WO2010083594A1 - Perforation resistant multilayer textile composite material and method for making same - Google Patents

Abstract

The invention relates to a method for making a multilayer textile material resistant to potential perforation by a sharp object, and to said material as such. The method includes the following steps: a) contacting one or more layers of a non-woven material including a certain amount of thermofusible fibres with one or more layers of a woven material so as to form a multilayer material; b) consolidating the layers of the multiplayer material from step a) using a first mechanical processing in order to interlace some fibres of the non-woven material into the woven material; c) subjecting the consolidated multilayer material from step b) to thermal processing resulting in the fusion of some of the thermofusible fibres of the non-woven material into the woven material; and d) letting the material from step c) cool down in order to obtain the multilayer composite material.

Description

 PERFORATION-RESISTANT MULTI-LAYER TEXTILE COMPOSITE MATERIAL AND METHOD FOR MANUFACTURING THE SAME

Field of the invention

The subject of the present invention is a multilayer composite textile material intended in particular, but not exclusively, for the manufacture of soles of safety shoes ensuring the protection of persons against penetration into the foot through the sole, of pointed objects such as nails, points, shrapnel, etc. The invention also relates to a method of manufacturing this composite material and its use in the manufacture of safety shoes.

Description of the prior art

The use of metal plates in the manufacture of safety shoes has been known for a long time and this method is the most used to date. However, the introduction of a rigid metal plate greatly complicates the making of a safety shoe. In addition, it does not cover the entire surface of the sole which can cause injuries around the outskirts of the sole. In addition, the metal plates have the disadvantage of being rigid, heavy and detectable by metal detectors, which may not be desirable in military applications.

To remedy these problems, various solutions based on textile materials have been imagined and patented.

U.S. Patent No. US 5,578,358 (Foy et al.) Discloses materials made of several layers of poly-aramid fabric, densely consolidated but not bonded together except on the sides. The filaments of these tissues have titers of less than 500 decitex. The materials thus formed are designed to withstand the perforation of clothes by objects such as ice picks. This material, however, can not achieve the level of performance required in the footwear industry except by employing a high number of layers of fabric and proceeding to the complex assembly of the shoe.

US patents no. US 5,996,255 (Ventura) and no. US 6,167,639 (Ventura) describe the use of several layers of densely consolidated fabric, but not tied together, attached to the edges of a shoe. This material is effective to the disadvantage of requiring a complex assembly of the shoe and uses poly-aramid fabrics Kevlar ^® type, these fabrics being made with filaments of 70 to 200 dtex.

U.S. Patent No. US 6,368,989 (Pascual et al.) Discloses a sole made from several layers of poly-aramid fabric, bonded together by a polyethylene resin matrix without, however, ensuring that the composite is saturated with the resin. The assembly thus created can be glued or stitched to the base of the shoe. The number of layers varies between 4 and 10 to obtain the desired results and this construction, if it can achieve performance at the desired perforation, is a very expensive solution to solve the problem of perforation through the base of the shoe.

European patent no. EP 1 613 185 B1 (Fenzi) discloses an improvement of the aforementioned patent no. No. 6,368,989, using only a reduced number of poly-aramid fabrics, the other layers being made from high tenacity polyester filaments. The fabric layers are bonded together and not impregnated with thermoplastic resin, and they are further coated with mineral powder filled polyester or acrylic resin, such as finely ground aluminum silicates, to increase the resistance to perforation by a point. The products obtained have the disadvantage of having too much flexibility in many applications and require additional inserts to increase the stiffness of the shoe.

The patent application no. WO 2006/040679 A2 (Fenzi) mentions the removal of poly-aramid fabric layers and the use of high tenacity polyester fabrics only, with emphasis on the weaving method of these fabrics.

The final assembly of the first assembly remains identical to that described in the aforementioned patent EP 1 613 185 in the name of the same inventor. Fabrics assembled by gluing with resin can not be recycled at the end of the life of the shoe.

U.S. Patent No. 5,994,245 (Marier et al.) In the name of the Applicant, discloses a laminated insulating insole consisting of a resilient foam layer and a fiber mat, the fibers partially penetrating the mattress by needling. The sole is further reinforced by impregnation of the mattress with a thermoplastic resin, a latex or a solvent containing a resin. The thus impregnated mattress is then heated to a temperature between 100 and 200 ⁰ C to allow the curing of the resin or the evaporation of the solvent. Although the sole has interesting properties, it lacks flexibility due to the non-optional use of the cured resin.

