The Evolution of Nylon Yarns for Automotive Carpeting Applications

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RadiciGroup at 51th Dornbirn Man Made Fibres Congress - 19-21 September 2012.
"The evolution of Nylon Yarns for Automotive Carpeting Applications"

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The Evolution of Nylon Yarns for Automotive Carpeting Applications

  1. 1. “The Evolution of Nylon Yarns forAutomotive Carpeting Applications” Arturo Andreoni Marketing Manager Radifloor® Roberto Vedovati Radifloor® AutomotiveYarn Manager RADICIGROUP 51° Dornbirn Man Made Fibers Congress 19 – 21.09.2012
  2. 2. The sequence1. RadiciGroup2. The Nylon BCF Carpet Market in Europe3. The Automotive Market in Europe4. The Nylon BCF Carpet Yarn Evolution5. The Wear Resistance of BCF Carpet Yarns6. Conclusions
  3. 3. 1. RADICIGROUP
  4. 4. RadiciGroupRadiciGroup is one of the most active chemicals companies at an international level.Its diversified businesses operate worldwide and are focused on Chemicals,Plastics and Synthetic Fibres.The Group has total control over its production chain, from chemical intermediates,such as adipic acid and polyamide 6 and 66, to engineering plastics, and man-madefibres..RadiciGroup’s products are exported all over the world, and are the starting-point fordevelopments in the clothing, sport, furnishings, automotive, electrical/electronicand appliances sectors. 3,500 employees 1,238 million euros 2011 Turnover Radici Partecipazioni
  5. 5. A Worldwide PresenceEUROPEMendrisio (CH)Stabio (CH)Podborany (CZ)Overath (D)Hamburg (D)Lüneburg (D)Reutlingen (D)Tröglitz (D)Viernheim (D)Selbitz (D)La Carolina (ES)Saint Priest (F)Szentgotthard (H)Andalo Valtellino (IT)Ardesio (IT)Casnigo (IT) AMERICA ASIAChignolo d’Isola (IT)Gandino (IT) Buenos Aires (RA) Noida (IND)Novara (IT) Rio Grande (RA) Shanghai (CN)Trivero (IT) Araçariguama (BR) Suzhou (CN)Villa d’Ogna (IT) São José dos Campos (BR)Savinesti (RO) Gastonia (USA)London (UK) Wadsworth (USA)
  6. 6. Sustainability According to RadiciGroup1) Organizational Models ISO 9000, ISO 14000, OHSAS 18000, SA 8000, ISO 50001, ISO 14064.2) Certifications (mandatory and voluntary) along with R&D efforts• REACH• LCA applied to all main products.• Eco-Profiles, EPDs, Ecolabel, Oekotex3) Kyoto protocol parameters : 20/20/20 +20% recycled materials.4) Sustainability as an approach to corporate governance,an approach based on GRI Global Reporting Initiative protocol.
  7. 7. 2. THE NYLON BCF CARPET MARKET IN EUROPE
  8. 8. Nylon BCF/NSF in EUROPE, the PRODUCERS scenario 1990 2000 2012 ICI Fibres DuPont - DuPont - Enka - Rhone Poulenc Rhodia - Nordfaser - Bayer - Snia - Enichem - Wellman Wellman - Radici Radici Radici Aquafil Aquafil Aquafil Beaulieu Group Beaulieu/ Domo Beaulieu /Xentrys ITC / Balta ITC / Balta ITC / Balta Allied - BASF - 15 7 4
  9. 9. Nylon BCF in EUROPE, Nylon BCF EU27 Productionthe PRODUCTION (Kton/year)scenario 2004 186 2005 187The reduction to 4 nylon 2006 187BCF producers in 2012 has 2007 187been driven by: 2008 163• the exit from the fibres 2009 135 2010 145business of big integrated 2011 128chemicals groups.•The erosion of carpets 100 80use in the floorcoveringmarket. 60 Others (%) Floorcoverings 40• And by interfibre 51 Carpets 20 38competition (mainly PP). 0 EU 2000 EU 2011
  10. 10. 100 Automotive (%) 50 Contract Residential 0 Nylon BCFNylon BCF in EUROPE, the DEMAND by end useToday the overall opportunity for nylon BCF in Europeancarpets (excluding export) is reduced to about 100Kton/y with some recovery in the Automotive “premiumbrand” sector.
