CA2401440A1 - Composite material - Google Patents
Composite material Download PDFInfo
- Publication number
- CA2401440A1 CA2401440A1 CA002401440A CA2401440A CA2401440A1 CA 2401440 A1 CA2401440 A1 CA 2401440A1 CA 002401440 A CA002401440 A CA 002401440A CA 2401440 A CA2401440 A CA 2401440A CA 2401440 A1 CA2401440 A1 CA 2401440A1
- Authority
- CA
- Canada
- Prior art keywords
- composite material
- endless filaments
- nonwoven
- multicomponent
- titre
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
- B29C70/22—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least two directions forming a two dimensional structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/02—Layered products comprising a layer of synthetic resin in the form of fibres or filaments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H13/00—Other non-woven fabrics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0809—Fabrics
- B29K2105/0818—Fleece
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2904—Staple length fiber
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Nonwoven Fabrics (AREA)
- Laminated Bodies (AREA)
Abstract
The invention relates to a composite material, comprising a microfilament no n- woven fabric with a mass per unit surface area of 40 to 200 g/m2, whereby a non-woven fabric made from a melt-spun and drawn multi-component endless filament with a titre of 1.5 to 5 dtex is directly bonded to form a web and the multi-component endless filaments are optionally spread with and fixed t o micro-endless filaments with a titre of 0.1 - 1.2 dtex, up to a degree of 80 %, by means of a prefixing process and then bonded to a thermoplastic synthetic material by means of an injection moulding process.
Description
COMPOSITE MATERIAL
DESCRIPTION
The invention relates to a composite material, consisting of a microfilament nonwoven fabric with surface weights of 50-200g/mz, which is directly bonded to a thermoplastic synthetic material by an injection molding process.
Lining parts for motor vehicle interiors are known from document EP 0 968 806, in which a microfibre nonwoven material is placed in a mold and bonded with a thermoplastic synthetic material by an injection molding process. Such injection molding or "direct injection molding" (DIN
processes) allow a rational manufacture of lining parts in the field of motor vehicle interiors. The microfibre nonwoven fabric preferably consists of polyester fibres which function as binder layer for a decorative layer to be subsequently applied.
In the course of increasing demands on the automotive industry, new requirements are placed on the suppliers. For example, the finishing parts used in the interior of a motor vehicle must have a decor with attractive optic and haptic. The parts must be recyclable and must have a high color and light consistency, especially hot light consistency, a low tendency to soiling, a high abrasion resistance, humidity resistance, flame resistance, cleanability, a low tendency or no tendency to off gassing and low cost. Moreover, rational, cost advantageous manufacturing processes for the manufacture of the lining parts is desired.
It is an object of the invention to provide a composite material as well as a process for its manufacture, which accommodate the mentioned requirements.
This object is achieved in accordance with the invention by a composite material which includes a microfilament nonwoven fabric with surface weights of 50-250 g/m2 whereby the nonwoven fabric includes meltspun and drawn multicomponent endless filaments with a titre of 1.5-Sdtex directly laid into a nonwoven web, wherein the multicomponent endless filaments, optionally after a preconsolidation, are split to at least 80% into micro endless filaments with a titre of 0.1-1.2 dtex and consolidated and bonded to a thermoplastic synthetic material by an injection molding process. The composite material has a high specific fibre surface and relatively low surface weights as well as a high opacity. The fineness of the filaments allows a good printability as well as embossability and thereby decoration design of the nonwoven fabric used in accordance with the invention for the manufacture of the composite material. The thermoplastic synthetic material thereby does not penetrate the nonwoven fabric.
Preferably, the composite material is one wherein the nonwoven fabric consists of meltspun, aerodynamically drawn multicomponent endless filaments with a titre of 1.5-3dtex immediately laid into a nonwoven web, the multicomponent endless filaments being split to at least 80% into micro endless filaments with a titre of 0.1-0.3dtex and consolidated. The composite material has an isotropic filament distribution in the nonwoven, whereby the further processing is relatively independent of the machine direction and thereby very advantageous for the material utilization.
Preferably, the composite material is one in which the multicomponent endless filament is a bicomponent endless filament consisting of two incompatible polymers, especially a polyester and a polyamide. Such a bicomponent endless filament has a good splittability into micro endless filaments and causes an advantageous ratio of strength to surface weight. At the same time, the composite material in accordance with the invention can be well cleaned and wiped off because of the polymers used and their filament structure and has a high abrasion resistance, which means it is easy care.
