilled or can also be covered or laminated with other materials to accept more decorative or functional properties can. In the arrangement of other materials, it is usually advantageous if the other material together with the nonwoven fabric 1 into the mold 20 is inserted. During the forming of the nonwoven fabric 1 then puts the additional material to the nonwoven fabric 1 and connects, for example, by an intervening adhesive or by adhesive fibers with the nonwoven fabric 1 ,

The item 23 can be largely arbitrarily shaped in the x, y and z directions. Due to the structure of the nonwoven fabric 1 with elongated loops in the outer layers 2 and 3 However, different properties will be set in the x and y directions. In particular, the thermoforming ability can be different, so that the x and y direction of the nonwoven fabric 1 when inserting the nonwoven fabric 1 into the mold 20 should be considered accordingly.

15 shows a highly compressed article 23 , on which on the outsides above and below each another material 30 is arranged. In the nonwoven fabric 1 is still, although not as clearly as in the other embodiments, the structure with two outer layers 2 . 3 and a liner 4 to recognize. The z-orientation of the filaments 5 in the liner 4 is largely canceled. They now essentially have an xy orientation. The filaments 5 in the liner 4 but still support the filaments 5 in the outer layers 2 . 3 , The liner 4 has a plurality of bonding sites, which form a compact network.

In 16 is outlined a vehicle to which the various uses of the article according to the invention are indicated. The item 23 can be used with appropriate shaping and processing both in the passenger compartment and in the engine and luggage compartment. It can be used as a trunk floor or side cover to show decorative and soundproofing properties. In the passenger compartment he can Because of its static strength can be used as a headliner or as a hat rack, but also as a ground cover, for example on the rear seat, it can be used for sound insulation due to its acoustic properties. To avoid reflections from the ground to the passenger compartment, the underbody can also be used with the article 23 be disguised. Due to the solid outer structure of the article 23 in the outer layers 2 respectively. 3 and / or possible additional functional layers is also a sufficient strength of the article 23 given to water, rockfall or wind currents. Similar properties will be required when cladding the wheel arches. Also you can with the appropriate article 23 getting produced. The particularly good acoustic properties of the article 23 They are ideal for engine compartment encapsulation both in the passenger compartment and in the exterior. The noise can with the article 23 isolated and / or absorbed. With appropriate equipment of the article 23 It can even be used as an acoustic heat shield to shield both noise and heat from the passenger compartment.

The invention is not limited to the illustrated embodiments. Variations within the scope of the claims are possible. In particular, the storage box must 8th not be stationary, but it can also be moved, even if the stationary storage field 8th has proved to be very beneficial. The page areas 10 may have shapes other than those shown. It is also possible on a page area 10 completely dispense with the filaments 5 only to condense on one side to an outer layer. The filaments may have a round or non-round, a solid or hollow cross-section. The probing can be done with binders or by melting the filaments. An advantage of the invention may also be that the new product replaces articles made of glass fibers, which in themselves have a higher strength, but make the processing, handling or recycling of semi-finished products and articles more difficult. difficult. The required properties of the article can already be in the nonwoven fabric or later in the manufacture of the article itself in the individual layers 2 . 3 . 4 , in some areas of the article 23 and / or throughout the article 23 be set. This results in a variety of predeterminable parameters that allow an individual production of the article. With the article high density differences can be achieved at least partially high thickness of the article. A special feature of the nonwoven fabric, in contrast to the prior art, is that it is not a composite body despite the individual layers, but because of the filaments which extend into the individual layers, it is a uniform nonwoven fabric with a different network structure is.

