506891 A7 B7 五、發明說明（ί ) [詳細說明] 裝i I (請先閱讀背面之注意事項再填寫本頁) 本發明關於一種複合材料，由一種單位面積重量50〜 200克/nf的微長絲不織布構成，該微長絲不織布直接利用 一道射出成形程序與一種熱塑性塑膠接合。 在文獻歐洲專利EP 0 968 806發表了汽車內艙用的襯 裡部件，其中將一種微纖維不織布放入一模，並利用一道 射出成形程序與一種熱塑性塑膠接合。這種射出成形程序 或「直接射出成形程序（direct injection moulding)(DIM)」 可將在汽車內部區域用的襯裡部件的製造合理化。該微纖 維不織布宜由聚酯纖維構成，該聚酯纖維的作用係作爲結 合層以結合到以後要施覆的裝飾層。 f·· 經濟部智慧財產局員工消費合作社印製 在汽車工業的要求日益升高之際，對於供應商也有新 的要求。因此，汽車內部區域用的襯裡部件的裝飾要有吸 引人的外觀與觸感。這些部件要能夠回收，且有高度的顏 色不褪性(Echtheit)與耐光不褪色性(Lichtechtheit)，特別是 耐熱光不褪色性(Heifiechtheit)，污染傾向小，耐刮損性高 ，耐濕，耐火，耐洗，釋出氣體(Ausgasimg)的傾向很小或 、沒有，且成本低。此外，還需有製造該襯裡部件的合理廉 價的方法。 本發明的目的在提供一種複合材料及其製造方法，它 能符合上述需求。 依本發明這種目的係用一種複合材料達成，該複合材 料由一種單位面積重量50〜200克/m2的微長絲不織布構成 ，其中，一種不織布由纖度1·5〜5dtex的熔紡牽伸的多成 3 本紙張尺度適用中國國家標準（CNS)A4規袼（210 X 297公釐） 506891 Α7 Β7 五、發明說明（y) 背 之 /i % 事 項 再 填 寫 頁 分無端長絲構成，該多成分無端長絲直接倂成不織布，且 其中該多成分無端長絲如有必要’可在預鞏固作業後至少 80%劈分成纖度0·1〜1·2 dtex的微無端長絲並鞏固化，利 用一道射出成形程序與一種熱塑性塑膠接合。此i複合材料 具有較大的纖維比表面積，而單位面積重量較小，且有高 度的不透光性。纖維的細度使本發明製造該複合材料所用 的不織布容易印刷及鐫印（壓花、拷花、軋印XPragen，英 :emboss)以及裝潢設計。在此，該熱塑性塑膠不透過該不 織布。 v 最好，該複合材料中，不織布由纖度1.S〜3dtex的 熔紡及空氣動力牽伸的多成分無端長絲構成，該多成分無 端長絲直接併成不織布，且其中該多成分無端長絲至少 80%劈分成纖度〇·1〜0.3 dtex的微無端長絲並鞏固化。該 複合材料在不織布，長絲係呈各向同性(isotrop)的分佈， 如此，在進一步的加工時，較不受機器運轉方向影響，因 此很有利於材料充分利用。 經濟部智慧財產局員工消費合作社印製 最好，該複合材料中，該多成分無端長絲爲一種雙成 份無端長絲，由二種不相容的聚合物構成，特別是聚酯與 聚醯胺。這種雙成分無端長絲在微無端長絲中有良好可劈 分性，且造成有利的「強度對單位面積重量的比例」。同 時，本發明的複合材料由於所用的聚合物及其長絲構造， 故有良好可淸洗及可洗滌性，且具有高度耐磨損性，換言 之，它很容易維護。 最好，該複合材料中，多成分無端長絲的橫截面呈柑 本紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） 506891 經濟部智慧財產局員工消費合作社印製 A7 B7 五、發明說明（、） 橘瓣狀或是亦稱「派餅」的多片段式構造，其中，該片段 交替地各含有該二種不相容的聚合物的一種。除了這種柑 橘瓣狀多成分無端長絲多片段式構造外，該二種不相容的 聚合物在該多成分無端長絲中也可呈「擧對邊」（side-by-side)(s/s)的片段排列，它宜用於製造鬈曲（krausdn，英： crimp)的長絲。這種不相容的聚合物在該多成分無端長絲 中的片段排列方式顯示有極佳可劈分性。製造本發明的複 合材料所用的不織布具有良好的可深拉伸性或可變形性， 這種性質在平均強度値時有高拉伸能力及較低的模數値。 最好，另外在該複合材料中，該構成多成分無端長絲 的數種不相容的聚合物中至少有一種含有一添加劑，如顏 料色素、永久性作用的抗靜電劑、防火劑、及/或能影響嫌 水性質的添加物。利用這些添加物可減少或避免靜電荷， 且車內艙中可見的表面的耐熱光不褪色性改善。後染色的 產品達成的耐熱光不褪性^6(依德國工業標準DIN EN 20105-A02 測定）。> 依本發明製造一種複合材料的方法在於：由熔融物將 該多成分無端長絲紡ώ，牽伸，並直接併成絮狀物(Vlies， 英：fleece)，作預鞏固，並將此不織布利用高壓水柱鞏固 ，並同時劈分(分紗)(英：split)成爲纖度Centex的微 無端長絲，並利用射出成形程序與一種熱塑性塑膠接合。 如此所得的複合材料可在很短的循環周期時間(Taktzeit， 英：station time)中製造。此循環周期時間比起習知複合材 料構件來可從約50秒縮短到2〜5秒。 广 5 本紙張尺度適用中國國家標準（CNS)A4規袼（210 X 297公釐） -瞻裝i I (請先閱讀背面之注意事項再填寫本頁) · •^· 506防 1 A? 五、發明說明（士） 多成=1=¾的方_施方式，使該 程度 >跳。 械錢願絲的劈分 依本發明的複合材料中所使用的不織布宜仍做—道點 狀石牙光，以提高麵刮磨性。爲此，將該劈分及鞏固過的 不織布通過加熱的滾子，這些滚子至少有一個具碰起部 ，可使長絲互相呈點狀熔合❶、 製造本翻的複合材料所使用的不織布由於有良好性 質’如良好的可印刷性、高耐磨損性、及其良好醜光不 褪色性與觸感構造，故適合製造車門、柱、及/或行李艙的 襯層’儲帽間(Hutablage)、汽車頂(Autohimmel)、儀表板 (Armaturtafel)、及車輪套外襯層。 [實例一] 由一種纖度2.3dtex的側對側（s/s)的聚酯_聚醯 6,6(PES-PA6,6)的双成分無端長絲[重量比例pes/PA6,6爲 60/40]製造一種單位面積重量134g/m2的長絲 (Filamentflor)並在兩面用230巴的壓力作水柱針軋。此双 成分無端双成分無端長絲在水柱針軋作業(它造成起始長絲 同時劈分)後，纖度l.Odtex，厚度0.51mm。所求得的抗撕 裂強度，沿機器運轉方向爲372N，沿橫方向爲331N。 本紙張尺度適用中國國家標準（CNS)A4規袼（210 X 297公釐） - I I (請先閱讀背面之注意事項再填寫本頁) .- 經濟部智慧財產局員工消費合作社印製 506891 A7 B7 五、發明說明（$ ) [實例二] 由一種纖度1.8dtex的側對側（s/s)的聚酯-聚醯 6,6(PES-PA6,6)的双成分無端長絲[重量比例PES/PA6,6爲 50/540]製造一種單位面積重量137g/m2的長絲絨 (Filamentflor，英：filament pile)並在兩面用 230 巴的壓 力作水柱針乳。此双成分無端双成分無端長絲在水柱針軋 作業（它造成起始長絲同時劈分）後，纖度l.Odtex，厚度 0.52mm。所求得的抗撕裂強度，沿機器運轉方向爲457N ，沿橫方向爲373N。 [實例三] ’ 經濟部智慧財產局員工消費合作社印製 裝i I (請先閱讀背面之注意事項再填寫本頁) 由一種纖度2.4dtex的16片段的聚酯-聚醯6,6(PES-PA6,6)的双成分無端長絲[重量比例PES/PA6,6爲55/45]製 造一種單位面積重量l〇5g/m2的長絲絨(FilamentfloiO並在 兩面用230巴的壓力作水柱針軋。