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| Issue date:01/12/2008 |
| ATA Journal for Asia on Textile & Apparel - Dec 2008 Issue |
| Source:Journal for Asia on Textile & Apparel |
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| GINA features hybrid fabric as its outer skin |
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Characterized by high versatility and improved performance, engineered fabrics and textiles are being increasingly used by carmakers for the creation of the next-generation dream cars with enhanced style and functionality, Sanjay Gupta observes
When BMW launched their futuristic, shape-changing, fabric-covered concept car, GINA Light Visionary Model, in June this year, they underlined the rapidly evolving role for technical textiles in the automobile sector.
The most outstanding feature of GINA is its outer skin, which is made entirely out of an industrially produced hybrid fabric with a stabilizing mesh netting support and an outer layer that is both water-repellent and temperature resistant. Pulled taut around a frame of metal and carbon fiber wires, the fabric looks like normal sheet metal that can move over the skeleton of the car as it changes shape to expose headlights, instrument panel or the engine or when it artfully binds up as the door swings open without exposing the hinges.
While the design of GINA is very much a concept, the use of fabric in the outer shell has opened a completely new vista of design and functionality.
The proportion of textiles in a car has been increasing in recent times primarily in response to more stringent comfort, environmental and safety needs in industrialised countries like the USA, Japan and Western Europe.
An average family car is estimated to contain about 14-20 kg of textiles of which nearly two-thirds (about 45 square meters per car) are used for interior trim, that is, seat covers, roof and door liners and carpets.
The remainder goes to reinforce tyres, hoses, safety belts, airbags, to insulate and to dampen sound and vibration, and to filter brake-fluids, lubricants, fuel and air.
Interior trims have typically comprised of traditional textiles, which are now increasingly being replaced by more functional, new-generation technical textiles.
Global automotive interiors market was estimated to rise from US$165 billon in 2005 to US$210 billon by 2015.
Western Europe is a major car-producing region, where an estimate of 17.58 million tonnes of mobiltech (including automotive textiles) is consumed this year. Asia’s share is increasing and will touch 17.98 million tones at the same time. The growing Indian market alone is expected to consume 2,075,000 tonnes.
The fabrics used worldwide as surface materials for car interiors can be woven, knitted (both circular and warp-knitting) or nonwovens.
Woven fabrics represent the dominant application area in seat covers, head rests and door panels (see table).
Relative share (%) of car seat cover fabrics (2004 estimates) |
Fabrics are characterized by a large variety in design, stable shape retention and high mechanical resistance.
Circular knitted products also find application in seat covers, head rests and door panels in addition to head liners, sun roofs, pillars, parcel shelves, boot covers and more. These fabrics are characterized by high flexibility in design, high-grade optics, comfortable seat quality and high stretch rates. A high stretchy level is an important feature in complex shapes of seats.
Warp-knitted fabrics are formed by two to four warp systems for applications in door panels, headliners, pillars or boot covers. Nonwoven fabrics are usually used in interiors in non-visible applications such as backing substrates and carpet reinforcement, playing a vital role for increased comfort through noise damping.
Moreover, nonwoven’s are used extensively in the non-interior components such as filters, sound damping, mufflers, gaskets and seals, battery separators, and even in tyre reinforcement. They are now seeing increased usage in rigid composites for body parts such as fenders, hoods, and trunk lids, as well as in carbon composites for structural reinforcement composites, including dash panels.
Top three demands in automotive textile market
In terms of trends, the automotive textile market is being driven by demandsover increased functionality, lower environmental impact and higher security.
Functionality appeals to automobile consumers. The Honda Element features waterproof, stain resistant textiles in the interior.
Rolls-Royce’s new Phantom Coupe has optical fibres in textile linings to illuminate certain parts of the car interior, e.g. the roof, floor and door handles. The roof is lined with sophisticated optical fibres that can create the illusion of a dazzling sky at night.
The starry night is a guarantee in Rolls-Royce’s new Phantom Coupe |
Another crucial function of textiles in the auto interior is sound control. The microdenier fabrics, usually valued for their aesthetic and tactile properties, are favoured for efficient sound absorption of their greater surface area. Being lightweight, they reduce the weight of the vehicle and improve mileage.
Conductive textiles are being used for heating, electromagnetic shielding and for the collection or transmission of signals in a car. Yarn producer, Zimmermann, offers Novonic a stretchable, conductive ribbon suited to carry data, power and heat. Novonic is complemented by a texmate connector to the power supply or data source.
Polluting substances and processes driven away
Issues of sustainability and environmental protection are becoming more important. The ELV legislation in EU mandates that all of the components of the car must be recycled at the end of its life.
European countries have also taken measures to uphold sustainability through legislation. For instance, certain dyes and chemicals used in the auto industry have been banned, and PLA fibers - easier to recycle than polyesters - are used for mono-material construction of textile/ foam/ substrate for the instrument panel, door panel, and flooring.
In upholstery composites, harmful materials, e.g. PU foam, are substituted by nonwovens, multi-knits and recyclable spacer fabrics. Efficient, longer life nonwoven filters are increasingly adopted.
Airbags and seatbelts also gained notable significance, serving as a safeguard for the driver and the passengers in case of accident.
Research is on for a uniform smart airbag, which can perceive the size of the passenger or whether the seat is empty so as to take action accordingly. Also under development are safety devices associated with the seat belt along with other safety items, particularly for child passengers. The trend towards uncoated fabrics is anticipated to continue and so is the trend towards more airbags per car and full-size bags.
Dr Sanjay Gupta is Professor of Textile Design and Development at National Institute of Fashion Technology, Hauz Khas, New Delhi, India
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| Copyright © Adsale Publishing Limited. Any party needs to reprint any part of the content should get the written approval from Adsale Publishing Ltd and quote the source "ATA Journal for Asia on Textile & Apparel", Adsale Textile English Website - www.AdsaleATA.com. We reserve the right to take legal action against any party who reprints any part of this article without acknowledgement. For enquiry, please contact Editorial Department. |
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| Copyright © Adsale Publishing Limited. Any party needs to reprint any part of the content should get the written approval from Adsale Publishing Ltd and quote the source "ATA Journal for Asia on Textile & Apparel", Adsale Textile English Website - www.AdsaleATA.com. We reserve the right to take legal action against any party who reprints any part of this article without acknowledgement. For enquiry, please contact Editorial Department. |
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