Preparation of Textile Nonwoven Foams Using Elastomeric Binder Fibers for Automotive Cushioning Materials

The physical and mechanical properties of textile nonwovens have been exploited for the replacement of polyurethane (PU) foams in car interiors, in particular, cushioning materials for car seats. Polyethylene terephthalate (PET) hollow fibers and elastomeric bicomponent binder fibers were used to manufacture automotive nonwovens by carding processes, and post bonding processes such as needle punching, thermal bonding or through-air bonding. The physical and mechanical properties of nonwovens were thoroughly investigated with respect to the effects of bonding processes. The tensile strength and elongation for the nonwovens were significantly improved by the combined needle punching and through-air bonding processes. In comparison with the PU foam, the nonwovens showed a greater hardness, and their higher support factors ranging from 7.7 to 11.0 indicated the improved seating performances with better air permeability.