Preferably, the composite material is one in which the multicomponent endless filaments have a cross-section with orange type or also "pie" called multisegment structure, whereby the segments alternatingly include respectively one of the two incompatible polymers. Apart from this orange-type multisegment structure of the multicomponent endless filaments, a "side-by-side s/s"
segment arrangement of the incompatible polymers in the multicomponent endless filament is also possible, which is preferably used for the generation of curved filaments.
Such segment arrangements of the incompatible polymers in the multicomponent endless filament have proven to be very well splittable. The nonwoven used for the manufacture of the composite material in accordance with the invention has a good deep drawing ability or deformability, which is apparent in the medium strength values at a high stretchability and comparatively low module values.
DESCRIPTION
The invention relates to a composite material, consisting of a microfilament nonwoven fabric with surface weights of 50-200g/mz, which is directly bonded to a thermoplastic synthetic material by an injection molding process.
Lining parts for motor vehicle interiors are known from document EP 0 968 806, in which a microfibre nonwoven material is placed in a mold and bonded with a thermoplastic synthetic material by an injection molding process. Such injection molding or "direct injection molding" (DIN
processes) allow a rational manufacture of lining parts in the field of motor vehicle interiors. The microfibre nonwoven fabric preferably consists of polyester fibres which function as binder layer for a decorative layer to be subsequently applied.
In the course of increasing demands on the automotive industry, new requirements are placed on the suppliers. For example, the finishing parts used in the interior of a motor vehicle must have a decor with attractive optic and haptic. The parts must be recyclable and must have a high color and light consistency, especially hot light consistency, a low tendency to soiling, a high abrasion resistance, humidity resistance, flame resistance, cleanability, a low tendency or no tendency to off gassing and low cost. Moreover, rational, cost advantageous manufacturing processes for the manufacture of the lining parts is desired.
It is an object of the invention to provide a composite material as well as a process for its manufacture, which accommodate the mentioned requirements.
This object is achieved in accordance with the invention by a composite material which includes a microfilament nonwoven fabric with surface weights of 50-250 g/m2 whereby the nonwoven fabric includes meltspun and drawn multicomponent endless filaments with a titre of 1.5-Sdtex directly laid into a nonwoven web, wherein the multicomponent endless filaments, optionally after a preconsolidation, are split to at least 80% into micro endless filaments with a titre of 0.1-1.2 dtex and consolidated and bonded to a thermoplastic synthetic material by an injection molding process. The composite material has a high specific fibre surface and relatively low surface weights as well as a high opacity. The fineness of the filaments allows a good printability as well as embossability and thereby decoration design of the nonwoven fabric used in accordance with the invention for the manufacture of the composite material. The thermoplastic synthetic material thereby does not penetrate the nonwoven fabric.
Preferably, the composite material is one wherein the nonwoven fabric consists of meltspun, aerodynamically drawn multicomponent endless filaments with a titre of 1.5-3dtex immediately laid into a nonwoven web, the multicomponent endless filaments being split to at least 80% into micro endless filaments with a titre of 0.1-0.3dtex and consolidated. The composite material has an isotropic filament distribution in the nonwoven, whereby the further processing is relatively independent of the machine direction and thereby very advantageous for the material utilization.
Preferably, the composite material is one in which the multicomponent endless filament is a bicomponent endless filament consisting of two incompatible polymers, especially a polyester and a polyamide. Such a bicomponent endless filament has a good splittability into micro endless filaments and causes an advantageous ratio of strength to surface weight. At the same time, the composite material in accordance with the invention can be well cleaned and wiped off because of the polymers used and their filament structure and has a high abrasion resistance, which means it is easy care.
Preferably, the composite material is one in which the multicomponent endless filaments have a cross-section with orange type or also "pie" called multisegment structure, whereby the segments alternatingly include respectively one of the two incompatible polymers. Apart from this orange-type multisegment structure of the multicomponent endless filaments, a "side-by-side s/s"
segment arrangement of the incompatible polymers in the multicomponent endless filament is also possible, which is preferably used for the generation of curved filaments.
Such segment arrangements of the incompatible polymers in the multicomponent endless filament have proven to be very well splittable. The nonwoven used for the manufacture of the composite material in accordance with the invention has a good deep drawing ability or deformability, which is apparent in the medium strength values at a high stretchability and comparatively low module values.
