PT104843A - STRUCTURES OF THREE-DIMENSIONAL NON-FABRICS WITHOUT FORM FOR ACTIONAL ISOLATION AND ASSOCIATED PRODUCTION MECHANISM - Google Patents

Abstract

The present invention relates to non-woven tri-valent fabrics with fibers oriented in different directions, and surface shapes in predetermined regions (1). It comprises at least three layers, a top (2) and a bottom (3) and a layer of randomly oriented fibers (4), connected by means of fibers in the predetermined regions (5) and a special base technology IN THE CONFIGURATION OF THE NEEDLES IN THEIR SUPPORT PLATE INTEGRATED FROM THE MACHINE OF NON-FABRICS PRODUCED BY NEGATIVE TECHNIQUES, WHICH CAN BE PLACED IN DIFFERENT POSITIONS, AND A SPECIAL FEEDING SYSTEM? O, TO ENSURE THE FEEDING OF THE DIFFERENT LAYERS, FOR THE PRODUCTION OF THE PRODUCT.

Description

FIGURE FOR PUBLICATION

DESCRIPTION " THREE-DIMENSIONAL NON-FABRIC STRUCTURES WITH FORM FOR ACOUSTIC INSULATION AND ASSOCIATED PRODUCTION METHOD "

Field of the Invention The present invention relates to a three-dimensional non-woven structure, with surface shapes in predefined areas, using at least 3 layers, a conventional machine with an altered feeding system (10) and a special technique, based on the configuration of the needles on its support plate which is integral with the needle-free nonwoven production machine which can be needled in different positions.

state of art

Textile structures play an important role in the overall performance of a textile system. The three-dimensional structures are organized and integrated sets of fibers with multiaxial orientation. Due to the different orientation of the fibers, these types of structures have a high performance and are suitable for a wide range of applications such as acoustic insulation.

Non-woven products with various functions and applications are increasingly being used in technical applications due to their different functions and advantages. Nonwovens thus present an important position in the textile market for technical application. The most important advantages of non-woven fabrics are the low weight, flexibility and versatility, combined with direct production from 1 fibers, which means that they are produced quickly and inexpensively. The combination of the advantages of conventional non-woven fabrics with the properties of three-dimensional fibrous structures leads to the production of three-dimensional non-woven products with a large number of applications.

Nonwoven with three-dimensional structure are required for various technical applications, such as geotextiles, insulation, reinforcement of composites, civil engineering, among others.

This type of nonwoven can be used alone or in combination with other materials. Conventionally, they are produced from flat structures. In this case, in addition to the additional costs of the conversion processes, the irregularity is inevitably introduced into the final product due to the joints. There have already been several attempts to produce three-dimensional non-woven fabrics directly from the production technology. Sound insulation can be an important application of this type of fibrous structures. Several articles for acoustics have been developed to compensate for the undesirable attributes of noise pollution. Sound absorbing materials on the market are in the form of panels or laminates. These products are mainly used in motor vehicles, as well as in other situations including, airplanes, trains, houses and buildings.

Many of the acoustic problems can not be satisfactorily resolved by the mere use of primary insulation means which are applied to the sound sources, and secondary insulation means are normally required. These secondary means correspond, as a rule, to means which intervene in the transmission path of the acoustic energy. In this way, energy is reflected, or rather deflected, or converted into another form of energy, usually heat. In the first case, insulation is used, while in the second case the sound is attenuated. In the conventional process of sound attenuation, the main methods convert the acoustic energy, in the range of the average frequency, to a high frequency range, corresponding to heat, through the use of porous sound absorbers, where the extension of the conversion depends on its frequency range. The fact that porous absorbers are generally tested and used from the means to the high frequencies, is based on their physical attenuation properties. In order to attenuate an acoustic wave with the highest possible absorption, the material thickness needs to be at least 25% of the wavelength, to be attenuated, provided that the range of sound wave displacement is greater in its range. Thus, low frequencies determine the need to use large thicknesses of insulation material due to their large wavelengths. This effect can also be achieved by using low thickness materials in combination with air gaps. The insulation material in these cases is placed at a distance corresponding to λ / 4. However, the degree of absorption of aerial sounds a, describing the attenuation capacity, corresponds in the market to a slope configuration, in the high frequency range. 3

