Lightweight structures with new car technologies

Lightweight structures with new
car technologies
Julian Haspel
Application Development,
LANXESS Business Unit Semi-Crystalline Products
Automotive Days Poland
October 27-28, 2011
LANXESS – A premium supplier of high-tech plastics for
demanding technical applications
ƒ Main industries of LANXESS’ high-tech plastics are
automotive (>50%) and electro / electronics (>20%)
ƒ LANXESS’ leading high-tech plastic brands:
Durethan®, Pocan®
- Recognized as intelligent system solutions
- Combining mechanical strength with resistance to heat,
oils and abrasion
ƒ New service brand HiAnt®
- Tailored international customer service and in-depth
know-how in product, application, process and technology
development
ƒ Main Business Unit: Semi-Crystalline-Products (SCP)
belonging to Performance Polymers Segment
LANXESS provides premium high-tech plastics
Sources: JD Powers 08/2010; LANXESS own estimates
2
Others
Packaging
Sport / leisure
Construction
E&E
100%
50%
Automotive
0%
High-tech plastics
LANXESS – A leading development partner for the automotive
industry
ƒ More than 20 years of experience in compound technology
ƒ Inventor of the hybrid technology
ƒ Innovative materials and concepts for new application fields
in automotive and motorcycle manufacturing
ƒ Well acquainted with various demands by the automotive
industry
ƒ Valuable expertise from other industries (e.g. electro)
ƒ Important contribution to future E-mobility, alternative fuels
and flame protection
Valuable experience and focus on innovation
for the future of mobility
3
Growing car production and trend of weight reduction drive
demand for high-tech plastics
ƒ Global car production with annual growth of ~3.3%
Global production of light vehicles
[mn units]
ƒ Increased usage of high-tech plastics per car drives growth
of 7% p.a.
ƒ Global production of light vehicles will increase by 30%
within 5 years
ƒ Current high-tech plastic share in Western cars 15-17%
~+30%
~+10%
100
50
0
ƒ Chinese vehicles only consist of about 7% plastic
components Æ Growth potential
ƒ E-mobility further pushes high-tech plastics
Æ Total share of plastic expected to exceed 25%
2015e
Share of materials in automotive
production [%]
7
21
72
Innovations in high-tech plastics enable future mobility
2010
2005
1980
12
23
65
1990
14
27
17
18
31
32
High-tech plastics
Other materials
Ferrous metals
59
52
50
2000
2010
2015e
Sources: JD Powers 08/2010; Polymotive; Plastics Europe 2010; LANXESS own estimates; Handelsblatt.com (Oct. 21, 2010),
4
Comparison of different fuel economy standards worldwide
Comparison of actual and projected fuel economy for new passengers vehicles
70.00
Fuel economy (miles per gallon)
65.00
Solid points and lines: actual data
Hollow dots and dashed lines: nearest targets enacted
Smaller Hollow dots and dotted lines: proposed targets
60.00
55.00
50.00
45.00
40.00
35.00
30.00
25.00
20.00
2002
2004
2006
2008
2010
2012
2014
2016
2018
2020
Sources: AN, F., and A. Sauer. 2004. Comparison of Passenger Vehicle Fuel Economy and GHG Emission Standards Around the
World.
Pew Center on Global Climate Change, Washington, DC; Updated data obtained from “Passenger Vehicle Greenhouse Gas and
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Fuel Economy Standards: A Global Update“, The International Council for Clean Transportation, retrieved from there, July 2010
Increased use of high-tech plastics as basis for automotive
innovation
Thermoplastic in automobiles
Thermoplastic in trucks
Innovative materials lead to weight and cost reduction, greater safety and comfort
6
What is “Plastic/Metal Hybrid” (PMH)?
