EP3133196B1 - Volume nonwoven fabric - Google Patents

Description

The invention relates to a method for producing a volume nonwoven fabric, the volume nonwovens obtainable with the method and their uses.

Filling materials for textile applications are widely known. For example, fine feathers, down and animal hair, such as wool, have been used for a long time to fill blankets and items of clothing. Filling materials made of down are very comfortable to use, as they combine very good thermal insulation with low weight. However, the disadvantage of these materials is that they only have a low level of cohesion with one another.

An alternative to the use of down and animal hair is the use of nonwovens or nonwovens as filler material. Nonwovens are structures made of fibers of limited length (staple fibers), filaments (continuous fibers) or cut yarns of any kind and of any origin that in any way form a nonwoven (a pile of fibers) have been put together and connected to one another in some way. The disadvantage of conventional nonwovens or nonwovens is that they are less fluffy than voluminous filling materials such as down. In addition, the thickness of conventional nonwovens becomes thinner and thinner over a longer period of use.

An alternative to using such filler materials are fiber balls. Fiber balls contain more or less spherically entangled fibers, which usually have approximately the shape of a ball. For example, in the EP 0 203 469 A Described fiber balls that can be used as a filling or cushioning material. These fiber balls consist of spirally crimped interwoven polyester fibers with a length of about 10 to 60 mm and a diameter between 1 and 15 mm. The fiber balls are elastic and heat insulating. The disadvantage of the fiber balls is that, like down, feathers, animal hair or the like, they only have a low level of cohesion with one another. Such Fiber balls are consequently only poorly suited as filling material for flat textile materials, in which the fiber balls should lie loosely, since they can slip due to their poor adhesion. In order to avoid slipping in the flat textile materials, these are often stitched.

To improve the connection between fiber balls, the suggests EP 0 257 658 B1 suggest using fiber balls with protruding fiber ends that can also have hooks. The production of such materials is relatively complex and the fiber ends can kink or bend during transport, storage and processing.

The WO 91/14035 proposes to thermally solidify a nonwoven raw material of fiber balls and binding fibers into layers and then needling them. The nonwoven raw materials are guided in an air stream to a single spiked roller and deposited on a belt by this roller. A disadvantage of the products is that the stability is low without needling, since the binding fibers can only slightly stabilize the voluminous, loose fiber balls. In order to achieve sufficient stability, needling is carried out, which complicates the process and increases the density of the product in an undesirable manner.

The WO 2005/044529 A1 describes devices with which different materials can be homogenized in an aerodynamic process. The raw materials pass through rotating spiked rollers. The method can be used, for example, to process cellulose fibers, synthetic fibers, pieces of metal, plastic parts or granulates. Such relatively harsh processes are used, among other things, in waste management.

The invention is based on the object of providing a volume nonwoven fabric and a method for its production which combines various advantageous properties. The nonwoven fabric should in particular be voluminous and have a low density, and at the same time have high stability, in particular good tensile strength. It is said to have good heat insulation property with high softness, high compressive elasticity, light weight and a good adaptation to a body to be enveloped. At the same time, the nonwoven should have sufficient washing stability and mechanical stability in order to be able to be handled, for example, as a web product. In particular, the nonwoven should be able to be cut and rolled up. The nonwoven should be suitable for textile applications.

This object is achieved by methods, volume nonwovens and uses according to the patent claims. Further advantageous embodiments are described in the description.

1. (a) Bereitstellen eines Vliesstoffrohmaterials enthaltend Faserbällchen und Bindefasern,
2. (b) Bereitstellen einer Airlaid-Vorrichtung, die mindestens zwei Stachelwalzen aufweist, zwischen denen mindestens ein Spalt ausgebildet ist,
3. (c) Verarbeiten des Vliesstoffrohmaterials in der Vorrichtung in einem Airlaid-Verfahren, wobei das Vliesstoffrohmaterial den Spalt zwischen den Stachelwalzen passiert, wobei von den Stacheln Fasern oder Faserbündel aus den Faserbällchen herausgezogen werden,
4. (d) Ablegen auf einer Ablageeinrichtung, und
5. (e) thermisches Verfestigen unter Erhalt des Volumenvliesstoffes.

The subject of the invention is a method for the production of a volume nonwoven, comprising the steps:

1. (a) providing a nonwoven raw material containing fiber balls and binding fibers,
2. (b) providing an airlaid device which has at least two spiked rollers between which at least one gap is formed,
3. (c) processing the nonwoven raw material in the device in an airlaid process, wherein the nonwoven raw material passes the gap between the spiked rollers, fibers or fiber bundles being pulled out of the fiber balls by the spikes,
4. (d) placing on a storage device, and
5. (e) thermal bonding with retention of the volume nonwoven fabric.

The steps are carried out in the order (a) to (e).

A nonwoven-like product that has a relatively low density is generally referred to as volume nonwoven. In step (a) a nonwoven raw material is used. The term “raw material” denotes a mixture of the components that are to be processed together to form the volume nonwoven. The raw material is a loose mixture, i.e. the components have not been connected to one another, in particular not thermally connected, needled, glued or subjected to similar processes in which a targeted chemical or physical bond is created.

The nonwoven raw material in step (a) contains fiber balls. Fiberballs are well known in the technical field and are used as filling materials. They are relatively small and light fiber agglomerates that can be easily separated from one another. Structure and shape can vary depending on the materials used and the desired properties of the bulk nonwoven. In particular, the term fiber balls should be understood to mean both spherical and spherical shapes, for example irregular and / or deformed, for example flattened or elongated, spherical shapes. It has been found that spherical shapes and shapes approximating to the spherical shape show particularly good properties with regard to fluffiness and thermal insulation. Processes for producing fiber balls are known in the prior art and are for example in US Pat EP 0 203 469 A described.

The fibers can be distributed relatively evenly in a fiber ball, and the density can decrease towards the outside. It is conceivable, for example, that there is a uniform distribution of the fibers within the fiber balls and / or a fiber gradient. Alternatively, the fibers can be arranged essentially in a spherical shell, while relatively few fibers are arranged in the center of the fiber balls.

It is also conceivable that the fiber balls contain spherically wound and / or fluff-like fibers. In order to ensure good cohesion of the aggregate, it is advantageous if the fibers are curled. The fibers can be disordered or have a certain order.

According to one embodiment, the fibers in the interior of the individual fiber balls are tangled and arranged spherically in an outer layer of the fiber balls. In this embodiment, the outer layer is comparatively small in relation to the diameter of the fiber balls. This allows the softness of the fiber balls to be increased even further.

The type of fibers present in the fiber balls is fundamentally uncritical, provided they are suitable for forming fiber balls, for example through a suitable surface structure and fiber length. The fibers of the fiber balls are preferably selected from the group consisting of staple fibers, threads and / or yarns. Here, staple fibers, in contrast to filaments which have a theoretically unlimited length, are to be understood as fibers with a limited length, preferably from 20 mm to 200 mm. The threads and / or yarns also preferably have a limited length, in particular from 20 mm to 200 mm. The fibers can be present as monocomponent filaments and / or composite filaments. The titer of the fibers can also vary. The mean titer of the fibers is preferably in the range from 0.1 to 10 dtex, preferably from 0.5 to 7.5 dtex.

It has surprisingly been found that an advantageous volume nonwoven can be obtained if a volumizing nonwoven raw material containing fiber balls and binding fibers is processed in an airlaid process with spiked rollers. It has been found that, when the mixture is processed between spiked rollers in an airlaid process, efficient opening, mixing and alignment of the nonwoven raw material is achieved without the material being destroyed in the process. This was surprising because, for example, the fiber balls used as raw material are extremely filigree, so that it was assumed that they would be destroyed in such a device, which is at the expense of the stability and function of the end product.

