Non-woven Fabric for Automotive Interior Molded and Die-cut Structural Parts
Currently, nonwoven materials have more than 40 uses inside automobiles, and the area of such materials in each car exceeds 35m². Nonwoven materials for automobiles can generally be divided into three categories: ① Decorative materials, such as needle-punched carpets and trims; ② Insulation layers with sound and vibration absorption functions; ③ Filter materials.
Visible nonwoven materials used in automobiles only account for about 10% (approximately 3.5m²) of the total area, and they are usually standard needle-punched velvet nonwoven materials, available in various elasticities and prices. Microfiber-based artificial leather materials like Alcantara are the most unique and profitable nonwoven materials used in automobiles. Alcantara was invented by Toray Industries in 1970. It is a "sea-island" type bicomponent fiber composed of about 60% polyester and 40% polyurethane (PU). Then it is cut into short fibers, and the "sea" component is dissolved before needle punching and dyeing.
Many leading automobile manufacturers and customers believe that nonwoven materials have better breathability, softness, dyeability, and wear resistance than natural leather.
Nonwoven materials for automobiles are developing rapidly in the following three directions: ① Continuously using natural fibers in composite nonwoven materials; ② Developing nonwoven materials based on recycled carbon fibers; ③ New hybrid filter media.
Applications of nonwoven materials for automobiles
Although woven and knitted fabrics continue to dominate the automotive textile market, nonwoven materials are being used more and more due to their key advantages such as light weight, low cost, and sound insulation. For example, Johnson Controls (a company that manufactures automotive seats, overhead systems, doors, dashboards, and interior electronics) is using more nonwoven materials in automotive components because nonwoven materials can be produced at high speed, at low cost, and are easy to mold.
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