Mechanically interlocked nonwoven industrial fabric

1. A nonwoven industrial fabric comprising a first layer secured to a second layer, with each layer comprising a plurality of profiling protrusions, with each profiling protrusion forming at least one flow-through aperture, wherein:

(a) at least a portion of the flow-through apertures of the first layer is aligned with at least a portion of the flow-through apertures of the second layer;

(b) in addition to the plurality of profiling protrusions, the first layer also comprises a plurality of deformable securing protrusions integral to the first layer;

(c) the second layer comprises a plurality of detents integral to the second layer; and

(d) the first layer is secured to the second layer by a plurality of locking pairs, each locking pair comprising a deformed securing protrusion lockably engaged with a detent.

2. The nonwoven industrial fabric according to claim 1 , wherein the plurality of locking pairs includes at least one locking pair formed by a detent integral with the first layer lockably engaged with a securing protrusion integral with the second layer.

3. The nonwoven industrial fabric according to claim 1 , wherein in each locking pair, the deformed securing protrusion:

i) protrudes through a detent opening; and

ii) has an enlarged free end lockably engaged with the detent.

4. The nonwoven industrial fabric according to claim 3 , wherein the detent opening is located in a profiling protrusion.

5. The nonwoven industrial fabric according to claim 3 , wherein hot staking is used to form the enlarged free end.

6. The nonwoven industrial fabric according to claim 1 , wherein in each locking pair, the detent comprises constriction of a detent region that receives and retains the securing protrusion.

7. The nonwoven industrial fabric according to claim 4 , wherein clinching is used to form each securing protrusion, each detent and each locking pair.

8. The nonwoven industrial fabric according to claim 1 , wherein the first layer and the second layer are both made of a material selected from the group consisting of a metal, a thermoplastic and a thermoset.

9. The nonwoven industrial fabric according to claim 8 , wherein the material is a thermoplastic.

10. The nonwoven industrial fabric according to claim 1 , wherein the first layer is further secured to the second layer by bonding, and the bonding is selected from the group consisting of through transmission laser welding; ultrasonic welding, adhesives and chemically-reactive systems.

11. The nonwoven industrial fabric according to claim 8 , wherein a surface of at least one of the first layer and second layer is treated by a method selected from the group consisting of vapor deposition, nanoparticle treatment and plasma treatment.

12. The nonwoven industrial fabric according to claim 1 , wherein the first layer is made of a first material and the second layer is made of a second material different from the first material.

13. The nonwoven industrial fabric according to claim 1 , wherein the first layer has a first thickness and the second layer has a second thickness that is different from the first thickness.

14. The nonwoven industrial fabric according to claim 1 , wherein:

i) a first set of abutting strips of the first layer is oriented parallel to a second set of abutting strips of the second layer; and

ii) both of the first set of abutting strips and the second set of abutting strips are oriented in either: a longitudinal direction of the nonwoven fabric, or in a width direction of the nonwoven fabric.

15. The nonwoven industrial fabric according to claim 1 , wherein an exterior surface of at least one of the first layer and the second layer has an averaged surface roughness of between 1 micron and 100 microns.