Bahir Dar UniversityBahir Dar UniversityEthiopian Institute of Textile and Ethiopian Institute of Textile and

Fashion TechnologyFashion Technology

Seminar on: Design and Development Seminar on: Design and Development of Automotive Textiles of Automotive Textiles

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Contents

2.2. Other Car Parts

1. Introduction2. Different Automotive Parts

2.1. Car Interior

3. Discussion

5. References 4. Summary

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1. Introduction

• Mobility is a fundamental requirement of all human activity.• Cars embody personal freedom and for some an expression of

individuality.• People are spending more time in their cars, commuting longer

distances to work on a daily or weekly basis.

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…cont.

• Textile design and color will inevitably be an essential tool in creating these interiors.

• Textiles provide a means of decoration and a warm soft touch to the seats and the interior of the car, but they are also used in more functional applications.

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•The car in fact has become an office, a living room and a shopping bag on wheels.•Changing the car interior design of an existing model is an economical way to revamp a model that is not selling well.

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2. Different Automotive Parts

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2.1. Car Interior

Technical Requirement•Aesthetic •Comfort and safety•Recycling•Ease of disassembly•Labor factor

Previous material used

polyurethane foam

Method - Cut and sew

Disadvantages •Recycling •Commonization of materials and disposal factors

Current fiber/material used•Polyester •Polyester non-wovenMethod - 3-D knitting

Parts •Seat covering•Metal springs•Seat pan/Cushion •Seat back/Squab

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1. Seat

Technical Requirement•Sound and vibration insulation dimensional stability•Interior appearance soft touch•Light-weight anti - soiling•Thin profile and rigid safety•Flex or vibrate

Previous material used

PVC

Method - Cut and sew

Disadvantages •Recycling •Commonization of materials and disposal factors

Current fiber/material used•Polyester •Polyester non-wovenMethod - 3-D knitting

Parts •Layers•Core

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2. Headliners

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Technical Requirement•Aesthetic •Soft touch

Current fiber/material used•Polyurethane foam laminate•A foil or film made from polyolefin, PVC•Wood/wood-veneer/synthetic leatherMethod - 3-D knitting

Parts •Layers

113. Door Casing

Technical Requirement•UV, light fastness•Degradation •Thermal resistance against delamination and distortion•Abrasion resistance•Sound absorption

Current fiber/material used•Polypropylene•Polyester Method – needle-punched non-wovens

Parts •Face fabric•Back fabric

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4. Parcel shelf

Technical Requirement•Low gloss (no glare or reflections on the windscreen)•Soft touch Pleasant aesthetics Non-fogging•Resistance to heat ageing UV stability•Resistance to low temperature and•High abrasion resistance Non-odorous

Current fiber/material usedPlastic foil with textile materialMethod – 3-D knitting

135. Dashboard

Technical Requirement•UV light resistant•Heat resistant

Current fiber/material used•PVC•Raised-warp knit fabricMethod – injection mouldingMetal frames/rigid foam/cardboardnonwovens

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6. Sunvisors

Technical Requirement•Strength•Abrasion resistance•Soft and flexible•Resistant to UV degradation

Previous material used

Nylon

Current fiber/material usedHigh tenacity continuous filament polyester yarnMethod woven fabric (twill or sometimes satin) they allow maximum yarn packing within a given area for maximum strength and good abrasion resistance.

DisadvantagesLow resistant to UV degradation

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7. Seat belts

Technical Requirement•The fabric should withstand the force of the hot propellant chemicals and more importantly they must not penetrate through the fabric to burn the car occupant.•Thermal resistant•Lighter and thinner•Packing compactness•Controlled air permeability

Current fiber/material used•Nylon 66 coated with Neoprene rubber•Silicone coatingsMethod – woven from high tenacity multi-filament nylon 66 yarns

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8. Air Bags

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Airbags operate by a triggering device, which sets off explosive chemicals when it senses an impact at above approximately 35 km/h is about to happen. This causes the bag to inflate, which cushions and restrains the human body from hitting a harder object. It inflates and deflates all within a fraction of a second – less than the time to blink an eye.

Technical Requirement•Odour free•The adsorption and retention capacity of the filter for odours•Resistant to micro-organisms•Resistant to extremes of temperature

Current fiber/material used•Polypropylene non woven electret fabric with adsorption by activated carbon.•microfibersMethod – multi-layer non-woven fabric

189. Cabin air filters

There are three basic ways in which the filters work. •The first is by mechanically filtering out solid particles through fine pores in the nonwoven fabric.•The second is by imparting an electrostatic charge to the fibre, which then attracts solid particles electrostatically.•The third mechanism, is by the use of activated carbon which adsorbs gases and is therefore also capable of removing odours.

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Recent research has shown that the air quality inside a car can be several times poorer than the air quality outside, especially if the car is driven closely behind another vehicle.