  11. 11. 3. THE AUTOMOTIVE MARKET IN EUROPE
  12. 12. Top 10 assembly forecast - data by brand - EU Brand 2011 2012 2013 Volkswagen 2.315.419 2.342.089 2.298.255 Mercedes Benz 1.208.591 1.269.199 1.390.964 Ford 1.148.443 1.154.982 1.295.338 Peugeot 1.284.516 1.144.138 1.200.663 Audi 1.079.469 1.131.062 1.164.749 Opel - Vauxhall 1.207.337 1.077.736 1.145.272 BMW 974.849 1.020.548 1.051.999 Renault 1.224.069 958.679 939.146 Citroen 987.453 908.801 902.285 Fiat 782.634 735.142 822.133 Top 10 total assembly 12.212.780 11.742.376 12.210.804 Top 10 (% of regional total) 72,6 71,5 71,4
  13. 13. Car classification - car segment Car classification American British English Euro Car Segment Examples English Microcar, Microcar Smart Fortwo Bubble car A-segment mini cars Renault Twingo, Ford Ka, Fiat 500, Tata City car Nano, Suzuki AltoSubcompact car Ford Fiesta, Volkswagen Polo, Opel Supermini B-segment small cars Corsa, Citroën DS3, Peugeot 207 C-segment medium Ford Focus, Opel Astra, Toyota Auris, Compact car Small family car cars Volkswagen Golf, Chevrolet Cruze Ford Mondeo, Hyundai Sonata, Opel Mid-size car Large family car Insignia, Chevrolet Malibu, IKCO Samand D-segment large cars Entry-level Compact Acura TSX, Alfa Romeo 159, Mercedes luxury car executive car C-Class, BMW 3 Series, Cadillac CTS Ford Crown Victoria, Holden Full-size car E-segment executive Commodore, Chevrolet Impala Executive carMid-size luxury cars Lexus GS, BMW 5 Series, Jaguar XF, car Volvo S80, Chrysler 300Full-size luxury AUDI A-8, BMW 7 Series; Mercedes S- Luxury car F-segment luxury cars car Class
  14. 14. 4. THE NYLON BCF CARPET YARN EVOLUTION
  15. 15. BCF vs Staple (*)(*) : Bulk Continuos Filament
  16. 16. Tufted BCF vs. Needle PunchCompared with Needle- punch made from staple, we can obtain carpets with improved:• Cleanability• Aesthetics• Coverage , also at reduced weight• Perceived Quality• Wear resistance
  17. 17. Floor carpet type by car segment non woven low weight non woven high weight avg > 320 gsm PA6 BCF >400 gsm PA66 spun <350gsm 500 gsm today ≥400 gsm PA6 BCF non woven (needle punch) tuft 400 gsm PA6 non woven low weight non woven high avg 340 gsm BCF >500 gsm PA66 spunup to 2004 <350gsm weight avg 500 gsm BCF PA6 400 gsmPA66 spun non woven (needle punch) tuftCAR Segmentclassification A B C1 C2 D1 D2 E1 E2 F1 F2 •A: mini cars •D: large cars •B: small cars •E: executive cars •C: medium cars •F: luxury cars
  18. 18. BCF yarn type by dpf and by car segment BCF PA6 8 and 10 DPF today BCF PA6 8 DPF non woven (needle punch) tuft BCF PA6 10 BCF PA6 10 DPFup to 2004 and 20 DPF non woven (needle punch) tuftCAR Segmentclassification A B C1 C2 D1 D2 E1 E2 F1 F2 •A: mini cars •D: large cars •B: small cars •E: executive cars •C: medium cars •F: luxury cars
  19. 19. Evolution of the dpf for the BCF yarns 10X 10XUp to2004 19 DPF 10 DPF 10X 10X In theToday future ? 8 DPF 7 DPF
  20. 20. Top: sectional view of a fine gauge. Bottom: sectional view of a coarse gauge Carpet construction evolutionSuitable Gauge Gauge Needlesfor yarn (inches) (in mm) (per type meter) 5/64’’ with: 1/10’’20-10 dpf 1/10 2.54 mm 394 Top: sectional view of a fine gauge.8 dpf 5/64 1.98 mm 504 Bottom: sectional view of a coarse gaugeGauge: distance between two needle points on tufting machines
