Method for producing a nonwoven fabric used as an engine hood insulator material

A method for producing an engine hood insulator material, the method comprising:

• mixing fibers in a blending unit such that the fibers are blended;
• dosing the blended fibers such that the weight of the dosed blended fibers is between 40 g/m2 and 150 g/m2;
• carding the dosed blended fibers so that the dosed blended fibers are of a plurality of web forms;
• crossing-laying the plurality of web forms on top of one another;
• drafting the cross-laid plurality of web forms in a draft unit;
• needle punching the drafted cross-laid plurality of web forms in a needle punching unit so as to entangle the fibers;
• passing the needle-punched plurality of web forms through a hot calendar so as to adjust a surface smoothness and thickness;
• coating the hot-calendared plurality of web forms with a chlorfluorocarbon or flame retardant material in a foam machine in order to provide water repellency or flame retardancy;
• passing the coated hot-calendared plurality of web forms through cylinders so as to provide a pre-dried material;
• fixing the pre-dried material in a drum dyer so as to chemically cross-link the pre-dried material and to produce a semi-finished non-woven material;
• applying a polymer emulsion in dots over an entire surface of the semi-finished non-woven material with rotary screen printing;
• scattering a thermoplastic or thermoset or an elastomer powder onto the dots of the polymer emulsion such that the thermoplastic or thermoset or elastomer powder is retained by the dots;
• removing excess powder between the dots;
• infrared heating the semi-finished non-woven material so that the scattered thermoplastic or thermoset or elastomer powder is melted in an infrared oven so as to adhere to the dots on the entire surface of the semi-finished non-woven material;
• passing the infrared-heated semi-finished non-woven material through cooling cylinders so as to cool the melted spots of thermoplastic or thermoset or elastomer powder to adhere to the surface of the semi-finished non-woven material;
• cold calendaring the semi-finished non-woven material under pressure so as to obtain a layer of the engine hood insulator material;
• and
• winding the layer of engine hood insulator material on winding benches.