1. Automotive Textiles

2. Tires The tyre is the interface between a vehicle and the road surface. A tyre is a textile reinforced composite structure where various textile components are embedded in a rubber matrix The textile carcass (known as the casing) is the backbone structure of a tyre and it is made of high tenacity tyre cords.

4. Sulfron

6. 9/7/2019Automotive Textile6 ESSENTIAL PROPERTIES OF TIRE CARS Essential properties of a tire card High breaking strength High elasticity Good beat resistance compression Uniformly structure Low hygroscopic High time deformations During stretching

7. Tire cords Tyre cords are produced from high tenacity, continuous filament nylon 6, nylon 6.6, polyester or viscose (normally used in the casing structure) Breaker or belt layers are made of high modulus fibres, frequently para- aramid (e.g. Kevlar), glass, or steel. Nylon 6 and nylon 6.6 fibres : provided unique strength, excellent adhesion and high fatigue strength, they had poor resistance to flat-spotting-corrected by heat setting Global automotive radial-ply tyre casings are reinforced with polyester (polyethylene terephthalate) fibres. However, polyester tyre cord needs a 2-stage dipping process compared to the 1-stage process used for nylon and viscose cords. Amongst the high-tenacity tyre cords, polyester creeps the least under load.

8. Viscose : Although nylon and polyester tyre cords are stronger than viscose, viscose is superior to nylon in high-speed impact. Polyester also resists high-speed impact well, but loses modulus and strength faster than viscose at 150°C. Viscose's dimensional stability to moisture is not good but the fibre is easier to process than nylon and polyester. Glass fibre has a relatively high modulus and strength compared to other high- tenacity reinforcing fibres such as nylon, polyester, and viscose. These properties are successfully utilised in the belt of bias-belted tyre construction steel cord: high strength and stiffness, is used for belt construction in radial automotive tyres. Steel cord reinforced radial-ply tyres provide high puncture and cut resistance. They help to increase tread life. Steel cord sidewalls absorb flexing better than other materials Kevlar particularly for high performance car tyres. lighter tyres for better performance. Outstanding thermal resistance, very good thermomechanical responses, accompanied by good fatigue resistance and dimensional stability, make Kevlar an ideal fibre to reinforce high speed tyres for rally and racing

9. Tire processing

10. 9/7/2019Automotive Textile10 YARN MATERIALS AND COUNTS - TIRE CORDS MaterialReferenceYarn count (dtex)Twist (T/m) RayonCV1220×2590 RayonCV2440×2410 PolyamidePA940×2472 PolyamidePA1880×2335 PolyamidePA2100×2315 PolyesterPES1100×2472 PolyesterPES1100×2354 PolyesterPES1440×3316 PolyesterPES1670×2410 polyesterPES2200×2360 Poly aramidAR1680×2330 Poly aramidAR2520×2280

11. 5.Nylon tyre cord fabric The nylon tyre cord is prepared from high tenacity continuous filament yarn by twisting and plying. There are two main types of nylons used as tyre cords, they are- 1. Nylon-6 2. Nylon-6,6 The characteristics of nylon-6 and nylon-6,6 differ slightly and are controlled by the manufacturing process, types of stabilizers and additives used. Nylon tyre cord fabric provides strength to a tyre. The tyre industry consumes nearly 98% of the total nylon tyre consumption. The nylon tyre cord fabric is 100% technical Textile. Nylon tyre cord fabric gradually replaced the usage of rayon and polyester cords in the tyre industry.

12. 5.Nylon tyre cord fabric PRODUCT CHARACTERISTICS Nylon 6 grey are dipped tyre cord fabrics having 1. High strength 2. Fatigue resistance 3. Impact resistance 4. High adhesion The tyre cords are generally available with the fabric characteristics of 930 dtex, 1400 dtex, 1870 dtex, 2100 dtex. The crirical specifications drive the characteristics such as breaking strength, elongation, adhesion, ply twists and hot air shrinkage.

