Textiles in Transportation
(MOBILTECH)
presentation
by
NITRA
Textiles in Transportation
Market Size
–
It is about 23% of the total technical textiles market. However, in
India its share is 7 % in technical textiles market.
Auto makers sold 160,794 cars in
August compared with 120,681 in the
same month a year earlier, the
Society
of
Indian
Automobile
Manufacturers (SIAM) announced in
New Delhi today (Sept. 9, 2010).
Domestic Market
(2010-12)
Rs. Crores
Nylon tyre cord
Seat belt webbing
Air bag
Car body covers
Seat covers
fabric/Upholstery
Automotive interior
carpets
Headliners
Insulation felts
Sunvisors/Sunblinds
Helmets
Airlines disposable
Webbing for aircrafts
Aircraft Upholstery
TT usage in railway
TOTAL
2,425
22
35
17
868
290
59
494
154
759
5
5
1
2
5,145
MOBILTECH
Land – Air/Space - Water
•
upholstery, car interior, carpets
•
tires, car elements, filters,
•
Heat, cable & sound insulation,
•
safety systems - airbags, seat belts
•
Protective covers for land crafts, boats, aircrafts
•
sailcloth, inflatable boats
•
Envelopes of balloons
•
Special equipment for military vehicles,
Some of these textiles are visible while the others are concealed.
Visible components: upholstery, carpets, seat belts, headliners etc.
Concealed components – tyre cords, hoses, belts, airbags, air and fuel filters,
noise and vibration dampening and body panel reinforcement in composites etc.
FIBRE COMPOSITION IN
AUTOMOTIVES
APPLICATION
AREAS
FIBRES / PRODUCTS
USED
UPHOLSTERY
Polyester, wool,
nylon, acrylic
Polyester, Nylon, HT *
rayon, steel & aramid
TYRE CORDS
& FABRICS
0.5
4.2
COMPOSITE
Glass, carbon, aramid,
HT polyester &
polyethylene
RUBBER REIN- HT polyester, aramid
FORCEMENT
SEAT BELTS
5.5
0.2
2.6
HT polyester
3.5
15.4
AIRBAGS
Nylon - 6,6, nylon - 4,6
CARPETS
Nylon, polyester,
polypropylene
0.4
cotton
jute
polyester
polypropylene
polyethylene
polyamide
viscose
acrylic
Percent share of Various Fibers
in Automotives
Source: David Rigby Associates
Textiles in Passenger Cars
GENERAL MOTORS
TATA MOTORS
DAEWOO
PORSCHE
TOYOTA
SUZUKI
MAHINDRA MOTORS
VOLVO
BMW
HONDA
FIAT
FORCE MOTORS
FORD
HYUNDAI
NISSAN MOTORS
HINDUSTAN MOTORS
Textile Materials used in
Car Interiors
TEXTILES USED IN CARS (Kg)
~20 kg
Seat Covers
Selection of fabric:
Apart from the properties such as strength &
comfort properties, the fabric should also have
–
–
–
–
–
–
Resistance to Sun Light & UV (strength & color fastness)
Abrasion Resistance
Reduced Flammability
Odour free
Antistatic
Soil resistance.
Composition of seat cover
It is a trilaminate consisting of
face fabric, foam and scrim lining
on the back.
The specifications of the laminate
depend on where the laminate is
used: seat central panel or back
or door panel...
– PET face fabric
– The foam is PE-PU or Polyether-PU;
the latter being more hydrolysis
resistant & is suitable for humid
climates
– Foam density – 26 to 45 Kg/m3, 2 to
22 mm thick, fire resistant.
– The scrim fabric is warp knitted (nylon
or Polyester), 30-90 g/m2
Q C & Testing
(Seat Covers)
Accelerated ageing: Light & UV
Abrasion – Taber/Martindale/ Schopper
Peel bond adhesion
Color fastness – perspiration, crocking
Flammability
Strength – tensile/tear; seam strength
Stretch and set
Surface resistivity (antistatic)
Stain resistivity
Water wicking
Resistance to micro organisms
Fogging
Odour
Odor test
It is measured to determine the odor propagation of the
interior materials.
