Nonwoven textiles in automotive Interior, upholstery, insulation and filtering applications

Transcription

1 T-POT Seminar Technical textiles/recycling Nonwoven textiles in automotive Interior, upholstery, insulation and filtering applications Dipl.-Ing. Bernd Gulich Sächsisches Textilforschungsinstitut e.v. an der Technischen Universität Chemnitz, Germany (Saxon Textile Research Institute) Contents 1. Introduction / Statistics 2. Stitch bonded nonwovens with finer mesh structures 3. Three-dimensional nonwovens for upholstery 4. Nonwovens for back moulded soft-touch parts 5. Filled nonwovens in material flows 6. Nonwovens in filtration 7. Nonwovens for shielding effects 8. Summary 1

2 1. Introduction / Statistics 1. Introduction / Statistics Worldwide production of automotive textiles Production in 1,000 tonnes Fabrics, Knits 953 1,125 1,170 1,221 1,214 Nonwovens Composites Others Source: Frost & Sullivan 2

3 1. Introduction / Statistics Application of nonwovens in cars 1. Introduction / Statistics Textiles used in cars [kg] Carpets, coverings Upholstery 4,5 2,2 4,5 Belts, hoses Tyres Safety belts 1,2 0,9 1,5 1,6 3,5 Airbags Textiles in composites Others (e.g. filters) Source: David Rigby and others Upholstery materials including sub-upholstery textiles 6 3

4 2. Stitch bonded nonwovens with finer mesh structures Stitch bonded nonwoven type Malivlies cover fabrics for hat racks Fig.: KARL MAYER Malimo 2. Stitch bonded nonwovens with finer mesh structures F... mesh rows per 25 mm Malivlies F 18 (72 meshes/cm²) Malivlies F 22 (88 meshes/cm²) Malivlies (gauge F 24) Stitch length 1.0 mm Malivlies F 24 (96 meshes/cm²) 4

5 2. Stitch bonded nonwovens with finer mesh structures Malivlies decorative fabric with activatable adhesive at the back Mass per unit area: 210 g/m² 10 % bicomponent fibres 3. Three-dimensional nonwovens for upholstery One of the first applications of nonwovens as upholstery of car seats: Start at Mercedes-Benz in 1992 with upholstery fabric Karo III Mass: 150 g/m² Thickness: 2.3 mm Malivlies - Application Fig.: KARL MAYER Malimo 5

6 3. Three-dimensional nonwovens for upholstery Caliweb - Use as sub-upholstery in car seats Cover fabric Multiknit Thermo-calibrated with use of % of solid profile fusible fibres respectively % of bi-component fibres Fig.: Techtex GmbH 3. Three-dimensional nonwovens for upholstery Flatbed lamination line with powder scatterer at STFI (Schott & Meissner) Powder scatterer 20 g/m² Glueing web 12 or 24 g/m² Tendency: PUR => Co-polyester => Co-polyamid Fig.: Herbert Meyer GmbH 6

7 3. Three-dimensional nonwovens for upholstery Main advantages of CALIWEB vs. PUR foam PUR foam CALIWEB Layers 2 fabric layers 2 fabric layers 1 foam layer adhesive layers 1 adhesive layer polyurethane + polyester only polyester Recyclability moderate/bad excellent Emissions/Fogging/0dor effects strong low Air permeability reduced unlimited (upholstery layer) Moisture transport very low good (capillary effect) Microclimate of seats low/poor fine/improved Price low moderate 3. Three-dimensional nonwovens for upholstery Principle of moisture storage and transportation (Spacer nonwoven type NAPCO made of two different nonwoven layers) Cross-section nonwoven Cross-section fibre bundles 7

8 4. Nonwovens for back moulded soft-touch parts Nonwoven materials used for soft-touch effect in reverse injection 4. Nonwovens for back moulded soft-touch parts Nonwoven materials used for soft-touch effect in reverse injection Cross-section Knitted fabric Adhesive web Nonwoven (intermediate layer) Blocking film 8

9 4. Nonwovens for back moulded soft-touch parts Special requirements to textile components for back moulding with soft-touch effect Decorative layer Formability Form stability Light fastness Ageing stability Intermediate layer Formability Temperature resistance Elasticity of compression Closed surface Formation of composites from decorative layer, intermediate layer and blocking layer is possible within one processing step 5. Filled nonwovens in material flows Conception for closed material flows in production of moulded parts Innovative composites by partial needle-punching Additional stability by hollow space structures Wasteless production Solution for internal recycling Implementation is realised at present by a well-known automotive supplier 9

10 5. Filled nonwovens in material flows Needle-punched spacer nonwoven prefabricated nonwoven layer N 1 6 MD fibre bundle distance as a result of needling intensity 2 prefabricated nonwoven layer N 2 7 CD fibre bundle distance as a result of needle row distance 3 fibre bundle delivered from layer N 1 8 machine direction (MD) 4 fibre bundle delivered from layer N 2 9 fibre bundle length as a result of spacer profile thickness 5 puncture 5. Filled nonwovens in material flows Filling material Nonwoven 1 Nonwoven 2 Filled needle-punched spacer nonwovens 10

11 6. Nonwovens in Filtration Nonwovens becoming more and more important with regard to filtration processes in the motor vehicle: - composites of no less than two nonwovens; - gradient filters of several nonwovens becoming smaller, their number of pores becoming bigger; - surface-modified filters: a layer of nano fibres is deposited onto the surface of a filtering textile material serving as a supporting structure; - combination of a PBT meltblown web with a thick layer of cellulose fibres; - thermobonded webs of polyester micro fibres (8 µm 20 µm) so as to allow coarse dust filtration in air-conditioning systems; - meltblown nonwovens of PP and spunbonded webs of PP as supporting webs in fine dust filtration; 11

12 7. Nonwovens for shielding Development of share in electronic parts in vehicle value type mid-range car 5 % 25 % 35 % up-range car 10 % 30 % 40 % Metallised spunbonded nonwovens sputtered with aluminium or coppered Applications in cars: shielding of cables and electronic components sun protection materials 8. Summary Increasing comfort and equipment requires quantitative and qualitative developments in nonwoven applications: Synthetic materials and other materials in known applications and with known functions are more and more substituted by nonwovens Nonwovens will be used for novel applications with novel functions Nonwovens in applications known for cars need to fulfil novel functions, which is due to design-related developments Application of recyclable materials 12

13 8. Summary Textiles in Cars - Development in Use Amount in kg in a typical mid-range car 2000 Year Total Product and application like New product for known application New product for new application Textile waste management in Germany & developments in textile recycling technology Thank you for your attention! Please contact: Phone: Fax: bernd.gulich@stfi.de 13