Conventional acoustic insulation materials include: cork, foam, compressed fibers, fiberglass rolls, fiber, non-woven and multilayer nonwoven fabrics. At the level of fibrous nonwoven, thermoplastic fibers have been widely used as materials for sound insulation. Laminated non-woven with thermoplastic fibers, have also been used for sound insulation. The selection of a specific insulation material depends on several factors including cost, thickness, weight, sound attenuation performance and the actual use / handling of the insulation material. Attenuation through sound insulation occurs either by absorption of sound through the insulation material, or by reflection of sound waves to the outside of the receiving area. Sound attenuation is measured by the ability of the material to absorb incident sound waves (sound absorption) and / or through the ability of the material to reflect incident sound waves (reflection). Ideally, a sound attenuating material has a high sound absorption coefficient and / or high sound loss transmission capacity. U.S. Patent No. 5,841,081 issued November 24, 1998 discloses a method for attenuating sound waves from a source to a receiving area comprising a molded, three-dimensional, organic microfiber nonwoven having a percentage of 15% by weight or more, of heat activated fibers. The nonwoven has a thickness of 0.5 cm or more and a density of at least 250 kg / m3. The heat activated fibers are attached to one another and to the microfibers at various points of contact. In this way, the resulting product can be shaped into a variety of shapes. By adding an appropriate amount of bulky fibers with high denier, a greater attenuation capacity is obtained, as well as a good flexural strength. U.S. Patent 6,376,396, issued May 23, 2002, relates to a nonwoven sound insulation material containing thermoplastic fibers for use in the acoustic frequency range of 100 to 5000 Hz. This material is especially used in combination with porous insulating materials to increase acoustic absorption at low frequencies. This nonwoven containing thermoplastic fibers is permanently compacted to a specific flow resistance of RS = 800-1400 Ns / m3 in two steps, through a compaction mechanical process and a subsequent pressure and heat treatment. U.S. Patent 6,937,111 B2 issued 05/05/2005 discloses an acoustic sound attenuation insulation material containing a nonwoven of thermoplastic fibers having an average diameter of 7 microns, the acoustic insulation material having a thickness below 3 mm and a density greater than 50 kg / m3e is considered a sound insulation material. US 6220388 B1 is a patent published 04-04-2001 which discloses an acoustic insulation panel for sound absorption and attenuation. The sound insulation panel comprises a central inner layer including several cells, and another membrane disposed on at least one side of the central inner layer, to cooperatively form a group of chambers for sound attenuation. Each of the other membranes comprises an inner substrate corresponding to a sound absorbing nonwoven consisting of thermoplastic microfibers, laminated and another face for protecting the inner substrate, formed by a sound absorbing non-woven fabric, of thermoplastic fibers . The central inner layer comprises a honeycomb-like structure, formed by cells of the interconnected side walls, to create groups of cells. US 6723416 Blpublished 20-04-2004 presents a three-dimensional composite fibrous structure and its method of production. The three-dimensional structure is produced with layers of continuous filaments alternating perpendicularly with the planar surface and layers of short, dense fibers which are permanently heat bonded in a continuous process or at certain locations to the layers of filaments. The continuous filament layers represent a fabric, braid or net, having pleats or raised-shaped shapes in the layers of short fibers. In the production process all layers of the laminate are jointly subjected to a shrinkage process at a certain temperature between the softening and melting point of the fabric. To obtain the three-dimensional composite, at least two layers of nonwoven are bonded to a layer of fabric. The non-woven layers are formed by fibers which are bonded together by mechanical and / or thermal processes so that a repetitive geometric pattern formed by elevations or corrugations is created in the direction of the surface by means of folds. The three-dimensional composite is composed of a wrinkled fabric and both layers of nonwoven which are attached to the wrinkled fabric but not to each other, so that both sides of the fabric, elevations and depressions are formed in the nonwoven. Among the elevations are hollow spaces, which are permeable to fluids and absorb particles and dust. US 7060344 B2 published 13-06-2006 discloses a three-dimensional shaped structure comprising a nonwoven formed of fibers and / or filaments having low diameters. Nonwoven fibers with randomly oriented fibers at the level of their distribution and with a high degree of crimping with partially oriented fibers are preferably used to form the shaped structure. The process for producing the three-dimensional structure is based on heating, deformation and cooling. During the heating process, the fibers approach their melting point and are only partially molten. The structure is based on the thermoplastic components, due to their molding capabilities, but can be composed of thermoplastic and non-thermoplastic components. The physical characteristics of the fibers are important, as is the structure casting process. Structures are formed by combining heat and pressure, such as those commonly used in molding tools, in the stamping, printing or calendering processes.