To date, there is no known composite material to overcome the disadvantages noted for the materials described in the prior art.

There is therefore a real need for a new textile composite material and a simplified manufacturing process that makes it possible both to produce a rigidity-proof fitting first and resistant to the perforation of a pointed object, by using a simple method of making the same. -this. Summary of the invention

The present invention therefore aims to meet the needs mentioned above.

The invention therefore firstly relates to a method of manufacturing a multilayer textile material resistant to possible perforation by a pointed object, said method comprising the following steps: a) contacting one or more layers of a nonwoven material comprising a certain amount of hot melt fibers, with one or more layers of woven material to form a multilayer material; b) consolidating the layers of the multilayer material from step a) by a first mechanical treatment to interlace some of the fibers of the nonwoven material in the woven material; c) subjecting the consolidated multilayer material from step b) a heat treatment causing some of the hot melt fibers of the nonwoven material to melt in the woven material; and d) cooling the material from step c) to obtain the multilayer composite material.

The invention also relates to a multilayer composite material resistant to possible perforation by a pointed object, said material comprising at least one layer of a woven material adjacent to at least one layer of a nonwoven material comprising fibers, the nonwoven material comprising a certain amount of thermofusible fibers intermixed through the layer of woven material, some of these intermingled hot melt fibers having melted by heat treatment, thereby consolidating said multilayer composite material.

This material in practice is obtained by the process mentioned above. The invention further relates to the use of the multilayer composite material defined above, for the manufacture of the first assembly or as a false molded used in the manufacture of safety shoes or orthoses.

As indicated above, the textile composite material according to the invention is presented as a first assembly and can be used for mounting shoes resistant to perforation, assembly made according to methods commonly used in the industry of footwear such as the Strobel technique, the gluing technique or the injection technique.

The manufacture of a first assembly can advantageously use the properties of the nonwoven composite materials used in the industry as mounting inserts, for their longitudinal flexibility, their torsional rigidity, their resistance to fatigue, the ability to dispel the static electricity or to exhibit antibacterial properties.

The multilayer composite material according to the invention can achieve the performance required by the legislator, and uses a combination of fabrics and nonwoven mats combined and consolidated preferentially needling which is ensured rigidity by a heat treatment or impregnation with a chemical binder.

The invention and its advantages will become more apparent from the following nonlimiting description with reference to the accompanying drawings.

Brief description of the drawings

Figure 1a is a schematic sectional view of a multilayer textile composite material according to a first preferred embodiment of the invention. Figure 1b is an enlarged view of a portion of the composite material shown in Figure 1a.

Figure 2 is a schematic view of an equipment used for the manufacture of the composite material according to a second preferred embodiment of the invention.

Figure 3 is a schematic sectional view of a composite material according to a third preferred embodiment of the invention.

Detailed description of the invention

As indicated above, the invention relates to a multilayer composite material resistant to possible perforation by a pointed object.

This multilayer composite material comprises at least one layer of woven material adjacent to at least one layer of a nonwoven material comprising fibers, a portion of which is transferred through the woven material by the mechanical treatment.

The material may contain two or more layers of woven material. The material may also contain two or more layers of nonwoven material. The invention is not limited to the number of layers of woven or nonwoven material used to construct it, nor in the arrangement of the layers relative to each other.

Preferentially, the woven material is constructed of continuous filaments arranged in the form of three-dimensional or plain weave. More preferably, the filaments are continuous and arranged in the form of three-dimensional armor.

The woven material may have a basis weight of about 200 to 1000 g / m ² (grams per square meter), preferably about 500 to 850 g / m ² . By "about" it is to be understood that the measurements indicated in this patent application have a precision which can not be less than the accuracy of the apparatus which made it possible to obtain said measurements. It is commonly accepted that a 10% accuracy of a measurement is acceptable and includes the term "about".

The woven material may be polyester, polyamide, polyaramid, polyolefin or glass filaments, or composite fabrics made of co-mixed filaments. Preferably, the woven material may consist of polyester filaments or polyamide of high tenacity of title ranging from about 250 decitex to 1800 decitex, preferably from about 420 to 1100 decitex.