13. 5.Nylon tyre cord fabric PROCESS FLOWCHART Polymerization of caprolactam to manufacture nylon chips Extraction and drying of chips Melt spinning of chips to manufacture nylon tyre yarn Preparation of cord from tyre yarn by twisting and plying Recycling of nylon-6 waste

14. 9/7/2019Automotive Textile14 SAFETY DEVICES Textiles acts as an adding value for safety measures. Safety plays an important role in the present day context. Safety has become the index page of our book called “LIFE” SAFETY DEVICES Seat beltsAir bags

15. Seat belt webbing Seat belts function as a safety harnesses which secure the passengers in a vehicle against harmful movements during collision or similar incidents. Seat belts minimize injuries during accidents. Seat belts are woven narrow fabric made from nylon filament yarns or high tensile polyester filament yarn. The load specification is an important criterion for usage vehicles.

16. 9/7/2019Automotive Textile16 SEAT BELTS ® About 1 kg of textiles fiber per car is consumed in seat belts ® The seat belt controls the forward movement of the wearers in a controlled manner during sudden deceleration of the vehicle. ® Seat belts are designed to work in co-ordination with air bags in advanced car designs. ® Polyester fiber is preferable for produce seat belts because of its important properties like maximum extension (24- 30%),good abrasion resistance and Light weight. ® Inflatable seat belt is the recent development. ® Inflatable seat belt is the combination of air bags and seat belts

17. Seat belt webbing The seat belts are made from nylon filament yarn or polyester filament yarn which is woven to produce the webbing pattern. The linear density of man made yarns must be stuck between 100 dtex and 3000 dtex, preferably 550-1800 dtex. The filament linear density should be between 5 dtex and 30 dtex, preferably 8-20 dtex. A typical seat belt is made of 320 ends of 1100 dtex polyester each. The majority weft yarns prepared from polyester are 550 dtex. The critical characteristics of the webbing are: 1. Abrasion resistance 2. Resistance to light and heat 3. Capable of being removed and put back in place easily and good retraction behavior. 4. The load bearing capacity of seat belts is 1500 KGs.

18. Air bags WHAT IS AIR BAG? It is a safety device aimed at preventing or minimizing injury to passenger when such an accident occurred. Air bags have been efficient to put a stop to severe head and chest injured in adults when auto mobile accident have occurred. Front air bags : the air bag component for the driver side is situated in the centre of the steering wheel, where as the passenger side component (if required ) can be found in the dash board above the glove box. Side airbags : there are three different types of side air bag Roof-mounted side air bags designed to protect the head and neck. Door-mounted side airbags designed to protect the chest Seat-mounted airbags designed to protect the chest & head.

19. 7.Air bag PRODUCTION CHARACTERISTICS 1.The air bag are made in following manner 2. The yarn or fabric primarily nylon 66, lighter denier, lower dpf and silicon coated. 3. Approximately 1.8 square meter of fabric is used per air bag module 4. Nylon 66 is used as a key raw material.

20. 9/7/2019Automotive Textile20 AIR BAGS THE AIR BAGS PROCESS- A TEXTILE PERSPECTIVE FIBRE YARN FABRIC COATING CUT/SEW

21. Fibers for airbag Filament yarn made from nylon 6.6 is strong, resistant to ageing, and abrasion resistant. The most important and commercially accepted fibre for airbag manufacturing is nylon 6.6, although some airbags are made of nylon 6 and polyester The modulus of the yarn is lower than that of polyester. This characteristic facilitates a uniform distribution of stress peaks across the nylon fabric during dynamic loading when the airbag inflates, which results in fewer unnecessary injuries

22. Air bag WORKING PROCEDURE OF AIRBAG Airbags inflate, or deploy, quickly -- faster than the blink of an eye. Imagine taking one second and splitting it into one thousand parts. In the first 15 to 20 milliseconds, air bag sensors detect the crash and then send an electrical signal to fire the airbags. Typically a squib, which is a small explosive device, ignites a propellant, usually sodium azide. The azide burns with tremendous speed, generating nitrogen, which inflates the airbags. Within 45 to 55 milliseconds the airbag is supposed to be fully inflated. Within 75 to 80 milliseconds, the airbag is deflated and the event is over.

