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The Success of Nonwoven Materials for Lightweight and Acoustic Efficient Components in Underbody Applications
Dr Egon Moos, Product Manager Underbody Systems, Röchling Automotive
Tuesday, April 4, 2017 · 3:36 p.m. · 17m 43s
In the past, underbody covers have been produced from GMT (glass mat reinforced thermoplastics) by compression molding. To improve the aerodynamic performance and thus reduce emissions, more and more underbody parts have been applied year by year. As more parts also mean a higher weight, the lightweight aspect came into focus. The increasing demand for lightweight resulted in the development of a new material group, called LWRT (light weight reinforced thermoplastics). Only with the combination of nonwoven materials improved properties, such as lightweight and better acoustic performance, could be obtained. Nonwoven materials are still used quite often as acoustic absorbers which then need some kind of supporting material.
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00:00:00
thank you very much for the introduction and good afternoon ladies and gentleman
00:00:05
no i have to pleasure uh to tell you something about and nobody applications refer to a talks
00:00:11
about interior so the interior uh materials you see
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you can touched and you can feel them
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but for and about a applications you hardly know that they are existing in
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the car and i try to get your emotion on the spot
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my presentation is about the success of non load materials for like
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great and acoustic efficient components in on the body application
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first i give your short introduction about about our company then
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i will talk about requirements for on the body
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systems and there you will see there are many requirements
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that are mary contradiction rick contradicted their requirements
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and therefore it is hard to fulfil these requirements just put a
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one material therefore multilayer material classically number of materials our fate
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i will show you three of these materials and make some comparisons and concluding remarks
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rushing group is a family owned a company founded in eighty
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twenty two so nearly two hundred year old and
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um power divisions are industry medical and automotive
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about half of the turnover remake which uh automotive the division
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we are uh our global supplier for uh for these parts and therefore we are um
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find burnt light especially were also our customers are
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and coming to the requirements of a nobody components here you can see it
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on the buddy system off a b. m. w. uh seven serious
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the main component a requirement is ergonomics because with a good
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ergonomics you can improve for your fuel and the
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mission saving of your vehicle and a forever deny mixes the driver that means you cover more and more
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of your car and while you're covering more and more of your car you introduce
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additional weight to this car therefore it is very important that you introduce lightweight materials
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the second uh and requirement we have heard already today for
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the interior also is acoustic acoustic performance
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the car you can improve it by the um by the and and nobody
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covers when you have absorbing or damping material so you can play
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as we just heard in the previous talk about interiors it's the same as system you
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have absorption you have damping of combination and with this you can improve that acoustics
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contamination that means the dirt and the snow uh of of the parts corrosion corrosion of the
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body invite most of the budding lights are still in metal in steel which can corrode
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you are a body invite structures goes with other medium so we have
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different approaches on that or even with the plastics are uh
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yeah composite materials about corrosion is not so uh the important you have a um
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trash requirements for example pedestrian impact so the front part of your car has to have
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a certain stiffness or can be from a a certain material the management that means
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you have still to come bastion engine they are you generate heat you have to
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pull components you have to get a heat out of your uh engine bay
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you have um the exhausts a pipe still going for a couple of years in future there
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you have to have the right material you have to protect your components in the car
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how must be robust if you're driving on the bed wrote the the part should not be damaged or fall off
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temperatures the billy to you know we are working all the volume as a
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polymer fibres uh at some certain temperature there will be a um
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uh some yeah degradation and therefore you have to select right materials
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and flute and absorption that means uh if you drive in the rain
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part can absorb water and get heavy so this is of course not want
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going back about thirty years uh we had to first material which has been used in on
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the but the application this mature disclose called classmate reinforced channel plastic the g. m. t.
