Nonwoven

Abstract

The present invention relates to a nonwoven that includes superposed plies of fibers, such that a binder web is positioned between two plies and heat sealed to the at least two plies, and that it is not stitched. The heat sealing of the plies makes the nonwoven extremely solid and sets the orientation of the fibers, which can no longer move during the processing of the nonwoven. The fibers are, in fact, held by weld points that are non-continuous and are distributed over the entire surface, unlike stitching.

1 . A nonwoven comprising at least two superposed plies of fibers; a binder web positioned between the at least two plies and being heat sealed, wherein the nonwoven is not stitched. 
     
     
         2 . The nonwoven according to  claim 1 , wherein it is a pultrusion nonwoven. 
     
     
         3 . The nonwoven according to  claim 1 , wherein the plies comprise oriented fibers. 
     
     
         4 . The nonwoven according to  claim 1 , wherein two superposed plies have different fiber orientations. 
     
     
         5 . The nonwoven according to  claim 1 , wherein the binder web is a thermoplastic. 
     
     
         6 . The nonwoven according to  claim 1 , further comprising a surface web. 
     
     
         7 . The nonwoven according to  claim 2 , wherein the binder web has a melting point above a pultrusion temperature. 
     
     
         8 . The nonwoven according to  claim 3 , wherein the binder web has a basis weight less than or equal to the basis weight of the fibers of the plies. 
     
     
         9 . The nonwoven according to  claim 3 , wherein certain fibers are reinforcing fibers. 
     
     
         10 . The nonwoven according to  claim 1 , wherein the plies comprise carbon fibers. 
     
     
         11 . A process for producing a nonwoven comprising superposing plies of fibers and at least one binder web between two plies of fibers to form an assembly; and, heating sealing the assembly. 
     
     
         12 . The process according to  claim 11 , further comprising positioning a surface web on the plies of fibers before heat sealing. 
     
     
         13 . A pultruded profile comprising a nonwoven comprising at least two superposed plies of fibers; a binder web positioned between the at least two plies and being heat sealed, wherein the nonwoven is not stitched.