Celstran® LFRT Automotive

Transcription

Celstran® LFRT
Automotive
PERFORMANCE DRIVEN SOLUTIONS
© 2013 Celanese LFRT-007 AM 10/13
Celanese Maintains Leading Position in
Engineered Materials
Service temperature
Engineering Polymers
High-Performance
Polymers (HPP)
(TI1 > 150°C)
Engineering
Polymers (ETP)
(TI1 90 – 150°C)
Basic
Polymers
LCP
– Vectra® /Zenite®
PPS
– Fortron®
PCT
– Thermx®
PET
– Impet®
PBT
– Celanex®
PBT Alloy
– Vandar®
TPC-ET
– Riteflex®
POM
– Hostaform®/Celcon®
UHMW-PE
– GUR®
Long Fiber and
Continuous Fiber
Reinforced Thermoplastics*
Amorphous
LFRT
– Celstran®, Factor ®
Compel®
CFR-TP
– Celstran® Tapes,
Rods and Profiles
Partially crystalline
TI1 = Temperature Index
* with Matrix Polymers: PP, PA, PPS, PBT, POM and others on request
2
Global Network – Strong Global Presence
Winona, MN
Oberhausen, Germany
Industriepark Hoechst,
Frankfurt, Germany
Kaiserslautern, Germany
Sulzbach, Germany
Auburn Hills, MI
Florence, KY
Beijing, China
Wilmington, NC
Bishop, TX
Shelby, NC
Al Jubail,
Saudi Arabia
Guangzhou, China
Hong Kong
Seoul, Korea
Tochigi, Japan
Tokyo, Japan
Fuji City, Japan
Nanjing, China
Shanghai, China
Nantong, China
Taipei, Taiwan
Dafa, Taiwan
Kuantan, Malaysia
Singapore
Suzano, Brazil
São Paulo, Brazil
Celanese
Strategic Affiliates
Ventures of Affiliates
Celanese Engineered Materials – A Global Footprint
3
1,000s of Products in 1,000s of Applications
Across Dozens of Industries
4
High Performance Materials Properties
Product
Extreme
Temperature
Medical
Grade
Chemical
Abrasion
Resistance Resistance
Dielectric
Strength
Functional
Aesthetics
Celanex®
(Polyester engineering resins)
Celstran® */ Factor® /
Compel®
(Long fiber reinforced
thermoplastics)
Fortron®
(Polyphenylene sulfide)
GUR®
(Ultra-high molecular weight PE)
Hostaform® POM
(Polyacetals)
Thermx®
(polycycohexylene dimethylene
terephthalate)
Vectra® / Zenite®
(Liquid crystal polymer)
*Only Celstran made from Fortron or other high-temperature base polymers
5
Enabling Eco-Friendly Innovation: Efficient Transportation
Bumper-to-Bumper Performance
Speaker Grilles, Knobs, Handles and Levers
Door/Lock/Window
Hostaform®/
Celcon®
POM,
Celstran® LFRT, Celanex® PBT
Hostaform®/Celcon® POM, Celstran® LFRT,
Celanex® PBT
Multi-functional Roof
Hostaform®/Celcon® POM, Celanex® PBT,
Fortron® PPS, Celstran® LFRT
Cockpit Environment
Hostaform®/Celcon® POM,
Celanex® PBT, Vandar® PBT,
Riteflex® TPC-ET
Mirror Housings
Celanex® PBT, Celstran® LFRT
Wiper Plenums
Hostaform®/Celcon® POM, Celanex®
PBT, Celstran® LFRT
Lighting Housings
Celanex® PBT, Vectra® LCP,
Fortron® PPS
Advanced Fuel Delivery
Underbody
Skid Plates
Front End Modules
Celstran® LFRT,
Celanex® PBT,
Impet® PET
Celanex® PBT,
Celstran® LFRT
Instrument Panels
Electrical
Celanex®
Fortron® PPS, Celanex® PBT,
Riteflex® TPC-ET
Fortron®
PBT,
PPS,
Vectra® LCP, Zenite® LCP, Thermx® PCT
Celstran® LFRT
Power Distribution
Celstran® LFRT, Celanex® PBT,
LCP, Zenite® LCP, Fortron® PPS
Vectra®
Seating & Restraint
Hostaform®/Celcon® POM, Celstran®
LFRT, Riteflex® TPC-ET, Celanex®
PBT, Vandar® PBT
6
Enabling Eco-Friendly Innovation: Efficient Transportation
Solutions for Hybrid and Electric Vehicles
Door Modules
Celstran® LFRT, CFR-TP
Instrument Panel
Cross Car Beam
Seating
Power Distribution Celanex®
PBT, Vectra® LCP, Zenite®
LCP, Thermx® PCT
End Caps
Celanex® PBT
Cell Separators
Celanex® PBT
Filler Necks / Fuel Caps
Celanex® PBT
Vapor Control Valves
Celanex® PBT,
Fortron®
PPS
EE Controls
Celanex®
LCP, Fortron® PPS, Thermx®
PCT
Separator
Film GUR®
UHMW-PE
Fuel Rails
Fortron®
PPS
Fuel Pumps /
Delivery Modules
Hostaform®/
Celcon® POM,
Celanex® PBT,
Fortron® PPS
Front End
Modules
