Textiles in Transportation

presentation

by

NITRA

(MOBILTECH)

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 2,425

Seat belt webbing 22

Air bag 35

Car body covers 17

Seat coversfabric/Upholstery

868

Automotive interiorcarpets

290

Headliners 59

Insulation felts 494

Sunvisors/Sunblinds 154

Helmets 759

Airlines disposable 5

Webbing for aircrafts 5

Aircraft Upholstery 1

TT usage in railway 2

TOTAL 5,145

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,

MOBILTECH

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

0.5

0.4

5.5

2.6

3.5

15.4

0.2

4.2

cotton

jute

polyester

polypropylene

polyethylene

polyamide

viscose

acrylic

Source: Dav id Rigby Associates

APPLICATION AREAS

FIBRES / PRODUCTS USED

UPHOLSTERY Polyester, wool, nylon, acrylic

TYRE CORDS & FABRICS

Polyester, Nylon, HT * rayon, steel & aramid

COMPOSITE Glass, carbon, aramid, HT polyester & polyethylene

RUBBER REIN-FORCEMENT

HT polyester, aramid

SEAT BELTS HT polyester

AIRBAGS Nylon - 6,6, nylon - 4,6

CARPETS Nylon, polyester, polypropylene

Percent share of Various Fibers

in Automotives

Textiles in Passenger Cars

GENERAL MOTORS TOYOTA BMW FORD

TATA MOTORS SUZUKI HONDA HYUNDAI

DAEW OO MAHINDRA MOTORS FIATNISSAN MOTORS

PORSCHE VOLVOFORCE 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 offace fabric, foam and scrim liningon the back.The specifications of the laminatedepend on where the laminate isused: seat central panel or backor door panel...– PET face fabric

– The foam is PE-PU or Polyether-PU;the latter being more hydrolysisresistant & is suitable for humidclimates

– Foam density – 26 to 45 Kg/m3, 2 to22 mm thick, fire resistant.

– The scrim fabric is warp knitted (nylonor Polyester), 30-90 g/m2

Q C & Testing(Seat Covers)

Stretch and set

Surface resistivity (antistatic)Stain resistivityWater wicking

Resistance to micro organisms Fogging

Odour

Accelerated ageing: Light & UV

Abrasion – Taber/Martindale/ SchopperPeel bond adhesionColor fastness – perspiration, crocking

FlammabilityStrength – tensile/tear; seam strength

Odor test

It is measured to determine the odor propagation of theinterior materials.

• The specimen (either dry or wet) is placed in an air tightcontainer for a specified time (2 to 24 hrs) andtemperature (70 to 800C). Then the odour is evaluatedby 3 to 6 persons and is graded in a scale of 1 to 5 or1to10.

Fogging Test

• Tested for all interior and airventilation systems for thepresence of volatile organicconstituents (VOC)

• The specimen is placed in aclosed glass container and heatedat a specified temperature for aspecified time.

• The volatile compounds arecollected on a glass plate or on asilver foil and the optical propertyof the glass plate or the increase inweight of the foil is measured todetermine the fogging value.

Accelerated ageing: Light & UV radiation-Seating fabric

Standard Black Panel

Temp (oC)

RH (%) Wav elength(

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 Min 6 on blue

wool

JASO M 403 83±±±±3 50±±±±5 300-400 100 /200 Min 3

HES D

6506/MS 300-

32

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 Min 6 on blue

wool

Mahindra/

Ford/SAE J

1885/ TSL

2100G

Dark: 38±±±±2

Light: 89±±±±3

Dark: 95±±±±5

Light: 50±±±±5

340 250 Min 3

SES: Suzuki Engineering Standard, GME: General Motors Europe Engineering Standards, HES: HyundaiEngineering,Standard,SAE:Society of Automotive Engineers,TSL:Toyota Engineers Standards

Accelerated ageing test

Seat BeltsMultilayer 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 asSupplemental Restraint System (SRS) or Supplemental

Inflatable Restraints.

Fabrics for Airbag

• The fabric from which the air bag is made mustwithstand the force of the propellant chemicals. Moreimportantly, the hot gases must not penetrate the fabricand burn the skin of the car occupant.

• The earlier airbags were Neoprene coated Nylon 6,6 butlighter 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, controlledair permeability (about 10L/m2/min) and be capable ofbeing folded up into a confined space for over 10 yearswithout deterioration.

• Some tests require 75% property retention after 4000hrs at 90-1200C, the equivalent of 10 yrs. UV exposureand also cold cracking resistance down to -400C.

• Recently, Nylon 4,6 (Akzo) with melting point of 2850Chas been introduced especially for airbags.