• The specimen (either dry or wet) is placed in an air tight
container for a specified time (2 to 24 hrs) and
temperature (70 to 800C). Then the odour is evaluated
by 3 to 6 persons and is graded in a scale of 1 to 5 or
1to10.
Fogging Test
• Tested for all interior and air
ventilation
systems
for
the
presence of volatile organic
constituents (VOC)
• The specimen is placed in a
closed glass container and heated
at a specified temperature for a
specified time.
• The volatile compounds are
collected on a glass plate or on a
silver foil and the optical property
of the glass plate or the increase in
weight of the foil is measured to
determine the fogging value.
Accelerated ageing: Light & UV radiation-Seating fabric
Standard
Black Panel
Temp (oC)
RH (%)
Wavelength(
nm)
Exposure
hours
Requirement
on grey scale
SES N 3295
89±3
50±5
300-400
185 (at 60
W/m2)/40M
J
Min 3
GME 60292
115±3
20±5
300-400
80±16
JASO M 403
83±3
50±5
300-400
100 /200
Min 3
HES D
6506/MS 30032
89±3
50±5
300-400
354
Min 3
GMW 3414
Cycle B
108±3
25±5
420
192
Min 3
Volks Wagon
AG PV 1303
100±3
20±10
320
46
Mahindra/
Ford/SAE J
1885/ TSL
2100G
Dark: 38±2
Light: 89±3
Dark: 95±5
Light: 50±5
340
250
Min 6 on blue
wool
Min 6 on blue
wool
Min 3
SES: Suzuki Engineering Standard, GME: General Motors Europe Engineering Standards, HES: Hyundai
Engineering, Standard, SAE: Society of Automotive Engineers, TSL: Toyota Engineers Standards
Accelerated ageing test
Seat Belts
Multilayer woven narrow fabrics
– Maximum yarn packing for a given
area to have maximum strength
– Twill or Satin
– HT PET yarns (320 ends of 1100 dtex or 260
ends 1670 dtex)
– Softer & flexible along the length for
comfort
– Rigidity along the width to enable it to
slide easily between buckles and
retract smoothly into housings
– Scuff resistant but not unpleasantly
hard edges
– Resistant to microorganisms
Performance Standards
(Seat Belts)
– Restrain a passenger weighing 90 Kg involved in
a collision at 50 Km/h into a fixed object
– Minimum straight pull strength 30kN/50mm
– Accelerated ageing
– Finished product – resistance to fastening &
unfastening 10,000 times
How airbags work ?
• The design is conceptually simple; a central "Airbag control unit"
(ACU) monitors a number of related sensors within the vehicle:
–
–
–
–
–
–
–
accelerometers,
impact sensors,
side (door) pressure sensors,
whell speed sensors,
gyroscopes,
brake pressure sensors and
seat occupancy sensors.
When the requisite 'threshold' has been reached or exceeded, the airbag
control unit will trigger the ignition of a gas generator propellant to rapidly
inflate a nylon fabric bag.
As the vehicle occupant collides with and squeezes the bag, the gas
escapes in a controlled manner through small vent holes.
The airbag's volume and the size of the vents in the bag are tailored to each
vehicle type, to spread out the deceleration of (and thus force experienced
by) the occupant over time and over the occupant's body, compared to a
seat belt alone.
Working of Airbag
Airbag
(As a supplemental restraint)
Frontal airbag
The auto industry and research and regulatory communities
have moved away from their initial view of the airbag as a
seat belt replacement. The airbags are now designated as
Supplemental Restraint System (SRS) or Supplemental
Inflatable Restraints.