The cited patents are based on the use of thermoplastic materials (fibers), in order to create shapes through the application of heat, due to the melting of the fibers, and to increase acoustic performance at low frequencies. The non-woven three-dimensional shape shown in this patent does not show any type of thermoplastic materials and the forms are automatically developed in the nonwoven production process using a special technique. The acoustic performance at low frequencies is very good due to the three-dimensionality of the fibrous structure. Furthermore, the three-dimensional fibrous nonwoven is produced in a single step, requiring no further processes, such as heating and cooling. The combination of the advantages of conventional non-woven fabrics with the superior properties of three-dimensional fibrous structures leads to the production of fibrous structures required for many technical applications such as geotextiles, insulation, reinforcement of composites, civil engineering, among others. This type of nonwoven can be used alone or in combination with other materials, as in the case of composites. Currently they are produced from flat structures. In such cases, in addition to the high costs of the conversion processes, irregularities are inevitably introduced into the final product in the connecting zones. There have been several attempts to produce three-dimensional non-woven fabrics directly from the nonwoven production process. WO 2005/007962 published 01/27/2005 discloses a three-dimensional sandwich nonwoven comprising at least two separate but interconnected layers with discrete bonds which provide for the creation of small spaces between the two non-woven layers. -fabric. These are very fine products with absorption properties. The thickness ranges from 1 to 9 mm and the surface mass in the range of 20 - 1000 g / m2. The method of producing this product comprises two different steps: in the first stage the nonwoven is formed from fibers or filaments on the two sides of a spacing device, in the second step selected fibers of at least one nonwoven are transferred between the apertures in the spacing device, to the adjacent non-woven fabric, creating an integrated structure. High pressure water jets are used to interconnect groups of fibers between the spacers. No. 5,475,904 issued December 12, 1995 discloses a method and a device for producing composite layers, and final composites from these obtained, wherein two layers are needle jointly between longitudinal guide tubes, which maintains a space between the layers and between the downward positioning movement of the needles, the tubes maintain a distance between the layers and between the connections created by the needling process. The interconnecting material consists of resin, glue, fibers, tubes, wires, wires and / or electrical conductors. The obtained composite product exhibits some mechanical strength, while retaining the ability to be formed. In this regard, a paste of dough which is moistened with water is placed between the two layers, which are needled through the paste. The thickness of the product obtained is indeterminate. WO 2007/125248 published 08-11-2007 discloses a method characterized by the use of a pleat device for application to a moving nonwoven containing a proportion of fibers and / or thermoplastic filaments, an initial fold in the non woven in the form of a sharp tip through blades arranged radially at the end of the pleat device, this initial pleat creation can be made by keeping the device at a certain temperature, or by heating the non-woven in movement. This invention is more particularly applied to the textile industry, especially in the production of non-woven fabrics. The invention of the present invention is novel and involves an inventive step, taking into account all other patents described above in the state of the art. The system for producing the three-dimensional nonwoven in the present invention does not use any spacing plate between the layers, nor means for advancing and guiding the two layers of base nonwoven, and in this sense it is possible to use a conventional machine of production of non-woven needles. Moreover, in the present invention, high pressure water jets in combination with rigid spacing devices are not used to produce the final product.