此双成分無端双成分無 端長絲在水柱針軋作業(它造成起始長絲同時劈分)後，纖 度O.ldtex，且在作結束的班光(Glatten英：slieken)後，厚 度爲0.48mm。所求得的抗撕裂強度，沿機器運轉方向爲 302N，沿橫方向爲303N。 [實例四] 由一種纖度2.1dtex的16片段的聚酯-聚醯6,6(PES-PA6,6)的双成分無端長絲[重量比例PES/PA6,6爲70/30]製 造一種單位面積重量244g/m2的長絲絨(Fil醒entflor)並在 7506891 A7 B7 V. Description of the invention (ί) [Detailed description] Install i I (please read the precautions on the back before filling this page) The present invention relates to a composite material consisting of a micro unit weight of 50 ~ 200 g / nf. The filament non-woven fabric is composed of a micro-filament non-woven fabric directly bonded to a thermoplastic by an injection molding process. The European patent EP 0 968 806 discloses a lining part for an inner compartment of an automobile, in which a microfiber nonwoven is put in a mold and is joined to a thermoplastic plastic by an injection molding process. This injection molding process, or "direct injection molding (DIM)", can rationalize the manufacture of lining parts for the interior area of automobiles. The microfiber non-woven fabric is preferably composed of a polyester fiber which functions as a bonding layer for bonding to a decorative layer to be applied later. f ·· Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs As the requirements of the automotive industry are increasing, there are new requirements for suppliers. Therefore, the decoration of the lining parts for the interior area of the car must have an attractive appearance and touch. These parts must be recyclable, and have high color fastness (Echtheit) and light fastness (Lichtechtheit), especially heat fast light fastness (Heifiechtheit), low pollution tendency, high scratch resistance, high humidity resistance, Refractory, washable, little or no tendency to release gas (Ausgasimg), and low cost. In addition, there is a need for a reasonably inexpensive method of manufacturing the liner component. The object of the present invention is to provide a composite material and a method for manufacturing the same, which can meet the above requirements. This object according to the present invention is achieved by a composite material consisting of a microfilament nonwoven fabric with a weight per unit area of 50 to 200 g / m2, wherein one nonwoven fabric is drawn by melt spinning with a fineness of 1.5-5 dtex More than 3% of this paper size applies the Chinese National Standard (CNS) A4 Regulations (210 X 297 mm) 506891 Α7 Β7 V. Description of the invention (y) The / i% item on the back is filled in and the endless filaments are formed. Multi-component endless filaments are directly woven into nonwoven fabric, and if necessary, the multi-component endless filaments can be split into at least 80% of micro-endless filaments with a fineness of 0 · 1 ~ 1 · 2 dtex after pre-consolidation operation and consolidated. , Using an injection molding process to join a thermoplastic. The i-composite material has a large fiber specific surface area, a small weight per unit area, and high opacity. The fineness of the fibers makes the non-woven fabric used in the manufacture of the composite material of the present invention easy to print and emboss (emboss, copy, emboss