The spiked rollers are preferably arranged in pairs in the device so that the metal spokes can interlock. The meshing of the metal spokes creates a dynamic sieve, whereby the nonwoven raw materials can be separated and evenly distributed. In addition, in the case of the fiber balls, treatment with spiked rollers arranged in pairs can lead to a loosening of the fiber structure without destroying the ball shape as a whole. Fibers or fiber bundles can be pulled out of the balls in such a way that they are still connected to the fiber balls, but protrude from the surface. This is beneficial as the pulled out Fibers hook the individual balls together and thereby increase the tensile strength of the volume fleece. In addition, a matrix of individual fibers can be formed in which the balls are embedded, which increases the softness of the volume nonwoven.

At the same time, the method has the advantage that the binding fibers are connected very closely to the fleece balls. It is assumed that some of the binding fibers are also introduced into the fiber balls by the spines. As a result, the proportion of glue points between the fiber balls and the binding fibers increases significantly during thermal consolidation. This is one of the reasons why the nonwovens are extremely stable. Thus, the nonwoven fabric according to the invention is significantly more stable than products from conventional processes in which only fiber balls are opened or carded and then mixed with binding fibers.

The special properties of the product are preserved, among other things, because the process is carried out as an airlaid process. The term "airlaid process" (aerodynamic process) denotes the fact that the nonwoven raw material containing fiber balls and binding fibers is processed and deposited in the air stream with the spiked rollers. The nonwoven raw material is fed to the spiked rollers in an air stream and processed by them. This has the advantage that the nonwoven raw material remains in a loose, voluminous form during processing with the spiked rollers, but is intensively mixed, with the spikes penetrating the fleece balls. The method differs significantly from conventional methods in which webs of nonwoven raw material are carded. In such carding processes, the nonwoven raw materials are essentially oriented. Because of the immobility of the web material, a mixing, opening and mutual penetration of the components is not achieved as in the airlaid process according to the invention, where the nonwoven raw material passes the spiked rollers in loose form in the air stream. According to the invention, it is thus possible to obtain a product whose density is even lower than that of the fiber balls used.

It was found that the method enables a very even distribution of the raw material on the depositing belt and a very homogeneous volume fleece can be obtained in which the volumizing material is evenly distributed. The homogeneous distribution of the volumizing material is of great advantage, particularly with regard to the thermal insulation properties and softness as well as for the recovery of the volume fleece.

According to the invention, a very homogeneous volume nonwoven can be obtained in which the volume-giving fiber material is present in a very homogeneous and evenly distributed manner. This was surprising as it had to be assumed that the filigree fiber balls, but also other filigree components such as down, would be destroyed when treated with spiked rollers.

Practical tests have shown that particularly good results are obtained with the method according to the invention if it comprises one or more of the following steps:
The nonwoven raw material is placed as evenly as possible in the airlaid device, comprising at least one pair of spiked rollers, in which the components are opened and mixed with one another. The fibers can then be deposited in a conventional manner for web formation, for example on a sieve belt, a sieve drum and / or a conveyor belt. The formed web can then be consolidated in a conventional manner. Thermal consolidation, for example with a belt furnace, has proven particularly suitable according to the invention. This makes use of the fact that the binding fibers are closely connected to the fiber balls. It is also possible to avoid undesired compression of the volume nonwoven, as would occur, for example, in the case of hydroentanglement or needling. The use of a double-belt hot air oven has proven particularly suitable. The advantage of using such a hot air oven is that a particularly effective activation of the binding fibers can be obtained while at the same time smoothing the surface and maintaining the volume.

According to an advantageous embodiment of the invention, the spiked rollers are arranged in rows. The spiked rollers are thus advantageously arranged in at least one row. The advantage of the arrangement of the spiked rollers in at least one row is that the metal spokes of the adjacent spiked rollers can interlock. Thus, each roller can simultaneously form a pair with each of its neighboring rollers, which can function as a dynamic screen. The rows can also be in pairs (double rows) in order to obtain a particularly good opening and mixing of the fibers and fiber balls. The spiked rollers are thus advantageously arranged in at least one double row. It is also conceivable that at least part of the fiber material is guided several times through the same spiked rollers by means of a return system. For example, a revolving endless belt or aerodynamic means such as tubes through which the material is blown upwards can be used for the return. The belt can be arranged in an advantageous manner between two rows of spiked rollers. Furthermore, the endless belt can also be guided through several double rows of spiked rollers arranged one behind the other or one above the other.

The device has spiked rollers. When two opposing rollers rotate, which form a gap for the passage of nonwoven raw material, the spikes preferably mesh with one another in an offset manner. The spikes preferably have a thin, elongated shape. The spines are long enough to allow a good penetration of the materials and the fiber balls. The length of the spines is preferably between 1 and 30 cm, in particular between 2 and 20 cm or between 5 and 15 cm. The length of the spines can be at least 5 or at least 10 times as large as the widest diameter of the spines.

The gaps between the spiked rollers through which the nonwoven raw material passes are preferably so wide that the nonwoven raw material is not compressed when it passes. Rather, opening the nonwoven balls loosens up the material. The spines preferably each have a length on both sides which corresponds to more than 50%, preferably at least 60%, at least 70% or at least 80% of the (narrowest) width of the gap. Preferably the spines point on both Each side has a length that corresponds to more than 50% to 99% or 60% to 95% of the (narrowest) width of the gap.

The device preferably has at least two pairs, preferably at least 5 pairs or at least 10 pairs of spiked rollers, and / or the device preferably has at least 2, at least 5 or at least 10 gaps between the spiked rollers. Such devices allow particularly efficient processing of the nonwoven raw material.

The device is preferably designed so that the contact surface of the spiked rollers with the nonwoven raw material is as large as possible. A plurality of spiked rollers is preferably present, for example at least 5, at least 10 or at least 20 spiked rollers. Preferably there are at least 5, at least 10 or at least 20 gaps between adjacent pairs of rollers through which the nonwoven raw material can pass. The rollers can, for example, have a cylindrical shape. Usually, the cylindrical rollers are firmly connected to the spikes. It is also conceivable to equip a roller core with revolving spiked belts. There are preferably several levels so that the material is processed several times.

For opening the fiber raw material, the device could have 2 to 10 rows arranged in pairs, each with 2 to 10 spiked rollers. You could have four rows arranged in two pairs, each with five spiked rollers. Such airlaid devices are available, for example, under the brand name “SPIKE” Air-Laid -anlage from the company Formfiber Denmark APS. The process is an airlaid process, i.e. an aerodynamic fleece formation process, ie the fleece formation takes place with the aid of air. The basic principle of this process consists in the transfer of the nonwoven raw material into an air stream, which enables a mechanical distribution of the nonwoven raw material in the machine longitudinal and / or transverse direction and finally a homogeneous deposit of the nonwoven raw material on a suction conveyor belt.

Air can be used in a wide variety of process steps. According to a particularly preferred embodiment of the invention, the entire transport of the nonwoven raw material takes place aerodynamically during the formation of the nonwoven, for example by means of an installed air system. It is also conceivable, however, that only special process steps, for example the removal of the fibers from the spiked rollers, are supported by additional air.

Practical tests have shown that the airlaid process is carried out in particular with one or more of the following steps:
The processes of nonwoven raw material preparation or nonwoven raw material dissolution are expediently placed directly upstream of the nonwoven formation process. The optional mixing with non-fiber materials, for example down and / or foam parts, is preferably carried out immediately during the distribution of the fiber material in the web formation system.

With the aid of air as a transport medium, the material (the nonwoven raw material or its components) can be transported via a supply and distribution system into the nonwoven forming unit, where a targeted opening, swirling and, at the same time, homogeneous mixing and distribution takes place. In order to be able to easily control the material supply, the supply for each material component is advantageously carried out separately.