Preferably, the composite material is furthermore one in which at least one of the incompatible polymers forming the multicomponent endless filament includes an additive, such as color pigments, permanently active anti-statics, flame retardants and/or additives influencing the hydrophobic properties, in amounts up to 10% per weight. With these additives, static charges can be reduced or avoided and the hot light fastness of the surfaces visible in the motor vehicle interior improved. A hot-light fastness of >_6 determined according to DIN EN 20105-A02 was achieved with re-dyed products.
The process in accordance with the invention for the manufacture of the composite material consists in that multicomponent endless filaments are spun from the melt, drawn and immediately laid down into a nonwoven web, a preconsolidation is carried out and the nonwoven consolidated by high-pressure fluid jets and simultaneously split into micro endless filaments with a titre of 0.1-1.2 dtex and bonded to a thermoplastic synthetic material by an injection molding process. The composite material so obtained can be manufactured at very short cycle times.
The cycle times can be reduced compared to lrnown composite components from about 50 to 2-5 seconds.
Preferably, the process for the manufacture of the composite material is carried out in such a way that a consolidation and splitting of the multicomponent endless filaments is carried out in which the possibly preconsolidated nonwoven is impacted at least once on each side with high-pressure waterjets and after a drying process placed in an injection mold and injected from behind with a thermoplastic synthetic material. T'he composite material thereby has a good surface and a degree of splitting of the multicomponent endless filaments >80%.
Preferably, the nonwoven used in the composite material in accordance with the invention is also subjected to a point calendaring for an increase in abrasion resistance.
The splitted and consolidated nonwoven is therefor guided through heated rollers of which at least one roller has protrusions which lead to a point form melting of the filaments to one another.
The nonwoven used for the manufacture of the composite material in accordance with the invention because of its properties such as good printability, high abrasion resistance as well as its good hot-light fastness and the haptic design suited for the manufacture of door, column and/or trunk linings, hat rests, motor vehicle roof liners, dashboards as well as wheel well linings.
Example 1 A filament nap with a surface weight of 134g/m2 is produced from a side-by-side (s/s) polyester-polyamide 6.6 (PES-PA 6.6) bicomponent endless filament with a titre of 2.3 dtex and a weight ratio of PES/PA 6.6 of 60/40, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of 1.0 dtex and a thickness of 0.51mm. For the tear resistance, 372N were measured in machine direction and 331N in transverse direction.
Example 2 A filament nap with a surface weight of 137g/m2 is produced from a side-by-side (s/s) polyester-polyamide 6.6 (PES-PA 6.6) bicomponent endless filament with a titre of 1.8 dtex and a weight ratio of PES/PA 6.6 of 50/50, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of 1.0 dtex and a thickness of 0.52mm. For the tear resistance, 457N were measured in machine direction and 373N in transverse direction.
Example 3 A filament nap with a surface weight of lOSg/mz is produced from a 16 segment (pie) polyester-polyamide 6.6 (PES-PA 6.6) bicomponent endless filament with a titre of 2.4 dtex and a weight ratio of PES/PA 6.6 of 55/45, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of 0.1 dtex and after a finishing smoothing a thickness of 0.48mm. For the tear resistance, 302N were determined in the machine direction and 303N in transverse direction.
Example 4 A filament nap with a surface weight of 244g/m2 is produced from a 16 segment (pie) polyester-polyamide 6.6 (PES-PA 6.6) bicomponent endless filament with a titre of 2.1 dtex and a weight ratio of PES/PA 6,6 of 70/30, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of 0.1 dtex and after a finishing smoothing a thickness of 0.90mm. For the tear resistance, 763N were determined in the machine direction and 739N in transverse direction.
Example 5 A filament nap with a surface weight of 131g/mz is produced from a 16 segment (pie) polyester-polyamide 6:6 (PES-PA 6.6) bicomponent endless filament with a titre of 2.0 dtex and a weight ratio of PES/PA 6.6 of 70/30, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of O.ldtex and after a finishing smoothing a thickness of 0.53mm. For the tear resistance, 309N were determined in the machine direction and 284N in transverse direction.
The process in accordance with the invention for the manufacture of the composite material consists in that multicomponent endless filaments are spun from the melt, drawn and immediately laid down into a nonwoven web, a preconsolidation is carried out and the nonwoven consolidated by high-pressure fluid jets and simultaneously split into micro endless filaments with a titre of 0.1-1.2 dtex and bonded to a thermoplastic synthetic material by an injection molding process. The composite material so obtained can be manufactured at very short cycle times.
