Microfiber nonwoven composite

Abstract

A microfiber nonwoven composite includes: at least one layer S that contains a first fiber component; and at least one layer M that contains a second fiber component. The second fiber component is forced at least in part into the layer S. Fibers of the first fiber component comprise melt-spun include filaments deposited as a nonwoven fabric, and which are at least partially split and solidified to form elementary filaments having an average titer of less than 1 dtex. Fibers of the second fiber component include melt-blown fibers.

What is claimed is: 
     
         1 . A microfiber nonwoven composite, comprising:
 at least one layer S that contains a first fiber component; and   at least one layer M that contains a second fiber component,   wherein the second fiber component is forced at least in part into the layer S,   wherein fibers of the first fiber component comprise melt-spun composite filaments deposited as a nonwoven fabric, and which are at least partially split and solidified to form elementary filaments having an average titer of less than 1 dtex,   wherein fibers of the second fiber component comprise melt-blown fibers.   
     
     
         2 . The microfiber nonwoven composite according to  claim 1 , wherein the microfiber nonwoven composite has an average pore diameter of less than 20 μm and/or a smallest pore diameter of less than 11 μm. 
     
     
         3 . The microfiber nonwoven composite according to  claim 1 , wherein the first fiber component is at least partially penetrated into the layer M. 
     
     
         4 . The microfiber nonwoven composite according to  claim 2 , wherein the at least partial penetration of the second fiber component into the layer S and/or of the first fiber component into the layer M is by hydrofluid treatment. 
     
     
         5 . The microfiber nonwoven composite according to  claim 1 , wherein a titer of the elementary filaments is from 0.01 dtex to 0.8 dtex. 
     
     
         6 . The microfiber nonwoven composite according to  claim 1 , wherein a portion of the elementary filaments of the first fiber component is at least 20 wt. % relative to a total weight of the nonwoven fabric. 
     
     
         7 . The microfiber nonwoven composite according to  claim 1 , wherein the melt-blown fibers are formed from polymers having an MFI according to ISO 1133 of 100 to 3000 g/10 min. 
     
     
         8 . The microfiber nonwoven composite according  claim 1 , wherein the melt-blown fibers have a fiber titer of 0.5 μm to 5 μm. 
     
     
         9 . The microfiber nonwoven composite according to  claim 1 , wherein a portion of melt-blown fibers in the microfiber nonwoven composite is at least 20 wt. % relative to a total weight of the microfiber nonwoven composite. 
     
     
         10 . The microfiber nonwoven composite according to  claim 1 , further comprising at least one other layer C that contains staple fibers and/or filaments, wherein the fibers and/or filaments of the layers S, M, and/or C at least partially penetrate one another. 
     
     
         11 . The microfiber nonwoven composite according to  claim 1 , wherein the microfiber nonwoven composite has a sound absorption rating (1000 Hz) of greater than 0.4 and/or a sound absorption rating (2000 Hz) of greater than 0.8 and/or a sound absorption rating (2000 Hz) of greater than 0.8, with a mass per unit area of less than 150 g/m 2 . 
     
     
         12 . The microfiber nonwoven composite according to  claim 1 , wherein the microfiber nonwoven composite has a mean flow pore diameter of less than 20 μm with a mass per unit area of less than 200 g/m 2 . 
     
     
         13 . The microfiber nonwoven composite according to  claim 1 , wherein the microfiber nonwoven composite has a fraction filtration efficiency (particle size 1-4.7 mm) of greater than 60% and/or a fraction filtration efficiency (particle size>5 mm) of greater than 80. 
     
     
         14 . A method for producing the microfiber nonwoven composite according to  claim 1 , comprising the following steps:
 providing at least one first layer S′ that contains composite filaments melt-spun and deposited as a nonwoven fabric and/or providing a composite nonwoven comprising the layer S′ as surface layer;   applying at least one second layer M′ that contains melt-blown fibers to the layer S′ and/or to a side of the composite nonwoven that has the layer S′ as surface layer so as to form a composite nonwoven having the layers S′ and M′; and/or applying at least one composite nonwoven comprising the layer M′ as surface layer to the layer S′ and/or to a side of the composite nonwoven that has the layer S′ as surface layer such that M′ and S′ form adjacent layers while embodying a composite nonwoven having the layers S′ and M′;   performing a hydrofluid treatment of the composite nonwoven having the layers S′ and M′ such that the composite filaments of the first layer S′ are at least partially split and simultaneously solidified as elementary filaments having an average titer of less than 1 dtex and are bonded to the melt-blown fibers of the second layer M′ to form a combined layer,   wherein the melt-blown fibers of the layer M′ penetrate at least partially into the layer S′.   
     
     
         15 . Use of the microfiber nonwoven composite according to  claim 1  as a sound insulation layer and/or as a component of sound insulation layers, as a barrier layer in home textiles, as packaging materials, and/or as filter medium. 
     
     
         16 . The microfiber nonwoven composite according to  claim 4 , wherein the hydrofluid treatment comprises hydraulic entanglement. 
     
     
         17 . The microfiber nonwoven composite according  claim 8  wherein the fiber titer is 1.0 μm to 4 μm. 
     
     
         18 . The microfiber nonwoven composite according  claim 17  wherein the fiber titer is 1.8 μm to 3.6 μm.