The nonwoven raw material is then preferably treated with at least two spiked rollers with which the fiber material is processed or dissolved. Particularly good results are achieved when the nonwoven raw material is passed through a series of rotating shafts equipped with metal spokes (the so-called spikes) as a spiked roller. In a preferred embodiment, the adjacent spiked rollers rotate in opposite directions. As a result, particularly strong forces can act on the nonwoven raw material. The meshing of the metal spokes creates a dynamic sieve that allows high throughput rates. The procedure thus differs significantly from a procedure as in WO91 / 14035 , with the nonwoven raw material of only one single spiked roller is guided and deposited. In this case, forces cannot act on the material with the associated structural changes as in the method according to the invention.

The web is advantageously formed on a screen belt with suction. A random fleece structure without pronounced fiber orientation can be created on the screen belt, the density of which is related to the intensity of the prohibition. A layer structure can be implemented by arranging several web forming units in one line.

The advantage of aerodynamic nonwoven formation is that the fibers and any further constituents that may be present in the nonwoven raw material can be arranged in a random layer, which enables a very high isotropy of properties. In addition to the structure-related aspects, this embodiment offers economic advantages resulting from the investment volume and the operating costs for the production systems.

According to one embodiment of the invention, the web formation takes place in several web-forming units arranged one behind the other. It is thus conceivable that a deposit belt, for example a screen belt with suction, is guided successively through a plurality of web forming units, in each of which a layer of a web is deposited. A multi-layer fleece can be produced in this way.

In a further step (e) the fleece is thermally consolidated. Preferably, no pressure is exerted on the nonwoven fabric. For example, thermal consolidation can take place in an oven without applying pressure. This has the advantage that the nonwoven is very bulky, although it has a high strength. The bonding of the fleece can be supported in a conventional manner, for example chemically by spraying with binding agent, thermally by melting previously added adhesive powder and / or mechanically, e.g. B. by needling and / or hydroentanglement.

Practical tests have shown that the web formation is preferably carried out with a device for producing a fiber web, described in the publication WO 2005/044529 , can be done with very good results. On the advantageous embodiments of the device described therein from page 2, line 25 to page 4; Line 9, from page 4, line 15 to page 5, line 9, and on page 6, line 22 to page 7, line 19 are hereby incorporated by reference.

In a preferred embodiment, the proportion of fiber balls is 50 to 95% by weight, preferably 60 to 95%, in particular from 70 to 90%, and / or the proportion of binding fibers in the bulk nonwoven is 5 to 40% by weight, preferably 7 to 30% by weight and particularly preferably from 10 to 25% by weight, based in each case on the total weight of the nonwoven raw material.

The fiber balls preferably contain or consist of fibers selected from synthetic polymers, in particular fibers made of polyester, in particular polyethylene terephthalate, polyethylene naphthalate and polybutylene terephthalate; and natural fibers, in particular fibers made of wool, cotton or silk, and / or mixtures thereof and / or mixtures with other fibers.

In principle, the fiber balls can consist of a wide variety of fibers. The fiber balls can be natural fibers, for example wool fibers and / or synthetic fibers, for example fibers made of polyacrylic, polyacrylonitrile, pre-oxidized PAN, PPS, carbon, glass, polyvinyl alcohol, viscose, cellulose, cotton, polyaramides, polyamideimide, polyamides, especially polyamide 6 and Polyamide 6.6, PULP, preferably polyolefins and very particularly preferably polyesters, in particular polyethylene terephthalate, polyethylene naphthalate and polybutylene terephthalate, and / or mixtures of those mentioned hereof and / or consist thereof. According to a preferred embodiment, fiber balls made of wool fibers are used. Particularly dimensionally stable and well insulating bulk nonwovens can be obtained here. According to a further preferred embodiment, fiber balls made of polyester are used in order to achieve particularly good compatibility with the usual further components within the volume nonwoven or in a nonwoven composite. In a preferred embodiment, contain Fiber balls additionally themselves binding fibers, which preferably have a length of 0.5 mm to 100 mm.

The nonwoven raw material in step (a) contains binding fibers in addition to the fiber balls. These binding fibers are loose fibers and are not a component of the fiber balls. In a preferred embodiment, these binding fibers are designed as core / sheath fibers, the sheath being polybutylene terephthalate, polyamide, copolyamides, copolyesters or polyolefins such as polyethylene or polypropylene, and / or the core being polyethylene terephthalate, polyethylene naphthalate, polyolefins such as polyethylene or polypropylene, polyphenylene sulfide , aromatic polyamides and / or polyesters. The melting point of the shell polymer is usually higher than that of the core polymer, for example by more than 10 ° C.

• Fasern mit einem Schmelzpunkt, der unterhalb des Schmelzpunkts des zu bindenden volumengebenden Materials liegt, vorzugsweise unterhalb von 250°C insbesondere von 70 bis 230°C, besonders bevorzugt von 125 bis 200°C. Geeignete Fasern sind insbesondere thermoplastische Polyester und oder Copolyester, insbesondere PBT, Polyolefine, insbesondere Polypropylen, Polyamide, Polyvinylalkohol, oder auch Copolymere sowie deren Copolymere und Gemische
• verklebende Fasern, wie unverstreckte Polyesterfasern.

The fibers commonly used for this purpose can be used as the binding fibers. Binding fibers can be uniform fibers or also multi-component fibers. Particularly suitable binding fibers according to the invention are fibers of the following groups:

• Fibers with a melting point which is below the melting point of the volumizing material to be bound, preferably below 250 ° C, in particular from 70 to 230 ° C, particularly preferably from 125 to 200 ° C. Suitable fibers are in particular thermoplastic polyesters and / or copolyesters, in particular PBT, polyolefins, in particular polypropylene, polyamides, polyvinyl alcohol, or also copolymers and their copolymers and mixtures
• adhesive fibers, such as undrawn polyester fibers.

Binding fibers particularly suitable according to the invention are multicomponent fibers, preferably bicomponent fibers, in particular core / sheath fibers. Core / sheath fibers contain at least two fiber materials with different softening and / or melting temperatures. Core / sheath fibers preferably consist of these two fiber materials. The component with the lower softening and / or melting temperature is on the fiber surface (cladding) and to find the component that has the higher softening and / or melting temperature in the core.

In the case of core / sheath fibers, the binding function can be performed by the materials which are arranged on the surface of the fibers. A wide variety of materials can be used for the jacket. According to the invention, preferred materials for the jacket are PBT, PA, polyethylene, copolyamides or also copolyesters. Polyethylene is particularly preferred. A wide variety of materials can also be used for the core. According to the invention, preferred materials for the core are PET, PEN, PO, PPS or aromatic PA and PES.

The advantage of the presence of binding fibers is that the volume-giving material in the volume nonwoven is held together by the binding fibers, so that a textile cover filled with the volume nonwoven can be used without the volume-providing material shifting significantly and without thermal bridges due to the lack of filler material are formed.

The binding fibers preferably have a length of 0.5 mm to 100 mm, more preferably 1 mm to 75 mm, and / or a titer of 0.5 to 10 dtex. According to a particularly preferred embodiment of the invention, the binding fibers have a titer of 0.9 to 7 dtex, more preferably 1.0 to 6.7 dtex, and in particular 1.3 to 3.3 dtex.

The proportion of binding fibers in the volume nonwoven is set depending on the type and amount of the other components of the volume nonwoven and the desired stability of the volume nonwoven. If the proportion of binding fibers is too low, the stability of the bulk nonwoven deteriorates. If the proportion of binding fibers is too high, the volume fleece becomes too strong overall, which is at the expense of its softness. Practical tests have shown that a good compromise between stability and softness is obtained if the proportion of binding fibers is in the range from 5 to 40% by weight, preferably 7 to 30% by weight and particularly preferably from 10 to 25% by weight. A volume nonwoven fabric can be obtained that is stable enough to be rolled and / or folded. This makes it easier Manageability and further processing of the volume nonwoven. Such a volume fleece is also washable. For example, it is stable enough to withstand three household washes at 40 ° C without disintegration.

