plastics in automotive - lanxess · plastics in automotive department of polymers, faculty of...

Plastics in Automotive

Department of Polymers, Faculty of Chemical Technology,

Institute of Chemical Technology, Prague

Lanxess Mobility Days

Prague, November 22 – 23, 2012

JAN RODA

2

Institute of Chemical Technology, Prague

INSTITUTE OF CHEMICAL TECHNOLOGY, PRAGUEFaculty of Chemical Technology, Department of Polymers

� metals

� ceramics

� glasses

� polymers – plastics, elastomers

�hybrids – composites, sandwiches, lattices, foams

Five broad families of materials

FACULTY OF CHEMICAL TECHNOLOGY

DEPARTMENT OF POLYMERS



Metals – rel. high moduli, soft, easily deformed, high-strength alloys

Ceramics – high moduli, brittle

low tolerance for stress concentration and for high contact – stresses,

stiff, hard, abrasive resistant (cutting tools)

Glasses – non-crystalline, amorphous

hard, brittle, vulnerable to stress concentrations

Plastics (thermo*, reacto* ) – low moduli, elastic deflection can be large,

creep, strength, properties depend on temperature strongly ,easy to shape

(in single operation), low coefficient of friction

Elastomers – service temperature above Tg

very low modulus, enormous elastic extension

Hybrids – combination of two or more materials in a predetermined configuration

and scale, fiber–reinforced composites – polymer matrix + fibres of glass,

carbon, polymer

Blends of materials



Polymer types

Thermoplastics

Thermosets (reactoplastics)

Fibres

<Elastomers>

Reinforced polymers, foams, blends, alloys

World polymer production

Plastics 70 %

Fibers

synthetic 13 %

regenerate 1.2 %

natural 8.5 %

Elastomerssynthetic 4.5 %

natural 2.8 %





15,0%

23,5%

5,0%5,0%

20,5%

6,5%

3,0%

21,5%

Rest of Asia

China

JapanLatin AmericaNAFTA

Europe

CIS

Middle East.

Africa

World Production 2010 - 264 Mt/a



39,0%

27,3%

7,5%

5,6%

20,6%

Packaging

Others

Building & Construction

Automotive

Electrical & Electronic

European Plastics Demand by Segments 2010

9FACULTY OF CHEMICAL TECHNOLOGY


Difference in mechanical properties of plastics and elastomers

Materials Weight (kg) Weight (%)

Regular steel 738 40.0

High and medium strength steel 237 12.9

Stainless steel 34 1.8

Other steels 15 0.8

Iron castings 136 7.4

Aluminum 143 7.7

Magnesium 5 0.3

Copper and brass 29 1.6

Lead 20 1.1

Zinc castings 5 0.2

Powder Metal 19 1.1

Other metals 2 0.1

Plastics/composites 155 8.4

Rubber 84 4.5

Coatings 13 0.7

Textiles 22 1.2

Fluids and lubricants 97 5.3

Glass 48 2.6

Other 41 2.2

Annual Breakdown of Materials Content in US Light Vehicles



Various polymers are used in over 1 000 different parts of all shapes and sizes

in cars, from instrument panels and interior trim to bumpers and radiator

grilles, fuel tanks and engine parts. The material selection for a particular

application will depend primarily on the ability to meet the required

specification and also on polymer price and total systems cost. The total

systems cost includes the cost of the polymer, processing cost and tooling and

assembly cost, and is a prime consideration for cost-conscious car

manufacturers.

Commodity polymers, engineering polymers and high performance plastics

are used to manufacture more demanding applications in the car. The most

valued properties of engineering plastics for automotive applications are their

high heat resistance, dimensional stability, strength and resistance to a range of

chemicals. These properties have led to their replacement of traditional

materials such as metal and thermosets in motor vehicles.



28,0%

9,0%

11,0%12,0%

4,0%

11,0%

11,0%

1,0%

3,0%10,0% Polyolefins

Polyamides

PET, PBTPVC

PUR

Elastomers

OtherEng. resin blends

PC, ABS, and blends

POM

Plastics types in a typical mid-size Ford vehicle in 2010. Not including

tires.



Usage of plastics in North American Light Vehicles in %

Polypropylene 24

Polyurethanes 16

Nylon 10

ABS 7

Polyvinyl chloride 8

Polyethylene 5

Polycarbonate 5

Polyvinyl butyral 2

Other 22

approx 150 kg plastics per vehicle ∼8 % of weight



Plastics in modern automotive vehicles

� fundamental role in construction

in comfort

in ecological aspects

� use and selection of material is influenced

- global trends in cost

- fuel economy targets

- environmental factors

improved fuel economy (reduced

environ.footprint)

consumption, CO2 emission

fuel engine efficiency, vehicle weight,

aerodynamic drag

� legislation – reuse

recovery

recycling



Plastics in modern automotive vehicles

� choice of material

mechanical and physical properties

ageing

surface properties

styling requirements

visual appearance

touch

� enviromental aspects

emission

recylability



28,0%

9,0%

11,0%12,0%

4,0%

11,0%

11,0%

1,0%

3,0%10,0% Polyolefins

Polyamides

PET, PBTPVC

PUR

Elastomers

OtherEng. resin blends

PC, ABS, and blends

POM

Breakdown of plastics types in a typical mid-size Ford vehicle in 2010.

