professor dave greenwood polymer innovation network talk 30.04.15
TRANSCRIPT
Automotive Polymers30 April 2015
David Greenwood
Professor, Advanced Propulsion Systems
WMG, University of Warwick, UK
There are many drivers for Energy Efficiency
EnergyEfficiency
Industrial Opportunity
Climate Change &Air Quality
Consumer demand
Energy Security
$
Source:Cornell University from Edwards 2001
Source:Adweek
Regulations drive CO2 reduction in most markets
Regulations for CO2 reduction aredriving technology change
Consumers appear largelyambivalent at point of purchase
“real world” fuel economy is ofmost practical interest
EU regulations have put aprice on CO2 at €95/g/kmthrough fines
US CAFE does similarly
China prevents sale of non-compliant vehicles
Currently pass-car focus, butother sectors likely to follow.
Broad consensus on passenger car roadmap
To meet CO2 reduction targets vehicle weights mustreduce by 20-30 kg every year
Weight reduction required by different vehicle segments
Source: Automotive Council UK 2013
35 kg/year
17 kg/year
But CO2 reduction comes at a price
• €30/(g/km) proven acceptable in western mass market
• Uptake of hybrids at ~€95/(g/km) breaking into early majority market
• EV’s at €300/(g/km) currently confined to early adopters
Source: Ricardo 2014
Weight reduction is worth 2 to 5 Euros per kg
For manufacturers facingfines:
• Average car emissions140g/km CO2
• 100kg weight reductiongives ~ 4% CO2 reduction(5.6g/km)
• At €95/(g/km) this is €532
• i.e weight saving has avalue of €5.3/kg
• This is on top of any costsaving through switch toplastics
For those not facing fines,but selling on fueleconomy:
• Market has already provenwillingness to pay€30/(g/km) for powertrainimprovements
• i.e weight saving has avalue of €1.7/kg
• This is on top of any costsaving through switch toplastics
Plastics are already widely use in automotive industry
Sources: Plastics Europe, Determinants of U.S. PassengerCar Weight. International Journal of Vehicle Design 65 (1),
73-93 , F2012-E09-006 Proceedings FISITA 2012 WorldAutomotive Congress
End of Life Directivefrom 1 Jan 2015
• 85% recyclable or reusable or• 95% recyclable or recoverable
Affects material selection anddesign, e.g. mixed materials, joiningsystems
* Automotive Council UK, Lightweight Vehicle & Powertrain Structures, Low Carbon Vehicle Event 2013
• In addition to switches, handles, fasteners, grills, cup holdersand many other small components, plastics are usedextensively within the major vehicle systems:
• Powertrain
– Covers, air induction, oil pan, coolant system, lubricationsystem, hoses
– Typically require high temperature polymers with chemicalresistance
• Lighting
– optical clarity, complex geometry, aesthetics
• Vehicle
– Plastic bumpers facilitate compliance with pedestrian impactrequirements
– Reinforced plastics in door module can reduce weight andimprove NVH
– Closures provide opportunities for lightweighting: non-structural, consolidation of multiple parts
• Interior
– For large mouldings, e.g. instrument panel, foam injectionmoulding can reduce weight
– Seat systems targeted for weight reduction*
• Electrical
– Cables, insulation, cases, connectors
– Increased electrification and use of in-vehicle electronics
Greater use of current polymer technology can deliverfurther weight savings
• The Multi Material LightweightVehicle (MMLV) wasdeveloped by Magna and Fordas a US DOE project
• Weight saving of 364 kg usingcommercially availablematerials and productionprocesses
Component Material Weight saving
structural oil pan CFRP 30%
engine cover & mount CFRP 30%
cam carrier CFRP + Al 20%
wheels CFRP 30%
coil springs GFRP 35-55%
seats CFRP 40%
instrument panel beam & duct CFRP 35%
interior trim plastic foam 40%
rear window polycarbonate 35%
Sources: MMLV: Life Cycle Assessment," SAE Technical Paper 2015-01-1616, 2015 , Vehicle Lightweighting, Society Automotive Analysts, Oct 2014
Plastics in hybrid and electric powertrains
New components and systems offer new applications forautomotive polymers
• Batteries
– Electrically insulating fixtures, cases
– High voltage connectors
– Electrical sub-assemblies
• Downsizing engines and increased boost pressures raiseunder-bonnet temperatures
– Chemically resistant plastics in EGR circuit
– Complex moulded manifolds for optimised air flow
• Lightweight chassis components to reduce energyconsumption in electric vehicles - €6-8/(g/km)
Pure Power XSP Lithium Pouch BatterySupporting structure
GM Volt Battery Pack. Repeating frames andmanifolds made from injection moulded GFRP
BMW i3 uses plastics throughout thevehicle for reduced weight and abilityto form complex geomtetries:- CFRP body- Seat shell- Roof frame & pillar reinforcement- Insulating foam- Spring aids- Instrument panel
Future Developments ?
• Polymer gears
– Currently used for low load applications but WMG research is findingroutes to powertrain use
• 3D Printing
– Complex geometry, Removes bulk of supply chain, Reducesmaterial waste, Maintains digital thread
– Used now for rapid prototyping
– ? Line-side component printing ?
– ? Mass personalisation ?
• Smart materials
– Variable transparency, air flow control, increasing conductivitywith temperature, self-healing composites
• Improved materials – Nano composites
– Self-lubricating
– Lower density resins
Strati: 3D printed, concept electric car
Thank You
David Greenwood
Professor, Advanced Propulsion Systems
WMG, University of Warwick, UK