XPragen, emboss) and decoration design. Here, the thermoplastic is impermeable to the nonwoven. v Preferably, in the composite material, the non-woven fabric is composed of melt-spun and aerodynamically drawn multi-component endless filaments having a fineness of 1.S to 3dtex, and the multi-component endless filaments are directly combined into a non-woven fabric, and the multi-component endless At least 80% of the filaments are split into micro-endless filaments with a fineness of 0.1 to 0.3 dtex and consolidated. The composite material has an isotropy distribution in the non-woven fabric and the filaments. In this way, during further processing, it is less affected by the direction of the machine's operation, so it is beneficial to the material to make full use of it. The consumer cooperative of the Intellectual Property Bureau of the Ministry of Economic Affairs has the best printing. In this composite, the multi-component endless filament is a two-component endless filament composed of two incompatible polymers, especially polyester and polyfluorene. amine. Such bicomponent endless filaments have good cleavability in micro-endless filaments and result in an advantageous "ratio of strength to weight per unit area". At the same time, the composite material of the present invention has good washability and washability due to the polymer and its filament structure used, and has high abrasion resistance, in other words, it is easy to maintain. Preferably, the cross-section of the multi-component endless filaments in this composite material is citrus paper standard applicable to Chinese National Standard (CNS) A4 specifications (210 X 297 mm) 506891 Printed by A7 B7, Employee Cooperative of Intellectual Property Bureau, Ministry of Economic Affairs 5. Description of the invention (,) The orange petal-shaped or multi-segment structure also known as "pie", wherein the segments alternately each contain one of the two incompatible polymers. In addition to this citrus petal-like multi-component endless filament multi-segment structure, the two incompatible polymers can also be "side-by-side" in the multi-component endless filament ( s / s), which is suitable for making krausdn (crimp) filaments. The arrangement of the segments of this incompatible polymer in the multicomponent endless filaments shows excellent cleavability. The non-woven fabric used for manufacturing the composite material of the present invention has good deep stretchability or deformability. This property has a high stretchability and a low modulus at an average strength of 値. Preferably, in the composite, at least one of the incompatible polymers constituting the multi-component endless filaments contains an additive such as a pigment, a permanent antistatic agent, a fire retardant, and / Or additives that can affect the nature of water. The use of these additives can reduce or avoid electrostatic charge, and the heat-resistant light does not fade on the surface visible in the cabin. The heat-fast light fastness achieved by the post-dyed products ^ 6 (determined according to the German industrial standard DIN EN 20105-A02). > The method for manufacturing a composite material according