Abstract

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.

IPC Classes  ?

• D06N 3/00 - Artificial leather, oilcloth, or like material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
• D04H 5/03 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet
• D04H 1/4382 - Stretched reticular film fibresComposite fibresMixed fibresUltrafine fibresFibres for artificial leather
• D04H 1/492 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
• D04H 1/498 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
• B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
• B32B 5/06 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer needled to another layer, e.g. of fibres, of paper
• B32B 7/09 - Interconnection of layers by mechanical means by stitching, needling or sewing