Physical and compressional characteristics of a novel 3D fibrous structure – application in comparison between PU foam and 3D fibrous structure

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The question of the recycling of the polyurethane (PU) foam, especially in the automotive industry represents one of the main technology thrust and challenge of the car manufacturers and the Original Equipment Manufacturers’ (OEM) since 2000. Indeed, it is nowadays necessary for car industry to promote ecological methods of development in regard to new consumer sensibility. New textile products present the best alternative solutions to answer this issue of replacement of the PU foam. Based on this fact, a new three-dimensional (3D) fibrous structure made of polyester (PET) material has been developed in order to replace PU foam in automotive trim. These new manufactured 3D fibrous structures are laminated with needle-punched and spun-bonded sheets. The sheets are made of 100% PET, in order to obtain a mono component product. Characterization of physical and mechanical properties of these new 3D fibrous structures, testing methods have to be developed. Based on the automotive specifications, a methodology has been set up to test the compression behavior of these new products. In order to answer the issue of replacement, some PU foam products have also been characterized, and comparisons with alternative products have been conducted. The results of this study show interesting properties of the new 3D fibrous structure in terms of compression behavior when compared to the PU foam.