Not including tires.



Polypropylene (PP)

E= 0.8 – 1.1 – 2.5 GPa /reinf.

Tm = 170 °C

Tg = -10 °C

UUT = 90 °C

isotactic

semicrystalline

variety of application

Application:

unreinforced interior trim, storage bins, instrument panels

chalk-reinforced bumper fascia

glass fiber-reinforced battery trays

rubbery modified polymer

CH CH2

CH3n



Polyethylene (PE)

E= 0.2 – 0.4 – 0.7 – 1.4 GPa

Tm = 110-130 °C

Tg = -80 °C

UUT = 70 °C

semicrystalline

different types – LDPE, LLDPE, HDPE

Application:

trim duct – works

reservoirs for fluids

multilayer fuel tanks

CH2 CH2

n





Polyethylene terephthalate (PET)

E = 2,5-3,1 GPa

Tm = 265 °C

Tg = 75°C

UUT= 70-100°C

semicrystalline

low cost material

Application:

fibers for carpeting application

fabrics, seat covering , floor mats

films

n

O C CH2 CH2 O C

O O





Polybutylene terephthalate (PBT)

Et = 2,5-10(filled)GPa

Tm = 225 °C

Tg = 65°C

UUT= 130 – 150 °C

semicrystalline, similar to PET

Perfect mechanical ant thermal properties, good dimensional stability,

moisture absorption, chem.resistance

glass fiber reinforced ( 15/30%) or unreinforced

Application:

electric systems, plug collectors, fuse boxes, etc.

underhood components,

housing and brackets, handles, mirror housing

C O CH2 CH2 CH2 CH2 O C

O

O n

• Pocan PBT Typical application

.





Polycarbonate (PC)(from Bisphenol A and COCl2)

E = 2.2 – 2.5 GPa

Tf = 230°C

Tg = 150°C

UUT= 125 °C

amorphous polymer

excellent optical clarity and toughness

blends – improved toughness

Application:

lenses, glazing

Blends of PC with ABS and PBT

C

CH3

O

CH3

O C

O n





Acrylonitrile-butadiene-styrene copolymer (ABS)

Tg = 105°C

UUT= 90°C

amorphous

good impact

excellent balance of properties – impact strength, stiffness, thermal

stability, can be painted or chromed

Application:

chromed trim

interior and exterior trim components

CH2 C

CH3

CN n

CH CH2

m

E = 2,2-2,9 GPa

CH2 C

CH3

CN

n

CH2 CH CH CH2

o





Polyvinyl chloride (PVC)

E = var GPa

Tg = 80 °C

UUT= 60°C

amorphous

good toughness, flexibility

Application:

vinyl trim for leather, wear resistant coatings, cable insulations, wiring,

roof rack coverings, grips, moulded plugs,

dashboard , sun visors

CH CH2

Cl n





Polymethylmethacrylate (PMMA)

E = 2,9GPa

Tg = 115 °C

UUT= 60-80°C

amorphous

clear, tough, perfect weatherability,scratch resistance

Application:

glazings

lenses

CH2 C

CH3

C

O

CH3

O n



Polyurethanes

� different structures

(diversity in composition and application)

� basic structural unit – chemical bond

and different form of polymer → diverse

applications

Application:

bumpers, gaskets

fascias, instrument panels

heating, ventilation, air conditioning seals

air filter, headliner foam

seatings, adhesives

sound isolation

NH C O

O



Different processing methods

RIM polyurethane

formation of complex shapes

� bumpers, fascias, spoilers – energy absorption

Structural RIM and reinforced RIM

glass fibres or mica -RRIM

glass fibre mesh-SRIM

� body panels

Thermoplastic PUR elastomers (TPU)

� bulk products, adhesives, coatings



― noise, vibration, harshness reduction

― seating comfort

― sealing application

� lightweight, flexibility in design, resiliency

PUR foams

(a) flexible, (b) semiflexible, (c) rigid

- (seat) cushions, seat backs, armrest, head-rest, steering wheel,

instrument panels

- sound, noise, vibration reduction

- (density 30 - 50 kg/m3)

Thermoplastic foams

– expanded PP, PE

– energy management, insulation

Foam for automotive



Polyamide 6 (PA 6)

unreinforced E = 3 GPa

glass fiber reinforced E = 9 GPa

Tm = 220 °C

Tg = 50 °C

UUT= 150 °C

semicrystalline

Application:

engine covers

handles

fans

shrouds

fibres - carpeting

NH (CH2)5 C

O n

Coolant Circuit

OilCircuit

StructuralParts

Others (electric / electronic, covers, ...)