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and it has been developed at that time from russia language that at that time a different name and
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yeah we can see again the first uh a non woven application that is the glass fibre mat
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the glass fibre mat is generated by needle punching of cut to
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last forever so you first uh produce a mat and
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then you have a double pal press where you integrate this with the polymer in the most cases this was polypropylene
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and you uh produce sheets the sheets you can see on the right side blue
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you heat up the sheets uh and you have a press hydraulic press where
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you uh press the parts that that's what we do on that
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uh_huh
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what
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now it works
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sell the sister g. m. t. a part production process you have this uh glass
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fibre reinforced map which the the seated up in an oven twenty thirty degrees
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you place it in the mode you closed remote there cooling time is cut out here in the video
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but anyway this is the process you have a flow of material and you generate the part
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this product was it three series b. m. w. engine under she looked
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and it has been produced about four hundred thousand parts per year
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part has the size of about point seven square meter which is not a very large and
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uh and therefore will see what we'll have in future larger parts which are higher
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sizes and therefore the need for the lower weight and is necessary
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so here again uh the g. m. t. had this great care unit
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area about uh more than two thousand grams per square meter
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and in the upcoming yes they have been developments to reduce dissuade
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uh yeah significantly to about one thousand grams per square
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meter so in two thousand nine we reach
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this goal but it doesn't mean that we have stopped the development of material after that
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it's just that the one thousand grams per square meter is sort
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of bottom line of material in the and everybody uh application
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we started two thousand three richard b. m. w. with the material from uh
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asked alone now today humble from us it's called that's there's a polite
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but you didn't have acoustic performance and in two thousand
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six bustling has developed its own material called civilised
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which then had this acoustic performance and even wait
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saving properties in regard to the previous material
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here is a cross section of um our l. w. r. t. v.
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we have a three layout uh s. sandwich structure with different
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glass fibre content in the skin in the core layer
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and we produce a this product uh with the las
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a troll says over the cutting process i know you're all familiar with these processes so i don't have to go
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so much in the tape and here we have a regular unit era of about one thousand
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four hundred grams this is our standard material where we which we propose to every car
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manufacture uh for uh let's say for entry if you want
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to use lightweight uh materials in the under body
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and the big advantage compared to a compact material like injection molding are g. m. t. is
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it everywhere on your part you have the same way per unit area in this case one thousand four hundred grams but
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to can have it in different thickness s. and with a
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different witnesses you will have different uh um acoustic performance
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so you're gonna detail to have glass fibres you have polypropylene fibres
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and you have a needle met so the needle punching is a
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very important step of your product because with a needle
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function you can generate the lifting of two material so when you get up the material
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the glass fibre remember that initial stress situation and therefore
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the material will go up and increase their eight
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and then um we'll have a a hate for for production with the different thickness is
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so i've already talked about this multi functionality of the requirements
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and therefore we are using non woven city no why the uh
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a weight range and of course to purchase this uh materials on the market
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you go from about fifteen grams per square meter to about four hundred
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grams per meter and most of these materials are adjustable polypropylene based
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it can be could be either aspen bond or needle plunged
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depending on the weight or on the application me
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and the functions are yeah look and feel maybe not for under body you will think
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the the and the body cover nobody will look and nobody a real field but
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you know the workers they have it in the hand and if you're looking on on
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the bentley a continental uh you will see in the back to relief user
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some part of it you can see if you look a little under the car or a big yeah
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issue in and nobody is is this don't chip performance them to performance you can uh
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play on it depending on the the stiffness of your material and uh
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and the combination of your material so a polyester non woven with a three four hundred grams per square
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meter uh almost a fulfils all customer requirements in
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the stone cheaper performance also for processing um
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if you are heating for example with the contact eating you need
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a different uh processing a non woven there's a cover layer
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in this case we are using mainly a polyester and for acoustic optimisation
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a different uh materials that can be used and there's another uh
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thing that that will live and i drove public or coating on which can applied on the non moments
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for uh applications under the engine where there's only one hundred probably uh is is needed
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so here's a typical example of a such an um material for
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an nobody application this is called the the light for
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four is only the the name for a development and uh
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the way community area is one thousand one hundred grams
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and we have the processing an acoustic layers on top we have
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the stone to performance and acoustic players coming then we
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have the core layer of glass p. p. for stiffness also or caustic and we have some other processing like
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of course you can make symmetric a built up or estimated buildup is
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is uh are depending on what your role uh in your and
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than development here is the uh the parts we are making it this
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is um the undivided cover of the mercy that's that's class
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one part has the size of a one square meter so we have
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to square meters um under the car and the weight is
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one thousand one hundred grams per square meters of about two point
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one kilograms in wait for this acoustic uh i'm element
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since the message assessed last has a very high uh acoustic the amount we also have
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additional uh absorbers on these parts and in this case it's also a number of material
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we call it the felt in the back type because there is the number one
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which is covered by us in a layer of um yeah last week
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this is the absorb
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so i'll wait saving is a big issue aim for
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a cost to debut effort already and are works
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we could uh get a a minus fifty percent in
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the b. m. w. x. five serious from earlier
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twenty eleven to model your twenty thirteen so that the the latest one and just uh by
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almost using the same design of the part but using the like wait a reinforced plastic material
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and the six kilogram in weight of course um you have also different
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cost situation between these two uh parts uh in in total
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about uh acoustic performance uh of non woven survey upright
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already today we measure this in the alpha cabin
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you can the higher the value it is uh the better it is
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uh on your this is the kind of absorbing material which need
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to stop support so the support can be either g. m. t.