The binding fibers can be connected to one another and / or to the other components of the volume nonwoven by thermofusion. Hot calendering with heated, smooth or engraved rolls, by pulling through a hot air tunnel oven, hot air double belt oven and / or by pulling through a drum through which hot air flows has proven particularly suitable. The advantage of using a double-belt hot air oven is that the binding fibers can be activated particularly effectively while smoothing the surface while maintaining the volume.

In addition, the volume nonwoven fabric can also be consolidated in that the optionally pre-consolidated fiber web is exposed to fluid jets, preferably water jets, at least once on each side.

In a preferred embodiment, the mixture contains at least one further component that is not fiber balls or binding fibers. The total proportion of such further components is preferably up to 45% by weight, up to 30% by weight, up to 20% by weight or up to 10% by weight.

Such further components are preferably selected from further fibers, further volumetric materials and other functional additives.

According to one embodiment, further fibers that are not binding fibers are contained as a further component. Such fibers can provide the nonwovens with special properties, such as softness, optical properties, fire resistance, tear resistance, conductivity, water management or the like. Since these fibers are not in the form of fiber balls, they can have a wide variety of surface properties and, in particular, can also be smooth fibers. For example, silk fibers can be used as additional fibers in order to give the volume nonwoven fabric a special sheen. The is also conceivable Use of polyacrylic, polyacrylonitrile, pre-oxidized PAN, PPS, carbon fibers, glass fibers, polyaramides, polymanimide, melamine resin, phenolic resin, polyvinyl alcohol, polyamides, in particular polyamide 6 and polyamide 6.6, polyolefins, viscose, cellulose and preferably polyester, especially polyethylene terephthalate, polyethylene naphthalate and polybutylene , and / or mixtures thereof. The proportion of further fibers in the volume nonwoven is advantageously from 2 to 40% by weight, in particular from 5 to 30% by weight. The further fibers preferably have a length of 1 to 200 mm, preferably 5 mm to 100 mm, and / or a titer of 0.5 to 20 dtex.

According to one embodiment, further volumetric materials that are not fiber balls, in particular down, fine feathers or foam particles, are contained as a further component. The other materials can influence the density and provide the material with other desired properties. The use of down or fine feathers is particularly preferred in textile applications, particularly in the clothing sector, which can improve the thermal properties. If, according to the invention, down and / or fine feathers are used as volumetric material, their proportion in the volume nonwoven is, for example, 10 to 45% by weight, preferably 15 to 45% or at least 15% by weight. The term down and / or fine feathers is understood according to the invention in the conventional sense. In particular, down and / or fine feathers are understood to mean feathers with a short keel and very soft and long, radially arranged feather branches, essentially without hooks.

According to one embodiment, further functional materials that are not fibers or volume-giving materials are contained as a further component. Numerous such additives are known in the technical field, such as colorants, antibacterial substances or odorous substances. In a preferred embodiment, the volume nonwoven contains a phase change material. Phase change materials (PCM) are materials whose latent heat of fusion, heat of solution or heat of absorption is significantly greater than the heat that they can store due to their normal specific heat capacity (without the phase change effect). The phase change material can be in Particle shape and / or fiber-like shape contained in the material composite and be connected, for example, via the binding fibers with the remaining components of the volume nonwoven. The presence of the phase change material can support the insulating effect of the volume nonwoven.

The polymers used to produce the fibers of the volume nonwoven fabric can contain at least one additive selected from the group consisting of color pigments, antistatic agents, antimicrobials such as copper, silver, gold, or hydrophilicizing or hydrophobicizing additives in an amount of 150 ppm to 10% by weight . The use of the named additives in the polymers used allows adaptation to customer-specific requirements.

In a preferred embodiment, the density of the volume nonwoven is at least 5%, preferably at least 10%, even more preferably at least 25% lower than the density of the nonwoven balls used in step (a). This is advantageous since a particularly voluminous nonwoven fabric is obtained which, regardless of this, has a very high stability.

In a preferred embodiment, the method is carried out in such a way that the volume fleece obtained in step (e) is not mechanically consolidated. This is advantageous because a product with a very low density is obtained.

In particular, in the process of steps (a) to (e) there is no needling, hydroentanglement and / or no calendering. Surprisingly, the very voluminous nonwovens of the invention are highly stable even without such additional process steps and despite the low density. Preferably, the nonwoven raw materials are also not carded.

After the thermal bonding in step (e), the bulk nonwoven can be subjected to a bonding or refinement of a chemical nature, such as, for example, an anti-pilling treatment, a hydrophilization or hydrophobization, an antistatic treatment, a treatment to improve the fire resistance and / or to change it of tactile properties or gloss, one Treatment of a mechanical nature such as roughening, sanforizing, sanding or a treatment in a tumbler and / or a treatment to change the appearance such as dyeing or printing.

The volume nonwoven according to the invention can contain further layers, whereby a nonwoven composite is formed. It is conceivable that the further layers are designed as reinforcement layers, for example in the form of a scrim, and / or that they comprise reinforcement filaments, nonwovens, woven fabrics, knitted fabrics and / or scrims. Preferred materials for forming the further layers are plastics, for example polyester, and / or metals. The further layers can advantageously be arranged on the surface of the volume nonwoven. According to a preferred embodiment of the invention, the further layers are arranged on both surfaces (top and bottom) of the volume nonwoven.

The volume nonwoven according to the invention is outstandingly suitable for the production of a wide variety of textile products, in particular products that are supposed to be light, stable and also thermophysiologically comfortable. The invention therefore also relates to a method for producing a textile material, comprising producing a volume nonwoven fabric in a method according to the invention and further processing to form the textile material.

The textile material is selected in particular from clothing, molded materials, padding materials, filling materials, bedding, filter mats, absorbent mats, cleaning textiles, spacers, foam substitutes, wound pads and fire protection materials.

The volume fleece can therefore be used in particular as a molding, cushioning and / or filling material, in particular for clothing. The molding, cushioning and / or filling materials are also suitable for other applications, for example for seating and reclining furniture, pillows, cushion covers, duvets, mattresses, sleeping bags, mattresses, mattress covers.

The term garment is used according to the invention in the conventional sense and preferably includes fashion, leisure, sport, outdoor and functional clothing, in particular outerwear, such as jackets, coats, vests, pants, overalls, gloves, hats and / or shoes. Due to the good heat-insulating properties of the volume nonwoven it contains, articles of clothing which are particularly preferred according to the invention are heat-insulating articles of clothing, for example jackets and coats for all seasons, especially winter jackets, coats and vests, ski and snowboard jackets, pants and overalls, thermal jackets and coats and vests, ski and snowboard gloves, winter hats, thermal hats and slippers.

Due to the good shock-absorbing and breathable properties of the volume nonwoven it contains, items of clothing which are particularly preferred according to the invention are those with shock-absorbing properties at particularly stressed areas, for example goalkeeper trousers, cycling and riding trousers.

The invention also relates to a volume nonwoven obtainable by the method according to the invention. The volume nonwovens according to the invention are characterized by a special structure and special properties that are realized by the special manufacturing process. In particular, very light nonwovens can be produced that have exceptional stability. The nonwovens can also have very good heat-insulating properties and high softness, high compressive elasticity, good resilience, good washability, low weight, high insulation properties and good adaptation to a body to be wrapped.

The thickness of the volume fleece can for example be between 0.5 and 500 mm, in particular from 1 to 200 mm or between 2 and 100 mm. The thickness of the volume fleece is preferably selected as a function of the desired insulation effect and the materials used. Usually, good results are achieved with thicknesses (measured according to test specification EN 29073 - T2: 1992) in the range from 2mm to 100mm.

The basis weights of the volume nonwoven according to the invention are adjusted depending on the desired application. Basis weights, measured according to DIN EN 29073: 1992, in the range from 15 to 1500 g / m ² , preferably from 20 to 1200 g / m ² and / or from 30 to 1000 g / m ² and / or from 40 have proven to be useful for many applications up to 800 g / m ² and / or from 50 to 500 g / m ² .

