The application of nonwovens in automobiles continues to expand, also because they are easy to handle during assembly. They can be tailored to function and can utilize processes such as thermoforming, embossing, coating and printing. Together, they make cars safer, more attractive, more durable, more cost-effective and more sustainable. Due to its versatility and numerous advantages, nonwovens are also widely used in other vehicles and vehicles-aircraft, trains, ships, spacecraft and satellites.
"The automotive industry is one of the world's largest markets for industrial performance materials, with a market potential of more than 2 billion euros," said Frank Heislitz, CTO of Freudenberg Performance Materials (Freudenberg Performance Materials). "Overall, the market is growing by more than 7% per year. This is faster than the growth of global automotive production."
He said that the main driver of this growth is the replacement of traditional materials with innovative high-performance materials. These lightweight, high-performance material solutions also support the trend towards electric vehicles.
According to data provided by EDANA, nonwovens tend to be 15%-30% lighter than traditional materials, which can reduce the weight of cars by more than 2kg. In the entire life cycle of this car, the use of non-woven fabrics can save 55kg of carbon dioxide emissions. Therefore, if it is taken into account that 13 million cars are registered in the EU every year, the use of non-woven fabrics will save 800000 tons of carbon dioxide emissions. This is equivalent to reducing the number of passenger cars on the road by 250000.
Texel's Marc-Andre, Drouin, said he saw customers continue to pursue more and more lightweight materials, and some applications that use 800 to 1200g/m2 can now be as low as 300g/m2. As a needle-punched nonwovens manufacturer, Texel has faced no small challenge, but the company is ready for the challenge.
"We have a variety of needled materials with the same performance and lighter weight, especially the Scrim (scrim) layer of the roof lining." He said.
In addition to traditional automotive applications (including headliners and some trunk linings), Texel has teamed up with Lydall to develop insulation for the car's turbocharged zone. "We even see the demand for high-temperature materials, because manufacturers want all parts of the car to be protected." Drouin said.
Good feel and appearance
In addition to being more environmentally friendly, the application of nonwovens can also enhance the appearance of the car. Nonwoven technology enables designers to design a fabric with properties such as softness, strength, flexibility and even appearance. Nonwoven manufacturers can add stain resistance and even a smoother appearance to it.
South Korean nonwovens supplier Toray recently won a reputation in the automotive market with its Ultrasuede fabric, which is said to help achieve luxurious designs and looks. The Ultrasuede will be applied to three models produced by Toyota Motor Corporation-the interior of the Lexus LS500 and LS500h, and the F SPORT model, which is currently undergoing a complete redesign. These vehicles will all feature canopies and sun visors made of Ultrasuede, which F-SPORT will also use in their seats. This is Lexus's first application of Ultrasuede materials.
The Ultrasuede is produced with advanced Japanese technology, with uniform texture, smooth and luxurious feel and appearance, and its excellent adaptability to interior upgrade applications. These are all important reasons why Lexus models use this fabric.
Toray developed this suede-textured microfiber nonwoven Ultrasuede in 1970 using its microfiber manufacturing and processing technology. Its outstanding texture and high functionality have been fully developed in more than 45 years of development history, and have won high praise in various fields, including fashion, home interior decoration, daily necessities and car interiors. It is widely regarded as a high-grade, high-quality material.
Choose China
While growth in developed markets such as North America and Western Europe is tied to the economic cycle, growth prospects for new vehicles are stronger in developing markets, particularly China, Southeast Asia and India.
According to Detlev Kappel, Tenowo's sales manager, demand in China continues to be strong, with car manufacturers such as BMW, Volkswagen, Audi and Mercedes enjoying continued growth in the region. "Tenowo is a member of a complex supply chain network in China and Asia. We have also been very successful in working with Chinese car manufacturers. We are considered an important high-quality supplier in China." He said.
Tenowo's Chinese factory is operating at full capacity, and the company has developed many new products, such as NVH high-performance flame-retardant products, high-loft nonwovens and nonwovens for chassis parts. However, they face challenges due to rising raw material prices in China, especially fiber prices.
