t-pot workshop technical textiles & textile recycling 30 · pdf file4 t-pot workshop...

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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)

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)

T-POT Seminar Technical textiles/Recycling


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

Contents

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Source: Frost & Sullivan

1791521199776Others

976736521443284Composites

11411110710995Nonwovens

1,2141,2211,1701,125953Fabrics, Knits

20052000199519901985

Production in 1,000 tonnes

Worldwide production of automotive textiles


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Application of nonwovens in cars



Textiles used in cars [kg]

4,5

3,5

1,61,50,91,2

4,5

2,2

Carpets, coverings

Upholstery

Belts, hoses

Tyres

Safety belts

Airbags

Textiles incompositesOthers (e.g. filters)

Source: David Rigby and others

Upholstery materials including sub-upholstery textiles6


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Stitch bonded nonwoven type„Malivlies“ cover fabrics for hat racks

Fig.: KARL MAYER Malimo

32

4

5

6


Malivlies F 24(96 meshes/cm²)



F... mesh rows per 25 mm

Malivlies (gauge F 24)

Stitch length… 1.0 mm


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Malivlies decorative fabric with activatable adhesive at the back

Mass per unit area: 210 g/m²10 % bicomponent fibres



One of the first applications of non-wovens as upholstery of car seats:Start at Mercedes-Benz in 1992with upholstery fabric „Karo III“Mass: 150 g/m²Thickness: 2.3 mm

Malivlies - Application

Fig.: KARL MAYER Malimo


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Thermo-calibrated with use of- 6–9 % of solid profile fusible fibres

respectively- 12–18 % of bi-component fibres

Caliweb®- Use as sub-upholstery in car seats

Fig.: Techtex GmbH

Multiknit

Cover fabric



Fig.: Herbert Meyer GmbH

Powder scatterer ≈ 20 g/m² Glueing web ≈ 12 or 24 g/m²

Tendency: PUR => Co-polyester=> Co-polyamid

Flatbed lamination line withpowder scatterer at STFI

(Schott & Meissner)


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Main advantages of CALIWEB® vs. PUR foam

Layers 2 fabric layers 2 fabric layers1 foam layer -------2 adhesive layers 1 adhesive layerpolyurethane + polyester onlypolyester

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

PUR foam CALIWEB®



Principle of moisture storage and transportation(Spacer nonwoven type NAPCO® made of two different nonwoven layers)

Cross-section nonwoven Cross-section fibre bundles


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Nonwoven materials used for soft-touch effect in reverse injection



Nonwoven materials used for soft-touch effect in reverse injection – Cross-section

Knitted fabric

Adhesive web

Nonwoven(intermediatelayer)

Blocking film


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Decorative layer

Formability

Form stability

Light fastness

Ageing stability

Special requirements to textile components for back moulding with soft-touch effect

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



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-knownautomotive supplier

Conception for closed material flowsin production of moulded parts


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6

7 8

9

42

3

1

5

Needle-punched spacer nonwoven

1 prefabricated nonwoven layer N° 1 6 MD fibre bundle distance as a result of needling intensity2 prefabricated nonwoven layer N° 2 7 CD fibre bundle distance as a result of needle row distance3 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 thickness5 puncture



Nonwoven 1 Nonwoven 2

Filling material

Filled needle-punchedspacer nonwovens


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- 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;

Nonwovens becoming more and more important with regard to filtration processes in the motor vehicle:

6. Nonwovens in Filtration

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Development of share in electronic parts in vehicle value

Metallised spunbonded nonwovens sputtered withaluminium or coppered –Applications in cars:

• shielding of cables and electronic components

• sun protection materials

40 %30 %10 %up-range car

35 %25 %5 %mid-range car

201020041990type

7. Nonwovens for shielding


Increasing comfort and equipment requires quantitative and qualitative developments in nonwoven applications:

• Synthetic materials and other materials in known applicationsand 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

8. Summary

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Textiles in Cars - Development in Use

103--New product for new

application

159--New product for known

application

101420Product and application

like 2000

352620Total

202020102000

YearAmount in kg in a typical

mid-range car

8. Summary


Thank you for your attention!

Please contact:Phone: 0049 371 5274 204Fax: 0049 371 5274 153E-mail: [email protected]

Textile waste management in Germany & developments in textile recycling technology

t-pot workshop technical textiles & textile recycling 30 · pdf file4 t-pot workshop...

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