In a preferred embodiment, the density of the volume nonwoven is low. It is preferably less than 20 g / l, less than 15 g / l, less than 10 g / l or less than 7.5 g / l. The density can, for example, be in the range from 1 to 20 g / l, in particular from 2 to 15 g / l or from 3 to 10 g / l. For many applications of volume nonwovens it is preferred that the density is not higher than 10 g / l, in particular not higher than 8 g / l. is. The density is preferably calculated from the weight per unit area and the thickness. According to the invention, however, advantageous, particularly stable bulk nonwovens with higher densities can also be produced.

In contrast to the known products which contain volumizing materials, the volume nonwoven according to the invention is characterized by a high maximum tensile strength. For example, the tensile strength can be set in such a way that the volume nonwoven can be easily produced, processed and used as a web product. The volume fleece can be cut and rolled up. It can also be washed without losing its functionality.

The volume fleece according to the invention is characterized by a stability that can be adjusted surprisingly well. For many applications it has proven to be advantageous if the volume fleece has a high maximum tensile strength, measured in accordance with DIN EN 29 073-3: 1992 in the context of this application. The maximum tensile strength is generally identical in the longitudinal and transverse directions. The values given below preferably apply to both the longitudinal and the transverse direction.

In a further embodiment it is preferred that the volume nonwoven has a high stability. It preferably has a maximum tensile force of at least 2 N / 5cm, in particular of at least 4N / 5cm or at least 5N / 5cm.

The volume nonwoven preferably has a maximum tensile force in at least one direction of at least 0.3N / 5cm, in particular from 0.3N / 5cm to 100N / 5cm, at a weight per unit area of 50g / m ² .

According to a preferred embodiment of the invention, the volume nonwoven has a maximum tensile strength at a weight per unit area of 15 to 1500 g / m ² , preferably from 20 to 1200 g / m ² and / or from 30 to 1000 g / m ² and / or from 40 to 800 g / m ² and / or from 50 to 500 g / m ² in at least one direction of at least 0.3N / 5cm, in particular from 0.3N / 5cm to 100N / 5cm.

1. (i) bei einem Flächengewicht von 15-50 g/m² in mindestens einer Richtung von mindestens 0,3N/5cm, insbesondere von 0,3N/5cm bis 100N/5cm auf,
2. (ii) bei einem Flächengewicht zwischen 50 und 100 g/m² in mindestens einer Richtung von mindestens 0,4N/5cm, insbesondere von 0,4N/5cm bis 100N/5cm auf,
3. (iii) bei einem Flächengewicht von 100-150 g/m² in mindestens einer Richtung von mindestens 0,8N/5cm, insbesondere von 0,8N/5cm bis 100N/5cm auf,
4. (iv) bei einem Flächengewicht zwischen 150 und 200 g/m² in mindestens einer Richtung von mindestens 1,2N/5cm, insbesondere von 1,2N/5cm bis 100N/5cm auf,
5. (v) bei einem Flächengewicht von 200 bis 300 g/m² in mindestens einer Richtung von mindestens 1,6N/5cm, insbesondere von 1,6N/5cm bis 100N/5cm auf,
6. (vi) bei einem Flächengewicht zwischen 300 und 500 g/m² in mindestens einer Richtung von mindestens 2,5N/5cm, insbesondere von 2,5N/5cm bis 100N/5cm auf,
7. (vii)bei einem Flächengewicht von 500 bis 800 g/m² in mindestens einer Richtung von mindestens 4N/5cm, insbesondere von 4N/5cm bis 100N/5cm auf, und
8. (viii) bei einem Flächengewicht zwischen 800 und 1500 g/m² in mindestens einer Richtung von mindestens 6,5N/5cm, insbesondere von 6,5N/5cm bis 100N/5cm auf.

Gegenstand der Erfindung sind auch Volumenvliesstoffe gemäß jeder einzelnen der Fallgruppen (i) bis (viii).According to a further preferred embodiment of the invention, the volume fleece has a maximum tensile strength

1. (i) with a basis weight of 15-50 g / m ² in at least one direction of at least 0.3N / 5cm, in particular from 0.3N / 5cm to 100N / 5cm,
2. (ii) with a basis weight between 50 and 100 g / m ² in at least one direction of at least 0.4N / 5cm, in particular from 0.4N / 5cm to 100N / 5cm,
3. (iii) with a basis weight of 100-150 g / m ² in at least one direction of at least 0.8N / 5cm, in particular from 0.8N / 5cm to 100N / 5cm,
4. (iv) at a basis weight between 150 and 200 g / m ² in at least one direction of at least 1.2N / 5cm, in particular from 1.2N / 5cm to 100N / 5cm,
5. (v) with a basis weight of 200 to 300 g / m ² in at least one direction of at least 1.6N / 5cm, in particular from 1.6N / 5cm to 100N / 5cm,
6. (vi) with a basis weight between 300 and 500 g / m ² in at least one direction of at least 2.5N / 5cm, in particular from 2.5N / 5cm to 100N / 5cm,
7. (vii) with a basis weight of 500 to 800 g / m ² in at least one direction of at least 4N / 5cm, in particular from 4N / 5cm to 100N / 5cm, and
8. (viii) at a basis weight between 800 and 1500 g / m ² in at least one direction of at least 6.5N / 5cm, in particular from 6.5N / 5cm to 100N / 5cm.

The invention also relates to volume nonwovens according to each of the case groups (i) to (viii).

The volume nonwoven fabric preferably has a maximum tensile strength ratio [N / 5cm] / thickness [mm] of at least 0.10 [N / (5cm * mm)], preferably at least 0.15 [N / (5cm * mm)] or at least 0, 18 [N / (5cm * mm)]. The density is preferably not higher than 10 g / L, in particular not higher than 8 g / L. It is unusual for a volume nonwoven fabric with a low density to achieve such a high HZK (based on the thickness).

The volume fleece preferably has a maximum tensile strength ratio [N / 5cm] / weight per unit area [g / m2] of at least 0.020 [N * m ² / (5cm * g)], preferably at least 0.025 [N * m ² / (5cm * g)] or at least 0.030 [N * m ² / (5cm * g)]. The density is preferably not higher than 10 g / L, in particular not higher than 8 g / L. It is unusual for a volume nonwoven fabric to achieve such a high HZK based on the weight per unit area.

The volume nonwoven preferably has a maximum tensile elongation of at least 20%, preferably at least 25% and in particular more than 30%, measured in accordance with DIN EN 29 073-3. The density is preferably not higher than 10 g / L, in particular not higher than 8 g / L.

The volume fleece according to the invention is characterized by good heat-insulating properties. It preferably has a heat transfer resistance (R _CT value) of more than 0.10 (K * m ² ) / W, more than 0.20 (K * m ² ) / W or more than 0.30 (K * m ² ) / W on. The density is preferably no higher than 10 g / L, in particular no higher than 8 g / L. In the context of this application, the heat transfer resistance is either measured in accordance with DIN 11092: 2014-12, or based on DIN 52612: 1979 in accordance with what is described below Procedure. It was found that the results for both methods are comparable. The procedure according to DIN 11092: 2014-12 is carried out with a thermoregulation model of human skin at T _a = 20 ° C, ϕ _a = 65% RH

The volume nonwoven fabric preferably has a quotient of heat transfer resistance R _CT [Km ² / W] / thickness [mm] of at least 0.010 [Km ² / (W * mm)], preferably at least 0.015 [Km ² / (W * mm)]. The density is preferably not higher than 10 g / L, in particular not higher than 8 g / L. It is uncommon for a low density bulk nonwoven fabric to achieve such a high R _CT (based on caliper).

The volume nonwoven fabric preferably has a quotient of heat transfer resistance R _CT [Km ² / W] / surface weight [g / m ² ] of at least 0.0015 [Km ⁴ / (W * g)], preferably at least 0.0020 [Km ⁴ / (W * g)] or at least 0.0024 [Km ⁴ / (W * g)]. The density is preferably not higher than 10 g / L, in particular not higher than 8 g / L. It is unusual for a volume nonwoven fabric to achieve such a high R _CT value based on the basis weight.