  21. 21. To summarize, the BCF yarn evolution experience application final dpf tufting gauge touch description applicationmats for after-market 19,1 1/10" rough matsSTANDARD FOR MATSBUSINESS mainly OES 15,5 1/10" medium mats and some OEMonly small projects on 5/64" main floor 14,0 5/64" medium main floor, mats standard for 1/10" floor, luggage and flooring and mats 10,2 1/10" ( 5/64") soft mats STANDARD FOR floor, luggage and SAMTVELOUR 5/64" 8,0 5/64" (1/16") very soft mats under devepolment floor, luggage andfor high quality carpet 7,2 5/64" (1/16") extreme soft mats ( mats included)
  22. 22. 5. THE WEAR RESISTANCE OF BCF CARPET YARNS
  23. 23. Carpet functionality in a car•Cleanability•Aesthetics•Haptics (optical & touch feeling)•Coverage at reduced weight•Perceived Quality•Wear resistance
  24. 24. Carpet Requirements in a car• A carpet surface must withstand a specified amount of foot and cargo abrasion.• Driver and passenger front foot wells are most prone to wear from occupants’ feet, particularly from: • Entering and exiting the vehicle • Normal foot and body movement while travelling in the vehicle• Heel mats (vinyl or TPO) enhance wear characteristics in the area of the accelerator and brake pedal.• Accessory floor mats are still ‘options’.
  25. 25. Wear resistance, EU Taber Tests• Test and requirements differ between OEMs, e.g.:• BMW (Tufted ) – H18/1000 revs/10N – weight loss, aspect, Grey Scale• Ford (Tufted ) – H18/2000 revs/10N – weight loss, aspect• Toyota (Tufted ) – H18/300 revs/10N – weight loss, aspect• Note – Conditions for non-woven carpets are usually less severe and are assessed mainly on aspect
  26. 26. Wear resistance, Taber test samples Differences in colour between abraded/non abraded area (central area)
  27. 27. Wear resistance, Taber test results Abrasion grey scale testSample No. colour Gauge pile weight (g/m2) (g) dpf (1÷5) result 12 beige 5/64" 350 0,09 10 >3 OK 8 black 5/64" 400 0,057 10 >3 OK 4 black 5/64" 420 0,08 10 >3 OK 5 beige 5/64" 450 0,034 10 >3 OK 1 black 5/64" 320 0,051 8 >3 OK 9 beige 5/64" 330 0,04 8 >3 OK 2 beige 5/64" 390 0,04 8 >3 OK 3 black 5/64" 500 0,032 8 >3 OK 7 beige 5/64" 500 0,028 8 >3 OK 13 beige 5/64" 290 0,09 7 >3 OKTest conditions: Test targets:H18 wheels, 10N, 1000 cycles Weight loss < 0,25 g Grey scale > 3
  28. 28. Conclusions• Let me thanks MAGNA Eybl (Ebergassing – Austria): – Mr. Walter Ecker (B.U. Manager & Dev. Automotive Carpet M.gr).• This development project gave us the possibility to dismantle some prejudices regarding the adoption of lighter carpets without loosing performances.• Because we have demonstrated that there is no correlation between lower dpf yarns and less wear resistance!• We continue to explore the way low dpf yarns for H.P. Carpets applications behave in the car industry.
  29. 29. Thank You To contact us : RADICIFIL SpA Via Europa, 41I-24020 CASNIGO (BG)www.radicigroup.com

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