The cycle times can be reduced compared to lrnown composite components from about 50 to 2-5 seconds.
Preferably, the process for the manufacture of the composite material is carried out in such a way that a consolidation and splitting of the multicomponent endless filaments is carried out in which the possibly preconsolidated nonwoven is impacted at least once on each side with high-pressure waterjets and after a drying process placed in an injection mold and injected from behind with a thermoplastic synthetic material. T'he composite material thereby has a good surface and a degree of splitting of the multicomponent endless filaments >80%.
Preferably, the nonwoven used in the composite material in accordance with the invention is also subjected to a point calendaring for an increase in abrasion resistance.
The splitted and consolidated nonwoven is therefor guided through heated rollers of which at least one roller has protrusions which lead to a point form melting of the filaments to one another.
The nonwoven used for the manufacture of the composite material in accordance with the invention because of its properties such as good printability, high abrasion resistance as well as its good hot-light fastness and the haptic design suited for the manufacture of door, column and/or trunk linings, hat rests, motor vehicle roof liners, dashboards as well as wheel well linings.
Example 1 A filament nap with a surface weight of 134g/m2 is produced from a side-by-side (s/s) polyester-polyamide 6.6 (PES-PA 6.6) bicomponent endless filament with a titre of 2.3 dtex and a weight ratio of PES/PA 6.6 of 60/40, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of 1.0 dtex and a thickness of 0.51mm. For the tear resistance, 372N were measured in machine direction and 331N in transverse direction.
Example 2 A filament nap with a surface weight of 137g/m2 is produced from a side-by-side (s/s) polyester-polyamide 6.6 (PES-PA 6.6) bicomponent endless filament with a titre of 1.8 dtex and a weight ratio of PES/PA 6.6 of 50/50, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of 1.0 dtex and a thickness of 0.52mm. For the tear resistance, 457N were measured in machine direction and 373N in transverse direction.
Example 3 A filament nap with a surface weight of lOSg/mz is produced from a 16 segment (pie) polyester-polyamide 6.6 (PES-PA 6.6) bicomponent endless filament with a titre of 2.4 dtex and a weight ratio of PES/PA 6.6 of 55/45, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of 0.1 dtex and after a finishing smoothing a thickness of 0.48mm. For the tear resistance, 302N were determined in the machine direction and 303N in transverse direction.
Example 4 A filament nap with a surface weight of 244g/m2 is produced from a 16 segment (pie) polyester-polyamide 6.6 (PES-PA 6.6) bicomponent endless filament with a titre of 2.1 dtex and a weight ratio of PES/PA 6,6 of 70/30, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of 0.1 dtex and after a finishing smoothing a thickness of 0.90mm. For the tear resistance, 763N were determined in the machine direction and 739N in transverse direction.
Example 5 A filament nap with a surface weight of 131g/mz is produced from a 16 segment (pie) polyester-polyamide 6:6 (PES-PA 6.6) bicomponent endless filament with a titre of 2.0 dtex and a weight ratio of PES/PA 6.6 of 70/30, and subjected on both sides to a waterjet needling at pressures of up to 230 bar. The bicomponent endless filaments after the waterjet needling which leads to a simultaneous splitting of the starting filaments has a titre of O.ldtex and after a finishing smoothing a thickness of 0.53mm. For the tear resistance, 309N were determined in the machine direction and 284N in transverse direction.
Claims (10)
1. Composite material consisting of a microfilament nonwoven with surface weights of 50-200g/m2, whereby the nonwoven consists of multicomponent endless filaments with a titre of 1.5-5 dtex which are meltspun, drawn and immediately laid into a nonwoven, and wherein the multicomponent endless filaments, possibly after a preconsolidation, are split at least up to 80% into micro endless filaments with a titre of 0.1-1.2 dtex and consolidated and bonded with a thermoplastic synthetic material by an injection molding process.
2. Composite material according to claim 1, characterized in that the nonwoven consists of multicomponent endless filaments with a titre of 1.5-3 dtex which are meltspun, aerodynamically drawn and immediately laid into a nonwoven web and the multicomponent endless filaments, possibly after a preconsolidation, are split at least up to 80% into micro endless filaments with a titre of 0.1-0.3 dtex and consolidated.
3. Composite material according to claim 1 or 2, characterized in that the multicomponent endless filament is a bicomponent endless filament of two incompatible polymers, especially a polyester and a polyamide.