According to the invention, a heat-insulating item of clothing is understood to mean an item of clothing containing a volume nonwoven fabric with a heat transfer resistance, at a weight per unit area of 15 to 1500 g / m ² , preferably from 20 to 1200 g / m ² and / or from 30 to 1000 g / m ² and / or from 40 to 800 g / m ² and / or from 50 to 500 g / m ² , from at least 0.030 (K * m ² ) / W, in particular from 0.030 to 7,000 (K * m ² ) / W.

In addition, the volume nonwoven has a heat transfer resistance with a weight per unit area of 15 to 1500 g / m ² , preferably 20 to 1200 g / m ² and / or 30 to 1000 g / m ² and / or 40 to 800 g / m ² and / or from 50 to 500 g / m ² , from at least 0.030 (K * m ² ) / W, in particular from 0.030 to 7,000 (K * m ² ) / W.

1. a. bei einem Flächengewicht von 15-50 g/m² von mindestens 0,030 (K*m²)/W, insbesondere von 0,030 (K*m²)/W bis 0,235 (K*m²)/W auf.
2. b. bei einem Flächengewicht zwischen 50 und 100 g/m² von mindestens 0,100 (K*m²)/W, insbesondere von 0,100 bis 0,470 (K*m²)/W auf.
3. c. bei einem Flächengewicht von 100-150 g/m² von mindestens 0,200 (K*m²)/W, insbesondere von 0,200 bis 0,705 (K*m²)/W auf.
4. d. bei einem Flächengewicht zwischen 150 und 200 g/m² von mindestens 0,300 (K*m²)/W, insbesondere von 0,300 bis 0,940 (K*m²)/W auf.
5. e. bei einem Flächengewicht von 200-300 g/m² von mindestens 0,400 (K*m²)/W, insbesondere von 0,400 bis 1,410 (K*m²)/W auf.
6. f. bei einem Flächengewicht zwischen 300 und 500 g/m² von mindestens 0,600 (K*m²)/W, insbesondere von 0,600 bis 2,350 (K*m²)/W auf.
7. g. bei einem Flächengewicht von 500-800 g/m² von mindestens 1,000 (K*m²)/W, insbesondere von 1,000 bis 3,760 (K*m²)/W auf, und
8. h. bei einem Flächengewicht zwischen 800 und 1500 g/m² von mindestens 1,600 (K*m²)/W, insbesondere von 1,600 bis 7,000 (K*m²)/W auf.

Gegenstand der Erfindung sind auch Volumenvliesstoffe gemäß jeder einzelnen der Fallgruppen (a.) bis (h.).According to a further preferred embodiment of the invention, the volume nonwoven has a heat transfer resistance

1. a. at a basis weight of 15-50 g / m ² of at least 0.030 (K * m ² ) / W, in particular from 0.030 (K * m ² ) / W to 0.235 (K * m ² ) / W.
2. b. at a basis weight between 50 and 100 g / m ² of at least 0.100 (K * m ² ) / W, in particular from 0.100 to 0.470 (K * m ² ) / W.
3. c. with a basis weight of 100-150 g / m ² of at least 0.200 (K * m ² ) / W, in particular from 0.200 to 0.705 (K * m ² ) / W.
4. d. at a basis weight between 150 and 200 g / m ² of at least 0.300 (K * m ² ) / W, in particular from 0.300 to 0.940 (K * m ² ) / W.
5. e. at a basis weight of 200-300 g / m ² of at least 0.400 (K * m ² ) / W, in particular from 0.400 to 1.410 (K * m ² ) / W.
6. f. at a basis weight between 300 and 500 g / m ² of at least 0.600 (K * m ² ) / W, in particular from 0.600 to 2.350 (K * m ² ) / W.
7. G. at a basis weight of 500-800 g / m ² of at least 1,000 (K * m ² ) / W, in particular from 1,000 to 3,760 (K * m ² ) / W, and
8. H. at a basis weight between 800 and 1500 g / m ² of at least 1,600 (K * m ² ) / W, in particular from 1,600 to 7,000 (K * m ² ) / W.

The invention also relates to volume nonwovens according to each of the case groups (a.) To (h.).

The heat transfer resistance (R _CT ) was measured in accordance with the exemplary embodiments of this application based on DIN 52612: 1979 with a two-plate measuring device for samples with dimensions of 250 mm x 250 mm: In the center of the measurement setup is a film that can be heated by means of a constant electrical power P. The film is covered both above and below with a pattern of the same material. Above and below the pattern there is a copper plate, which is kept at a constant temperature (T _outside ) by means of an external thermostat. The temperature difference between the heated and unheated side of the sample is measured by means of a temperature sensor. The entire measurement setup is insulated against internal and external temperature losses by means of styrofoam.

1. 1. Zwei Muster werden auf 250 mm x 250 mm ausgestanzt.
2. 2. Jedes der zwei ausgestanzten Muster wird mit einem Dickentaster mit 0,4g Anpressdruck auf seine Dicke gemessen und ein Mittelwert gebildet (d).
3. 3. Der oben beschriebene Messaufbau wird zusammengesetzt und das Thermostat auf T_außen = 25°C eingestellt. Dabei wird der Abstand der beiden Metallplatten so eingestellt, dass die Muster um 10 % komprimiert werden, damit ein ausreichender Kontakt der Muster zu den Platten und der beheizbaren Folie gewährleistet wird.
4. 4. Eine Temperaturdifferenz ΔT wird generiert, indem die elektrisch beheizbare Folie mit einer Leistung P (P = 10V oder 30V) geheizt wird und T_außen über einen Thermostat konstant gehalten wird.
5. 5. Nach dem Erreichen des thermischen Gleichgewichts wird die Temperaturdifferenz ΔT übernommen.
6. 6. Die Wärmeleitfähigkeit des Materials wird nach folgender Formel berechnet: $$\mathrm{\lambda }=\mathrm{P}*\mathrm{d}/\left(\mathrm{A}*\mathrm{\Delta T}\right)\left[\mathrm{W}/\left(\mathrm{m}*\mathrm{K}\right)\right]$$
   
7. 7. Der Wärmedurchgangswiderstand (R_CT) wird nach folgender Formel berechnet: $${\mathrm{R}}_{\mathrm{CT}}=\mathrm{d}/\mathrm{\lambda }=\mathrm{\Delta }\mathrm{T}*\mathrm{A}/\mathrm{P}\left[\left(\mathrm{K}*{\mathrm{m}}^2\right)/\mathrm{W}\right].$$
   

The heat transfer resistance is measured with the measurement setup described in the following way.

1. 1. Two patterns are punched out to 250 mm x 250 mm.
2. 2. Each of the two punched-out samples is measured with a thickness probe with 0.4 g of contact pressure on its thickness and an average value is formed (d).
3. 3. The measurement setup described above is put together and the thermostat is set to T _outside = 25 ° C. The distance between the two metal plates is set so that the pattern is compressed by 10% so that sufficient contact between the pattern and the plates and the heatable film is ensured.
4. 4. A temperature difference ΔT is generated by heating the electrically heatable film with a power P (P = 10V or 30V) and keeping T constant _outside via a thermostat.
5. 5. After reaching thermal equilibrium, the temperature difference ΔT is adopted.
6. 6. The thermal conductivity of the material is calculated using the following formula: $$\mathrm{\lambda }=\mathrm{P}*\mathrm{d}/\left(\mathrm{A.}*\mathrm{\Delta T}\right)\left[\mathrm{W.}/\left(\mathrm{m}*\mathrm{K}\right)\right]$$
   
7. 7. The thermal resistance (R _CT ) is calculated using the following formula: $${\mathrm{R.}}_{\mathrm{CT}}=\mathrm{d}/\mathrm{\lambda }=\mathrm{\Delta }\mathrm{T}*\mathrm{A.}/\mathrm{P}\left[\left(\mathrm{K}*{\mathrm{m}}^2\right)/\mathrm{W.}\right].$$
   

1. (1) Es werden 6 Proben übereinander gestapelt (10x10cm)
2. (2) die Höhe wird mit einem Zollstock gemessen
3. (3) die Proben werden mit einer Eisenplatte beschwert (1300g)
4. (4) nach einer Minute Belastung wird die Höhe mit einem Zollstock gemessen
5. (5) das Gewicht wird entfernt
6. (6) nach 10 Sekunden wird die Höhe der Proben mit dem Zollstock gemessen
7. (7) nach einer Minute wird die Höhe der Proben mit dem Zollstock gemessen
8. (8) die Wiedererholung wird errechnet indem die Werte aus den Punkten 7 und 2 ins Verhältnis gesetzt werden.