Claims (106)

Molded article containing a nonwoven fabric ( 1 ) with a plurality of filaments ( 5 ), characterized in that the filaments ( 5 ) in at least one first outer layer ( 2 ), preferably a second outer layer ( 3 ) and an intermediate layer ( 4 ) of the nonwoven fabric ( 1 ) are arranged such that the nonwoven fabric ( 1 ) in the intermediate position ( 4 ), preferably in each of the individual layers ( 2 . 3 . 4 ) a network of filaments ( 5 ), the individual filaments ( 5 ) others of the filaments ( 5 ) and thereby a multiplicity of contact points ( 7 ) form that the filaments ( 5 ) at many of the points of contact ( 7 ) and that the network of the intermediate layer ( 4 ) has a pressure-stable structure, which counteracts a pressure at least in the z-direction, so that the nonwoven fabric ( 1 ) and thus the article ( 23 ) by stabilizing at least one of the outer layers ( 2 . 3 ) is rigid. Article according to the preceding claim, characterized in that each of the filaments ( 5 ) in the nonwoven fabric ( 1 ) in at least two, preferably three of the layers ( 2 . 3 . 4 ) is located. Article according to one of the preceding claims, characterized in that the networks of the outer layers ( 2 . 3 ) have a tensile and pressure-stable structure at least in the x / y direction. Article according to one of the preceding claims, characterized in that the networks of the individual layers ( 2 . 3 . 4 ) are designed according to the requirements of the semifinished product or article. Article according to one of the preceding claims, characterized in that the networks of a deformation of the nonwoven fabric ( 1 ) counteract from the given state. Article according to one of the preceding claims, characterized in that the filaments ( 5 ) in the outer layers ( 2 . 3 ) substantially in the x and y direction of the nonwoven fabric ( 1 ) are oriented. Article according to one of the preceding claims, characterized in that the filaments ( 5 ) in the intermediate position ( 4 ) compared to the filaments ( 5 ) in the outer layers ( 2 . 3 ) a more pronounced orientation in the z-direction of the nonwoven fabric ( 1 ) exhibit. Article according to one of the preceding claims, characterized in that the filaments ( 5 ) in the outer layers ( 2 . 3 ) in the x-direction at least 3 times the thickness (d _V ) of the nonwoven fabric ( 1 ). Article according to one of the preceding claims, characterized in that the filaments ( 5 ) between two points of contact ( 7 ) Filament sections ( 6 ) and the filament sections ( 6 ) a situation ( 2 . 3 . 4 ) Filament sections ( 6 ) an adjacent layer ( 2 . 3 . 4 ) and thereby a multiplicity of further contact points ( 7 ) forming the filament sections ( 6 ) in such a way that the individual layers ( 2 . 3 . 4 ) firmly adhere to each other. Article according to one of the preceding claims, characterized in that the filament sections ( 6 ) support each other Article according to one of the preceding claims, characterized in that filament sections ( 6 ) a deformation of the nonwoven fabric ( 1 ) due to the reinforcement by the other filament sections connected to them ( 6 ) resist. Article according to one of the preceding claims, characterized in that filament sections ( 6 ) a deflection due to the reinforcement by the other filament sections connected to them ( 6 ) resist. Article according to one of the preceding claims, characterized in that the network has a local longitudinal extent of at least one outer layer ( 2 . 3 ), which in the deflection of the nonwoven fabric ( 1 ) would have to occur from the given state, counteracts. Article according to one of the preceding claims, characterized in that the network is designed in such a way that it is a tensile force (Z) and / or a shear force (S) and thus a local extension counteracts in any direction. Article according to one of the preceding claims, characterized in that in the intermediate layer and / or in at least one outer layer ( 2 . 3 ) the ratio length / diameter of a plurality of the filament sections ( 6 ) is selected such that these filament sections ( 6 ) can also be loaded on pressure. Article according to one of the preceding claims, characterized in that the networks of the individual layers ( 2 . 3 . 4 ) of the nonwoven fabric ( 1 ) support each other. Article according to one of the preceding claims, characterized in that the network of the intermediate layer ( 4 ) is substantially uniform, so that no partial weak points of the nonwoven fabric ( 1 ) arise. Article according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) in the xz or yz cross-section, in particular with respect to the two outer layers ( 2 . 3 ), asymmetrical, so that on the respective outer layer ( 2 . 