The Future of Airbags

Until recently, most of the strides made in auto safety were in front and rearimpacts, 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 thandesigning front airbags. This is because much of the energy from a front-impactcollision 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 arelatively 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 fiveor six milliseconds!

Shaped Airbags

Side AirbagThere are essentially twotypes of side airbagscommonly used today, theside torso airbag and theside curtain airbag.

Side airbag inflated Knee airbag

It is located beneath the

steering wheel. Knee airbags

are designed to reduce leg

injury.

Knee Airbag

Side Torso Airbag

Side-impact airbags or sidetorso airbags are a category ofairbag usually located in theseat, and inflate between theseat occupant and the door.These airbags are designed toreduce the risk of injury to thepelvic and lower abdomenregions. Some vehicles are nowbeing equipped with differenttypes of designs, to help reduceinjury and ejection from thevehicle in rollover crashes.

Side tubular or curtain airbag

The 1998 model BMW 7 were fitted witha tubular shaped head side airbags, the"Head Protection System (HPS)" asstandard equipment. This is anindustry's first in offering head protectionin side impact collisions. This airbagalso maintained inflation for up to sevenseconds for rollover protection.However, this tubular shaped airbagdesign has been quickly replaced by aninflatable 'curtain' airbag for superiorprotection. 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 longinflatable curtain airbag that protects all 3 rows of

seats of high end vehicles.

Seat belt airbag

In 2009, the S-class ESF safety concept car showcasedseatbelt airbags. They will be included standard on theproduction Lexus LFA in late 2010, and the 2011 FordExplorer will offer rear seatbelt airbags as an option.

Rear curtain airbag

In 2008, the Toyota iQlaunched featuring the first

production rear curtain shield

airbag to protect the rearoccupants' heads in the event

of a rear end impact.

Center airbag

In 2009, Toyota developed the firstproduction rear-seat center airbag

designed to reduce the severity of

secondary injuries to rearpassengers in a side collision.

On motorcycles

• Various types of airbags were tested onmotorcycles by the UK TransportResearch Laboratory in the mid 1970s.

• In 2006 Honda introduced the firstproduction motorcycle airbag safety systemon its Gold Wing motorcycle. Honda claimsthat sensors in the front forks can detect asevere frontal collision and decide when todeploy the airbag, absorbing some of theforward energy of the rider and reducingthe velocity at which the rider may bethrown from the motorcycle.

• Airbag suits have also been developed foruse by Motorcycle Grand Prix riders. Theyare connected to the motorcycle by a cableand deploy when the cable becomesdetached from its mounting clip, inflating toprotect 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)

ITEMUNIT REQUIRED VALUE

Mass per unit area Kg/m2 2.0 + 0.15

Thickness 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

QUALITY REQUIREMENT FOR

SOUND ABSORBING MATERIALS

(Silencer Pad)

ITEMUNIT REQUIRED VALUE

Thickness mm As per the end use

Density 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 feltsN

Flammability (Max.) Cm/Min 10

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

Sound Absorption Test

Nonwoven Applications

• Bonnet: Bi-component yarn (nylon6 sheath with PET

cover) to reinforce acoustic insulation

• Air-filters: nonwoven with activated carbon andantibacterial chemicals to remove malodours

• Carpets: less weight, low cost & recycling -needle felt PP

• Surfaces such as window seals, dash boardcomponents – PET & Nylon 66 flocked surfaces toeliminate rattles & squeaks as well ascontributing to overall aesthetics.

Automotive Carpet Structure

1. Decorative top layer of fiberTufted 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 2-

door 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

ITEM UNIT

REQUIRED VALUE

Type 1 Type 2 Type 3 Type 4 Type 5

Mass per unit area g/m2Shall conform to drawing

Tensile Strength (MIN.) Kg/50mm 20 20 8(Warp), 35(Weft)

35 20

Elongation normal state (MIN.) (%) 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

Fogging (Max.) (%) 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

Flammability (Max.) Mm/Min 80 80 80 80 80

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 Combustionof a Vertical Specimen

• Deterioration of Visibility due to Smoke

• Toxicity IndexIt determines the toxicity of the products ofcombustion in terms of small molecular speciesarising when a small sample of a material is

completely burnt.

• 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)

Toxic Gases

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

• Methenamine tablet

• Steel plate : Æ 205mm

• Pass if :

charred area

<= 25.4mmfrom inner edge : OK

Carpet

ASTMD 5859-76

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 92-504

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

NF P 92-503

Common FR Test Methods

Cigarette Burning Test Match Test

Carpet Testing

Upholstery Test

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 300-8

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 Test Facilities for Automotive Fabrics

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 300-32, 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