Es werden 5, 20 oder 100 Messungen an unterschiedlichen Probestücken durchgeführt und die Messwerte werden gemittelt.In addition, the volume fleece according to the invention advantageously has a high restoring force. For example, the volume nonwoven fabric preferably has a recovery of more than 50, 60, 70, 80 or more than 90%, the recovery being measured in the following manner:

1. (1) 6 samples are stacked on top of each other (10x10cm)
2. (2) the height is measured with a folding rule
3. (3) the samples are weighted with an iron plate (1300g)
4. (4) after one minute of loading, the height is measured with a folding rule
5. (5) the weight is removed
6. (6) after 10 seconds, the height of the specimen is measured with a folding rule
7. (7) After one minute, the height of the samples is measured with a folding rule
8. (8) the repetition is calculated by comparing the values from points 7 and 2.

5, 20 or 100 measurements are carried out on different test pieces and the measured values are averaged.

Due to its high stability, the volume nonwoven can be rolled up and processed further, for example as a web product, without any problems.

• eine Dichte nicht höher als 10 g/l, insbesondere nicht höher als 8 g/L und
• eine Höchstzugkraft von mindestens 2 N/5cm, und
• einen Wärmedurchgangswiderstand R_CT von mindestens 0,20 Km²/W, und
• gegebenenfalls einen Quotienten Wärmedurchgangswiderstand R_CT [Km²/W] / Dicke [mm] von mindestens 0,010 [Km²/(W*mm)].

The volume fleece preferably has the following properties:

• a density not higher than 10 g / l, in particular not higher than 8 g / l and
• a maximum tensile force of at least 2 N / 5cm, and
• a thermal resistance R _CT of at least 0.20 Km ² / W, and
• if necessary, a quotient of thermal resistance R _CT [Km ² / W] / thickness [mm] of at least 0.010 [Km ² / (W * mm)].

In particular embodiments of the invention, a volume fleece can be produced as follows:
120 g / m ² of 35% by weight fiber balls made of 7 dtex / 32 mm PES are siliconized (Dacron Polyester Fiberfill Type 287) to which 40% mPCM 28 ° C PC temperature enthalpy, 30% by weight fiber balls are applied made of CoPES binding fiber and 35% by weight of down and / or fine feathers and feathers from Minardi in a "SPIKE" air-laid system from Formfiber Denmark APS, which has four rows of five spiked rollers arranged in two pairs for opening the fiber raw material , placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 10 mm at 155 ° C. The residence time is 36 seconds. A rollable sheet material is produced.

150 g / m ² of 50% by weight fiber balls made of wool and 50% by weight fiber balls made of CoPES binding fiber are used in a "SPIKE" air-laid system from Formfiber Denmark APS, which is arranged in two pairs to open the fiber raw material Has rows with five spiked rollers each, placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 12 mm at 155 ° C. The residence time is 36 seconds. A rollable sheet material is obtained.

150 g / m ² of 50% by weight fiber balls made of silk and 50% by weight fiber balls made of CoPES binding fiber are produced in a "SPIKE" air-laid system from the company Formfiber Denmark APS, which has four rows arranged in two pairs with five spiked rollers each, placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 12 mm at 155 ° C. The residence time is 36 seconds. A rollable sheet material is obtained.

Embodiments

Various volume nonwovens were produced and the properties determined. Thickness, density, basis weight, maximum tensile strength, maximum tensile force elongation, recovery and thermal resistance (R _CT ) were determined according to the methods described above.

Embodiment 1

125 g / m ² of 35% by weight fiber balls made of 7 dtex / 32 mm PES are siliconized (Dacron Polyester Fiberfill Type 287), 30% by weight fiber balls made of CoPES binding fiber and 35% by weight of a down-feather mixture in a ratio of 90 : 10 from Minardi Piume Srl in a "SPIKE" air-laid system from Formfiber Denmark APS, which has four rows of five spiked rollers arranged in two pairs for opening the fiber raw material, placed on a carrier belt and placed in a double belt oven from the company Bombi Meccania solidified with a band gap of 14 mm at 178 ° C. The residence time was 43 seconds. A rollable sheet material was obtained with a thickness of 8 mm and a density of 15.2 g / l.

Embodiment 2

56 g / m ² of 80% by weight fiber balls made of 7 dtex / 32mm PES are siliconized (Dacron Polyester Fiberfill Type 287) and 20% by weight CoPES binding fiber in a "SPIKE" air-laid system from Formfiber Denmark APS, which has four rows arranged in two pairs, each with five spiked rollers, to open the fiber raw material, placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 1 mm at 170 ° C. A rollable sheet material was obtained with a thickness of 6.1 mm. The material had a density of 9.18 g / L.

Embodiment 3

128 g / m ² of 80% by weight of fiber balls made of 7 dtex / 32 mm PES are siliconized (Dacron Polyester Fiberfill Type 287) and 20% by weight of CoPES binding fiber in a "SPIKE" air-laid system from Formfiber Denmark APS , which has four rows arranged in two pairs, each with five spiked rollers, to open the fiber raw material, placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 4 mm at 170 ° C. A rollable sheet material was obtained with a thickness of 7.5 mm. The material had a density of 17.07 g / L.

Embodiment 4

128 g / m ² of 80% by weight fiber balls made of 7 dtex / 32 mm PES are siliconized (Dacron Polyester Fiberfill Type 287) and 20% by weight CoPES binding fiber in the "SPIKE" air-laid system from Formfiber Denmark APS, the to open the fiber raw material has four rows arranged in two pairs, each with five spiked rollers, placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 30 mm, ie without stressing the fiber web, at 170 ° C. A soft, rollable sheet material was obtained, with a thickness of 25 mm. The material had a density of 5.12 g / L.

Embodiment 5

723 g / m ² of 80% by weight fiber balls made of 7 dtex / 32 mm PES are siliconized (Dacron Polyester Fiberfill Type 287) and 20% by weight CoPES binding fiber in a "SPIKE" air-laid system from Formfiber Denmark APS, which has four rows arranged in two pairs, each with five spiked rollers, to open the fiber raw material, placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 50 mm at 170 ° C. A rollable, stable web material with a thickness of 50 mm was obtained. The material had a density of 14.5 g / L.

Embodiment 6

112 g / m ² of 85% by weight of fiber balls (MICROROLLO® 222 SM from A. Molina & C.) and 15% by weight of PET / PE binding fiber are produced in a "SPIKE" air-laid system from Formfiber Denmark APS, which has four rows arranged in two pairs, each with five spiked rollers, is placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 40 mm at 180 ° C. A rollable, stable web material with a thickness of 17 mm was obtained. The material had a density of 6.5 g / L, a maximum tensile force of 3.84 N / 5 cm and a maximum tensile force elongation of 29%, as well as an R _CT value of 0.323 Km ² / W (at P = 10V).