Fabrics for Airbag
• The fabric from which the air bag is made must
withstand the force of the propellant chemicals. More
importantly, the hot gases must not penetrate the fabric
and burn the skin of the car occupant.
• The earlier airbags were Neoprene coated Nylon 6,6 but
lighter and thinner silicon coated versions soon followed.
Latter, uncoated fabrics have appeared.
• Airbags vary in size and configuration
– driver side airbags: from 35 lit capacity upwards
– for front passengers: form about 65 lit capacity upwards
Fabrics for Airbag
–
–
–
–
–
–
–
–
–
–
High bursting Strength
Fire retardance
Light weight,
Compact-folding ability,
Low cost.
Reduced skin abrasion (softness)
High tear propagation Resistance
High anti slip properties to the seam
Resistance against Ageing
Defined Dimension stability
Airbag
(Fabric Quality Requirements)
• HT multi filament nylon 6,6 – 210, 420 and 840 denier
• High tear strength, high anti seam slippage, controlled
air permeability (about 10L/m2/min) and be capable of
being folded up into a confined space for over 10 years
without deterioration.
• Some tests require 75% property retention after 4000
hrs at 90-1200C, the equivalent of 10 yrs. UV exposure
and also cold cracking resistance down to -400C.
• Recently, Nylon 4,6 (Akzo) with melting point of 2850C
has been introduced especially for airbags.
The Future of Airbags
Until recently, most of the strides made in auto safety were in front and rear
impacts, even though 40 percent of all serious injuries from accidents are the
result of side impacts, and 30 percent of all accidents are side-impact collisions.
Many carmakers have responded to these statistics (and the resulting new
standards) by beefing up doors, door frames and floor and roof sections.
Cars that currently offer side airbags represent the new wave of occupant
protection.
Engineers say that designing effective side airbags is much more difficult than
designing front airbags. This is because much of the energy from a front-impact
collision is absorbed by the bumper, hood and engine, and it takes almost 30 to
40 milliseconds before it reaches the car's occupant. In a side impact, only a
relatively thin door and a few inches separate the occupant from another vehicle.
This means that door-mounted side airbags must begin deploying in a mere five
or six milliseconds!
Shaped Airbags
Side Airbag
There are essentially two
types of side airbags
commonly used today, the
side torso airbag and the
side curtain airbag.
Knee airbag
It is located beneath the
steering wheel. Knee airbags
are designed to reduce leg
injury.
Knee Airbag
Side airbag inflated
Side Torso Airbag
Side-impact airbags or side
torso airbags are a category of
airbag usually located in the
seat, and inflate between the
seat occupant and the door.
These airbags are designed to
reduce the risk of injury to the
pelvic and lower abdomen
regions. Some vehicles are now
being equipped with different
types of designs, to help reduce
injury and ejection from the
vehicle in rollover crashes.
Side tubular or curtain airbag
The 1998 model BMW 7 were fitted with
a tubular shaped head side airbags, the
"Head Protection System (HPS)" as
standard equipment. This is an
industry's first in offering head protection
in side impact collisions. This airbag
also maintained inflation for up to seven
seconds
for
rollover
protection.
However, this tubular shaped airbag
design has been quickly replaced by an
inflatable 'curtain' airbag for superior
protection.
Curtain airbag
• Curtain airbags have been said to reduce brain injury
or fatalities by up to 45% in a side impact with an
SUV. These airbags come in various forms (e.g.,
tubular, curtain, door-mounted) depending on the
needs of the application. Many recent have a long
inflatable curtain airbag that protects all 3 rows of
seats of high end vehicles.
Rear curtain airbag
In 2008, the Toyota iQ
launched featuring the first
production rear curtain shield
airbag to protect the rear
occupants' heads in the event
of a rear end impact.
Center airbag
In 2009, Toyota developed the first
production rear-seat center airbag
designed to reduce the severity of
secondary
injuries
to
rear
passengers in a side collision.