4. Composite material according to one of claims 1 to 3, characterized in that the multicomponent endless filaments have a cross-section with an orange-like multisegment structure, whereby the segments alternatingly include respectively one of the two incompatible polymers and/or have a "side-by-side" structure.
5. Composite material according to one of claims 1 to 4, characterized in that at least one of the incompatible polymers forming the multicomponent endless filament includes an additive, such as color pigments, permanently active antistatics, flame retardants, and/or additives which influence the hydrophobic properties, in amounts up to 10% per weight.
6. Process for the manufacture of a composite material according to one of claims 1 to 5, characterized in that the multicomponent endless filaments are spun from the melt, drawn and immediately laid into a nonwoven web, a preconsolidation is possibly carried out, and the nonwoven web is consolidated by high-pressure fluid jets and simultaneously split into micro endless filaments with a titre of 0.1-1.2dtex and consolidated, and bonded with a thermoplastic synthetic material in an injection molding process.
7. Process according to claim 6, characterized in that the consolidation and splitting of the multicomponent endless filaments is carried out such that the possibly preconsolidated nonwoven is impacted at least once from each side with high-pressure fluid jets.
8. Process according to claim 6 or 7, characterized in that the dying of the multicomponent endless filaments is carried out by dope dying and/or re-dying.
9. Process according to one of claims 6 to 8, characterized in that the nonwoven is point calendared for the manufacture of the composite material.
10. Composite material according to one of claims 1 to 9, characterized in that it is used for the manufacture of door, column and/or trunk linings, hat rests, motor vehicle ceiling linings, dashboards as well as wheel well linings.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE10009280.2 | 2000-02-28 | ||
DE10009280A DE10009280B4 (en) | 2000-02-28 | 2000-02-28 | Composite material and process for its production |
PCT/EP2001/000456 WO2001064416A1 (en) | 2000-02-28 | 2001-01-17 | Composite material |
Publications (1)
Publication Number | Publication Date |
---|---|
CA2401440A1 true CA2401440A1 (en) | 2001-09-07 |
Family
ID=7632657
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002401440A Abandoned CA2401440A1 (en) | 2000-02-28 | 2001-01-17 | Composite material |
Country Status (7)
Country | Link |
---|---|
US (1) | US20030148096A1 (en) |
EP (1) | EP1259366A1 (en) |
AR (1) | AR027425A1 (en) |
AU (1) | AU2001235424A1 (en) |
CA (1) | CA2401440A1 (en) |
DE (1) | DE10009280B4 (en) |
WO (1) | WO2001064416A1 (en) |
Families Citing this family (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE60122501T2 (en) * | 2000-05-16 | 2007-02-01 | Polymer Group, Inc. | METHOD FOR PRODUCING A NONWOVEN FABRIC WITH FISSILE FIBERS |
DE10222440A1 (en) * | 2002-05-22 | 2003-12-04 | Porsche Ag | Wheel arch liner for a vehicle |
US20040231914A1 (en) * | 2003-01-02 | 2004-11-25 | 3M Innovative Properties Company | Low thickness sound absorptive multilayer composite |
US7320739B2 (en) * | 2003-01-02 | 2008-01-22 | 3M Innovative Properties Company | Sound absorptive multilayer composite |
US20040131836A1 (en) * | 2003-01-02 | 2004-07-08 | 3M Innovative Properties Company | Acoustic web |
EP1543934A1 (en) * | 2003-12-17 | 2005-06-22 | Intier Automotive Eybl GmbH (Ebergassing) & Co. OHG | Part with textile decoration |
DE102004054246A1 (en) * | 2004-09-27 | 2006-04-06 | Carl Freudenberg Kg | Arrangement of a plate-shaped filter element in a gas filter housing |
US7500541B2 (en) * | 2004-09-30 | 2009-03-10 | Kimberly-Clark Worldwide, Inc. | Acoustic material with liquid repellency |
BRPI0516389A (en) * | 2004-10-22 | 2008-09-02 | Dow Global Technologies Inc | process to form a conformed three-dimensional article and apparatus |