3 ) acting different tensile and compressive forces (Z, D) can be recorded. Article according to one of the preceding claims, characterized in that the density of the nonwoven fabric ( 1 ) in the networks of external layers ( 2 . 3 ) higher than in the network of the intermediate layer ( 4 ). Article according to one of the preceding claims, characterized in that the filaments ( 5 ) Are bicomponent filaments or biconstituent filaments. Article according to one of the preceding claims, characterized in that the filaments ( 5 ) Are spunbond fibers or meltblown fibers. Article according to one of the preceding claims, characterized in that the filaments ( 5 ) of thermoplastic material combinations, for example of PET, PBT, PP, PE or PA as a structural component and CoPET, CoPBT, PP or PE as an adhesive component of the filaments ( 5 ) are prepared, which have different melting temperatures. Article according to one of the preceding claims, characterized in that the thickness of the filaments used ( 5 ) depending on the requirement profile of the article ( 23 ) and the manufacturing process and have a value of less than 40 microns or 20 dtex, preferably between 7 and 38 microns or 0.5 and 15 dtex. Article according to one of the preceding claims, characterized in that in a spatial element of the intermediate layer ( 4 ) the number of points of contact ( 7 ) lower than in the outer layers ( 2 . 3 ). Article according to one of the preceding claims, characterized in that the compounds of the contact points ( 7 ) for the further processing of the nonwoven fabric ( 1 ) and then in the same or changed number, size, strength and / or angle of the interconnected filaments ( 5 ) can be restored. Article according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) on at least one outer layer ( 2 . 3 ) is coated with other materials, such as fibers, nonwovens, textiles, leather, paper or films, in particular glued, bonded, laminated or laminated to the properties of the article ( 23 ) to influence. Article according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) and / or the material with which the nonwoven fabric ( 1 ) is made up of a single material or different but related materials. Article according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) and / or the material with which the nonwoven fabric ( 1 ), is provided with additives for changing the product properties, in order to 23 ), for example water repellent, oil repellent, flame retardant or with improved abrasiveness. Article according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) in the article ( 23 ) Has areas of different characteristics with respect to air flow resistance, Young's modulus, thickness, density, strength and / or acoustics. Article according to one of the preceding claims, characterized in that in the article ( 23 ) different areas with different density of connections of the contact points ( 7 ) and / or thickness of the respective layers ( 2 . 3 . 4 ) available. Article according to one of the preceding claims, characterized in that the thickness of the article ( 23 ) substantially by a change in the thickness of the intermediate layer ( 4 ) is changeable. Article according to one of the preceding claims, characterized in that the thickness of the article ( 23 ) is between 2 and 30 mm, preferably between 2 and 15 mm. Article according to one of the preceding claims, characterized in that the article ( 23 ) has a basis weight between 500 and 2500 g / m ² , preferably 500-1800 g / m ² . Article according to one of the preceding claims, characterized in that the density of the connections of the contact points ( 7 ) in the intermediate position ( 4 ) in the nonwoven fabric ( 1 ) of the starting material less than in the outer layers ( 2 . 3 ) and for the article ( 23 ) of the final product ( 23 ) at least in a single area except for the density of the outer layers ( 2 . 3 ) can be increased. Article according to one of the preceding claims, characterized in that the article ( 23 ) has a dimensional stability and / or acoustic properties, as required in particular for automotive applications. Article according to one of the preceding claims, characterized in that the article ( 23 ) is to be used as a headliner, engine encapsulation, heat shield, underbody, wheel arch, engine compartment, interior or trunk lining. Article according to one of the preceding claims, characterized in that the article ( 23 ) has better acoustic and / or mechanical properties compared to articles of the prior art with, for example, the same dimensions as the thickness and / or the same weight per unit area. Article according to one of the preceding claims, characterized in that the acoustic properties on thickness, density, modulus of elasticity, Poisson's number, porosity and / or air flow resistance of the filaments ( 5 ), the nonwoven fabric ( 1 ) and / or the networks of the layers ( 2 . 