The polyester or polyamide filaments preferably have a shrinkage of about 3 to 12% at a temperature of about 200 ⁰ C, more preferably the shrinkage is about 4 to 7%.

The nonwoven material used for the manufacture of the multilayer composite material according to the invention may preferably comprise at least one nonwoven mat.

Preferably, the nonwoven mat or mattresses used have a weight per unit area of between about 80 and 800 g / m ² , more preferably between about 150 and 650 g / m ² .

The nonwoven mat may include polyester fibers, polyamide, poly aramid, cellulose such as lyocell ^® rayon, coextruded fibers, polyolefin or a mixture of these fibers.

Many other features can be added using appropriate functionalized fibers. Thus, the nonwoven mat may further comprise about 2 to 10% of electrically conductive fibers. Preferably, these electrically conductive fibers comprise nylon fibers coated with silver or nickel, stainless fibers, coated fibers. of carbon or any other fiber having electrically conductive properties

For example, 2% of conductive fibers made of Nylon ^® coated with silver, such as Nobel's Xstatic ^® , can achieve a resistance of less than 100 Ohms, which is below the electrical conductivity standards used in the field. safety shoes Other conductive or antistatic fibers may be used such as carbon-coated fibers, fibers impregnated with copper salts, stainless steel fibers The proportions of these fibers in the non-woven mixtures determine the level of desired resistivity and make the first conductive or antistatic mounting

In addition, the nonwoven mat may contain from about 10 to 50% of fibers with bactericidal properties. Preferably, these fibers with bactericidal properties comprise compounds of silver, trichlosan, or any other compound with bactericidal properties.

In addition, the nonwoven mat may contain from about 10 to 100% heat-fusible fibers

Once constructed, the multilayer composite material according to the invention can also be provided with at least one surface fabric. Preferably, this fabric may optionally comprise fibers with bactericidal properties, which are particularly useful when the composite material is used for the manufacture of insoles. removable shoes or orthoses, thus avoiding the proliferation of bacteria within the shoe The different layers of the composite material are consolidated with each other by a mechanical treatment allowing certain fibers of the nonwoven material to pass through the layer of woven material, followed by a heat treatment. The multilayer composite material then has a resistance to perforation of more than 1200 N according to ASTM F2412 / 2413 or more than 1100 N without the tip being apparent according to EN12568 2008

The puncture resistance of a first non-woven mounting used for conventional walking shoes ranges from 150 to 300 N (N for Newton) according to its basis weight of 500 to 1300 g / m ² when the measurement is made in accordance with ASTM F2412 / 2413. It was first envisaged to solve this problem by manufacturing a high density nonwoven composite material. However, the basis weight required to obtain the 1200 N strength required by this standard was 5000 g / m ² with a density of 0.40 grams per cubic centimeter, ie a thickness of 12.5 mm, which would make the first mounting too thick and too heavy to be used according to the techniques used in the footwear industry Maximum thickness tolerable for a mounting height is between 2.5 and 6 mm

It has been envisaged to introduce woven materials into the nonwoven material by passing the polyester fibers through a fibrous mattress pre-consolidated by low needling so that the fibers can be entrained by the barbs or asperities of the fibers. needles through the tissue or fabrics used in this case as a barrier to the penetration of the tip during the perforation test

Various fabrics have been experimented to determine the nature, the composite material and the number of woven layers required to obtain a composite resistant to a minimum force of 1200 N perforation according to ASTM F2412 / 2413

Table 1 below summarizes the results of tests on various individual tissues Table 1

Table 1 shows that Cordura ^® nylon-based fabrics have the highest FP / G factor (the highest puncture force to the basis weight of the fabric). However, it is expected that five layers of fabric with a basis weight of approximately 350 g / m ^{2 will be required} and the number of layers may be reduced to four if the weight of Nylon ^® fabric is at least 435 g / m ^2. . Thus, as tested fabrics were selected for use in making the composite subject of the present invention with a puncture resistance of 320 N according to ASTM F 2412/2413. By perforating three layers of these freely superposed fabrics, this assembly showed a puncture resistance of 870N. When three layers of these fabrics were superimposed and combined by needling and then heated according to the method described, the resistance to perforation increased to 1426 N. This has benefited from a consolidation effect of the structure to produce a product responding to the needs without significant addition of material, whereas it would have been necessary to add several additional layers of fabric to achieve the expected result

In Table 1, tests 5 and 7 show the positive impact of a blocking of the yarns of the composite material woven by thermo-fixing of the woven composite material at 200 ^° C. for 4 minutes.