Auto parts supplier Autoneum has realized the potential of the Chinese market and recently announced plans to add four new factories in the country, significantly expanding its production capacity in China, and despite the fierce market competition in this region, its expansion plan will further lay the foundation for profitable growth.
In fact, the Swiss company has made an advance layout for the Chinese market: there are six factories, three wholly-owned and six joint ventures in China. It is wholly owned by Chongqing factory (established in 2006), Taicang factory (2010) and Shenyang factory (2011). The joint venture factories with Rite Co., Ltd. are located in Guangzhou (2003), Tianjin (2004) and Wuhan (2013).
According to company executives, the large number of orders from around the world makes it necessary to increase production capacity in China, the world's largest auto market. A new JIT(Just In Time) factory has been built in Autoneum in the eastern city of Yantai, Shandong Province, and has already started producing the front wall sound insulation pad and carpet series. About 250000 Chinese-made cars a year will use components made at the Yantai plant. The new plant, the seventh of its Autoneum in China, focuses on sustainable production processes: production waste from a blend of wool and polyester fibers will be recycled and reused in the manufacture of components.
The Yantai plant is one of the first in Autoneum to be designed based on digital 3D simulation. Due to the use of computer simulation manufacturing (CBMS) technology, the machine setup, production cell layout and the deployment of workshop workers have been simulated in the planning stage, which enables Autoneum to design and use factories ideally, improve the working environment, increase production efficiency and realize related cost savings. The knowledge gained from the application of virtual reality technology in Yantai will provide experience for CBMS-based design of other new factories in the Autoneum global production network.
On the occasion of the grand opening of the Yantai plant, Mr. Martin Hirzel, CEO of Autoneum, said, "China's new car sales will reach 26 million this year, and this number will exceed 29 million by 2020, which is worthy of being the world's leading auto market. Therefore, we must seize the opportunity of the rapid development of China's auto market, provide customers with innovative lightweight products nearby, and at the same time increase our market share in China!"
He further emphasized: "The Chinese market continues to introduce and produce light components for various vehicles. At the same time, Autoneum are also supporting the expansion of China's electric vehicles and reducing transportation-related carbon dioxide emissions, thereby supporting production in the global automotive market. Sustainable development in the highest regions."
The new plant in Yantai is just the beginning. In just a few weeks, Autoneum's new plant in Changsha, Hunan, will also begin mass production of carpet systems, front wall sound insulation pads and cab liners for American and Chinese automakers. The annual capacity of the Changsha plant will reach about 1.4 million components. The massive 11000-square-metre factory also combines productivity and sustainability: waste from carpets and felt will be fully recycled.
The factory in Pinghu, Zhejiang, about 100 kilometers southwest of Shanghai, is still under construction, and there is another production plant in Shenyang, Liaoning, in the northeast. Starting in autumn 2018, the Autoneum Pinghu plant will produce body chassis systems for European and Chinese automakers. In 2018, Shenyang will also provide windshields, waterproof jackets and carpet systems for models produced by German customers.
Autoneum customers in China include European, American and several Chinese automakers.
Contrary to earlier expectations, the company's net sales in 2017 were only slightly higher than the previous year due to a sharp decline in light vehicle production in the United States. The 2017 EBIT margin forecast to date is over 8%.
From India to Global
Autotech Nonwovens, founded in 2012, is India's first non-woven fabric felt manufacturer and currently accounts for 35% of India's domestic roof lining market. The company plans to start expanding outside India in 2018.
Autotech latest investment will support the foreign market. This is a state-of-the-art Andritz neXline needling production line with high output, which combines fiber opening and mixing, pipe feeding, carding, cross-laying, pulling, needling and winding technologies. The entire process is controlled by the ProDyn closed-loop system to meet the most stringent requirements for product appearance. The highly reliable ANDRITZ needling technology meets the highest quality standards of the products.