Different mechanisms and devices have been introduced in the last decades to increase the performance of needle-free nonwoven machines with the aim of creating some designs and / or configurations of the fibers in the final product. Examples of such mechanisms are disclosed in the following documents: US 0162203 AI published 07-11-2002, US 6584659 B2 published 01-07-2003, US 7107658 B2 published 19-09-2006, US 6622359 B2 published on 23-09 2003 and US 6785940 BI published on 09-09-2004 show devices for needleing nonwoven materials with a holder which receives at least one needle plate and is guided reciprocally either in the direction of needle penetration or in the direction of the nonwoven.

On the other hand, UK 2376473A published 18-12-2002, discloses a needle-free fabric producing machine in which the plates between which the ready-to-needle beads of fibers circulate are movable in order to provide advantageous structural conditions , which allow the increase of the penetration density. The machine further includes a needle plate which reciprocates in both directions in the direction of needle penetration and in the direction of passage of the material and comprises a support plate of the movable fiber webs and a movable top plate which in turn assembly define the non-woven passageway. These two plates with movement in the nonwoven passage direction can be controlled in synchronism with respect to the needle plate which is mounted above the top plate shown. The base plate and top plate, which define the passage of the nonwoven, may be controlled by different cams US 0103975 AI published 03-06-2004 discloses a ball covered by a nonwoven produced by needling a mantle of fibers in a range of angles, including a set of angles that are not perpendicular to the flat base of the fiber mantle. The range of angles is preferably obtained by flexing the fiber mantle during the needling process, thus, the fiber mantle is suitably flexed in its working direction through the needle-free machine. The needle plate of the machine is also preferably bent. U.S. Patent 0011060 AI published on 01/20/2005 discloses a non-woven needle device with at least one needle plate which is reciprocally driven in the needle penetration direction and with a fiber mantle support base with movement opposite that of the needle plate which is a brush-type rubber mat 11, thereby forming a conveyor belt. The needle plate comprises needle sections, which have a certain distance from each other, which extends at least through a section, in the direction of movement of the conveyor belt. The conveyor belt and the needle plate can be moved back and forth reciprocally by means of traction movement during movement of the non-woven conveyor transversely to the direction of movement of the conveyor belt, to an extent corresponding to the distance between the needle sections, or into corresponding multiples. In order to obtain a configurations with hair, during the needling of the non-woven fabric, the latter is conveyed on a needle-like base made of a rotating brush type carpet, through the needling device, so that the needles penetrate the fibers of the non-woven fabric to create the loops on the conveyor belt. The formation of the raised fibers occurs only in sections where the nonwoven may provide a surface drawing formed by the superficially raised fibers. It is also necessary to ensure the strength of the conveyor belt which is in contact with the surface of the non-woven fabric during the non-woven needling process. DE patent 1660783 published 01/15/76 discloses a device for needling fiber veils, or the like, due to the use of needle plates (attached to a needle beam) which have an upward and downward movement. This needle beam is divided into two segments, which are positioned close to each other. These segments are guided in their ascending and descending movements so they can not move out of their positions. The needle plates are moved through a main shaft 12 and in accordance with some clutches. The different needle plates can provide different needle densities