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2.2. Other Car Parts

Technical Requirement•Allow the flow of electrolyte but prevent actual particles migrating•Vibration resistance

Previous material usedFiber glass

Current fiber/material used•Polyester•Specialist acrylic resin (to stabilize and to help with fabrication)Method – Woven fabric

DisadvantageNot economical

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1. Battery separators

• Every battery needs a separator of some description to mechanically separate the anode from the cathode and to prevent short circuits.

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• Electric lead–acid batteries such as those used in motor cars consist of two plates, an anode (+) and a cathode (-) in dilute sulphuric acid.

• When discharging, chemical reactions take place, the anode is converted from lead peroxide to lead sulphate and the cathode from pure lead to lead sulphate.

An effective well-designed separator is essential for long battery life – 6 years is now a common requirement.

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Lead sulphate particles build up on the battery plates and need to be retained, otherwise they would eventually cause a short circuit. This is achieved by a physical barrier or a separator

Technical Requirement•Resistant to fluids and heat•Sound absorbent •Durable to last the life of the vehicle

Previously used materials

Phenolic-resinated waste shoddy fabric/fiber glass/polyurethane foams

Current fiber/material usedPolyester/polypropyleneMethod –nonwovens

DisadvantageRecycling

Parts •Face layer•Internal layer•Back layer

242. Bonnet (hood) liners

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These are generally made from a laminate material the main function of which is to absorb and dampen engine noise.More recently, bonnet liners are being designed entirely in polyester or entirely in polypropylene to facilitate recycling and to remove the fibre-glass, a potential skin irritant. Spun-bonded non-wovens, such as Lutrador (Freudenberg), are well-suited because they allow deepdraw, well-defined moulding to the required shape.

Technical Requirement•Road noise reduction•Increased road safety•Reduce spray in wet conditions•Protection of the bodywork

Previous material usedPVC

Disadvantages •Stiffness •Hardness•Heavy

Current fiber/material used•Polypropylene•Polyester•Coated with specially formulated SBR latexMethod – needle-punched nonwovens

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4. Wheel arch liners

Technical Requirement•Resistant to UV light radiation, rain, frost/minute ice crystals, ozone, micro-organisms, dirt and traffic fumes•Dimensional stability under all weather conditions•Abrasion resistance•Soil resistance•Aesthetics

Previous material used•A variety of coated fabrics•Rubberized cotton•PVC-coated cotton, nylon and polyester

Current fiber/material used•A triple-textile laminate with spun-dyed acrylic fibres in the top layer.•Polyester twill-woven fabric – inner surface•Rubber – middle layer

Disadvantages Poor resistance to micro-organisms

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5. Hood Material for convertibles

Technical Requirement•High tenacity•Thermal stabillity

Previous material usedSteel cordDisadvantages •High weight•Moisture corrosionCurrent fiber/material used•Rayon •A resorcinol–formaldehyde latex (RFL) bonding system was required to promote adhesion of the smoother rayon to rubberMethod – Cord

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6. Tyres

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Dunlop, who in 1888 first used textiles, a canvas fabric, as rubber tyre reinforcement.

Early tyres used woven fabric which was later replaced by a unidirectional arrangement of cords sometimes with a small number of weft threads across them.

The car radial tyre contains about 4 to 7% of its total weight of textile material.

Technical Requirement•Dimensional stability•Moisture, oil, chemical and temperature resistance•Strength•Couse good adhesion to the rubber

Previous material used

CottonDisadvantages Poor abrasion resistance

Current fiber/material used•Polyester•Aramids Method –Cord

307. Hoses and Belts

• The performance of these articles also relies very much on the bond strength between the textile and the rubber matrix.

• Both hoses and belts rely almost entirely on the textile component for actual physical strength and various fibres have been used, including cotton, rayon, glass, nylon and polyester.

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3. Discussion

• Textiles application other than apparel usages are called technical textiles.

• Technical textiles have different field of applications i.e. agriculture, building, medical, transport, etc.

• The automobile industry is the largest user of technical textiles, with about 20 kg in each of the 45 million cars made every year world-wide.

• Textiles are present in many forms in the automobile ranging from the seats to battery separators, from headliners to bonnet liners.

• The automotive industry requires knowledge of several disciplines, textile chemistry, fabric technology, plastics’ science, production engineering and interior fabric design.

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4. Summary

• As it is observed synthetic fibers are used for the production of different car parts.

• In Ethiopia synthetic fiber production is not yet practiced.• Car assembling is started in recent years, after 1991.• To mention some of the car assemblers: Holland cars, MIE

(Gelly), Defence (Bishoftu)…Debre Markos Electric bus• So in near future there will be a high demand for car interior

and other parts.• EiTEX is a stakeholder in this regard to influence the

government so that the investors incorporated in this sector.

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References •Walter Fung and Mike Hardcastle, ‘Textiles in automotive engineering’, Cambrige England, Woodhead Publishing Limited, 2001.•A R Horrocks and S C Anand, ‘HANDBOOK OF TECHNICAL TEXTILES’, Cambrige England, Woodhead Publishing Limited, 2000.•J W S Hearle, ‘High-performance fibers’, Cambrige England, Woodhead Publishing Limited, 2001

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5. References

Thank you!!!