automotive interior solutions optimised performance and surface aesthetics

7/24/2019 Automotive Interior Solutions Optimised Performance and Surface Aesthetics

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Automotive

Interior SolutionsOptimised performance and surfaceaesthetics


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2 . Borealis / Borouge

Production

Customer Service Centre/

Sales Office

Head Office

Innovation Centre

Building on Borealis unique Borstar technology and

their experience in polyolefins of more than 50 years,

Borealis and Borouge provide innovative, value creating

plastics solutions for the infrastructure - pipe systems

and power and communication cables - automotive and

advanced packaging industries. In addition, Borealis

offers a wide range of base chemicals from melamine

and plant nutrients to phenol and acetone.

Borealis and Borouge are leading providers of chemical and

innovative plastics solutions that create value for society.

With sales of EUR 7.5 billion in 2012, customers in over

120 countries, and 5,300 employees worldwide, Borealis is

owned 64% by the International Investment Company (IPIC)

of Abu Dhabi and 36% by OMV, the leading energy group

in the European growth belt. Borealis is headquartered in

Vienna, Austria, and has production locations, innovationcentres and customer service centres across Europe and

Borealis and Borouge partners for long-term success


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Borealis / Borouge . 3

the Americas. Through Borouge, a joint venture between

Borealis and the Abu Dhabi National Oil Company (ADNOC),

one of the worlds major oil and gas companies, the

companys footprint reaches out of the Middle East to

Asia Pacific, the Indian sub-continent and Africa, where it

is also Borealis exclusive distributor. Established in 1998,

Borouge employs approximately 1,600 people, has

customers in more than 50 countries and headquarters inAbu Dhabi, UAE and Singapore.

Currently Borealis and Borouge have a manufacturing

capacity of more than 5.4 million tonnes of polyolefins

(polyethylene and polypropylene) per year. An additional

2.5 million tonnes is scheduled to come on-stream by

the end of 2013, creating the worlds largest integrated

polyolefins plant. Both companies continue to invest to

ensure that their customers throughout the value chain,

around the world, can always rely on superior products andsecurity of supply.


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6 Dedicated to automotive solutions

7 Satisfying aesthetic and performance demands

8 Lightweight structural components

9 Delivering premium surfaces

10 Processing for optimal property balancing

11 Natural fibre reinforcement

12 Solutions for interior applications

14 Creative innovation

15 Contact

Contents


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Engineering Applications a specialist Borealis and Borouge

business segment particularly focused on the development

of creative innovation polypropylene (PP) and thermoplastic

polyolefin (TPO) solutions for automotive applications.

Whether you are producing dashboards, door panels,

centre consoles, trims or structural components, Borealis

is the right partner for you. Our comprehensive ranges of

PP and TPO polymers and compounds have properties

that are balanced and tailored to precisely match your

application needs. As such they add value through helping

manufacturers to lower system costs, while providing reliable

performance to the highest global industry standards, as

well as enabling faster development-to-production cycles.

And, no less importantly, they reduce both material and

energy inputs for enhanced sustainability.

Staying ahead of trends

Our close working partnerships with OEMs and Tier

1 suppliers over many years have given us a unique

understanding of automotive value chain needs. Of special

importance is that our ongoing dialogue with partners

helps in the early identification of evolving market trends.

This allows us to focus the resources and scientific

skill-sets of our Innovation Centres on ensuring you have

the optimal, differentiated and integrated solutions that

meet tomorrows needs, before they become tomorrows

challenges.

Dedicated to automotive solutions

Door Cladding

Trim

Window Frame

Seat Carrier

Centre Console

Pedal Carrier

Dashboard Carrier

Dashboard


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Visual appearance is the first and dominant influence on

the buyers perception of vehicle quality. Our PP and TPO

resins and compounds are developed to make a positive

contribution to that perception through, for example, the

generation of appeal through low gloss, scratch resistant

interior trims and cladding that emphasise style, as well

as providing for the design freedom that complements

aesthetic objectives.

Sense of touch has a special relationship to the way

we connect with our surroundings and through it our

appreciation of comfort. The haptic characteristics of our

PP and TPO materials for passenger contact applications,

such as smoothness, grained effect, soft-touch or stiffness,

whichever is appropriate, are given special consideration

in materials development. No less attention is paid to the

materials low emission and odour, non-fogging and sound

dampening characteristics, which complete our perception

of quality and the comfort of our driving experience.

