Automotive

Textiles
 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.
Sulfron
 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

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 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.
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
Tire processing
YARN MATERIALS AND COUNTS -
TIRE CORDS
Material Reference Yarn count (dtex) Twist (T/m)
Rayon CV 1220×2 590
Rayon CV 2440×2 410
Polyamide PA 940×2 472
Polyamide PA 1880×2 335
Polyamide PA 2100×2 315
Polyester PES 1100×2 472
Polyester PES 1100×2 354
Polyester PES 1440×3 316
Polyester PES 1670×2 410
polyester PES 2200×2 360
Poly aramid AR 1680×2 330
Poly aramid AR 2520×2 280

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 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.
 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.
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

 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 belts Air bags

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 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.
 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

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 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.
 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.
 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.
 AIR BAGS
FIBRE
THE AIR BAGS PROCESS-
A TEXTILE PERSPECTIVE
YARN

FABRIC

COATING

CUT/SEW

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 Fibers for airbag
The most important and commercially accepted fibre
for airbag manufacturing is nylon 6.6, although some
airbags are made of nylon 6 and polyester
Filament yarn made from nylon 6.6 is strong, resistant
to ageing, and abrasion resistant.

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
 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.
 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
 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.
 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.
 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

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FIBRE PROPERTIES FOR AIR BAGS
Properties Nylon 66 polyester
Density(g/cm³) 1.14 1.39
Melting Point (ºC) 260 258
Energy to melt (J/kg) 620 303
Specific Heat capacity (J/g/K) 1.67 1.30

• 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.

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 FABRIC CHARACTERS FOR AIR
BAGS
Characters Nylon 66 Polyester
Air permeability (same weight) Low High
Abrasion Resistance High Low
Thermal Resistance High Low
Energy Absorption High Low
Stiffness in Cushion Low High
Ageing Performance Good poor

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 AIR BAG FABRIC SPECIFICATION

Weight (g/m²) 240 Target 240

Weave
Air permeability(L/100 cm²/min) 3.6 Below 10
Grey width (cm) 177
Reed Width 186
Properties warp Weft Target
Density(1/cm) 23 22
Tensile Strength(N/5cm) 3495 3025 2500
Elongation (%) 41.4 25.1 35/25
Tear Propagation resistance (N) 171 170 130

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 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.
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