DE602005004234T2 (en) * | 2004-11-10 | 2009-01-08 | Carl Freudenberg Kg | Stretchable nonwovens |
EP1710126B1 (en) * | 2005-04-04 | 2009-04-01 | Rieter Technologies AG | Sealed thin multi-layer sound absorber |
EP1775110B1 (en) * | 2005-10-11 | 2012-12-19 | Boshoku Automotive Europe GmbH | Plastic molded part with a non-woven layer partially impregnated by a plastic material and with a textile surface and method of producing the same |
PL2705754T3 (en) * | 2012-09-11 | 2017-07-31 | Hans-Martin Rolf | Baked good holder with non-woven fabric surface |
DE102012018852B4 (en) * | 2012-09-25 | 2016-01-07 | Carl Freudenberg Kg | Use of microfiber nonwovens for the production of decorative laminates |
SG11201610117QA (en) | 2014-06-12 | 2017-01-27 | K Fee System Gmbh | Single serve capsule with a calendered fibrous material |
EP3307647B1 (en) | 2015-06-10 | 2019-08-07 | K-fee System GmbH | Capsule with a three layer fleece |
MX2018000149A (en) | 2015-07-13 | 2018-03-23 | K Fee System Gmbh | Filter element having a cut-out. |
KR20180056690A (en) | 2015-09-18 | 2018-05-29 | 카-페 시스템 게엠베하 | Single Capsule Adapter |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4186235A (en) * | 1975-04-24 | 1980-01-29 | Imperial Chemical Industries Limited | Thermoplastics articles having a surface fused to cloth |
JPS5373267A (en) * | 1976-12-10 | 1978-06-29 | Toho Beslon Co | Molding of blended fiber mat and composite material |
US5204170A (en) * | 1991-08-01 | 1993-04-20 | Basf Corporation | High density structural reaction injection molded composite containing a fabric of nonwoven spunbonded fibers made of a polyester core sheathed in a polyamide skin embedded in a polyurethane matrix |
CA2112863A1 (en) * | 1993-01-05 | 1994-07-06 | Louis J. Ii Lamarca | Resiliently padded laminate construction and injection molded thermoplastic articles faced therewith |
US5759926A (en) * | 1995-06-07 | 1998-06-02 | Kimberly-Clark Worldwide, Inc. | Fine denier fibers and fabrics made therefrom |
US5783503A (en) * | 1996-07-22 | 1998-07-21 | Fiberweb North America, Inc. | Meltspun multicomponent thermoplastic continuous filaments, products made therefrom, and methods therefor |
US5965084A (en) * | 1996-10-29 | 1999-10-12 | Chisso Corporation | Process for producing non-woven fabrics of ultrafine polyolefin fibers |
US6200669B1 (en) * | 1996-11-26 | 2001-03-13 | Kimberly-Clark Worldwide, Inc. | Entangled nonwoven fabrics and methods for forming the same |
KR100449063B1 (en) * | 1997-04-14 | 2004-11-16 | 미츠비시 가스 가가쿠 가부시키가이샤 | Process for producing polycarbonate resin with high flowability |
DE59902625D1 (en) * | 1998-07-02 | 2002-10-17 | Intier Automotive Eybl Ges M B | Method for producing multilayer components |
DE19934442C2 (en) * | 1999-07-26 | 2001-09-20 | Freudenberg Carl Fa | Process for producing a nonwoven and nonwoven for producing cleanroom protective clothing |
DE10002778B4 (en) * | 2000-01-22 | 2012-05-24 | Robert Groten | Use of a microfilament nonwoven fabric as a cleaning cloth |
-
2000
- 2000-02-28 DE DE10009280A patent/DE10009280B4/en not_active Expired - Fee Related
-
2001
- 2001-01-17 AU AU2001235424A patent/AU2001235424A1/en not_active Abandoned
- 2001-01-17 EP EP01907454A patent/EP1259366A1/en not_active Withdrawn
- 2001-01-17 CA CA002401440A patent/CA2401440A1/en not_active Abandoned
- 2001-01-17 US US10/220,193 patent/US20030148096A1/en not_active Abandoned
- 2001-01-17 WO PCT/EP2001/000456 patent/WO2001064416A1/en not_active Application Discontinuation
- 2001-02-14 AR ARP010100667A patent/AR027425A1/en not_active Application Discontinuation
Also Published As
Publication number | Publication date |
---|---|
AR027425A1 (en) | 2003-03-26 |
AU2001235424A1 (en) | 2001-09-12 |
DE10009280B4 (en) | 2006-05-18 |
DE10009280A1 (en) | 2001-09-06 |
EP1259366A1 (en) | 2002-11-27 |
US20030148096A1 (en) | 2003-08-07 |
WO2001064416A1 (en) | 2001-09-07 |
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Legal Events
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EEER | Examination request | ||
FZDE | Discontinued |