3 . 4 ) are determined. Article according to one of the preceding claims, characterized in that the article ( 23 ) has a predetermined range of properties detectable by one or more of the following test methods: tensile strength according to DIN 53455, flexural strength according to DIN EN 63, notch impact strength according to DIN 53453, resistance according to DIN 52215 or ASTM C-384, Alpha Cabin Test according to RIETER test method, fire resistance according to FMVSS 302, deflection under temperature influence. Article according to one of the preceding claims, characterized in that the individual layers ( 2 . 3 . 4 ) have different insulation, absorption and / or reflection properties. Article according to one of the preceding claims, characterized in that the insulation absorption and / or reflection properties of the individual layers ( 2 . 3 . 4 ), starting from the nonwoven fabric used ( 1 ) and according to the requirements of the article ( 23 ) in the production of the article ( 23 ) by changing the networks of the layers ( 2 . 3 . 4 ) are influenced. Article according to one of the preceding Claims, characterized in that the mechanical properties by modulus of elasticity, area moments of inertia, compressive strength, tensile strength, flexural strength, impact resistance of the filaments ( 5 ) and / or the networks of the layers ( 2 . 3 . 4 ) are determined. Article according to one of the preceding claims, characterized in that the article ( 23 ) through the networks of the layers ( 2 . 3 . 4 ) has an inherent stability against sagging even at higher temperatures, for example at temperatures between 80 ° C and 100 ° C. Article according to one of the preceding claims, characterized in that the article ( 23 ) has a higher thermoformability compared to articles of the prior art, for example, with the same thickness and / or the same basis weight. Article according to one of the preceding claims, characterized in that in the article ( 23 ) Stiffening areas, in particular beads, ribs or eyes are arranged. Article according to one of the preceding claims, characterized in that at least individual regions of the article ( 23 ), in particular the stiffening areas are more compressed than areas with better acoustic properties. Article according to one of the preceding claims, characterized in that in strongly compressed areas of the article ( 23 ) the filaments ( 5 ) in the intermediate position ( 4 ) similar to the filaments ( 5 ) in the outer layers ( 2 . 3 ) a pronounced orientation in the xy direction of the nonwoven fabric ( 1 ) exhibit. Method for producing a molded article ( 23 ) from a nonwoven fabric ( 1 ) with a plurality of filaments ( 5 ), wherein the nonwoven fabric ( 1 ) as a semi-finished product in a mold ( 20 ), the shape ( 20 ) and the nonwoven fabric ( 1 ) under a predetermined temperature of a predetermined deformation force or a predetermined deformation pressure and then the shape ( 20 ) for removing the molded article ( 23 ), characterized in that the filaments ( 5 ) of the nonwoven fabric ( 1 ) in at least one first outer layer ( 2 ), preferably a second outer layer ( 3 ) and an intermediate layer ( 4 ) of the nonwoven fabric ( 1 ) are arranged such that the nonwoven fabric ( 1 ) in the intermediate position ( 4 ), preferably in each of the individual layers ( 2 . 3 . 4 ) a network of filaments ( 5 ), the individual filaments ( 5 ) others of the filaments ( 5 ) and thereby a multiplicity of contact points ( 7 ) form that the filaments ( 5 ) at many of the points of contact ( 7 ) and that the network of the intermediate layer ( 4 ) has a pressure-stable structure, which counteracts a pressure at least in the z-direction, so that the nonwoven fabric ( 1 ) by stabilizing at least one of the outer layers ( 2 . 3 ) is rigid, and that the temperature and the deformation pressure or the deformation force are chosen so that by their influence at the contact points ( 7 ) Compounds are reshaped and the nonwoven fabric ( 1 ) in the by the form ( 20 ) predetermined shape is fixed. Process according to the preceding claim, characterized in that a nonwoven fabric ( 1 ) with bicomponent filaments or biconstituent filaments, in particular of thermoplastic material combinations, for example of PET, PBT, PP, PE or PA as a structural component and CoPET, CoPBT, PP or PE as an adhesive component of the filaments ( 5 ), is used. Method according to one of the preceding claims, characterized in that the compounds of the contact points ( 7 ) solved by the influence of the temperature and / or the deformation pressure or the deformation force and then in the same or changed