Patents DE 518907 published 05-02-1931, US 2148511 published on 07/30/1937 and US 1742133 issued 12/31/29 are related to a needle-free fabrication machine, wherein the needle-pressing operation is performed by reciprocal movements performed by segments of needles pulling the fibers from the interior of the nonwoven, due to their downward movement. The needle plate is divided into more than one segment, each of which can be moved separately. A main shaft moves the needle segments. These needle segments also have movement in the direction of movement of the material. This movement towards the machine is as long as the movement of the needles in their action on the veil of fibers. The machine may be conveniently constructed of various widths, using a greater or lesser number of needle segments and associated operating means. The units will be of a size corresponding to the smallest type of machine, desirably built with 60 ". DE patent 1785256 published 02-09-1968 discloses a needle bar nonwoven production machine divided into several segments. A second source of fibers feeds the productive process, creating with the varied movement of the needle segments, designs in the final structure. DE 10036821 AI published on 03/22/2001 discloses a plate of non-woven needle needles having at least two successive but independent and spaced apart plates with needles which work with another device located on the plate non-woven pass-through base to create loops to achieve a wide variety of designs through the needle bonding process. The variation of speed and the working frequency of the needle plates helps to create different designs in the nonwoven.

All of these patents refer to some increments in needle-free machines to create special nonwoven fabrics with different fiber orientations, special configurations and designs in the final non-woven fabric. This new technology is however different in the process of producing the three-dimensional shaped non-woven fabric, since it is not based on needle segments, but its special configuration occurring only on a single needle plate. The different setting or positioning of the needles on the needle plate allows you to create surface shapes in predefined areas. On the other hand, this special technique can be applied in a conventional machine of needle-free nonwoven production, presenting a low cost, and an easy and fast production.

SUMMARY OF THE INVENTION The present invention relates to a three-dimensional nonwoven structure, comprising a nonwoven topsheet and a nonwoven underlayer, and a third layer based on randomly oriented fibers. These layers are attached in predefined areas using a special needling technique, leading to the creation of shaped shaped spaces according to requirements. The created spaces allow to obtain superficial forms in predefined areas in the upper and lower faces of the non-woven. These three-dimensional structures are produced in a single step, in different configurations, and can be applied where the final configuration of the product leads to better performance, mainly for sound insulation purposes.

To obtain this shaped three-dimensional needlework, a special technique is used, based on the configuration of the needle plate of the machine, which can be needle-punched in different positions and if required with needles of different lengths. These three-dimensional non-woven fabrics are produced in a single step using an intermittent process in different configurations. In the production of these types of structures it is possible to use all types of fibers. The final product developed using this special technique presents important characteristics when compared to other products commonly used in acoustic insulation such as low cost, easy and fast production , versatility according to the required thickness and dimensions and good performance for different specific applications.

DESCRIPTION OF THE DRAWINGS Figure 1 shows the cross-section of a three-dimensional needlework non-woven structure, with regular surface shapes in predefined areas. 1 - Shallow forms; 15 2 - Upper layer; 3 - Lower layer; 4 - Fibers oriented randomly; 5 - Connections. Figure 2 shows the top view of a three-dimensional needlework non-woven structure, with regular surface shapes in predefined areas. 1 - Shallow forms; 4 - Fibers oriented randomly; 5 - Connections. Figure 3 shows the adjustable components of a needle-free nonwoven production machine. These components may be varied to produce products with specific properties. 6 - Needle plate; 7 - Non-woven support base plate; 8 - Top plate; 9 - Needles; D - Distance between the base plate and the top plate. Figure 4 shows some needle plate configurations that can be used for the production of three-dimensional needle-shaped nonwoven with surface shapes in predefined areas. 4 - Fibers oriented randomly; 5 - Connections. Figure 5 shows the feed system and the draw system, developed for the production of three-dimensional needlework non-woven with surface shapes in predefined areas. 16 10 - Changed supply system. Figure 6 shows a comparison of acoustic insulation performance of a flat needle (according to the state of the art) non-woven with a three-dimensional non-woven needle with surface shapes. Figure 7 shows the acoustic performance of different products on the market compared to the invention presented here, non-woven three-dimensional needlework with surface shapes. Figure 8 shows a table comparing materials used in the three-dimensional surface-shaped nonwoven structure based on the present invention and flat (state of the art) non-woven fabrics.