Thus, the Autotech is able to produce all A- side fabrics, including but not limited to carpets, ceiling linings, hatrack shelves, shelves, seat back pads, luggage and side blanket fabrics. In addition, the company has further entered the field of automotive filter materials for engine intake and cabin air filtration applications.
According to company director Ankit Desai, when the Autotech Nonwovens was established in 2012, the Indian car market was going through a downturn. Sales of passenger cars stagnated between 2011 and 2013, making cost reduction a top priority. "However, considering the demographic trend of the younger population and the high GDP growth rate, the growth potential of this field has never been questioned and the market will recover sooner or later," he said. "The Indian car market is expected to exceed 5 million by 2020-2021."
Several automakers are investing in new car plants in India's western region (Gujarat), including Ford, Tata and Suzuki, which is expected to produce nearly 2 million new cars by 2020. Since 2012, Ford, Suzuki, Kia, SAIC, MG Motors, Mahendra (Mahindra) and Peugeot Citroen (Peugeot-Citroen) have established or plan to establish new production plants in India.
Indian consumer tastes have also shifted from cheaper small cars to more expensive and distinctive high-end cars and SUVs, with the SUV market growing fastest. This growth at the high end of the market has prompted automakers to provide more differentiation and quality packages for their newly released products.
According to Desai, Autotech is the only Asian nonwovens manufacturer besides Freudenberg-Vilene that can produce printed non-woven interlining and is the first to launch printed non-woven interlining in India.
"As the market shifts toward differentiation and strives to provide customers with a premium, tailored and personalized experience, printed nonwovens are a powerful alternative to expensive knitted/foam-lined canopy fabrics, which are often used in high-end models," he said. "Printed nonwoven canopy fabrics give OEM designers the flexibility to customize and personalize unique patterns and colors, add 3D texture and antibacterial finish to its canopy, while maintaining high wear resistance and bringing a luxurious look and feel to the car interior."
He added that Autotech's vision is to be a one-stop solution provider for all automotive accessories. "That's what sets us apart from our competitors." He said.
In order to achieve this goal, Autotech have been cooperating with market leaders and have developed a printed roof lining with 3D texture to bring a luxurious look and feel to the car interior. This series of non-woven fabrics is not only light in weight, but also has excellent abrasion resistance, durability, and is also competitive in terms of economy compared with other materials.
These features allow OEMs to move beyond the traditional double or triple layer composite fabric/foam support fabric, thereby reducing weight, cost, and other benefits of lightweight.
Desai said: "Due to its 3D appearance can provide unique design and pattern, this roof fabric is now the most sought after material in the automotive field. In the past, due to high import and other costs, as well as the lack of local production, the choice of these materials was limited, and India's major car manufacturers had to import these materials. Autotech are very lucky to work closely with our customers to provide this high-quality nonwoven to the market, thereby bringing positive changes to the Indian market."
Similarly, Freudenberg also provides better design opportunities for the market with its unique printed fabric, mainly due to its surpassing the surface of the traditional non-woven ceiling lining, and this Lutrador-based spunmelt nonwoven contains up to 90% recycled materials, improving the sustainability of the car, which is an important trend in the industry.
"This Lutraflor technology-based non-woven fabric from Codberg is used in car carpets, felts and trunk linings. It is lighter than competing materials and provides car designers with the possibility of saving fuel and reducing carbon dioxide emissions," Heislitz said. "Compared with traditional car carpets, these non-woven fabrics can reduce the weight by 40%."
In addition, Freudenberg's unique multi-layer composite materials can be used for molded body chassis and wheel hub liners, and 100 percent can be recycled. New products such as Freudenberg's innovative Evolon microfilament fabrics offer important advantages over traditional solutions. The adjustable flow resistance provides excellent sound absorption, especially in the frequency range of 600-6000hx.
Codberg's canopy lining materials are not only used for the canopy, but also for trunk linings and seat backs. Compared with composite knitted or foam fabrics, they have significant weight reduction potential.