number, size, strength and / or angle of the interconnected filaments ( 5 ) are restored. Method according to one of the preceding claims, characterized in that the temperature and / or the pressure less than 60 s on the nonwoven fabric ( 1 ) acts. Method according to one of the preceding claims, characterized in that at least one of the polymers of the filament ( 5 ) is heated to a temperature in the range of its melting temperature. Method according to one of the preceding claims, characterized in that hot steam is introduced into the mold ( 20 ) after it has been closed and released from it before it is opened. Method according to one of the preceding claims, characterized in that the mold ( 20 ) is sealed gas-tight. Process according to any one of the preceding claims, characterized in that the steam is in the form ( 20 ) is held at least temporarily during the forming process. Method according to one of the preceding claims, characterized in that the mold ( 20 ) immediately after the steam is released from the mold ( 20 ) is opened. Method according to one of the preceding claims, characterized in that the article ( 23 ) immediately after opening the mold ( 20 ) out of form ( 20 ) is taken. Method according to one of the preceding claims, characterized in that in the form ( 20 ), in particular the network of the intermediate layer ( 4 ) is compressed. Method according to one of the preceding claims, characterized in that the mold ( 20 ) before loading the nonwoven fabric ( 1 ) in the form ( 20 ) is preheated. Nonwoven fabric made of a variety of filaments ( 5 ) with at least one first outer layer ( 2 ), preferably a second outer layer ( 3 ) and an intermediate layer ( 4 ), each of the filaments ( 5 ) in at least two, preferably three of the layers ( 2 . 3 . 4 ) and the nonwoven fabric ( 1 ) has a planar extent in the x and y direction and a thickness (d _V ) in the z direction, characterized in that the nonwoven fabric ( 1 ) in the intermediate position ( 4 ), preferably in each of the individual layers ( 2 . 3 . 4 ) a network of filaments ( 5 ), the individual filaments ( 5 ) others of the filaments ( 5 ) and thereby a multiplicity of contact points ( 7 ) form that the filaments ( 5 ) at many of the points of contact ( 7 ) and that the network of the intermediate layer ( 4 ) has a pressure-stable structure, which counteracts a pressure at least in the z-direction, so that the nonwoven fabric ( 1 ) by stabilizing at least one of the outer layers ( 2 . 3 ) is rigid. Nonwoven fabric according to claim 1, characterized in that the nonwoven fabric ( 1 ) is a semi-finished, which is weiterverarbeitbar to a final product. Nonwoven fabric according to one of the preceding claims, characterized in that the networks of the outer layers ( 2 . 3 ) have a tensile and pressure-stable structure at least in the x / y direction. Nonwoven fabric according to one of the preceding claims, characterized in that the networks of the individual layers ( 2 . 3 . 4 ) are formed depending on the requirements of the semifinished product or the final product. Nonwoven fabric according to one of the preceding claims, characterized in that the networks of a deformation of the nonwoven fabric ( 1 ) counteract from the given state. Nonwoven fabric according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) is flat. Nonwoven fabric according to one of the preceding claims, characterized in that the filaments ( 5 ) in the outer layers ( 2 . 3 ) substantially in the x and y direction of the nonwoven fabric ( 1 ) are oriented. Nonwoven fabric according to one of the preceding claims, characterized in that the filaments ( 5 ) in the intermediate position ( 4 ) compared to the filaments ( 5 ) in the outer layers ( 2 . 3 ) a more pronounced orientation in the z-direction of the nonwoven fabric ( 1 ) exhibit. Nonwoven fabric according to one of the preceding claims, characterized in that the filaments ( 5 ) in the outer layers ( 2 . 3 ) in the x-direction at least 3 times the thickness (d _V ) of the nonwoven fabric ( 1 ). Nonwoven fabric according to one of the preceding claims, characterized in that the filaments ( 5 ) between two points of contact ( 7 ) Filament sections ( 6 ) and the filament sections ( 6 ) a situation ( 2 . 3 . 4 ) Filament sections ( 6 ) an adjacent layer ( 2 . 3 . 4 ) and thereby a multiplicity of further contact points ( 7 ) forming the filament sections ( 6 ) in such a way that the individual layers ( 2 . 3 . 