Another method consists in coating the fabrics with thermoplastic resin, in this case a polyurethane resin in the case of tests 8 to 10, this making it possible to block the composite material of the fabric while avoiding the displacement of the threads of the fabric under the pressure of the perforating elements and thus resist further perforation. By the same token we can consider reducing the number of layers of fabric 3 layers instead of 4 or 5. Moreover, it was shown that the coated side had to be placed in front of the perforating object because the resistance of the side The coating is approximately 50 N higher than the uncoated side (tests 9 and 11).

Here again, the combined effect of the heat-setting of the fabric and the coating makes it possible to obtain the highest strength, and as a corollary, it avoids the fraying of the threads during the cutting of the mounting bases of the shoe.

One of the objectives of the present invention is to reduce as much as possible the number of layers in the first mounting to facilitate the consolidation of the material. composite by needling. It has been envisaged to further exploit the interpenetration of the nonwoven fibers with the filaments of the fabrics to increase the barrier effect to the penetration of a sharp object.

To achieve this tightening effect of the material, polyester filaments or Nylon ^® with a high level of shrinkage were woven. These tissues were fixed on a picot frame leaving them a possibility of shrinking 7 to 10% in all directions and exposing them to a temperature of 200 ^° C. for 4 minutes in an oven. The resistance to perforation of tissues increases significantly as can be noted for the tissues of tests 11 and 12 (Table 1).

However, the values achieved are insufficient to achieve a two-layer mounting first resistant to a force of more than 1200 N perforation according to ASTM F2412 / 2413. In order to further consolidate this composite material and create an increased barrier effect, non-woven mattresses composed of a blend of polyester fibers and binder fibers were placed on and under two layers of fabric and then needled on both sides. other using needles having barbs capable of transporting the fibers of these mattresses through the two layers of fabric. This consolidation makes it possible to fill interstices between the filaments of the fabric.

The needling consolidation of the nonwoven fibers adjacent to the fabrics through the composite structure thus formed is reinforced during the thermo-fixation thereof. The delamination resistance is between the layers of tissue is increased so that during a tear test perpendicular to the first mounting, it is more than 100 pounds, the minimum resistance required is 80 books.

The method of manufacturing the multilayer textile material according to the invention comprises the following steps: a) contacting one or more layers of nonwoven material with one or more layers of woven material to form a multilayer material; b) consolidating the layers of the multilayer material from step a) by a first mechanical treatment to interlace some of the fibers of the nonwoven material in the woven material; and

c) subjecting the multilayer material from step b) a heat treatment causing some of the hot melt fibers of the nonwoven material to melt in the woven material; and d) cooling the material from step c) to obtain the multilayer composite material.

Preferably, the composite material is assembled by needling and is subjected to a sufficiently high temperature to ensure the fusion of the binder fibers and the bonding with the other constituent fibers of the nonwovens and with the filaments of the reinforcing fabrics. Simultaneous pressure by calender elements also makes it possible to reduce the thickness of the composite and to increase the density thereof.

The needling of the fibers of the nonwoven material through the woven material is preferably carried out using needles provided with low aggressiveness barbs to avoid damaging the woven material.

The needling may be performed with a number of perforations per square centimeter of about 30 to 500, preferably the number of perforations is about 50 to 150.

In addition, the needling can be achieved with penetration through the woven material of about 3 to 15 millimeters, preferably the penetration is about 6 to 13 millimeters.

Preferably, the heat treatment takes place at a temperature of 15O ⁰ C at 22O ⁰ C, preferably about 170 ⁰ C at 200 ⁰ C, for 2 to 5 minutes during which the multilayer material undergoes a withdrawal of 3 to 7% of its original dimensions. This This operation also makes it possible to stabilize the composite and to avoid the heat shrinkage of the first assembly during vulcanization operations when this method is used to manufacture the shoe.

The binder fibers of the fibrous batt may be chosen from polyolefin families such as polyethylene, polypropylene or an arrangement of the two polymers in the form of concentric fibers having a wall of lower melting point.