AirSystem

Fuel DeliverySystem

Durethan® – Typical automotive applications under the hood





Polyamide 66 (PA 66)

unreinforced E = 3 GPa

glass fiber reinforced E = 9 GPa

Tm = 260 °C

Tg = 50 °C

UUT= 170 °C

semicrystalline

Application:

air intake manifold, carpeting, under hood

n

NH (CH2)6 NH C (CH2)4 C

O O

PA 6 + PA 66 properties depends on moisture absorption – water = softness

PA 11 + PA 12 low moisture absorption - fuel lines

� > 90 % of polyamide use - PA 6 and PA 66

+ other nylons - PA 46, PA 612, semiaromatic types

� characterization

• semicrystalline materials - Tm

crystalline regions – stiffness, strength, chem. resistance, thermal stability

amorphous regions – impact resistance, elongation

• Tm determined by density of H bonds resp. amide bonds

PA66 - nylon 66 Tm ~ 260 °C

PA 6 – nylon 6 Tm ~ 220 °C

- slower crystallization rate

- lower crystallinity, higher H2O sorption

• water absorption – in amorphous region regulated by frequency of NHCO

bonds, Tg decreases with H2O concentration

Polyamide engineering plastic



• mechanical properties - determined by PA type, mol. weight, temperature,

moisture content, additives, copolymerization

- PA are notch sensitive - impact modifiers, moisture

- PA + glass resp. carbon fibers - increase of stiffness and strength (also

notched impack strength)

- PA66 > PA 6 fatigue resistance

- perfect abrasion resistance and coefficient of friction (improvement by

graphite or MoS2)

- hydrolysis of PA real, but hydrolysis resistance good

- good thermal stability (melt is sensitive), acceptable oxidation stability

- excellent chemical resistance

• additives: lubricants, nucleation agents, stabilizers, (oxidation, heat), impact

modifiers, plasticizer, reinforcement, glass fibers, nanofillers etc.



Polyamide engineering plastic

Polyamides in automotive

� the largest sector for PA, 34 % of world market

� successfully and continually replacing metals

� lower weight, cost and better functionality

- under the bonnet (hood) application ,air intake manifold (65 %), air and cooling

system, peripherals, throttle body housing, head cover, water-glycol circuit,

tubing of fuel system (major role in el. equipment), exterior part mirror housing,

door handless, wind screen wiper parts, roof frames, lock covers, wheel trims,

fuel filler caps, skirts, grilles

key lock system, rear mirror, push buttons, steering lock casings, ashtrays



PA6 Air Inlet Manifolds

Key performances:

•Long term temperature

resistance

•Pressure resistance

•Processability

•The best price/ performance

ratio

Comparison of the total cost of a 4 cylinders

air intake manifold made from aluminum vs PA6

Typical plan of an airbag



Plastics in the Interior of the Vehicle

� the largest share of plastics in cars

� the passenger compartment is dominated by plastics

� instrument panels – complex design

� a key application for plastics

(reduction of cost and weight, improvement of

aesthetics)

�instrument and airbag housingABS -- general purpose, high flow,blow molding

low gloss

PC-ABS blends -- unique combination of properties

PP modified by (thermoplastic) elastomer or glass reinforced PP

occupy the same application space

high stiffness

high toughness

economical engineering material



� dashmat panel – sound barrier

� headliner – functional parts below roof

� seat backs – steel vs. plastic (PC/ABS)

� seat base – more demanding

∼ long term creep resistance, reclining system, heating

� door handle, door module

� steering wheel

� levers, switches, bearings

� airbag and airbag covers



Plastics in Horizontal and Vertical Body Panels

� door panel, roof, floor, fender, hood, back panels

- the entry of plastics has been difficult

-fenders filled PC/ABS, nylon/PPO, filled thermosets

Plastics in the Exterior of the Vehicle

� bumpers (front, rear)

modified PP, ABS, PC/ABS

� underbody shields

glass – filled PP, ABS

� door handles

PC, PBT, nylon

� exterior mirror housing

many solutions – ABS, PC/ABS, nylon, EPDM



Plastics in the Powertrain

� after a long period the plastics succeeded under the hood

- the wiring (connector, insulation, power plugs, switches and

controls)

- radiator grill

Blends PA/PBT, modified PBT , PA

- heating and AC ducts and consoles

- air intake manifold

- different shields

� fuel tank (the largest plastic component)

HDPE or multilayer construction – HDPE plus EVOH copolymer

Plastics in Fuel Systems

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