The disclosure provides needled sandwich material structures in which a core nonwoven with vertically oriented fibres is used; and a method of manufacturing these sandwich material structures.

The disclosure provides needled sandwich material structures in which a core nonwoven with vertically oriented fibres is used; and a method of manufacturing these sandwich material structures.

Described is a composite made from a woven fabric, a non-woven fabric, or a knitted face fabric and a non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude into the non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric has a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point. The nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point. The woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together.

Described is a composite made from a woven fabric, a non-woven fabric, or a knitted face fabric and a non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric is needle punched such that fibers protrude into the non-woven fabric. The woven fabric, the non-woven fabric, or the knitted face fabric has a first polymer having a first melting point and a second polymer having a second melting point being higher than the first melting point. The nonwoven backing material comprises a third polymer having a third melting point and a fourth polymer having a fourth melting point being higher than the third melting point. The woven fabric, the non-woven fabric, or the knitted face fabric is further bonded to the nonwoven backing material applying heat to at least partially melt or soften the first polymer and the third polymer such that they bond together.

A ballistic material is made from spunlace nonwoven fibers mechanically entangled into a woven ballistic fabric. The spunlace nonwoven may comprise low denier fibers providing for a highly dense ballistic product.

A ballistic material is made from spunlace nonwoven fibers mechanically entangled into a woven ballistic fabric. The spunlace nonwoven may comprise low denier fibers providing for a highly dense ballistic product.

A method of forming a sheet material. The method comprises advancing an arrangement comprising a body of fibres and a reinforcing structure, wherein the reinforcing structure comprises splittable fibres. The method further comprises subjecting the arrangement to successive hydroentanglement steps, wherein in each such hydroentanglement step the arrangement is exposed to high pressure jets of liquid over a surface of the arrangement. Subjecting the arrangement to successive hydroentanglement steps causes the fibres of the body of fibres to entangle with each other and causes a mechanical bond to form between the fibres of the body of fibres and the reinforcing structure. The mechanical bond is caused by at least:

some of the fibres of the body of fibres being pushed by the high-pressure jets of liquid into gaps in the reinforcing structure;

at least some of the splittable fibres of the reinforcing structure splitting to form split fibres which reduces the space within the gaps such that the reinforcing structure constricts about fibres of the body of fibres which have been pushed in the gaps; and

at least some of the fibres of the body of fibres entangling with at least some of the split fibres and at least some of the splittable fibres of the reinforcing structure.

A method of forming a sheet material. The method comprises advancing an arrangement comprising a body of fibres and a reinforcing structure, wherein the reinforcing structure comprises splittable fibres. The method further comprises subjecting the arrangement to successive hydroentanglement steps, wherein in each such hydroentanglement step the arrangement is exposed to high pressure jets of liquid over a surface of the arrangement. Subjecting the arrangement to successive hydroentanglement steps causes the fibres of the body of fibres to entangle with each other and causes a mechanical bond to form between the fibres of the body of fibres and the reinforcing structure. The mechanical bond is caused by at least:

some of the fibres of the body of fibres being pushed by the high-pressure jets of liquid into gaps in the reinforcing structure;

at least some of the splittable fibres of the reinforcing structure splitting to form split fibres which reduces the space within the gaps such that the reinforcing structure constricts about fibres of the body of fibres which have been pushed in the gaps; and

at least some of the fibres of the body of fibres entangling with at least some of the split fibres and at least some of the splittable fibres of the reinforcing structure.

A composite nonwoven sheet material comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer, and wherein the pulp fibers are entangled with the reinforcement filaments and the microfibers. A process of producing a composite nonwoven sheet material, comprising: forming a fibrous web comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer; and hydroentangling the fibrous web to form the composite nonwoven sheet material.

A composite nonwoven sheet material comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer, and wherein the pulp fibers are entangled with the reinforcement filaments and the microfibers. A process of producing a composite nonwoven sheet material, comprising: forming a fibrous web comprising a reinforcement layer comprising mainly reinforcement filaments, a pulp layer comprising mainly pulp fibers, and a surface layer comprising mainly microfibers, wherein the pulp layer is interposed between the reinforcement layer and the surface layer; and hydroentangling the fibrous web to form the composite nonwoven sheet material.