Procedure in non woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties

Abstract

Procedure for obtaining non-woven fabrics with acoustic, thermal and filtering properties, obtained with a mechanical carding method or hydroforming and combined by spunlace or punching, and may or may not be reinforced with the aid of a resin polymer, characterized by using a novel mixture of fibers with different denier between 0.01 to 30, as well as fibers that may even be of synthetic, natural and/or mineral origin for acoustic, thermal, filtration, comfort and cleaning applications, for different markets.

Having described the invention above, the following is claimed as property: 
     
         1 . A process for obtaining non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties, characterized of the steps:
 a) Making a non-woven fabric with a mixture of fibers having a broad differential of denier by any of the methods such as: pneumatics formation, wet or mechanical, combined with processes like spunlace, punching, heat, sewing, chemical or combinations thereof.   b) Applying heat to the product derived from the process a) via wet or spunlace for drying in a process by hot air or by contacting with hot surfaces between 100° C. and 240° C. and provide an additional heat treatment if necessary between 80° C. and 250° C. to the product derived from the process a).   c) Adding a polymer resin, as an optional variation after the process a) and b), preparing a suspension of a water-based polymer resin to favour the properties of strength, rigidity, stability, forming, acoustic absorption, surface tension, efficiency and uptake in filtration and thermal resistance where the suspended polymer particles are incorporated into the non-woven fabric when altogether are passed through a pair of rollers.   d) The non-woven fabric impregnated with the polymer resin obtained in the process c) is dried by hot air or by contact with hot surfaces between 100° C. and 240° C., providing a thermal treatment between 100° C. and 250° C., for an additional thermo-bonding so that the polymer added to the non-woven fabric acquire stability and develop the properties described in the process c).   e) In a further variation to the processes a) and b) with the presence of low melting point fibers a thermal treatment is applied between 100° C. and 200° C. to activate these fibers and thus obtain a thermo-bonding, providing dimensional stability, durability and strengthen the structure.   
     
     
         2 . A process for obtaining non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties, according to  claim 1 , characterized because the fiber mixture includes a differential of denier between 0.01 denier and 30 denier, as well as its cross-sectional geometry can be circular, symmetrical or irregular solid or with internal spaces or combination thereof. 
     
     
         3 . A process for obtaining non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties, according to  claim 1 , characterized because the fiber mixture includes small fibers ranging from 3 mm to 150 mm long and up to continuous filaments. 
     
     
         4 . A process for obtaining non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties, according to  claim 1 , characterized because the combination of fibers includes fibers that are usual, synthetic, natural, mineral and thermoplastic, as polyester, polyolefin, polypropylene, polyamides, poly (lactic acid), acrylic, polyaramids, cellulose, cotton, rayon, fiberglass and low melting point fibers (of 110° C. to 200° C.), and these polymers are included in homopolymers or combinations thereof. 
     
     
         5 . A process for obtaining non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties, according to  claim 1 , characterized because the mixture of fibers includes combinations of denier, long, geometry and groups of fiber based on their origin, the latter also according to  claims 2 ,  3  and  4 . 
     
     
         6 . A process for obtaining non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties, according to  claim 1  subsection c), characterized because the polymer resin is found within the group comprising acrylic resins, polyurethanes, latex, styrene-acrylics, phenolic, vinyl or epoxy, as well as chlorofluorocarbons, surfactants and organic and inorganic phosphates and combinations thereof. 
     
     
         7 . A process for obtaining non-woven fabrics with acoustic, thermal, filtering, comfort and cleaning properties, according to  claim 1 , characterized because the weight of the non-woven fabric obtained in accordance with the  claims 1 - 6  is in the range of 40 to 2000 g/m 2 . 
     
     
         8 . Non-woven fabrics, products, derivatives and their applications, obtained using the procedure in accordance with  claims 1  to  7 , with acoustic, thermal, filtering, comfort and cleaning properties as resistance, rigidity, stability, forming, acoustic absorption, surface tension, efficiency and uptake in filtration and heat resistance, for the markets of the industry such as shoe, construction, automotive, filtration, clothing and cleaning.