Low melting point polyamide fibers can also be used as well as those based on amorphous low melting point polyester or concentric type fibers having a higher melting point core than amorphous co-polyester bark. or crystalline. This list is not limiting to these examples and can be extended to other polymers available in the form of fibers.

The constituent fibers of nonwovens are selected from the family of polyester fibers and nylon fibers or a mixture thereof. We can also introduce a proportion of cellulose fibers such as lyocell (Tencel ^® or generic name) or viscose in one or the other of the nonwoven composite of the constituents in order to impart thereto the ability to absorb d Foot humidity. Other constituent fibers, such as acrylic fibers, can be mixed in varying proportions with the synthetic fibers.

Polyester fibers can also be treated with silver salts, either by diffusion in an autoclave, in surface treatment or in bulk. For example, using 25% of a Fosshield ^® Foss Manufacturing polyester fiber provides antibacterial protection to the first assembly. Other active agents with antibacterial properties may also be used for these purposes. The choice of fibers will be influenced by the constraints of assembly and use of the shoes but also by the potential recycling method of the composite obtained. Compatible products will therefore be promoted which can be recycled by melting the polymers or by fraying.

A method that can be used as an alternative to heat-binding fibers for bonding the fibers of the nonwovens and the filaments of the fabrics of the needle-punched composite is to subject the composite material to a chemical treatment. Preferably, the material is totally or partially impregnated with resins based on acrylic latex, polyvinyl alcohol, styrene butadiene, to name only the main ones, in such quantities that the fiber-to-fiber bond is improved without however, too rigidify the composite material thus obtained and reduce the resistance to perforation of the composite. The resin which makes it possible to bind together the fibers of the composite may further contain antibacterial or antistatic agents if necessary.

It is also possible to combine with this mounting base elements such as high resilience polyurethane foams, such as those described in US Pat. US 5,994,245 in the name of the applicant, to improve the comfort of the safety shoe without the need to add additional resilient layer.

The composite material according to the invention also has the advantage of being composed of thermoplastic material and therefore of being able to be heat-molded to take the shape of the foot. It can then advantageously be used as perforated puncture-resistant mold to increase the resistance of a safety shoe to even higher levels or to provide puncture resistance and comfort to footwear with low puncture resistance. by simply adding this fake mold. FIGS. 1a and 1b illustrate a textile composite material (4) according to a preferred embodiment of the invention, obtained by needling two outer layers of nonwoven material (2) through three layers of woven material (1). ) and consolidated by thermal bond.

Figure 2 illustrates an equipment for manufacturing a multilayer composite material (4) according to another preferred embodiment of the invention. In this equipment, two layers of a nonwoven material (2) are unrolled on both sides of two layers of a woven material (1) and are subjected together to the perforation movement of a switchgear (a) which transfers the fibers of the nonwoven material layers (2) through the layers of the woven material (1) to form a intimately mixed composite material (3). The composite (3) thus formed is subjected to heat in an oven (b) and is also shrunk so as to densify the composite material. Additional compression using a calender (c) reduces the thickness of the composite material. The latter is then cut into finished product plates (4) intended to be cut in the form of mounting first.

Figure 3 illustrates another preferred embodiment of the invention, consisting of a puncture-resistant composite material (5) which incorporates a resilient foam layer (6). In this material, a nonwoven layer (2) is needled through two layers of fabric (1) and a layer of resilient polyurethane foam (6). This composite is consolidated by thermal bond.

Examples

The following examples illustrate the manufacture of various multilayer composite materials according to the invention.

Example 1

A 300 g / m ² nonwoven material made from polyester fibers with a consolidated 3.3 decitex titer of 60 perforations per centimeter was manufactured. square. On the feeding apron of a needling machine, the following layers are superimposed:

a first layer of a pre-consolidated non-woven material of 300 g / m ² ;

three layers of a polyester fabric coated with thermoplastic polyurethane resin, the coated side being oriented towards the needles which will perforate the various layers; and

a second layer of a pre-consolidated non-woven material of 300 g / m ² .

These layers are needled together by penetrating the multilayer composite material by 15 mm at the rate of 80 perforations per square centimeter. The product has a thickness of 6.5 mm.

The multilayer product is compressed in a calender heated to 190 ^° C. to obtain a thickness of 4.2 mm.

This composite material has a puncture resistance of 1150 Newtons according to ASTM F 2412/2413.

