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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
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
1. Introduction / Statistics
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
Source: Frost & Sullivan
1791521199776Others
976736521443284Composites
11411110710995Nonwovens
1,2141,2211,1701,125953Fabrics, Knits
20052000199519901985
Production in 1,000 tonnes
Worldwide production of automotive textiles
1. Introduction / Statistics
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
Application of nonwovens in cars
1. Introduction / Statistics
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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
1. Introduction / Statistics
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
2. Stitch bonded nonwovens with finer mesh structures
Stitch bonded nonwoven type„Malivlies“ cover fabrics for hat racks
Fig.: KARL MAYER Malimo
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
Malivlies F 24(96 meshes/cm²)
Malivlies F 22(88 meshes/cm²)
Malivlies F 18(72 meshes/cm²)
F... mesh rows per 25 mm
Malivlies (gauge F 24)
Stitch length… 1.0 mm
2. Stitch bonded nonwovens with finer mesh structures
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
Malivlies decorative fabric with activatable adhesive at the back
Mass per unit area: 210 g/m²10 % bicomponent fibres
2. Stitch bonded nonwovens with finer mesh structures
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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
3. Three-dimensional nonwovens for upholstery
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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
3. Three-dimensional nonwovens for upholstery
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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)
3. Three-dimensional nonwovens for upholstery
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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®
3. Three-dimensional nonwovens for upholstery
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
Principle of moisture storage and transportation(Spacer nonwoven type NAPCO® made of two different nonwoven layers)
Cross-section nonwoven Cross-section fibre bundles
3. Three-dimensional nonwovens for upholstery
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
Nonwoven materials used for soft-touch effect in reverse injection
4. Nonwovens for back moulded soft-touch parts
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
Nonwoven materials used for soft-touch effect in reverse injection – Cross-section
Knitted fabric
Adhesive web
Nonwoven(intermediatelayer)
Blocking film
4. Nonwovens for back moulded soft-touch parts
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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
4. Nonwovens for back moulded soft-touch parts
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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
5. Filled nonwovens in material flows
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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7 8
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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
5. Filled nonwovens in material flows
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
Nonwoven 1 Nonwoven 2
Filling material
Filled needle-punchedspacer nonwovens
5. Filled nonwovens in material flows
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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
- 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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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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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T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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
T-Pot Workshop Technical Textiles & Textile Recycling 30 Nov – 04 Dec 2009 – Chemnitz (DE)
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