Nonwoven product containing organic and/or mineral particles and its method of manufacturing

摘要

The non-woven flexible product having a bulk density of less than 1, comprises two layers of fibers or synthetic filaments stacked in Z direction perpendicular to a plane XY of the product subjected to a mechanical or hydraulic needling operation, and particulate fillers in the form of mineral and/or organic particles distributed monomodally or multimodally in the product and partially coated or encapsulated by a binding material capable of connecting the filaments or fibers. The organic and/or mineral particles are coarse particles. The non-woven flexible product having a bulk density of less than 1, comprises two layers of fibers or synthetic filaments stacked in Z direction perpendicular to a plane XY of the product subjected to a mechanical or hydraulic needling operation, and particulate fillers in the form of mineral and/or organic particles distributed monomodally or multimodally in the product and partially coated or encapsulated by a binding material capable of connecting the filaments or fibers. The organic and/or mineral particles are coarse particles having a size expressed in an equation as given in the specification. The coarse particles constitute nodes, mesh, fibers and filaments, and have a dimension d of >= 5x DMF, where DMF is the average diameter of fibers or filaments forming the layers of nonwoven product. The coarse particles have an average size of less than 200 mu m, which is 20% of the average size of the visible pores of layers of nonwoven product along the Z direction perpendicular to the XY plane of the nonwoven product. The mineral and/or organic particulate fillers comprise a population or fraction of particles of which the particle size is less than 20 mu m. The mineral and/or organic fillers are present with a weight ratio of 5-25 wt.% of the fibers or filaments forming the layers of the nonwoven product. The melting temperature of organic particles is lower than the fibers or filaments and less than or greater than the temperature for heat setting, drying, activation or crosslinking of the material forming the binder. The particles forming the fillers are organic particles and having a particle size of greater than 20 mu m. A part of the particles forming mineral and/or organic fillers consist of expandable particles with the temperature. The nonwoven product are made of reinforcement structures in the form of filaments, grid and/or textile of high stability characteristics, the mineral and/or organic particles partially coated or encapsulated by the binder establishing rigid connections or forming bypass between these structure for reinforcement and filaments or fibers of the layers by the binder. An independent claim is included for a process for manufacturing a non-woven flexible product.