Satisfying aesthetic and performance demands

Wide processwindow

Flowability

Cycle time

Density

Impact

Stiffness

Odour

Heat resistance

Light resistance

Haptic

Scratch resistance

Gloss

Class-A surface

PhysicalProperties

Stabilisation

Processability

SurfaceQuality


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Lightweight structural components

For applications, such as structural carriers, requiring optimal stiffness/toughness balance our reinforced PP compounds

provide the strength and durability to replace metals. In doing so, they enable significant vehicle weight savings and greater

fuel economy without any compromises in mechanical properties. Moreover, they give reliable, corrosion-free performance

throughout a vehicles lifespan.

GB215HP

BMW

BMW 7 series dashboard carrier in foamed

Fibremod GB215HP, a 20% long glass fibre

reinforced PP compound.

Benefits

- 20% weight saving replacement

of a previous 2-component construction

- Compatible with BMWs SGI injection

technology

- High stiffness and strength

- Excellent warpage behaviour

- Lower system costs

GD302HP

BMW

BMW rear seat carrier in Fibremod GD302HP, a

30% short glass fibre reinforced PP compound.

Benefits

- 35% weight saving replacement

of a hybrid steel-PUR concept

- Lower system costs

- Excellent impact behaviour

- Low warpage and high dimensional stability

GE277AI

VW

VW Golf A7 IP carrier in Fibremod GE277AI,

a 20% short glass fibre reinforced PP

compound.

Benefits

- Specifically designed to be processed with

Structural Foam Injection Moulding (SFIM)

- Combines high flowability with a high

stiffness/impact ratio

- High dimensional stability

- High weld strength


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Vehicle interior surfaces have a major influence on buyers

perception of quality. Where a quality feel and finish was

once considered the preserve of expensive, high-end

brands, today it is a common OEM goal across

economy-level cars as well. Because of that, interior

aesthetics provide car makers with an important

opportunity for differentiating their offerings from those of

competitors.

Borealis and Borouge PP and TPO materials meet OEMobjectives with optimised solutions that deliver surfaces

exhibiting:

Non-stickiness

Low gloss

High scratch resistance

Absence of flow marks (Tiger stripe-free)

Cosmetic surfaces

A number of new grades have been launched with this flowmark-free PP matrix. But also the existing grade slots were

upgraded so this Borealis innovation could contribute to

the avoidance of flow marks on applications across a very

broad processing window.

An optimal fit

Moreover, the visual and haptic aesthetics of interior

surfaces are supported by the excellent dimensional

stability of PP grades and advanced reactor thermoplastic

polyolefins (rTPO) that offer a low Coefficient of Linear

Thermal Expansion (CLTE). This allows closer gap

tolerances for more visually attractive finishes, when

design calls for parts made from materials with dissimilar

mechanical properties to be fitted in close proximity to

each other.

Underwritten by safetyAlthough not an appearance aspect of our PP and TPO

solutions, their impact resistance and non-splintering

performance are no less important, as they underwrite

visual value. In the event of collision these properties in

panels and fascias contribute to driver and passenger

safety adding a further comfort factor.

Maximising ambient lighting

Enhanced ambient light to increase appeal to the

style conscious buyer, as well as driver and passengerconvenience, is becoming a popular trend in automotive

interior design. As an answer to this, a growing number of

automakers are turning to translucent PP.

Borealis advanced PP solutions maximise ambient light to

create brighter, differentiated interiors, without design or

cost penalties.

Delivering premium surfaces

TigerStripes

[MSE]

Parameter B

ParameterA

40

30

20

10

0


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Borealis and Borouge PP and TPO solutions for interior

components are formulated to provide the characteristics

necessary for enhanced processing, including:

A broad processing window

High flow enabling ease of filling complex geometries

and long, thin wall constructions

Low shrinkage

Faster cycle times for increased machine utilisation andproductivity

However, Borealis offers processing guidelines that can

unlock the fuller potential of Borealis tailor-made solutions.

