Voluminous nonwoven composite and method for producing same

2:

• Nonwoven composite according to claim 1, wherein the second layer contains not only the one crimped staple fibers but also, in addition, other crimped staple fibers having a fineness from 1.2 to 2.1 dtex, wherein the crimped staple fibers comprise a mixture of 20 to 99 wt.-% of the one staple fibers and 1 to 80 wt.-% of the other staple fibers.

3:

• Nonwoven composite according to claim 1, wherein the staple fibers have a length of ≧2.5 cm, preferably up to 10 cm, particularly preferably up to 5 cm.

4:

• Nonwoven composite according to claim 1, wherein the density of the nonwoven composite amounts to ≦0.1 g/cm3, preferably 0.04 to 0.1 g/cm3.

5:

• Nonwoven composite according to claim 1, wherein the nonwoven composite has pores having a diameter of ≦0.4 mm, preferably of 0.2 mm to 0.4 mm.

6:

• Nonwoven composite according to claim 1, wherein the voluminous nonwoven composite has more than 5, preferably more than 10 pores per cm2 having a diameter of ≧0.2 mm.

7:

• Nonwoven composite according to claim 1, wherein it has a weight per surface area of 18 to 80 g/m2, wherein the weight proportion of the endless filaments preferably amounts to 10 to 70%, and the weight proportion of the crimped staple fibers preferably amounts to 30 to 90%.

8:

• Nonwoven composite according to claim 1, wherein it has a relief having discrete raised locations, which can be embossed during water-jet stabilization.

9:

• Nonwoven composite according to claim 1, wherein it has an additional embossing, which can be introduced by means of a thermo-calender and/or ultrasound calender, preferably after water-jet stabilization.

10:

• Nonwoven composite according to claim 1, wherein the endless filaments and/or the crimped staple fibers can be passed to water-jet stabilization in an inline process.

11:

• Nonwoven composite according to claim 1, wherein the layer composed of endless filaments and/or the layer composed of crimped staple fibers are slightly pre-stabilized.

12:

• Nonwoven composite according to claim 1, wherein the layer composed of endless filaments and/or the layer composed of crimped staple fibers can be passed to water-jet stabilization in an offline process.

13:

• Nonwoven composite according to claim 11, wherein the slightly pre-stabilized layers can be produced separately from one another and then can be passed to water-jet stabilization.

14:

• Nonwoven composite according to claim 1, wherein at least one additional layer of endless filaments and/or staple fibers can be passed to water-jet stabilization.

15:

• Nonwoven composite according to claim 1, wherein the endless filaments comprise monofilaments or bi-component filaments composed of polypropylene, polyethylene, polyester, polyamide, polylactide or their copolymers.

16:

• Nonwoven composite according to claim 1, wherein the staple fibers comprise viscose or cotton or of mono-component or bi-component fibers composed of polypropylene, polyethylene, polyester, polyamide, polylactide or their copolymers.

17:

• Nonwoven composite according to claim 1, wherein the one crimped staple fibers comprise one material, preferably polypropylene, and the other crimped staple fibers comprise a different material from the other, preferably polyester.

18:

• Nonwoven composite according to claim 1, wherein at least some of the endless filaments and/or at least some of the staple fibers have a non-round cross-section and/or are hollow.

19:

• Method for the production of a voluminous nonwoven composite, in which a first layer of melt-spun endless filaments, laid down in entangled manner, which have a fineness of 0.8 to 1.8 dtex, preferably of ≦1.3 dtex, particularly preferably of 1.0 to 1.2 dtex, and a second layer of crimped staple fibers, which have a fineness of 2.2 to 15 dtex, preferably of 4 to 10 dtex,
• are stabilized and intimately connected with one another exclusively by means of water jets.

20:

• Method according to claim 19, wherein the second layer contains not only the one crimped staple fibers but also, in addition, other crimped staple fibers having a fineness from 1.2 to 2.1 dtex, wherein the crimped staple fibers comprise a mixture of 20 to 99 wt.-% of the one staple fibers and 1 to 80 wt.-% of the other staple fibers.

21:

• Method according to claim 19, wherein a relief having discrete raised locations is embossed during water-jet stabilization.

22:

• Method according to claim 19, wherein an additional embossing is carried out by means of a thermo-calender and/or ultrasound calender, after water-jet stabilization.

23:

• Method according to claim 19, wherein the endless filaments and/or the crimped staple fibers are passed to water-jet stabilization in an inline process.

24:

• Method according to claim 19, wherein the layer composed of endless filaments and/or the layer composed of crimped staple fibers are slightly pre-stabilized.

25:

• Method according to claim 19, wherein the layer composed of endless filaments and/or the layer composed of crimped staple fibers are passed to water-jet stabilization in an offline process.

26:

• Method according to claim 24, wherein the slightly pre-stabilized layers are produced separately from one another and then passed to water-jet stabilization.

27:

• Method according to claim 19, wherein at least one additional layer of endless filaments and/or staple fibers is passed to water-jet stabilization.