Composite material

Abstract

The invention relates to a composite material, made from a microfilament nonwoven fabric having a mass per unit area of 40 to 200 g/m 2 , in which a nonwoven fabric, which is made from melt-spun, drawn, multi-component endless filaments having a titer of 1.5 to 5 dtex and directly laid up to form a fibrous web, and in which the multi-component endless filaments, optionally after prebonding, are split at least to 80% to form micro-endless filaments having a titer of 0.1 to 1.2 dtex and bonded, is bonded to a thermoplastic synthetic material using an injection-molding process.

What is claimed is:  
     
         1 . A composite material made from a microfilament nonwoven fabric having masses per unit area of 50 to 200 g/m 2 , the nonwoven fabric being made from melt-spun, drawn, multi-component endless filaments having a titer of 1.5 to 5 dtex and directly laid up to form a fibrous web, and in which the multi-component endless filaments, optionally after prebonding, are split at least to 80% to form micro-endless filaments having a titer of 0.1 to 1.2 dtex and bonded, and is bonded to a thermoplastic synthetic material using an injection-molding process.  
     
     
         2 . The composite material as recited in  claim 1 , wherein the nonwoven fabric is made from melt-spun, aerodynamically stretched multi-component endless filaments having a titer of 1.5 to 3 dtex and directly laid up to form a fibrous web, and the multi-component endless filaments, optionally after prebonding, are split to at least 80% to form micro-endless filaments having a titer of 0.1 to 0.3 dtex, and bonded  
     
     
         3 . The composite material as recited in  claim 1  or  2 , wherein the multi-component endless filament a bicomponent endless filament made from two incompatible polymers, particularly a polyester and a polyamide.  
     
     
         4 . The composite material as recited in one of claims  1  through  3 , wherein the multi-component endless filaments have a cross-section having an orange-like multi-segment structure, the segments in each case alternately containing one of the two incompatible polymers and/or having a “side-by-side” structure.  
     
     
         5 . The composite material as recited in one of claims  1  through  4 , wherein at least one of the incompatible polymers forming the multi-component endless filament contains an additive, such as color pigments, permanently acting anti-statics, flame retarding agents and/or additives that influence the hydrophobic properties, in amounts up to 10 percent by weight.  
     
     
         6 . A method for producing a composite material as recited in one of claims  1  through  5 , wherein multi-component endless filaments are spun from the melt, stretched, and directly laid up to form a web, prebonding is optionally carried out, and the nonwoven fabric is bonded using high-pressure fluid jets, and, at the same time, split into micro-endless filaments having a titer of 0.1 to 1.2 dtex, and bonded to a thermoplastic synthetic material using an injection-molding process.  
     
     
         7 . The method as recited in  claim 6 , wherein the multi-component endless filaments are bonded and split in that the nonwoven fabric, which has been prebonded if necessary, is impacted at least once on each side with high-pressure fluid jets.  
     
     
         8 . The method as recited in  claim 6  or  7 , wherein the multi-component endless filaments are dyed by spin-dyeing and/or overdyeing.  
     
     
         9 . The method as recited in one of claims  6  through  8 , wherein the nonwoven fabric for the production of the composite material is spot-calandered.  
     
     
         10 . The composite material as recited in one of  claims 1  to  9 , wherein it is used for the production of door, pillar, and/or trunk linings, rear window shelves, car roof linings, dashboards, as well as wheel house liners.