Composite nonwoven material containing continuous filaments and short fibres

Abstract

A nonwoven material consisting of a mixture containing continuous filaments and short fibres, the continuous filaments being substantially mechanically bonded to each other due to entangling of fibres and filaments. The continuous filaments in the material have a projected coverage of at least 1.1 and not more than 1.7. The invention also relates to a method of manufacturing such a nonwoven material.

1 . A nonwoven composite material consisting of a mixture containing continuous filaments and short fibres, the continuous filaments being substantially mechanically bonded to each other due to entangling of fibres and filaments, wherein the continuous filaments in the material have a projected coverage of at least 1.1 and not more than 1.7.  
   
   
       2 . The nonwoven composite material according to  claim 1 , wherein the continuous filaments in the material have a projected coverage between 1.2-1.6.  
   
   
       3 . The nonwoven composite material according to  claim 1 , wherein the short fibres comprises natural fibres and/or synthetic staple fibres.  
   
   
       4 . The nonwoven composite material according to  claim 3 , wherein the short fibres comprise at least 60 weight % of cellulose fibres.  
   
   
       5 . The nonwoven composite material according to  claim 4 , wherein the short fibres comprise 85-95 weight % of cellulose fibres.  
   
   
       6 . The nonwoven composite material according to  claim 1 , wherein the content of continuous filaments in the material is about 15-40 weight %.  
   
   
       7 . The nonwoven composite material according to  claim 1 , wherein the basis weight of the material is 40-100 g/m 2 .  
   
   
       8 . The nonwoven composite according to  claim 1 , wherein the short fibres are wetlaid fibres.  
   
   
       9 . The nonwoven composite material according to  claim 2 , wherein the continuous filaments in the material have a projected coverage between 1.3-1.6, and the short fibres comprise at least 70 weight % of cellulose fibres.  
   
   
       10 . The nonwoven composite material according to  claim 2 , wherein the continuous filaments in the material have a projected coverage between 1.3-1.6, and the short fibres comprise at least 85 weight % of cellulose fibres.  
   
   
       11 . The nonwoven composite material according to  claim 4 , wherein the short fibres comprise about 90 weight % of cellulose fibres.  
   
   
       12 . The nonwoven composite material according to  claim 1 , wherein the content of continuous filaments in the material is about 25-40 weight %.  
   
   
       13 . The nonwoven composite material according to  claim 1 , wherein the basis weight of the material is 50-80 g/m 2 .  
   
   
       14 . A method of manufacturing a nonwoven material comprising the steps of: 
 laying a layer of short fibres onto a web of unbonded continuous filaments;    hydroentangling the layers consisting of continuous filaments and short fibres to form a composite nonwoven material and thereafter drying the material;    wherein the web of continuous filaments has a projected coverage of at least 1.1 and not more than 1.7.    
   
   
       15 . The method according to  claim 14 , wherein the web of continuous filaments has a projected coverage between 1.2-1.6.  
   
   
       16 . The method according to  claim 14 , wherein the continuous filaments are spunlaid spunbond filaments.  
   
   
       17 . The method according to  claim 14 , wherein the short fibres are wetlaid onto the web of continuous filaments.  
   
   
       18 . The method according to  claim 14 , wherein the short fibres are airlaid onto the web of continuous filaments.  
   
   
       19 . The method according to  claim 14 , wherein the energy supply at the hydroentangling is at the most about 500 kWh/ton.  
   
   
       20 . The method according to  claim 19 , wherein the web of continuous filaments has a coverage of 1.3-1.6, and the energy supply at the hydroentangling is at most about 350 kWK/ton.