The effect of process parameters on the quality of needle-punched nonwoven components used in the automotive industry

Abstract

This study investigated the effect of process parameters on the quality of needled nonwoven (NW) components used in the automotive industry and addressed observed non-conformance. The 6.7dtex and 11dtex Polyester fibres were blended, carded, and needled using various process parameters. The effect of the depth of needle penetration, and stroke frequency on the nonwoven properties such as weight, thickness, tensile strength, dimensional stability, flammability, and wear resistance were investigated by running a series of controlled experiments that employed a 2x2 factorial design. The adhesive and binder were applied on the NW fabric and then tested using International Organisation for Standardization (ISO) test methods. Samples were randomly selected to minimise bias and improve generalisability. Statistical techniques were employed to analyse the collected data. Suitable methods included ANOVA, which determined the significance of the relationship between process parameters and quality attributes. Controlled testing conditions (laboratory and samples), equipment, materials, and testing methods throughout the experiments were used to ensure the reliability and validity of the results. Compliance with ethical guidelines was ensured when working with sensitive information or proprietary data. The findings of this study demonstrated that the fabrics manufactured from a blend of 6,7dtex and 11dtex PET fibres, finished with PE adhesive and latex binder achieved better performance because of their compact structure. The process parameters used achieved better mechanical properties of the structures needed for moulding and wear resistance properties needed for the service life and durability of the NW fabric for automotive applications. This study contributes significant results for application by automotive trim manufacturers in understanding the impact of the process parameters on the quality of nonwoven components and providing guidance to improve product quality. The significance of this study’s findings lies in their potential to offer a solution to the ongoing problems of NW component failures and contribute to knowledge preservation.