Detailed Description of the Invention The three-dimensional non-woven production system is composed of feed systems and mechanical systems, in combination with special techniques, based on the configuration of the needling plate (Figure 3, component 7) of the machine, which may be needled with needles in different positions.

This three-dimensional needlework (3D) comprises at least two separate but interconnected layers, filled with randomly oriented fibers (4), fed directly from the fiber-glimmer arrangement and with an irregular surface with shapes (1). This three-dimensional nonwoven is produced in a single step, using an intermittent process, in different configurations. In the production of this type of structures all types of fibers can be used.

In order to obtain the proposed three-dimensional non-woven fabric, two layers of nonwoven are fed from a special feeding system (Figure 5) into the non-woven machine where the needle plate, with beards, transfer fibers from one layer to another, creating bonds between the layers separated from each other, in predefined areas of the final structure, creating a three-dimensional structure with fibers in different orientations. In other areas, where the bond between the two non-woven layers is non-existent, the randomly oriented fibers inserted in the middle of the two layers create an uneven surface shape. A large number of three-dimensional shaped non-woven structures can be obtained.

With the technique of needle plate configuration, different needle positions on the same plate are used in order to allow the production of three-dimensional non-woven structures. This technique provides fiber binding in the machine direction only in the required areas according to the selected configuration of the needles on the needle plate. This configuration is based on the position of the needles, and in certain parts of the needle plate no needles are placed. The position of the needles on the board can be selected, taking into account certain predefined configurations, depending on the connection required for the three-dimensional structure. 18

The needleless areas of the needle plate lead to non-woven areas between the two layers of nonwoven or creating voids in the final structure where it is possible to insert randomly oriented fibers in order to create an irregular surface shape. In addition, needles of different lengths may be used at specific positions of the needle plate in order to create a greater entanglement of the fibers in the structure.

The specific needles used in the process are chosen according to the requirements of the material used for the production of the three-dimensional shaped structure. Different types of needles can be used without any kind of restriction. The designated distance between the non-woven carrier base plate and the upper pass-through plate, designated GAP, may be varied in order to control the thickness of the final product, taking into account the amount of material feeding the machine. At the same time, the base plate corresponds to the support plate of the feed material and controls the depth of penetration of the needles. Thus, it is an important parameter for controlling the stiffness of the structure and the surface configuration of the nonwoven shapes. On the other hand, if needles with different lengths are used, the variation of the positioning of the base plate allows controlling the depth of penetration of the needles of different length.

In order to obtain surface shapes continuously in the needle-free nonwoven structure, an intermittent process is used, the feed being suspended when the structure is being needle-punched, and the needle plate stopped when the feed process is advancing. In this way the needlework process is discontinuous and is controlled over a period of time ranging from 4 to 60 seconds, depending on the intensity of penetration required for the specific application defined. The intensity of penetration imposed on the nonwoven depends on the frequency of penetration, i.e. the number of times the needle plate rises and falls per minute and the density of the needle, i.e. the number of needles per cm, on the plate of needles.

In order to produce the three-dimensional needled nonwoven using the particular technique presented, a conventional needling machine can be used. The needle plate needs to be manually configured according to the required surface shapes, and two devices need to be added to the feed movement of the two (top and bottom) nonwoven layers. These two devices can be easily added and removed from the conventional needlework nonwoven production machine.

Different materials can be used to produce non-woven three-dimensional shaped. The variation of the type of fibers used can occur in the two layers of upper and lower nonwoven as well as in the intermediate layer used in the middle of these two layers, composed of randomly oriented fibers according to the requirements. The upper and lower layers of the three-dimensional structure are pre-pre-sized, having a low thickness. The randomly oriented fibers are integrated from the conventional nonwoven fabrication line 20, the fiber mantle forming process being preferably used, by carding, after the device for forming the various layers of veils, in order to orient and parallelize the fibers.