4 ) firmly adhere to each other. Nonwoven fabric according to one of the preceding claims, characterized in that the filament sections ( 6 ) support each other Nonwoven fabric according to one of the preceding claims, characterized in that filament sections ( 6 ) a deformation of the nonwoven fabric ( 1 ) due to the reinforcement by the other filament sections connected to them ( 6 ) resist. Nonwoven fabric according to one of the preceding claims, characterized in that filament sections ( 6 ) a deflection due to the reinforcement by the other filament sections connected to them ( 6 ) resist. Nonwoven fabric according to one of the preceding claims, characterized in that the network has a local longitudinal extent of at least one outer layer ( 2 . 3 ), which in the deflection of the nonwoven fabric ( 1 ) would have to occur from the given state, counteracts. Nonwoven fabric according to one of the preceding claims, characterized in that the net is designed such that it counteracts a tensile force (Z) and / or a shearing force (S) and thus a local longitudinal extent in any direction. Nonwoven fabric according to one of the preceding claims, characterized in that in the intermediate layer and / or in at least one outer layer ( 2 . 3 ) the ratio length / diameter of a plurality of the filament sections ( 6 ) is selected such that these filament sections ( 6 ) can also be loaded on pressure. Nonwoven fabric according to one of the preceding claims, characterized in that the networks of the individual layers ( 2 . 3 . 4 ) of the nonwoven fabric ( 1 ) support each other. Nonwoven fabric according to one of the preceding claims, characterized in that the network of the intermediate layer ( 4 ) is substantially uniform, so that no partial weak points of the nonwoven fabric ( 1 ) arise. Nonwoven fabric according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) in cross-section, in particular with respect to the two outer layers ( 2 . 3 ), asymmetrical, so that on the respective outer layer ( 2 . 3 ) acting different tensile and compressive forces (Z, D) can be recorded. Nonwoven fabric according to one of the preceding claims, characterized in that the density of the nonwoven fabric ( 1 ) in the networks of external layers ( 2 . 3 ) higher than in the network of the intermediate layer ( 4 ). Nonwoven fabric according to one of the preceding claims, characterized in that the filaments ( 5 ) Are bicomponent filaments or biconstituent filaments. Nonwoven fabric according to one of the preceding claims, characterized in that the filaments ( 5 ) Are spunbond fibers or meltblown fibers. Nonwoven fabric according to one of the preceding claims, characterized in that the filaments ( 5 ) of thermoplastic material combinations, for example of PET, PBT, PP, PE or PA as a structural component and CoPET, CoPBT, PP or PE as an adhesive component of the filaments ( 5 ) are prepared, which have different melting temperatures. Nonwoven fabric according to one of the preceding claims, characterized in that the thickness of the filaments used ( 5 ) depending on the requirement profile of an article to be produced from it ( 23 ) and has a value of less than 20 dtex, preferably between 1 and 15 dtex. Nonwoven fabric according to one of the preceding claims, characterized in that in a spatial element of the intermediate layer ( 4 ) the number of points of contact ( 7 ) lower than in the outer layers ( 2 . 3 ). Nonwoven fabric according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) on at least one outer layer ( 2 . 3 ) is coated with other materials, such as fibers, nonwovens, textiles, leather, paper or films, in particular glued, bonded or laminated to the properties of the nonwoven fabric ( 1 ) to influence. Nonwoven fabric according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) and / or the material with which the nonwoven fabric is coated, consists of a uniform material or different but related materials. Nonwoven fabric according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) and / or the material with which the nonwoven fabric ( 1 ) is provided with additives for changing the product properties. Nonwoven fabric according to one of the preceding claims, characterized in that the compounds of the contact points ( 7 ) for the further processing of the nonwoven fabric ( 1 ) and then in the same or changed number, size and / or angle of the interconnected filaments are recoverable. Nonwoven fabric according to one of the preceding claims, characterized in that the thickness of the nonwoven fabric ( 1 ) is between 5 and 40 mm, preferably between 8 and 30 mm. Nonwoven fabric according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) has a basis weight between 400 and 2500 g / m ² , preferably 400-1800 g / m ² . Process for forming a nonwoven fabric ( 1 ) according to one of the preceding claims, characterized in that the filament ( 5 ) to a storage field ( 8th ), an intermediate layer ( 4 ) of the nonwoven fabric ( 1 ) by depositing parts of the filaments ( 5 ) in a central area ( 9 ) of the filing field ( 8th ) and at least one outer layer ( 2 . 