For example, creating PP that exhibits very low gloss can

lead to the unwanted effect of reducing the materials

scratch resistance. Within the auto industry this often

means that the performance level of one property is traded

for the raised performance of the other, whereas the

contribution of both is essential and of equal value to the

finished part.

Borealis has developed specific processing parameters

for its own PP materials that allow very low gloss to be

achieved with no negative influence on scratch resistance.

Processing for optimal property balancing

Tooling for sustained appearance and performance

To ensure that interior components, like dashboard

fascias, inner door panels and pillar trims, maintain a

high aesthetic appearance over the long-term, material

scratch resistance is especially important to protect

against abrasions and marring. However, interior mouldings

predominantly use grained surfaces, determined by the tool

used, and these can have a negative impact on scratchresistance properties. Therefore Borealis materials for

interior applications have been developed specifically to

deliver improved grain effect in combination with superior

resistance to scratching.

Ultimate performance, however, is highly dependent on

tooling design as different grains exert varying influences

on the finished components degree of scratch resistance.

Gloss60[-]

Tool contact temperature []

11090 130 150 170 190 210

4.03.83.63.43.23.02.82.62.42.2


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A next step in lightweighting vehicles is the replacement of

traditional glass fibres and minerals in structural parts with

even lighter-weight, lower density fillers such as natural fibre

compounds (NFC), for example hemp and flax, and woodfibre compounds (WFC). Moreover, as renewable resources

they can make a positive contribution to sustainability within

the automotive industry.

Building on this potential, Borealis is engaged in the

development of a new generation of injection moulding PP

WFC grades for non-appearance and appearance interior

parts.

Customer values Sustainable, renewable sourced modifier

Light weight potential (8-10% weight saving)

High surface aesthetics (low gloss, excellent scratch

and good haptic characteristics)

New design effects

Energy efficient in processing

Product benefits versus conventional 20% mineral filled

PP copolymer

15C higher heat distortion temperature

Better scratch resistance and lower gloss

Equivalent shrinkage

Borealis PP WFC and NFC grades, bridging performance

needs between mineral filled and glass fibre reinforced PP,

are seen as having an ideal fit in applications ranging from

centre consoles and dashboards to door inner panels and

pillar covers.

Natural fibre reinforcement

Physical properties

PP Wood fibre 20%PP Talcum 20%

Charpy V-notched impact+23C [kJ/m2]

Tensile Modulus[MPa]

Gloss [%]

Density[g/cm3]

Scratchresistance

[dL*]

HDT A [C]

1.8

1,900

3

0.5

65-70

2,500

0.95

1.05

1.3

3

55

6

2,400


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Solutions for interior applications

Grade

Fillercontent[wt%]

Density[kg/m]

MFR230C/2.16kg

[g/10]

Flexural

modulus

[MPa]

Tensilestress

at yield[MPa]

Impact,Charpynotched

23C[kJ/m]

Impact,Charpynotched-20C[kJ/m]

HDT B(0.45Mpa)

[C]