For acoustic insulation, the surface-shaped three-dimensional needlework non-woven fabric disclosed in this patent has better performance than a conventional non-woven fabric (without shapes) with the same structural and compositional properties for the entire frequency range (Hz), presenting a high absorption (Figure 6), for the non-woven structures produced according to the specifications presented in Table 1. The highest value of acoustic absorption for the three-dimensional structure is obtained at 800 Hz, with a absorption coefficient of 0.83. The flat nonwoven yields the highest value at 400 Hz, corresponding to an absorption coefficient of 0.61. The performance checked is greater than 100% at 1000 Hz, about 55% at 1500 Hz and at 100 Hz, about 30% at 2500 Hz and more than 20% at 3000 and at 5000 Hz.

When compared to other products on the market, the three-dimensional (3D) surface shaped needlework structure developed within the scope of the present invention substantially increases the acoustic performance of nonwoven panels when compared to those reported in the literature ( Figure 7). The results of the performance evaluation show that the innovative three-dimensional structure presents a much better insulation to air sounds when compared to conventional products using a high thickness. 21

Considering the results obtained, and taking into account the characteristics of the nonwoven, it is possible to conclude that the arrangement of the fibers in the three-dimensional (3D) needlework structure with irregular surface shapes positively influences the acoustic performance, leading to a high acoustic insulation.

Lisbon, November 26, 2010 22

Claims (14)

A three-dimensional needlework (3D) structure characterized by having two layers of fibrous nonwoven (2 and 3), spaced apart but interconnected, with internal filling of randomly oriented fibers (4) and having surface shapes in predefined areas, which are bounded by interconnected areas (5), wherein the upper (2) and lower (3) layers are bonded by fibers. A three-dimensional shaped non-woven structure according to claim 1, characterized in that the fibers come from at least three layers and can be natural, unnatural or recycled. A three-dimensional shaped non-woven structure according to claim 1, characterized in that the fibers used in the three layers (2, 3 and 4) have a linear mass between 5 dtex and 50 tex and a length between 20 mm and 100 mm. A three-dimensional shaped non-woven structure according to claim 1, characterized in that the surface shapes may have different geometries, such as circular or elliptical. A three-dimensional shaped non-woven structure according to claims 1 to 3, characterized in that the density of the different layers and the final product is variable according to the specific requirements 1 of the application and according to the limitations of the non-woven production machine by needling. A three-dimensional shaped non-woven structure according to claims 1 to 5, characterized in that it can be produced in any width. A method of producing a conventional needled nonwoven structure comprising at least two separate but interconnected layers (2 and 3) and a third layer in the middle of randomly oriented fibers (4), and having surface shapes in predefined areas , characterized by: - selecting the needles according to the material; - needle plate configuration of the production machine, with different positions of the needles in the plate according to the required surface shape; - insertion of the special feeding system; - insertion of the different layers of non-woven into the machine for producing non-woven needles. A method of producing a formed three-dimensional needlework non-woven structure according to claim 7, characterized in that there is an intermittent process corresponding to the needle plate stop, when the feed is in operation, and when the feeding when the needle plate is in operation. A method of producing a shaped three-dimensional needlework nonwoven structure according to claim 7, characterized in that the nonwoven of the upper and lower layers are pre-needlened at a density of 25-75 penetrations / cm 2 and weighing between 50-300 g / m 2. A method of producing a formed three-dimensional needlework non-woven structure according to claims 7 to 9, characterized in that the length of fibers used in the layers (2, 3 and 4) varies between 20-100 mm. A method of producing a shaped three-dimensional needlework structure according to claims 7 to 10, characterized in that the linear mass of the fibers used in the three layers is less than 100 dtex. A method of producing a shaped three-dimensional needlework non-woven fabric according to claim 7, characterized in that one or more needle plates are used. A method of producing a formed three-dimensional needlework non-woven structure according to claims 7 to 12, characterized in that the length of the needles used can assume any size existing on the market. A method of producing a shaped three-dimensional needlework structure according to claim 13, characterized in that the depth of penetration of the needle needs to be positive. Lisbon, November 26, 2010 3