23. 7.Air bag WORKING PROCEDURE OF AIRBAG Airbags may save lives and guard against severe injuries in high speed collisions, if designed properly. However, the speed with which airbags inflate generates tremendous forces. Passengers in the way of an improperly designed airbag can be killed or significantly injured. Unnecessary injuries also occur when airbags inflate in relatively minor crashes when they're not needed In the past, the air bags were coated by Neoprene. Generally, coated air bags are preferred for driver’s seat and uncoated air bags for side seats. Recently, silicon coated and uncoated air bags have become very popular due to advantages such as extended service life, adaptation to heavy duty vehicles, reduced module size, cost reduction, improved recyclability

24. 7.Air bag THE COMPONENT OF AIR BAGS  Air bags production involves three different separate assemblies that combine to form the finished end product, the air bag module.  Air bag module assemblies are: 1.Propellant: It is consist of sodium azide combined jointly by means of an oxidizer, a stuff that facilities the sodium azide to burn up when ignite. 2.Inflator assembly: The inflator machinery, such as the metal container, the filter assemblage-stainless steel wire net with ceramic substance in the initiator are receive from outside dealer and examined. The machinery is after that brings together on an extremely automated manufacturing line. 3.Air Bag: The woven nylon air bag fabric is purchased from external dealers and examined for any material flaw. The air bag fabric is afterward die cut to the appropriate form and sewn, internally and externally, to appropriately join the two sides. Once the air bag is stitched, it is inflated and checked for any seam defects.

25. 7.Air bag 4. Final assembly of air bag module: The air bag assemblage is then mounted to the tested inflator assembly. After that, the air bag is fold up and the breakaway plastic horn and protection cover up is installed. Lastly, the completed element assemblage is examined and tasted. 5. Other components: The left over parts of the air bag system – the collide sensors and diagnostic monitor unit, the steering wheel linking coil and the display lamp-are joint with the air bag at some point in vehicle assembly. All the parts are joinedand communicate throughout a wiring harness.

26. 9/7/2019Automotive Textile26 AIR BAGS - over view Air Bags are relatively new application area for technical textiles. The air bags are designed to explode out of the dash board and side panels of the cars to product the driver and front seat passengers from hitting hard surface like dash board or wind shield during a collision. They are designed to product head,neck and chest. Durability and Stability are the main requirements. Nylon 66 & Polyester are the preferred material for air bag construction. High tensile and tear strength, heat stability, functionality, at extreme hot and cold conditions (-10 to 120º C) and good pack ability. Softness for reduced skin abrasion is desired. Air bags have to withstand very high levels of stress – on the one hand the extremely rapid inflation of air bag, on the other hand the impact of person to protected. It is essential that air fabric is tear resistant

27. 9/7/2019Automotive Textile27 FIBRE PROPERTIES FOR AIR BAGS The air bag fabric made from nylon 66 is preferred over polyester because of higher elongation, allowing the force to distribute widely, lower air permeability, higher seam strength. PropertiesNylon 66polyester Density(g/cm³)1.141.39 Melting Point (ºC)260258 Energy to melt (J/kg)620303 Specific Heat capacity (J/g/K)1.671.30

28. 9/7/2019Automotive Textile28 FABRIC CHARACTERS FOR AIR BAGS CharactersNylon 66Polyester Air permeability ( same weight )LowHigh Abrasion ResistanceHighLow Thermal ResistanceHighLow Energy AbsorptionHighLow Stiffness in CushionLowHigh Ageing PerformanceGoodpoor

29. 9/7/2019Automotive Textile29 AIR BAG FABRIC SPECIFICATION Weight (g/m²)240Target 240 Weave Air permeability(L/100 cm²/min)3.6Below 10 Grey width (cm)177 Reed Width186 PropertieswarpWeftTarget Density(1/cm)2322 Tensile Strength(N/5cm)349530252500 Elongation (%)41.425.135/25 Tear Propagation resistance (N)171170130

30. 9/7/2019Automotive Textile30 FUTURE TRENDS IN AIR BAGS TECHNICS Using composites, combination of materials, non- woven and films for air bags production. Development lighter and smaller bags. Introduce new coating polymers. Side air bags, Knee production air bag, Joint production air bags for pedestrian production. Create laws for adopting air bag as a must component of a Automobile.