The flexibility of the product obtained is very high and can not be used as a base for mounting safety shoes in this form.

Partial impregnation of the composite with acrylic resin is then carried out at a rate of 200 g / m ² , and after drying and crosslinking of this resin, a composite material is obtained which has good rigidity to allow the shoe to be fitted.

The resulting composite material has a puncture resistance of 1251 N according to ASTM F 2412/2413.

Example 2 A nonwoven material made from 6.7 decitex polyester fibers with a basis weight of 300 g / m ² is consolidated at 60 perforations per square centimeter. On the feeding apron of a needling machine, the following layers are superimposed:

a first layer of a pre-consolidated non-woven material of 300 g / m ² ; - three layers of polyester fabric coated with thermoplastic polyurethane resin, the coated side oriented towards the needles that will perforate the various layers. These layers were thermally fixed at a temperature of 190 ^° C. for 3 minutes; and

a second layer of a pre-consolidated non-woven material of 300 g / m ² .

These layers are needled together by penetrating the multilayer composite material by 15 mm at the rate of 80 perforations per square centimeter. The product has a thickness of 6.5 mm.

The multilayer product is compressed in a calender heated to 190 ^° C. to obtain a thickness of 4.2 mm.

This composite material has a puncture resistance of 1277N according to ASTM F 2412/2413.

The flexibility of the product obtained is very high and can not be used as a safety shoe mounting base in this form.

Partial impregnation of the composite with acrylic resin is then carried out and, after drying and crosslinking of this resin, a composite product is obtained which has good rigidity to allow the shoe to be fitted.

This final composite material has a puncture resistance of 1430 N according to ASTM F 2412/2413. Example 3

A non-woven material having a basis weight of 175 g / m ² made from a mixture of 70% polyester 3.3 decitex fibers and 30% heart-bark binding fibers, the binder part of which is a co-polymer. crystalline polyester at the melting point of 180 ^° C. is consolidated by needling at the rate of 60 perforations per square centimeter.

On the feeding apron of a needling machine, the following layers are superimposed:

a first layer of a pre-consolidated non-woven material of 175 g / m ² ; two layers of polyester fabric of 820 g / m ² made from filaments with a shrinkage rate at 200 ^° C. of 7%; and

a second layer of a pre-consolidated non-woven material of 175 g / m ² .

These layers are needled together by penetrating the multilayer composite material by 15 mm at the rate of 80 perforations per square centimeter. The product has a thickness of 6.8 mm.

The multilayer product is heated in an oven at 200 ⁰ C for 3 minutes, it is fixed so as to shrink in a controlled manner by about 7%. The product is compressed in a calender heated to 190 ^° C. to obtain a thickness of 5.0 mm.

This composite material has a puncture resistance of 1484N according to ASTM F 2412/2413.

The rigidity of the product obtained is very sufficient to form a base for mounting a safety shoe.

Example 4: A nonwoven material having a basis weight of 175 g / m ² made from 100% 3.3 decitex polyester fibers is needle-bonded at 60 perforations per square centimeter. On the feeding apron of a needling machine, the following layers are superimposed:

a first layer of a pre-consolidated non-woven material of 175 g / m ² ;

two layers of polyester fabric of 820 g / m ² made from filaments with a shrinkage rate at 200 ^° C. of 7%; and a second layer of a pre-consolidated non-woven material of 175 g / m ² .

These layers are needled together by penetrating the multilayer composite material by 15 mm at the rate of 80 perforations per square centimeter. The product has a thickness of 6.8 mm.

The multilayer product is impregnated with a single side using acrylic latex and then dried in an oven at 200 ⁰ C for 4 minutes, it is fixed so as to shrink in a controlled manner by about 7%. The product is then compressed in a calender heated to 190 ^° C. to obtain a thickness of 5.0 mm.

This composite material has a puncture resistance of 1350 N according to ASTM F 2412/2413.

The rigidity of the product obtained is very sufficient to form a base for mounting a safety shoe.

Example 5

A nonwoven material having a basis weight of 175 g / m ² made from a blend of 67% polyester 3.3 decitex fibers and 30% heart-bark binding fibers, the binder portion of which is crystal-polyester to 18O ⁰ C melting point and 3% fiber Nylon ^® coated with 1.8 decitex as silver is consolidated by needling at 60 perforations per square centimeter.