to the present invention is that the multi-component endless filament is spun, drawn from a melt, and directly combined into floes (Vlies, English: fleece), pre-consolidated, and This non-woven fabric is consolidated with a high-pressure water column, and at the same time split (splitting) (slit) into micro-endless filaments of fineness Centex, and the injection molding process is used to join a thermoplastic plastic. The composite material thus obtained can be manufactured in a short cycle time (Taktzeit, English: station time). This cycle time can be shortened from about 50 seconds to 2 to 5 seconds compared to conventional composite material components.广 5 This paper size applies the Chinese National Standard (CNS) A4 regulations (210 X 297 mm)-Zhuang i i (Please read the precautions on the back before filling this page) · • ^ 506 anti 1 A? 5 2. Description of the Invention (Shi) A formula of = 1 = ¾ is often used to make the degree > jump. Splitting of mechanically-wishable silk The nonwoven fabric used in the composite material according to the present invention should still be made-point-like stone dentin to improve surface abrasion. For this purpose, the split and consolidated nonwoven fabric is passed through heated rollers, and at least one of these rollers has an abutment portion, and the filaments can be fused with each other in a point shape to form a nonwoven fabric used in the composite material Due to its good properties, such as good printability, high abrasion resistance, and its good ugly fading and tactile structure, it is suitable for the manufacture of door, pillar, and / or luggage compartment liners. (Hutablage), car roof (Autohimmel), dashboard (Armaturtafel), and wheel liner outer lining. [Example 1] A polyester-polyfluorene 6,6 (PES-PA6,6) bicomponent endless filament with a side-to-side (s / s) fineness of 2.3 dtex [weight ratio pes / PA6, 6 is 60 / 40] A filament (Filamentflor) with a basis weight of 134 g / m2 was manufactured and needle-rolled with a pressure of 230 bar on both sides as a water column. This bicomponent endless bicomponent endless filament has a fineness of l.Odtex and a thickness of 0.51mm after a water column needle rolling operation (which causes the initial filament to be split simultaneously). The obtained tear resistance was 372 N in the machine running direction and 331 N in the transverse direction. This paper size applies Chinese National Standard (CNS) A4 Regulations (210 X 297 mm)-II (Please read the precautions on the back before filling out this page).-Printed by the Intellectual Property Bureau of the Ministry of Economic Affairs and Consumer Cooperatives 506891 A7 B7 V. Description of the invention ($) [Example 2] A polyester-polyfluorene 6,6 (PES-PA6,6) bicomponent endless filament with a fineness of 1.8dtex side-to-side (s / s) [weight ratio PES / PA6,6 is 50/540] A filament pile (Filamentflor, English: filament pile) with a basis weight of 137 g / m2 was manufactured and a water column needle milk was used on both sides with a pressure of 230 bar. This bicomponent endless bicomponent endless filament has a fineness of l.Odtex and a thickness of 0.52mm after a water column needle