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and nobody cover or a l. w. kept the undivided cover
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and you can see depending on the thickness of your material and also the composition of your
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material you can vary in a very wide range and this is of course uh
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our goal to find out together with our customer which is that
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correct range what do you want to have which frequencies
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do you want to absorb which is your package uh what
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wait can you introduce so it's a very wide field
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i also have to mention a non woven india nobody um um well
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yeah application from our company here in switzerland you know very well
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the material is called r. u. s. b. to ultra
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silent and it's uh yeah non moment without
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glass fibre so we're doing a non woven with glass fibres they are doing without plus fibres
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they are also in the market so uh well we divide the market upon us and with some of us
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a in this
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we have seen the transition in us where the started the fourth monday or with them in their
00:14:15
called fort fusion with the p. p. glass fibre
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based non mormon and later on during um
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during the running process this has been replaced by a pulley polyester based on
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of course we have some issues uh they are with these parts one of the issues is uh whatever
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absorption i've mentioned it already you know if you have a compact material no water or uh
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will be absorbed if you have a glass a p. p. material l. w. r. g. type is a polite type
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you have somewhat of absorption but not as high as with the non mormons or your
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we can see a water absorption zap to two hundred percent which
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of course uh the car gets a heavy then and
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it's not the two hundred percent uh in wait uh where the the customer is not so happy with
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but it's the drying time so if you have something you can see here you have
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more than one hundred percent uh water absorption but it dries within seven dollars
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it's quite comfortable but if it doesn't dry within the seven now so
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it's the last fifty percent of weight after the seven hours
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it's it's not okay and therefore we have to develop a such kind of materials where
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we have this trying time short or at least a water absorption not so high
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okay if you do now this eh combination of all these three materials i've presented to you to g. m.
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t. the glass it p. p. l. w. r. t. type and a non woven without glass fibre
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you see the advantages of the l. deputy type materials in the weight so
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between one thousand and a twelve hundred grams uh of material
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and also in in the processes that you have advantages because of the low pressure process you have
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you can make multi cavity to us you can make a large parts in one two will or can make
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three or four or even more parts in one uh to
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depending how big your presses are and uh the
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you have different extreme operations like uh what it that lays
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a punching or even follow volumes a pinch edge
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and if you do the comparison regarding the other uh
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them around properties you have in these materials
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you can see here uh the last five or p. p. v. uh based
00:16:34
material has some advantages regarding the water absorption and also to eat performance
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but uh uh as you see in the market all of these three
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materials are still uh existing and they are uh going parallel
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but uh really belief in in future we will have
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more lightweight materials under the car switch on
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especially developed for the whole way um and especially
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have uh this uh characteristics the customer needs
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no i'm coming to and short summary of my uh um um presentation
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so the lightweight and uh outstanding acoustic properties as well as
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better cost performance other drivers to use the number
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one based materials for on the body applications and we
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do this for more than thirty years uh successfully
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if you try we we see more and more on the body parts uh to improve the ergonomics
00:17:30
into reduced emissions so even higher need for lightweight
00:17:34
parts thank you very much for your attention
Conference Program
Welcome note
Mr Jan Ketteman, Consultant, Chemicals and Technical Consumables Schlegel & Partner, Germany
April 4, 2017 · 2:06 p.m.
The Mobility of the Future
Dominique Taffin, Senior Manager Industrial Design, Yanfeng Automotive Interiors
April 4, 2017 · 2:10 p.m.
161 views
Q&A - The Mobility of the Future
Dominique Taffin, Senior Manager Industrial Design, Yanfeng Automotive Interiors
April 4, 2017 · 2:31 p.m.
An industry in flux – From Motor City to Silicon Valley
Adrian Wilson, Editor Sustainable Nonwovens, Author Automotive Textiles
April 4, 2017 · 2:38 p.m.
Q&A - An industry in flux – From Motor City to Silicon Valley
Adrian Wilson, Editor Sustainable Nonwovens, Author Automotive Textiles
April 4, 2017 · 2:58 p.m.
Lightweight Textile Automotive Floor Systems - recent developments and future needs
Dr James Taylor, R&D Manager, Autoneum
April 4, 2017 · 3 p.m.
