Carpet Systems and Inner Dashes
Autoneum’s multifunctional carpet systems reduce noise entering the passenger compartment from the road or powertrain and in doing so help to enhance driver comfort. Autoneum produces both tufted carpets that are primarily applied in higher vehicle classes and non-woven carpets for small and mid-range vehicles. Whether tufted or non-woven, Autoneum’s carpet systems meet the high aesthetic requirements of customers concerning the vehicle interior and are lightweight, dirt-resistant and durable.
Inner dashes and floor insulators prevent engine bay or road noise from entering the vehicle cabin and are used in combination with carpet systems between the engine bay or underbody and the passenger compartment. Thanks to their lightweight, the insulators correspondingly reduce the weight of the vehicle, thereby resulting in lower fuel consumption and vehicle emissions.
Autoneum Offers Among Others the Following Products for Application in the Interior Floor:
- Inner dashes
- Non-woven carpets
- Tufted carpets
- Floor insulators
- Floor mats
- Spacers and crash pads
Combination of Insulation and Absorption
Inner dashes and floor insulators prevent the transfer of street noise into the passenger compartment. With Hybrid-Acoustics, Autoneum offers an innovative technology for such components that simultaneously insulates and absorbs noise.
Hybrid-Acoustics not only meets today’s but also future noise protection requirements of vehicle manufacturers. For example, the lower part of an inner dash needs more insulation as the noise of the engine and front wheels is particularly audible here. By contrast, the upper part of inner dashes requires more absorption as other parts of the car – such as the dashboard – already contribute towards insulation.
Hybrid-Acoustics enables the thickness and density – and hence the insulation and absorption capacity – of the components to be defined accurately within a centimeter without any additional materials or layers. It is done simply through the targeted engineering of the fibrous top layer. This can be achieved by means of 3D calculations and statistical energy analyses as well as modern production processes.
Components based on Hybrid-Acoustics largely consist of recycled cotton fibers and are correspondingly light. They are up to 50 percent lighter than conventional insulations made of heavy layer foam. The Hybrid-Acoustics technology accordingly makes an important contribution towards reducing vehicle weight and emissions.
The Lightweight “Classic”
The Ultra-Light technology facilitates enhanced acoustic comfort in cars while simultaneously reducing the vehicle weight and is today one of the classic products in Autoneum’s noise protection portfolio.
Prior to the market launch of Ultra-Light in 1998, vehicle manufacturers largely used insulations made of heavy layer foam to curb unwanted noise. Autoneum introduced a pioneering paradigm shift in its approach to reducing vehicle noise by focusing on the absorption of noise instead of the insulation method that had previously been practiced. While sound-insulating components block noise and prevent it from seeping through from the engine bay to the passenger compartment, sound-absorbing components “swallow” noise.
The benefits of this fundamental paradigm shift are obvious: products for the absorption of noise like inner dashes and floor insulators are made of lightweight materials such as fibers. Compared with heavier mineral oil-based insulations they enable weight savings of up to 50 percent to be made. Moreover, products based on Ultra-Light are easy to recycle.
Quantum Leap for Inner Dashes and Floor Insulators
Prime-Light is the latest advancement of Autoneum’s successful Ultra-Light technology and represents a quantum leap in terms of innovation within the segment of inner dashes and floor insulators for vehicles. Prime-Light components can be pressed into a wide variety of different shapes and sizes. This way they adjust optimally to the individual body-in-white shapes and take account of increasingly complex production processes in vehicle construction.
Prime-Light also convinces with a light weight while maintaining the same level of acoustic protection. Thanks to a 30 percent weight reduction compared with previous models,
Prime-Light-based inner dashes and floor insulators save more than two kilos of a vehicle’s weight in average.
Automobile manufacturers and end consumers equally benefit from this weight reduction: If, for instance, the weight of a vehicle is reduced by 100 kilograms by means of lightweight materials, this leads to a 0.55-liter reduction of gasoline and almost 13 grams less CO₂ emissions per 100 kilometers driven (based on total fuel consumption of 5.5 liters per 100 kilometers).
Prime-Light-based inner dashes and floor insulators consist of thermoplastic cotton felt compounds in which the share of recycled materials amounts to up to 50 percent depending on the application-specific composition. In order to achieve the greatest possible acoustic protection, Autoneum analyzes the ideal density and thickness of these components already in the design phase of new vehicle models.
Enhanced Driving Comfort
The Di-Light carpet innovation for compact and medium class vehicles is the most recent expansion of the company’s product portfolio. Thanks to its greater abrasion resistance and resilience, Di-Light is a more durable non-woven carpet and offers an attractive appearance even in highly curved carpet areas due to its uniform surface finish.
The non-woven carpet absorbs noise entering the passenger compartment from the road or engine bay, thereby contributing to enhanced driving comfort. In addition, Di-Light has a lighter weight than standard non-woven carpets while maintaining their benefits. Di-Light-based carpets therefore reduce fuel consumption and emissions at the same time.
The enhanced resistance/weight ratio and the homogeneous look and feel of the carpet are based on newly developed fibers. Depending on the product variant, they consist of up to
97% of recycled PET which is reflected in the carpet’s excellent environmental performance.
Premium Carpet Quality
This new technology for tufted carpets has a number of advantages compared to the non-woven carpets mainly used in the compact and medium class. Thus, also drivers of these vehicle classes benefit from the quality standard and the look and feel of premium carpeting.
Most notable is the fact that Clean-Tuft offers a clearly improved cleanability compared to non-woven floor coverings: In particular, small particles such as splinters or needles can be removed more easily and thoroughly because they do not adhere to the fabric.
Carpet systems based on Clean-Tuft are also a convincing proposition in terms of durability and abrasion resistance, being more robust than non-woven carpets and less susceptible to wear and tear. It is common for non-woven carpets to gradually lose their pile after several years in a vehicle. On the contrary, Clean-Tuft continues to offer high-quality haptic and an attractive appearance thanks to its virtually unchanged fiber shape and structure for the entire life of the vehicle.
Furthermore, Clean-Tuft rights itself much more rapidly after being subjected to strain, for example by passengers’ shoes, than conventional non-woven floor coverings and offers high stain-resistance thanks to its hydrophobic surface.
Ideal Acoustic Performance
With Tune-It, Autoneum is launching its latest innovation for non-woven carpets that makes the car of tomorrow lighter, more comfortable and environmentally friendly – while delivering ideal acoustic performance at the same time.
Tune-It is based on an innovative fiber combination in the carpet backing with which, for the first time, sound insulation and absorption can be tuned to the specific needs and geometry of the passenger cabin across the entire surface of the carpet. Thanks to this technological quantum leap it is now possible to define the optimum insulation and absorption performance already during the development phase of new vehicle models by means of computer-aided simulations. As a result, needlepunch carpets based on Tune-It provide ideal noise protection in the passenger cabin. In addition, given a weight advantage of up to 25 percent compared to standard needlepunch carpets, components based on Tune-It also support reduced fuel consumption and less vehicle emissions.
The outstanding environmental footprint of this carpet technology that consists of 100 percent PET is also reflected in the fact that Tune-It based components are fully recyclable. Compared to conventional carpet molding, where non-recyclable production waste can reach a share of
30 percent, off-cuts produced during the manufacture of Tune-It can be processed into pellets and completely returned into the carpet manufacturing process in the form of fibers.