On the feeding apron of a needling machine, the following layers are superimposed: a first layer of a pre-consolidated non-woven material of 175 g / m ² ; two layers of polyester fabric of 820 g / m ² made from filaments with a shrinkage rate at 200 ^° C. of 7%; and

a second layer of a pre-consolidated non-woven material of 175 g / m ² .

These layers are needled together by penetrating the multilayer composite material by 15 mm at the rate of 80 perforations per square centimeter. The product has a thickness of 6.8 mm.

The multilayer product is heated in an oven at 200 ⁰ C for 3 minutes, it is fixed so as to shrink in a controlled manner by about 7%. The product is compressed in a calender heated to 190 ^° C. to obtain a thickness of 5.0 mm.

This composite material has a puncture resistance of 1484 N according to ASTM F 2412/2413.

This composite material also has a resistance of less than 100 ohms.

The rigidity of the product obtained is very sufficient to form a base for mounting a safety shoe.

Example 6

A nonwoven material having a basis weight of 175 g / m ² made from a mixture of 67% fibers of 3.3 decitex polyester and 30% of core-bark binding fibers whose binder part is a co-crystalline polyester developed 18O fusion ⁰ C and 3% fiber ^® nylon coated with silver under 1 8 decitex, is consolidated by needling at 60 perforations per square centimeter.

On the feeding apron of a needling machine, the following layers are superimposed: a layer of a pre-consolidated non-woven material of 175 g / m 2; two layers of polyester fabric of 820 g / m ² made of filaments with a shrinkage rate at 200 ^° C. of 7%, these layers of polyester fabric were pre-shrunk in an oven for 3 minutes at 200 ^° C. VS; and a layer of high resilience polyurethane foam 3 mm thick.

These layers are needled together by penetrating 15mm the multilayer composite material at 80 perforations per square centimeter. The product has a thickness of 8.1 mm.

The multilayer product is heated in an oven at 200 ^° C. for 3 minutes. The product is compressed in a calender heated to 190 ^° C. to obtain a thickness of 6.7 mm.

This composite material has a puncture resistance of 1434 N according to ASTM F 2412/2413.

This composite material also has a resistance of less than 100 ohms.

The rigidity of the product obtained is very sufficient to form the mounting base of a safety shoe.

Example 7

A nonwoven material having a basis weight of 175 g / m ² made from a mixture of 67% fibers of 3.3 decitex polyester and 30% of core-bark binding fibers whose binder part is a crystalline co-polyester at the melting point of 18O ⁰ C is consolidated by needling at 60 perforations per square centimeter.

On the feeding apron of a needling machine, the following layers are superimposed: a layer of a pre-consolidated non-woven material of 175 g / m ² ;

four layers of polyester fabric with a taffeta structure of 865 g / m ² made from high-tenacity polyester filaments with a shrinkage rate at 200 ^° C. of 5%; and a second layer of a pre-consolidated non-woven material of 175 g / m ² .

All of these layers are needled together by penetrating 13 mm of the multilayer composite material at 125 perforations per square centimeter. The product has a thickness of 6.5 mm

The multilayer product is heated in an oven at 200 ^° C. for 3 minutes. The product is compressed in a calender heated to 190 ^° C. to obtain a thickness of 5.5 mm.

This composite material does not allow the perforation of a tip at a value of 1 100N according to EN12568: 2008

The rigidity of the product obtained is very sufficient to form the mounting base of a safety shoe.

Example 8

A non-consolidated material of 175 g / m ² made from a 34% blend of 3.3 decitex polyester fibers and 66% core-bark binder fibers, the binding portion of which is a co-binder. amorphous crystalline polyester having a softening point of 110 ^° C. is needle punched in a taffeta fabric assembly of 1050 g / m ² constructed from high tenacity polyester filaments of 55 Tex in the warp direction and having a weft made from filaments of 110 Tex.

On the feeding apron of a needling machine, the pre-consolidated layers described above are superimposed. They are assembled by needling using of needles penetrating 11 mm pre-consolidated layers at a rate of 125 perforations per square centimeter. The product has a thickness of 5.5 mm

The multilayer product is heated in an oven at 18O ⁰ C for 3 minutes. The product is compressed in a calender heated to 190 ^° C. to obtain a thickness of 4.8 mm.