Seat belt airbag
In 2009, the S-class ESF safety concept car showcased
seatbelt airbags. They will be included standard on the
production Lexus LFA in late 2010, and the 2011 Ford
Explorer will offer rear seatbelt airbags as an option.
On motorcycles
• Various types of airbags were tested on
motorcycles by the UK
Transport
Research Laboratory in the mid 1970s.
• In 2006 Honda introduced the first
production motorcycle airbag safety system
on its Gold Wing motorcycle. Honda claims
that sensors in the front forks can detect a
severe frontal collision and decide when to
deploy the airbag, absorbing some of the
forward energy of the rider and reducing
the velocity at which the rider may be
thrown from the motorcycle.
• Airbag suits have also been developed for
use by Motorcycle Grand Prix riders. They
are connected to the motorcycle by a cable
and deploy when the cable becomes
detached from its mounting clip, inflating to
protect the back.
Headliners
• It is multilayer construction:
– Decorative face fabric
– Soft touch PU foam
– Chopped glass mat
– Semi rigid PU foam (core material)
– Chopped glass mat
– Non-woven scrim fabric
All layers are hot pressed with thermo plastic
powder/film
QUALITY REQUIREMENT FOR HEAD LINER
(Resin Felt)
UNIT
REQUIRED VALUE
Kg/m2
2.0 + 0.15
mm
2.9 + 0.5
Apparent Bulk Density
g/cm3
0.38 – 0.67
Resin Contents (Min.)
(%)
26
Flexural Strength (Min.)
kg/cm2
60
Heat (Flexural Strength) (Min.)
kg/cm2
50
Humidity (Flexural Strength) (Min.)
kg/cm2
30
Flammability (Max.)
Mm/Min
80
ITEM
Mass per unit area
Thickness
QUALITY REQUIREMENT FOR
SOUND ABSORBING MATERIALS
(Silencer Pad)
UNIT
REQUIRED VALUE
mm
As per the end use
g/cm3
0.38 – 0.67
Moisture Contents (Max.)
(%)
15
Tensile Strength (Min.)
Kpa
59
Glass Fogging Rate (Max.)
(%)
10
Sound Absorbing Rate (ratio of
absorption & reflection factor)
(%)
Depending on the
component – Dash
board, engine felts…
Cm/Min
10
ITEM
Thickness
Density
Flammability (Max.)
Sound Absorption Test
Acoustic Impedance is a measure of the
propagation of sound waves in a
medium.
Sound insulation of a material is
measured with an impedance tube
wherein the test specimen is mounted at
one end of rigid, smooth and airtight
Impedance tube. Sound weaves are
generated in the tube and the sound
pressures are measured at locations
near to the sample. The a constant
related to the propagation of sound
waves in an acoustic medium
Nonwoven Applications
• Bonnet: Bi-component yarn (nylon6 sheath with PET
cover) to reinforce acoustic insulation
• Air-filters: nonwoven with activated carbon and
antibacterial chemicals to remove malodours
• Carpets: less weight, low cost & recycling needle felt PP
• Surfaces such as window seals, dash board
components – PET & Nylon 66 flocked surfaces to
eliminate rattles & squeaks as well as
contributing to overall aesthetics.
Automotive Carpet Structure
1.
Decorative top layer of fiber
Tufted BCF nylon or needle punched
PET or PP back, latex coated with
SBR or acrylic latex
2.
Thermoplastic material for thermal
moulding
Polyethylene powder, meldable fibers,
EVA or further thick layer of
compounded SBR latex
3.
Acoustic & vibration damping
layers
Heavy layer of shoddy fibers or PU
foam
CARPETS
• Carpets are classified according to their application and
location.
