Highloft needlepunched nonwovens

Abstract

The present disclosure relates to a highloft needlepunched fabric wherein said fabric may be formed by needlepunching a web at a penetration density of less than or equal to about 150 penetrations per square centimeter and a penetration depth of about 5-20 mm, wherein the needles are spaced apart 5 mm or greater.

1 . A method of needlepunching material to form a fabric comprising:
 forming a web; and   penetrating said web with a plurality of needles, at
 a penetration density less than or equal to about 150 penetrations per square centimeter, 
 a penetration depth of about 5-20 mm, and 
 wherein said needles are spaced apart 5 mm or greater. 
   
   
   
       2 . The method of  claim 1  wherein said plurality of needles are mounted on a needle board at a spacing in the range of about 8 to 20 mm. 
   
   
       3 . The method of  claim 1  wherein said needles define at least one row and said needles in a given row are offset from one another about 1-8 mm in a machine direction. 
   
   
       4 . The method of  claim 1  wherein said plurality of needles are mounted on a needle board, wherein the needle board includes in the range of about 1,000 to 5,000 needles. 
   
   
       5 . The method of  claim 1  wherein said web includes a first surface and a second surface and only said first surface is penetrated with said plurality of needles. 
   
   
       6 . The method of  claim 1  wherein said web includes a first surface and a second surface, and said penetration depth of said needles is different in said first surface as compared to said second surface. 
   
   
       7 . The method of  claim 1  wherein said web includes a first surface and a second surface and said penetration density of said first surface is different than said penetration density of said second surface.