This composite material has a puncture resistance of 1367 N when tested according to ASTM F2412 / 2413.

The rigidity of the product obtained is very sufficient to form the mounting base of a safety shoe.

Although several preferred embodiments of the invention have been described above and illustrated in the accompanying drawings, the invention is not limited to these embodiments alone. Changes and modifications could in fact be made by someone versed in the field without departing from the scope or spirit of the invention.

Claims

A method of manufacturing a multilayered textile material resistant to possible perforation by a pointed object, said method comprising the steps of: a) contacting one or more layers of a nonwoven material comprising a certain amount of hot melt fibers with one or more layers of a woven material to form a multilayer material; b) consolidating the layers of the multilayer material from step a) by mechanical treatment to interlace some of the fibers of the nonwoven material in the woven material; c) subjecting the consolidated multilayer material from step b) a heat treatment causing some of the hot melt fibers of the nonwoven material to melt in the woven material; and d) cooling the material from step c) to obtain the multilayer composite material. The method of claim 1, wherein the mechanical treatment is a needling of the fibers of the nonwoven material through the woven material. 3. The method of claim 2, wherein the needling is performed with a number of perforations per square centimeter of between about 30 and 500. The method of claim 2 or 3, wherein the needling is made with penetration through the woven material of about 3 to 15 millimeters. 5. Method according to any one of claims 1 to 4, wherein the heat treatment takes place at a temperature of 15O ⁰ C to 22O ⁰ C for 2 to 5 minutes. 6. Method according to any one of claims 1 to 5, wherein the heat treatment causes a withdrawal of the multilayer material from about 3 to 15% of the dimensions of said material before the heat treatment. The method of any one of claims 1 to 6, wherein the material further undergoes a calendering treatment during or after step c). The process according to any one of claims 1 to 7, wherein the multilayer material is further chemically treated comprising partial impregnation by coating or total immersion of the multilayer material in a latex prior to step c) or after step d). A multilayer composite material resistant to possible perforation by a pointed object, said material comprising at least one layer of woven material adjacent to at least one layer of a nonwoven material comprising fibers, the nonwoven material comprising a a certain amount of thermofusible fibers intermixed through the layer of woven material, some of these intermingled hot melt fibers having melted by a heat treatment, thereby consolidating said multilayer composite material. The material of claim 9, comprising at least two layers of woven material stacked and adjacent to at least one layer of nonwoven material. The material of claim 10, further comprising an adjacent resilient foam layer having at least two layers of woven material. 12. Material according to any one of claims 9 to 11, comprising two layers of nonwoven material between which are stacked at least two layers of woven material. The material of any one of claims 9 to 12, wherein the woven material is constructed of continuous filaments arranged as three-dimensional or plain weave, and has a basis weight of about 200 to 1200 g / m ² . The material of any one of claims 9 to 13, wherein the woven material is polyester, polyamide, poly-aramid, polyolefin or glass filaments, or composite fabrics made of co-mixed filaments. The material of any one of claims 9 to 13, wherein the woven material is polyester filaments or high tenacity polyamide of title ranging from 250 decitex to 1800 decitex. 16. Material according to claim 15, wherein the polyester or polyamide filaments have a shrinkage of 3 to 12% at a temperature of 200 ^° C. 17. Material according to any one of claims 9 to 16, wherein the nonwoven material comprises at least one nonwoven fiber mat, said mat having a basis weight of between 80 and 800 g / m ² . The material of claim 17, wherein the nonwoven web comprises polyester, polyamide, polyaramid, cellulose, coextruded fiber, polyolefin fibers, or a blend of these fibers. 19. The material of claim 17 or 18, wherein the nonwoven web further comprises about 2 to 10% of electrically conductive fibers. 20. Material according to any one of claims 17 to 19, wherein the nonwoven mat also contains fibers with bactericidal properties. 21. Material according to any one of claims 9 to 20, further comprising at least one fabric layer on the surface of the composite material, said at least one fabric optionally comprising fibers with bactericidal properties. The material of any of claims 9 to 21, said material having a greater puncture resistance of at least 1200 N according to ASTM F-2412 and / or ASTM F-2413. 23. Use of the multilayer composite material according to any one of claims 9 to 22, for the manufacture of mounting first or as molded false used in the manufacture of shoes or orthosis security.