Nonwoven havng a corrugated structure, intermediate product, and method for producing a nonwoven having a corrugated structure

Abstract

The invention relates to a three-dimensional structured nonwoven, which is formed from staple fibers (F1, F2, F3). In order to be able to produce such a nonwoven using simple means, the invention proposes providing groove channels (R) on at least one of its surfaces (O), which channels are milled into the surface (O) provided with the groove channels.

1 . A three-dimensional structured nonwoven (V) composed of staple fibers (F 1 , F 2 , F 3 ), characterized in that groove channels (R) exist on at least one of its surfaces ( 0 ), which channels are milled into the surface ( 0 ) provided with the groove channels (R). 
     
     
         2 . The three-dimensional structured nonwoven (V) according to  claim 1 , characterized in that in a region of the nonwoven (V) that borders directly on the groove channels (R), the fibers (F 1 , F 2 ) are preponderantly oriented parallel to the groove channels (R). 
     
     
         3 . The three-dimensional structured nonwoven (V) according to  claim 2 , characterized in that the fibers (F 1 , F 2 ) oriented preponderantly parallel to the groove channels (R) are present in a region that delimits the groove channels (R) laterally. 
     
     
         4 . The three-dimensional structured nonwoven (V) according to  claim 2  or  3 , characterized in that the nonwoven (V) has a different orientation of the fibers (F 3 ) below the groove channels (R). 
     
     
         5 . The three-dimensional structured nonwoven (V) according to  claim 4 , characterized in that the nonwoven (V) has a random orientation of the fibers (F 3 ) below the groove channels (R). 
     
     
         6 . The three-dimensional structured nonwoven (V) according to one of the preceding claims, characterized in that at least 10 groove channels (R) are formed per nonwoven width. 
     
     
         7 . The three-dimensional structured nonwoven (V) according to one of the preceding claims, characterized in that the groove channels (R) have a maximum depth of 5 mm. 
     
     
         8 . The three-dimensional structured nonwoven (V) according to one of the preceding claims, characterized in that the groove channels (R) run parallel to one another. 
     
     
         9 . The three-dimensional structured nonwoven (V) according to one of the preceding claims, characterized in that the groove channels (R) are configured to be continuous over the length of the nonwoven (V). 
     
     
         10 . The three-dimensional structured nonwoven (V) according to one of the preceding claims, characterized in that the groove channels (R) have a corrugated progression. 
     
     
         11 . An intermediate product for the production of a nonwoven (V) structured according to one of the preceding claims, wherein the intermediate product is present in the non-consolidated state, characterized in that the intermediate product is formed by a stack of fibers (F 1 , F 2 , F 3 ), into at least one surface of which groove channels (R) are milled. 
     
     
         12 . A method for producing a nonwoven (V) configured according to one of the above claims, comprising the following work steps:
 a) making available a fiber stack composed of fibers (F 1 , F 2 , F 3 ),   b) milling groove channels (R) into a surface ( 0 ) of the fiber stack,   c) consolidating the fiber stack provided with the groove channels (R) to produce the nonwoven (V).   
     
     
         13 . The method according to  claim 12 , characterized in that the length of the fibers (F 1 , F 2 , F 3 ) amounts to at least 10 mm. 
     
     
         14 . The method according to one of  claim 12  or  13 , characterized in that the fibers (F 1 , F 2 , F 3 ) have a gauge of 0.7-70 dtex. 
     
     
         15 . The method according to one of  claims 12  to  14 , characterized in that in working step b), the groove channels (R) are milled by means of a rotating roll that is provided with a fitting. 
     
     
         16 . The method according to  claim 15 , characterized in that the fitting consists of a fitting set, of pins, of hooks or of disks. 
     
     
         17 . The method according to one of  claims 12  to  16 , characterized in that in working step c), consolidation of the fiber stack to produce the nonwoven (V) takes place by means of application of an adhesive that glues the fibers (F 1 , F 2 , F 3 ) to one another. 
     
     
         18 . The method according to one of  claims 12  to  17 , characterized in that in working step c), consolidation of the fiber stack to produce the nonwoven takes place by means of application of heat, so that fibers (F 1 , F 2 , F 3 ) that lie against one another melt, at least partially, in the region of their contact zone, and a material-fit connection occurs between the fibers (F 1 , F 2 , F 3 ), due to the material of the fibers (F 1 , F 2 , F 3 ) melting into one another.