TYPES
APPLICATION
LOCATION
Type 1
Door trim, quarter trim
Inner side surface of 2door car passenger
compartment
Type 2
Trunk trim
Rear trunk inside
Type 3
Floor
Floor of passenger
compartment
Type 4
Cargo floor, High floor
High floor surface of vans
Type 5
Rear shelf
Shelf behind rear seat
QUALITY REQUIREMENT FOR CARPETS
REQUIRED VALUE
ITEM
Mass per unit area
Tensile Strength (MIN.)
UNIT
Type 1
g/m2
Type 3
Type 4
Type 5
Shall conform to drawing
20
20
(%)
3
3
3
3
3
Abrasion Resistance (MIN.)
Grade
3
3
3
3
3
Immersion Shrinkage (Max.)
(%)
1
1
1
1
1
Tear strength (MIN.)
kg
5
5
7(Warp)
10(Weft)
10
5
Crease Resistance
(%)
50 + 5
70 + 10
70 + 10
60 + 10
60 + 10
Fade Resistance (MIN.)
Grade
4
4
4
4
4
Heat Resistance (MIN.)
Grade
4 or
above
4 or
above
4 or above
4 or
above
4 or
above
(%)
15
15
15
15
15
Odor (MIN.)
Grade
4
4
4
4
.4
Color Fastness To Rubbing (MIN.)
Grade
4
4
4
4
4
Color Fastness To Washing (MIN.)
Grade
3
3
3
3
3
Mm/Min
80
80
80
80
80
Elongation normal state (MIN.)
Fogging (Max.)
Flammability (Max.)
Kg/50mm
Type 2
8(Warp),
35(Weft)
35
20
Indian Railways
Technical Requirements for
Fire Retardant Curtain & Upholstery
• Resistance to Spread of Flame
–
–
–
–
Size of the fabric damaged due to Fire
Time of Continued Burning after Extinction of fire
After Glowing
Release of Burning Particles
• Limiting Oxygen Index
– Minimum Concentration of Oxygen required in the
mixture with Nitrogen, which will Support Combustion
of a Vertical Specimen
• Deterioration of Visibility due to Smoke
• Toxicity Index
It determines the toxicity of the products of
combustion in terms of small molecular species
arising when a small sample of a material is
completely burnt.
Toxic Gases
•
•
•
•
•
•
•
Carbon dioxide (CO2)
Carbon monoxide (CO)
Formaldehyde (HCHO)
Nitrogen oxides (NO + NO2)
Hydrogen cyanide (HCN)
Acrylonitrile (CH2CHCN)
Phosgene (COCl2)
•
•
•
•
•
•
•
Sulphur dioxide (SO2)
Hydrogen sulphide (H2S)
Hydrogen chloride (HCl)
Ammonia (NH3)
Hydrogen fluoride (HF)
Hydrogen bromide (HBr)
Phenol (C6H5OH)
Additional Requirements for FR Property
Based on BS : 5852
• Cigarette
• Butane Gas
• Wooden crib
BIS Tests
• IS : 12467(Part 1) – Smouldering Cigarette
• IS : 12467(part 2) - Match Flame Equivalent
Requirements other than FR Property
•
•
•
•
•
•
Mass of Fabric
Breaking Strength
Tearing Strength
Colour Fastness to Dry and Wet Rubbing
Colour Fastness to Day Light
Dimensional Change
Common FR Test Methods
BS 5852 Part 1 "Match - test"
(on finished / unfinished CO - fabric)
Flame retardant against burning cigarettes
Length : ± 68mm
Diameter : ± 8mm
Mass : 1g nominal
igniting not less than 5mm not more
than 8mm
smouldering rate : 12 ± 3min / 50mm
pass if :not more than 50mm damage
within 60min : no flaming,
smoke, heat, glowing
Flame retardant for upholstery fabric
Flame Length : 35mm (vertical); Ignition Time : 20s;
Pass if : Flaming : max. 2min after removal of the burner, Smoke, heat, glowing :
max. 15min after removal, Max. 100mm damage ↔↕
German Railway - "Upholstery - Test"
Work Clothes
EN 533
• Flame length : 40mm (vertical); Ignition time : 10s
• Criteria : -after flame time; afterglow time; not charred area;
formation hole; molten / flaming debris; borders reached
Carpet
ASTMD 5859-76
• Methenamine tablet
• Steel plate : Æ 205mm
• Pass if :
charred area
<= 25.4mm
from inner edge : OK
NF P 92-504
Rate of spread of flame test: Flame length : 35mm (vertical)
Ignition : 30 times 5s with 3s intervals M1 if :- after flame time
max. 1s; no flaming debris; burning speed max. 2mm/s
NF P 92-503
Criteria : formation hole <20”; if yes ®NF P 90-504;
M1 if : After flame time max.5 - damage afterglow
max. 250mm; no molten / flaming debris
Common FR Test Methods
Cigarette Burning Test
Match Test
Carpet Testing
Upholstery Test
NITRA’s Test Facilities for Automotive Fabrics
1.