Q&A - Lightweight Textile Automotive Floor Systems - recent developments and future needs
Dr James Taylor, R&D Manager, Autoneum
April 4, 2017 · 3:33 p.m.
The Success of Nonwoven Materials for Lightweight and Acoustic Efficient Components in Underbody Applications
Dr Egon Moos, Product Manager Underbody Systems, Röchling Automotive
April 4, 2017 · 3:36 p.m.
Q&A - The Success of Nonwoven Materials for Lightweight and Acoustic Efficient Components in Underbody Applications
Dr Egon Moos, Product Manager Underbody Systems, Röchling Automotive
April 4, 2017 · 3:54 p.m.
Potential of nonwoven-based structures for the automotive industry
Dr. Bernd Gulich, Saxon Textile Research Institute (STFI)
April 4, 2017 · 3:59 p.m.
Q&A - Potential of nonwoven-based structures for the automotive industry
Dr. Bernd Gulich, Saxon Textile Research Institute (STFI)
April 4, 2017 · 4:24 p.m.
Vote of thanks
Mr Jan Ketteman, Consultant, Chemicals and Technical Consumables Schlegel & Partner, Germany
April 4, 2017 · 4:25 p.m.
Introduction
Joerg Sievert, COO, Freudenberg Filtration Technologies
April 5, 2017 · 9:14 a.m.
Q&A - Air Pollution and Health: Challenges and Opportunities for Policy-makers, Citizens, and the Industry
Nino Künzli, Deputy Director Swiss Tropical and Public Health Institute
April 5, 2017 · 10:02 a.m.
Health care is more than medical care!
Prof. Dr. Sebastian Probst, DClinPrac, RN, Professor of tissue viability and wound care at the University of Applied Sciences Western Switzerland, Geneva, Switzerland
April 5, 2017 · 2:07 p.m.
Q&A - Health care is more than medical care!
Prof. Dr. Sebastian Probst, DClinPrac, RN, Professor of tissue viability and wound care at the University of Applied Sciences Western Switzerland, Geneva, Switzerland
April 5, 2017 · 2:29 p.m.
Introduction and coordination of the presentations
Daniele Cazzuffi, IGS Past President CESI SpA, Italy
April 6, 2017 · 2:06 p.m.
The contribution of geotextiles to the global sustainability agenda
Russell Jones, IGS President Golder Associates, UK
April 6, 2017 · 2:10 p.m.
The behavior of earthworks with geotextiles after several decades
Jean Pierre Gourc, UJF Grenoble, France
April 6, 2017 · 2:31 p.m.
Q&A - The behavior of earthworks with geotextiles after several decades
Jean Pierre Gourc, UJF Grenoble, France
April 6, 2017 · 2:51 p.m.
New Horizons for Nonwoven Applications in Geotextiles
Pete Stevens, Terram Solutions Sales Manager, Berry Global
April 6, 2017 · 3 p.m.
112 views
Evaluation of durability aspects of nonwoven geotextiles for protection of PVC geomembranes in dams, reservoirs and canals
Francesco Fontana, AssINGeo President, Italy
April 6, 2017 · 3:13 p.m.
Q&A Evaluation of durability aspects of nonwoven geotextiles for protection of PVC geomembranes in dams, reservoirs and canals
Francesco Fontana, AssINGeo President, Italy
April 6, 2017 · 3:27 p.m.
The role of nonwoven geotextiles in geosynthetics and key global markets and trends
George Papagiannis, Sales & Marketing Manager Thrace Nonwovens & Geosynthetics, Greece
April 6, 2017 · 3:30 p.m.
Q&A - The role of nonwoven geotextiles in geosynthetics and key global markets and trends
George Papagiannis, Sales & Marketing Manager Thrace Nonwovens & Geosynthetics, Greece
April 6, 2017 · 3:38 p.m.
Correct design and proper applications of geocomposite drainage systems for landfills capping
Piergiorgio Recalcati, Technical Director Tenax SpA, Italy
April 6, 2017 · 3:41 p.m.
Conclusions
Daniele Cazzuffi, IGS Past President CESI SpA, Italy
April 6, 2017 · 4:01 p.m.
Recommended talks
UBER en Suisse Romande - Défis règlementaire, social et opérationnel pour un impact structurel sur la mobilité urbaine
Alexandre Molla, Directeur Uber Suisse Romande
Oct. 31, 2017 · 5:12 p.m.
440 views