Metal sheet
Polyamid 6 GR
7
Production process (1/3) – Deep-drawn metal sheet
8
Production process (2/3) – Injection molding
Open injection mold tool
9
Pre-positioned metal insert
Finished composite
Production process (3/3) – Finished product
10
Deformation under bending load
50
Force F [kN]
Plastic/metal composite profile
Closed sheet steel profile
Open sheet steel profile
F
Deformation f [mm]
11
f
340
Cross-section of a plastic/metal hybrid structure
Over-molded
edge
Over-molded
edge
Sheet metal profile
12
Molded
„button“
Plastic rib
structure
Molded
„button“
Typical application of Plastic/Metal Hybrid: front ends
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Examples of Plastic/Metal Hybrid front ends out of Durethan®
Audi A6 – 1998
Audi A4 – 2000
Ford Focus – 1998
Ford Fiesta – 2001
Renault Megane – 2002
Mazda Demio – 2002
Hyundai Getz – 2002
Kia Spectra – 2003
Mercedes Benz A – 2004
Chrysler 300C – 2004
VW Polo – 2001
Nissan Quest – 2003
BMW X3 – 2003
BMW 1er – 2004
BMW 3er – 2005
Mercedes Benz Vito – ‘03
Ford Galaxy – 2006
Ford S-Max – 2006
Audi TT – 2006
Hyundai Avant – 2006
Kia Carens – 2006
Kia Lotze – 2006
Ford Mondeo – 2007
Audi A5 – 2007
Audi A4 – 2007
Hyundai i30 – 2007
Hyundai Starex – 2007
Ford Kuga – 2008
Hyundai Genesis – 2008
Audi Q7 V12 – 2008
Audi A3 – 2008
Audi A7 – 2010
Audi A1 – 2010
Audi A8 – 2010
More than 70 models in mass-production
Far more than 50 mn parts on the road
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Hyundai Veracruz – 2006 Hyundai Santa Fe – 2006
Audi Q5 – 2008
Plastic/Metal Hybrid – Part of the body structure
15
Plastic/Metal Hybrid – Pedal box
ƒ Worldwide first pedal box
with PMH
ƒ Material Durethan BKV 30
H2.0
ƒ 10% cost and weight
advantages compared to
conventional design
ƒ Integration of numerous
functions
ƒ Ductile crash behavior
Shift gear
16
Automatic gear
Continuous fiber reinforced thermoplastic composites (CFT) –
Overview
ƒ State-of-the-art technology for aircrafts
ƒ Challenge: cost optimized and ready for mass production
alternatives for the automotive industry
ƒ High-tech plastics with glass, carbon, aramid or mixture
ƒ 2D semi-finished product (panel) based on a thermoplastic
matrix
ƒ Easy alteration to 3D shape
ƒ Fabrics or uni-directional fabric made of continuous filaments
ƒ Complete impregnation
CFT for demanding mobility solutions
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Advantages
ƒ Low weight – high strength
ƒ Excellent crash
performance
ƒ No corrosion and easier
recycling
ƒ Integration of functions
ƒ Possibility of complex
designs
ƒ Low investment
Challenges
ƒ Influence of temperature
and water absorption
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Weight related force / [N/g]
Continuous fiber reinforced thermoplastic composites (CFT) –
Advantages and challenges
Hybrid PA composite sheet
Hybrid steel sheet
Deflection / [mm]
High performance systems for greater safety, efficiency
and sustainability
Continuous fiber reinforced thermoplastic composites (CFT) –
Examples
Door impact beam
Steering column
One shot molding process
19
Innovative high-tech plastics for the future of mobility
20
LANXESS Semi-Crystalline Products –
High-tech plastics key for future sustainable mobility
9
Expertise in customer-oriented R&D and
cutting edge product properties
9
Cost and performance optimized solutions ready
for mass production
9
High-tech plastics material leadership and
engineering know-how
9
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Safe harbour statement
This presentation contains certain forward-looking statements, including assumptions, opinions
and views of the company or cited from third party sources. Various known and unknown risks,
uncertainties and other factors could cause the actual results, financial position, development or
performance of the company to differ materially from the estimations expressed or implied herein.
The company does not guarantee that the assumptions underlying such forward looking
statements are free from errors nor do they accept any responsibility for the future accuracy of
the opinions expressed in this presentation or the actual occurrence of the forecasted
developments.
No representation or warranty (express or implied) is made as to, and no reliance should be
placed on, any information, including projections, estimates, targets and opinions, contained
herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements
contained herein, and, accordingly, none of the company or any of its parent or subsidiary
undertakings or any of such person’s officers, directors or employees accepts any liability
whatsoever arising directly or indirectly from the use of this document.
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