Shrinkageindication

[%]Typical applications

Copolymers

BE677AI - 905 14 1,450 26 8 4 100 1.5 Door cladding, interior cladding

EG066AI - 905 22 1,000 20 38 8 81 1.5 Door cladding, interior cladding

BG055AI 2.5 920 22 1,850 35 3.5 1.5 108 1.5 Climate control housings

Homopolymers mineral filled

MD231U 20 1,050 6 2,700 36 3 1.2 125 1.1 Climate control parts

ME212U 20 1,050 13 3,100 32 3 1.5 120 1.1Climate control parts, interiortrims

PS65T20 20 1,050 23 2,700 32 2.5 1.5 110 1.1 Door Inserts, cladding

MD441U 40 1,220 6 4,700 32 2.4 1.2 132 0.9 Structural parts

Copolymers mineral filled

MG160AI 10 985 22 1,950 25 7.5 3.5 110 1.2 Interior trims

ME266U 20 1,050 12 2,500 28 6 2.5 115 1.1 Structural interior parts

ME268AI 20 1,050 12 2,400 26 6 2.5 100 1.1 Interior trims

EF267AI 20 1,040 16 2,500 27 6.5 2.8 105 1.1 Interior trims

FSC65T30 30 1,150 5 3,000 23 7 2.5 125 0.9 Structural parts

TPO Compounds

EE058AI 9 950 12 1,700 17 25 5 95 1.0 Dashboard, door cladding


EG163AI 10 960 25 1,400 19 45 6 92 1.1 Dashboard, door cladding


EE189HP 15 1,000 13 1,750 21 26 3.5 94 1.0 Dashboard, door cladding

EE288HP 20 1,040 12 2,050 23 16 3 95 0.9 Dashboard, door cladding

EE250AI 20 1,040 13 2,000 22 30 3.5 94 0.8 Dashboard, door cladding

EF261AI 20 1,040 14 1,800 18 45 4.6 94 0.7 Dashboard, door cladding

EG273HP 17 1,020 20 2,000 22 20 4 110 1.1 Dashboard, door cladding

EG265HP 20 1,040 21 1,800 18 55 6 97 0.7 Dashboard, door cladding


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n.r. = not relevant

Grade

Fillercontent[wt%]

Density[kg/m]

MFR230C/2.16kg

[g/10]

Flexural

modulus

[MPa]

Tensilestress

at yield[MPa]

Impact,Charpynotched

23C[kJ/m]

Impact,Charpynotched-20C[kJ/m]

HDT B(0.45Mpa)

[C]

Shrinkageindication

[%]Typical applications

Natural fibre reinforced

NJ200AI 20 975 18 2,500 33 4 1.5 136 1.1 Non-appearance interior parts

NJ201AI 20 975 23 2,150 30 4 1.5 126 1.1 Appearance inter ior parts

Glass fibre reinforced

GE277AI 20 1,040 12 4,200 85 11 9.5 155 0.8 Instrument panel carriers

GD302HP 30 1,160 3.5 5,600 65 24 13 155 0.5 Seat carriers

GB477HP 40 1,210 2.5 9,200 134 12 11 155 0.4 Seat carriers

Long glass fibre reinforced

GB601HP 60 1,470 n.r. 14,100 135 25 20 167 n.r. PP-LGF concentrate

BJ400HP - 905 90 1,350 25 4.5 2.2 88 1.6


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At Borealis and Borouge we are dedicated to developing

materials solutions which meet both the existing and the

projected needs of the industries we serve.

This process is guided by creative innovation:

Working with partners to identify needs before they

become challenges and developing solutions that add

value along the supply and production chain through to

and including the end user

Reducing the use of non-renewable resources through

creative design and where possible their replacement

with renewable raw materials

Lowering energy consumption in both production and

end-use, as well as emissions of damaging by-products

such as CO2

Minimising process dependence on fresh water reserves

Limiting and eliminating waste through continuous

efficiency improvements

To support these goals Borealis operates three world class

Innovation Centres. These are engaged in the development

of new materials and the improvement of existing materials,

as well as customer technical services ranging from

part design and prototype simulation to the production

and testing of batch samples and assistance with the

initiation of series production. They are also tasked with the

ongoing improvement of Borealis own methodologies and

processes.

Creative innovation


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Shestakoff-Fotolia.com

www.borealisgroup.com

www.borouge.com

[email protected]

Contact


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Disclaimer The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borealis extends no warrantiesand makes no representations as to the accuracy or completeness of the information contained herein, and assumes no responsibility regarding theconsequences of its use or for any printing errors. It is the customers responsibility to inspect and test our products in order to satisfy himself as to thesuitability of the products for the customers particular purpose. The customer is also responsible for the appropriate, safe and legal use, processingand handling of our products. Nothing herein shall constitute any warranty (express or implied, of merchantability, fitness for a particular purpose,compliance with performance indicators, conformity to samples or models, non-infringement or otherwise), nor is protection from any law or patent to beinferred. Insofar as products supplied by Borealis or its subsidiary companies are used in conjunction with third party materials, it is the responsibility ofthe customer to obtain all necessary information relating to the third party materials and ensure that Borealis products when used together with thesematerials are suitable for the customers particular purpose. No liability can be accepted in respect of the use of Borealis products in conjunction withother materials. The information contained herein relates exclusively to our products when not used in conjunction with any third party materials.

Contact:www.borealisgroup.comwww.borouge.comengineering.applications@borealisgroup.com

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automotive interior solutions optimised performance and surface aesthetics

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