rolling operation (which causes the initial filament to be split simultaneously). The obtained tear strength was 457N in the machine running direction and 373N in the transverse direction. [Example 3] 'Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs (I read the precautions on the back before filling out this page) A 16-segment polyester-polyfluorene 6,6 (PES with a fineness of 2.4 dtex -PA6,6) two-component endless filament [weight ratio of PES / PA6,6 is 55/45] to manufacture a filament velvet (FilamentfloiO with a weight per unit area of 105 g / m2 and a pressure of 230 bar on both sides as a water column needle The thickness of this two-component endless two-component endless filament after needle rolling in water column (which causes the initial filament to split at the same time) is O.ldtex, and the thickness after the end of the work (Glatten English: slieken) It is 0.48mm. The obtained tear resistance is 302N in the machine running direction and 303N in the transverse direction. [Example 4] A 16-segment polyester-polyfluorene 6,6 (PES- PA6,6) two-component endless filament [weight ratio of PES / PA6,6 is 70/30] Manufacture a kind of filament velvet (Fil Xingentflor) with a unit weight of 244g / m2 and
1^紙張尺度ii中國國家標準(CNS)A4規袼（2i〇 x 297公B 經濟部智慧財產局員工消費合作社印製 506891 A7 B7 五、發明說明（b) 兩面用230巴的壓力作水柱針軋。此双成分無端双成分無 端長絲在水柱針軋作業(它造成起始長絲同時劈分)後，纖 度O.ldtex，且在作結束的砑光（Glatten)後，厚度爲 0908mm。所求得的抗撕裂強度，沿機器運轉方向爲763N ，沿橫方向爲739N。 [實例五] 由一種纖度2.0dtex的16片段的聚酯-聚醯6,6(PES-PA6,6)的双成分無端長絲[重量比例PES/PA6,6爲70/30]製 造一種單位面積重量131g/m2的長絲絨絨(Filamentflor)並 在兩面用230巴的壓力作水柱針軋。此双成分無端双成分 無端長絲在水柱針軋作業（它造成起始長絲同時劈分)後’ 纖度O.ldtex，且在作結束的砑光（GlStten)後，厚度爲 0.53mm。所求得的抗撕裂強度，沿機器運轉方向爲309N ，沿橫方向爲284N。 s ^紙張尺度適用中國國家標準（CNS)A4規格（210 X 297公釐） ------------I -- (請先閱讀背面之注意事項再填寫本頁)1 ^ Paper size ii Chinese National Standard (CNS) A4 Regulations (2i0x 297 g B Printed by the Consumer Cooperatives of the Intellectual Property Bureau of the Ministry of Economic Affairs 506891 A7 B7 V. Description of the invention (b) Water pressure needle with 230 bar pressure on both sides The fineness of this two-component endless two-component endless filament after needle rolling in water column (which causes the initial filament to split at the same time) is O.ldtex, and the thickness after calendering is 0908mm. The obtained tear resistance is 763N in the machine running direction and 739N in the transverse direction. [Example 5] A 16-segment polyester-polyfluorene 6,6 (PES-PA6,6) with a fineness of 2.0dtex Made of two-component endless filaments [weight ratio of PES / PA6, 6 is 70/30] to produce a filament velvet (Filamentflor) with a unit weight of 131g / m2 and needle-rolled with a pressure of 230 bar on both sides. The endless bi-component endless filaments have a fineness of O.ldtex after needle rolling in a water column (which causes the initial filaments to split at the same time) and have a thickness of 0.53mm after the final calendering (GlStten). Tear strength, 309N in the machine running direction and 284N in the transverse direction. S ^ Paper size applies to China National Standard (CNS) A4 Specification (210 X 297 mm) ------------ I-(Please read the precautions on the back before filling this page)