Embodiment 7

151 g / m ² of 85% by weight of fiber balls (MICROROLLO® 222 SM from A. Molina & C.) and 15% by weight of PET / PE binding fiber are produced in a "SPIKE" air-laid system from Formfiber Denmark APS, which has four rows arranged in two pairs, each with five spiked rollers, is placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 40 mm at 180 ° C. A rollable, stable web material with a thickness of 19 mm was obtained. The material had a density of 6.1 g / L. A sample taken at another point with 167 g / m ^{2 had} a maximum tensile force of 5.14 N / 5 cm and a maximum tensile force elongation of 33%, as well as an R _CT value of 0.398 Km ² / W (at P = 10V).

Embodiment 8

There are 218 g / m ² of 85% by weight fiber balls (MICROROLLO® 222 SM from A. Molina & C.), 15% by weight PET / PE binding fiber in a "SPIKE" air-laid system from Formfiber Denmark APS, which has four rows arranged in two pairs, each with five spiked rollers, placed on a carrier belt and solidified in a double belt furnace from Bombi Meccania with a belt gap of 50 mm at 180 ° C for opening the fiber raw material. A rollable, stable web material with a thickness of 31 mm was obtained. The material had a density of 7.0 g / L. A sample taken at another point with 259 g / m ² had a maximum tensile force of 5.45 N / 5cm and a maximum tensile force elongation of 34%, as well as an R _CT value of 0.534 Km ² / W (at P = 10V).

Embodiment 9

Further properties of the nonwovens produced according to the examples were investigated. The results are summarized in Table 1. For comparison, the densities of the nonwoven balls are given in Table 2. The comparison shows that according to the invention it is easily possible to obtain products with a significantly lower density than that of the nonwoven balls used, and that although the density of the binding fibers is much higher. Therefore, particularly light volume nonwovens can be produced, which regardless of this have exceptionally high basis weights. The volume nonwovens also have very good recovery values, which is of great importance for textile applications. <u> Table 1 </u>: Density of the volume nonwovens (e.g. = example, FG = weight per unit area, HZK = maximum tensile force, HZKD = maximum tensile force elongation, WE = repetition, R _CT = heat transfer resistance, measured at P = 10V): E.g. thickness FG density HZK HZKD WE R _CT HZK / thickness HZK / FG R _CT / thickness R _CT / FG [mm] [g / m ² ] [g / L] [N / 5cm] [%] [%] [Km ² / W] [N / (5cm * mm)] [N * m ² / (5cm * g)] [Km ² / (W * mm)] [Km ⁴ / (W * g)] 1 8th 125 15.2 89.5 2 6.1 56 9.2 3 7.5 128 17.1 4th 25th 128 5.1 5 50 723 14.5 6th 17th 112 6.5 3.84 29 82% 0.323 0.22 0.034 0.019 0.0029 7th 19th 151 6.1 5.14 33 84% 0.398 0.27 0.034 0.021 0.0026 8th 31 218 7.0 5.45 34 76% 0.534 0.18 0.025 0.017 0.0024 Raw materials volume Weight density [ml] [G] [g / L] Dacron Polyester Fiberfill Type 287 500 5.795 11.59 Microrollo 222 SM 500 6.518 13.04

Claims (15)

1. A method for the manufacture of a volume nonwoven fabric, comprising the steps of:

   (a) providing a nonwoven fabric raw material, comprising fiber balls and binder fibers,

   (b) providing an airlaid device, comprising at least two spiked rolls, between which a gap is constituted,

   (c) processing of the nonwoven fabric raw material in the device in an airlaid process, wherein the nonwoven fabric raw material passes the gap between the spiked roles, wherein fibers or fiber bundles are pulled out of the fiber balls by the spikes,

   (d) depositing on a depositing facility; and

   (e) thermal consolidation to obtain a volume nonwoven fabric.
2. A method according to claim 1, wherein the device has at least 2 pairs, preferably at least 5 pairs or at least 10 pairs of spiked roles, and/or the device preferably has at least 2, at least 5 or at least 10 gaps between the spiked roles.
3. A method according to at least one of the preceding claims, wherein the portion of the fiber balls is 50 to 95 wt. %, preferably 60 to 95 %, especially from 70 to 90 %, and/or the portion of binder fibers in the volume nonwoven fabric is 5 to 40 wt. %, preferably 7 to 30 wt. %, and especially preferred 10 to 25 wt. %., each in relation to the total weight of the nonwoven fabric raw material.
4. A method according to at least one of the preceding claims, wherein the fiber balls comprise or consist of fibers selected from synthetic fibers, such as fibers of polyester, in particular polyethylene terephthalate, polyethylene naphthalene and polybutylene terephthalate, and natural fibers, such as wool, cotton or silk fibers and/or blends of the afore-mentioned and/or blends with additional fibers.
5. A method according to at least one of the preceding claims, wherein the binder fibers are configured as core/shell fibers, wherein the shell comprises polyethylene, polypropylene, polybutylene terephthalate, polyamide, copolyamide or copolyester, and/or wherein the core comprises polyethylene terephthalate, polyethylene naphthalate, polyolefines, such as polyethylene or polypropylene, polyphenylene sulfide, aromatic polyamide and/or polyester.
6. A method according to at least one of the preceding claims, wherein the nonwoven fabric raw material comprises at least one additional component, selected from additional fibers, additional volume-giving materials and further functional additives.
7. A method according to at least one of the preceding claims, wherein the density of the volume nonwoven fabric is at least 5%, preferably more than 10%, even more preferred at least 25% lower than the density of the fiber balls employed in step (a).
8. A method for the manufacture of a textile material, comprising the manufacture of a volume nonwoven fabric according to any of the preceding claims and further processing to a textile material, wherein the textile material is particularly selected from garments, shaping material, upholstering, filler material, bedspreads, filter mats, suction mats, cleaning textiles, spacers, foam replacement, wound dressings and fire protection materials.
9. A volume nonwoven fabric, obtainable according to a method of at least one of the preceding claims.
10. A volume nonwoven fabric according to claim 9, having a density in the range from 1 to 20 g/l, particularly from 2 to 15 g/l, especially preferred from 3 g/l to 10 g/l, wherein the density is preferably lower than 10 g/l.
11. A volume nonwoven fabric according to any of the preceding claims, which has at least one of the following properties:

    - a maximum tensile strength of at least 2 N/5cm, measured according to DIN EN 29 073-3,

    - a maximum tensile elongation of at least 20% measured according to DIN EN 29 073-3,

    - a thermal resistance R_CT of at least 0.20 Km²/W, and

    - a recovery of at least 70%, determined according to the method with the steps (1) to (8) as disclosed in the description.
12. A volume nonwoven fabric according to any of the preceding claims, which has the following properties:

    - a ratio of maximum tensile strength [N/5cm] / thickness [mm] of at least 0.10 [N/(5cm*mm)], and/or

    - a ratio of maximum tensile strength [N/5cm] / basis weight [g/m²] of at least 0.020 [N*m²/(5cm*g)], and/or

    - a ratio of thermal resistance R_CT [Km²/W] / thickness [mm] of at least 0.010 [Km²/(W*mm)].
13. A volume nonwoven fabric according to any of the preceding claims, which has the following properties:

    - a density lower than 10 g/l, und

    - an maximum tensile strength of at least 2 N/5cm, and

    - a thermal resistance R_CT of at least 0.20 Km²/W,

    - and optionally a ratio of thermal resistance R_CT [Km²/W] / thickness [mm] of at least 0.010.
14. A textile material, comprising a volume nonwoven fabric according to at least one of claims 9 to 13, wherein the textile material is particularly selected from garments, shaping material, upholstering, filler material, bedspreads, filter mats, suction mats, cleaning textiles, spacers, foam replacement, wound dressings and fire protection materials.
15. Use of a volume nonwoven fabric according to at least one of claims 9 to 13 for the manufacture of a textile material, wherein the textile material is particularly selected from garments, shaping material, upholstering, filler material, bedspreads, filter mats, suction mats, cleaning textiles, spacers, foam replacement, wound dressings and fire protection materials.