3 ) of the nonwoven fabric ( 1 ) by depositing further parts of the filaments ( 5 ) in at least one page area ( 10 ) of the filing field ( 8th ), and the like deposited filaments ( 5 ) through the central area ( 9 ), whereas those in the page areas ( 10 ) deposited parts of the filaments ( 5 ) compared to those in the central area ( 9 ) deposited parts of the filaments ( 5 ), so that those in the outer layer (s) ( 2 . 3 ) located parts of the filaments ( 6 ) substantially in the xy direction of the nonwoven fabric ( 1 ) and those in the intermediate position ( 4 ) located parts of the filaments ( 6 ) compared to the filaments ( 5 ) in the outer layers ( 2 . 3 ) a more pronounced orientation in the z-direction of the nonwoven fabric ( 1 ) and in the intermediate layer ( 4 ), preferably in each of the individual layers ( 2 . 3 . 4 ) a network of filaments ( 5 ), the individual filaments ( 5 ) others of the filaments ( 5 ) and thereby a multiplicity of contact points ( 7 ) form that the filaments ( 5 ) at many of the points of contact ( 7 ) and thereby the network of filaments ( 5 ) and that at least the network of the intermediate layer ( 4 ) is formed so that it has a pressure-stable structure, which counteracts a pressure at least in the z-direction, so that the nonwoven fabric by stabilizing at least one of the outer layers ( 2 . 3 ) becomes rigid. Process according to the preceding claim, characterized in that the filaments ( 5 ) oscillating on the storage field ( 8th ) are stored. Method according to one of the preceding claims, characterized in that the thickness potential of the nonwoven fabric ( 1 ), the outer layers ( 2 . 3 ) and the intermediate layer ( 4 ) inter alia by the width and shape of the central area ( 9 ) and the respective page areas ( 10 ) of the filing field ( 8th ) is determined. Method according to one of the preceding claims, characterized in that the thickness potential of the outer layers ( 2 . 3 ) and the intermediate layer ( 4 ) inter alia by the amplitude of the oscillating filing of the filaments ( 5 ) is determined. Method according to one of the preceding claims, characterized in that the amplitude is influenced inter alia by the delivery speed of the filaments ( 5 ) and the withdrawal speed of the nonwoven fabric ( 1 ) is determined. Method according to one of the preceding claims, characterized in that the filaments ( 5 ) to the storage field ( 8th ) are applied by the meltblown or spunlaying method. Method according to one of the preceding claims, characterized in that the filing of the filament ( 5 ) on the storage field ( 8th ) such that the probability of depositing a part of the filament ( 5 ) in the page area ( 10 ) of the filing field ( 8th ) is less than the probability of being deposited in the central area ( 9 ) or in its vicinity. Method according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) following the production of the outer layers ( 2 . 3 ) and the intermediate layer ( 4 ) is bonded to connect the contact points ( 7 ). Method according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) following the production of the outer layers ( 2 . 3 ) and the intermediate layer ( 4 ) connected to at least one further material layer, in particular glued, bonded or laminated. Process according to one of the preceding claims, characterized in that the further material layer applied by the meltblown process or glued on. Process according to one of the preceding claims, characterized in that as a further material layer fibers, nonwovens, Textile, leather, paper or foil material, in particular by gluing, bonding or laminating is applied. Method according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) following the production of the outer layers ( 2 . 3 ) and the intermediate layer ( 4 ) is deformed. Method according to one of the preceding claims, characterized in that the deformation is used to modify the network by placing existing connections at points of contact ( 7 ) and / or new connections are created. Method according to one of the preceding claims, characterized in that the deformation is used to change the network by reducing existing angles of the filaments crossing each other in a connection ( 5 ) and / or sizes of the connections are changed. Method according to one of the preceding claims, characterized in that the nonwoven fabric ( 1 ) following the production of the outer layers ( 2 . 3 ) and the intermediate layer ( 4 ) is changed in its density. Use of a nonwoven fabric ( 1 ) according to one of the preceding claims as a semi-finished product for technical components, in particular for insulation, Shaping or reinforcement in vehicle construction, civil engineering or medical engineering.