Non-woven material with particle filling

Abstract

A ply includes a fibrous nonwoven web fabric forming a foundational structure, wherein the foundational structure includes fibers forming first pores and is partially filled with particles, wherein the particles at least partially fill the first pores so as to form regions filled with particles, wherein the particles in the filled regions form second pores such that an average diameter of the particles is greater than an average pore size of more than 50% of the second pores.

1 - 18 . (canceled) 
     
     
         19 . A ply comprising:
 a fibrous nonwoven web fabric forming a foundational structure, wherein the foundational structure includes fibers forming first pores and is partially filled with particles, wherein the particles at least partially fill the first pores so as to form regions filled with particles, wherein the particles in the filled regions form second pores such that an average diameter of the particles is greater than an average pore size of more than 50% of the second pores.   
     
     
         20 . The ply as recited in  claim 19 , wherein the particles are spherical. 
     
     
         21 . The ply as recited in  claim 19 , wherein the particles form a sheet-like homogeneous distribution in the foundational structure. 
     
     
         22 . The ply as recited in  claim 19 , wherein at least a portion of the filled regions forms a coating of the foundational structure. 
     
     
         23 . The ply as recited in  claim 19 , wherein the particles are united with the fibrous nonwoven web fabric via a binder composed of organic polymers selected from the group consisting of polyvinylpyrrolidone, polyacrylic acid, polyacrylate, polymethacrylic acid, polymethacrylate, polystyrene, polyvinyl alcohol, polyvinyl acetate, polyacrylamide and copolymers thereof, cellulose and its derivatives, polyethers, phenolic resin, melamine resin, polyurethane, nitrile rubber (NBR), styrene-butadiene rubber (SBR) and latex. 
     
     
         24 . The ply as recited in  claim 23 , wherein a melting point of the binder is below a melting point of at least one of the particles and the fibers. 
     
     
         25 . The ply as recited in  claim 19 , wherein the particles have an average diameter between 0.01 and 10 μm. 
     
     
         26 . The ply as recited in  claim 19 , wherein the particles are fabricated from organic polymers selected from the group consisting of polypropylene, polyvinylpyrrolidone, polyvinylidene fluoride, polyester, polytetrafluoroethylene, perfluoro-ethylene-propylene (FEP), polystyrene, styrene-butadiene copolymers, polyacrylate and nitrile-butadiene polymers and copolymers thereof. 
     
     
         27 . The ply as recited in  claim 19 , wherein the fibers of the fibrous nonwoven web fabric are fabricated from organic polymers selected from the group consisting of polybutylene terephthalate, polyethylene terephthalate, polyacrylonitrile, polyvinylidene fluoride, polyether ether ketone, polyethylene naphthalate, polysulfone, polyimide, polyester, polypropylene, polyoxymethylene, polyamide and polyvinylpyrrolidone. 
     
     
         28 . The ply as recited in  claim 19 , wherein an average length of the fibers exceeds an average diameter of the fibers by at least a factor of two. 
     
     
         29 . The ply as recited in  claim 19 , wherein at least 90% of the fibers have an average diameter of not more than 12 μm. 
     
     
         30 . The ply as recited in  claim 19 , wherein at least 40% of the fibers have an average diameter of not more than 8 μm. 
     
     
         31 . The ply as recited in  claim 19 , wherein a thickness of the ply is not more than 100 μm. 
     
     
         32 . The ply as recited in  claim 19 , wherein a porosity of the ply is at least 25%. 
     
     
         33 . The ply as recited in  claim 19 , wherein the first and second pores form a labyrinthine microstructure. 
     
     
         34 . The ply as recited in  claim 19 , wherein the first and second pores have a pore size of not more than 3 μm. 
     
     
         35 . The ply as recited in  claim 19 , wherein an ultimate tensile strength force of the ply is at least 15 N/5 cm in a longitudinal direction. 
     
     
         36 . The ply as recited in  claim 19 , wherein the foundational structure is calendered.