Color Fastness to light
Xenon Arc
-For one sample
-For two sample
-For three sample
GME 60292, SAE J 1885, TSL 3600G,
TSL 0601, MS -300-35, AATCC 16 H
JASO M 403-83, HES D 6601,
JASO M 346, EDS-T-7415, GM 9538 P
Xenon Tester
(ATLAS)
2.
Color definition/difference
(XYZ & Lab value) (∆E)
CCM
Macbeth – 3100
Spectrophotometer
Macbeth-3100
3.
Abrasion resistance
(Taber Type) Abrader
wheel CS-10, H-22, & H-38
Up to 1000 cycles
Up to 1500 cycles
Up to 2000 cycles
SAE J1530 – A,
SES N3246,
JASO 403,
SAE J948,
MS 300-32,
SES N 3298,
Taber Abrasion
Tester (U.S.A.)
4.
Flammability
SAE J369, FMV SS 302, SES N 3245, HES
D-6003, JASO M 313, GM 9070P, MS 3008
Flammability tester
5.
Smell (Dry & Wet
condition)
TSL 3505G, TSM0505 G
Hot Air Oven
6.
Smell (40C- 95% RH X 400
HRS)
TSL 3505G
Humidity chamber
7.
Odor Properties
HES D6507, MS 300-32, FMLT 131-01
Hot Air Oven
8.
Glass Fogging
TSL 3608G, MS:300-54, EDS-T-7694-B,
TSM 0503G
U.V. Visible
spectrophotometer
NITRA’s Facilities
9.
Color Fastness to Crocking &
Rubbing
FLTM BN 107-01, JASO M313,
EDS-T-7643, MS 300-35
Motorised Crock Meter
10.
Water inclusion
5SFTS-0303-O
-
11.
Color Fastness to Rubbing After
Fade Resistance
MS 300-35
& Fade Resistance Condition
Xenon Tester And
Crock Meter
12.
Dimensional change by
Moisturing/immersion shrinkage
HES D 6506, JASO N 313-83, MS 30032, FLTN BN 105-01
Water Bath
13.
Dimensional stability against
humidity
MS 300-32
Humidity Chamber
14.
Dimensional Change By Heating
HES D 6506, FLTM-BN-105-01
Hot Air Oven
15.
Water Resistance/Repellency
HES D 6506, MS 300-32
Spray Tester
16.
Soil And Cleanability
MS 300-32, FLTM BN 112-08
Launder-o-meter
17.
Resistance To Bleeding
AN 101-01
Perstirometer
(James H. Heal)
18.
Resistance To Perspiration
AN 101-01
Perstirometer
(James H. Heal)
19.
Resistance To Heat
(100ºC For 8 Hrs.)
Hot Air Oven
20.
Resistance To Humidity
(40ºC-95% RH For 8 Hrs.)
Humidity Chamber
21,
Steaming In Auto-clave
(100ºC For 1 Hrs.)
Auto-clave