Fortron® PPS, Vectra® LCP,
Zenite ® LCP
Celstran® LFRT
Thermal Management
Fortron® PPS, Vectra® LCP,
Zenite ® LCP
Fuel Filters
Interconnects
Hostaform®/Celcon®
Powertrain
Celanex® PBT
Housings
Fortron®
PPS,
Celstran® LFRT,
®
Celanex PBT
Celanex® PBT
Motors/Generators
Fortron®
Thermal Management
Battery Pack Case
Hostaform®/Celcon®
PPS,
Celstran® LFRT
Electronic Control Modules
POM,
Celanex® PBT
POM,
Celanex®
LCP, Fortron® PPS, Thermx®
PCT
Fuel Line Body Clips
Celanex® PBT
7
Celstran® LFRT
Characteristics & Properties
Celstran® Thermoplastic Composites
STRUCTURAL
CONDUCTIVE
Glass
Stainless Steel
►
►
►
►
PEEK
► PBT/PET ► PC/ABS
PPS
► POM
► PP
TPU
► PPO
► PE
PA6 & 66
Aramid
► PPS
► TPU
► PA6 &
► POM
66
Carbon
► PEEK
► PPS
► TPU
► PA6 & 66
► PPS
► PPO
► PA6 & 66 ► PC/ABS
► POM
PRODUCT FORMS
Pellets
► ½"
► 1"
► Custom
Unidirectional Fiber
Reinforced Tapes
► 4"
► 10"
► 6"
► Custom
► 8"
A Wide Range of Resins, Fibers and Additives are Available for
New Product Solutions with Extended Material Property Ranges
9
Evolution of Long Fiber Technology
Step 1
Step 2
Step 3
Step 4
Short fiber granule
fiber length
= 0.2–0.4 mm
Wire-coated or
co-mingled fibers
Fully impregnated
long fiber granule
fiber length
= 11–25 mm
Fully impregnated
continuous fiber
reinforced tape
10
Celstran® LFRT – Fiber Structure
Celstran vs. Short fiber
► Celstran long fiber part maintains
shape due to fiber entanglement
► Short fiber part shows no fiber integrity
or structure
Burnoff Results
Fiber Matrix Carries Loads; Polymer Resistant to
Chemicals, Temperature, Other External Factors
11
Celstran® LFRT – Fully Wetted Fibers
► Celstran LFRT – Ticona
proprietary process
► Excellent pellet integrity
‒ Suitable for vacuum conveying
and conventional handling
► Does not rely on processing
BEFORE ABUSE
AFTER ABUSE
to wet fibers with resin
► Excellent surface aesthetics
► Consistent part quality and
performance
► Can be color matched
Simulated Abuse Causes Only Minor Flaking
12
Celstran® LFRT PP
The Right Polymer for Automotive Applications
► Stiff and tough, even in cold
temperatures
► Good mechanical performance
► Excellent dimensional stability
► Superior pellet integrity –
suitable
for bulk handling
► Colorability – for excellent
surface aesthetics
► Sound dampening
► Low carbon-emission grades
► Static dissipative grades
► EMI/RFI shielding grades
► Manufactured globally
High-Quality Pellets Make High-Quality Parts
13
Reasons to Consider Celstran® LFRT
► Design freedom
► Superior physical properties
► Low specific gravity
► Elevated temperature performance
► High impact strength and modulus
► Dimensional stability
► Creep resistance
► CTE similar to metals
► Ability to incorporate high fiber loadings
14
Celstran® LFRT
Coefficient of Thermal Expansion Similar to Metal
0.75
Steel
1.3
Aluminum
1.49
Magnesium
PBT-GF60
0.72
PPS-GF50
0.75
Cast metal
Celstran
0.83
PA66-GF60
0.92
PET-GF60
1.17
PP-GF40
0
0.5
1
1.5
2
CTE, in/inF * 10E-5
Celstran Reduces Stack Tolerances in Composite Assemblies
15
Celstran® LFRT
Exhibits Exceptional Toughness
Celstran
14
Notched Izod (ft-lb/in)
12
10
8
6
4
PP 40 SG
PA66 40 SG
TPUGF60
PPGF40
PPSGF50
PA66GF60
Mg
Al
0
PETGF60
2
Celstran is Tougher Than Many Other Materials
16
Celstran® LFRT Resin Comparison
40% LFRT DMA Curve
PA6-GF40-02
POM-GF40-01
PP-GF40-02
PPS-GF50
PA66-GF40-02
PC/ABS-GF40
ABS-GF40-05
3000000
Flexural Modulus
2500000
PP-GF40
PA6-GF40
PA66-GF40
PPS-GF50
2000000
Density
1.21
1.45
1.45
1.72
Notched Izod
5.1 ft lbs/in
6.9 ft lbs/in
6.9 ft lbs/in
7.0 ft lbs/in
1500000
1000000
500000
320
300
280
260
240
220
200
180
160
140
120
100
80
60
40
20
0
0
Temperature °C
17
Celstran® LFRT
Impact Strength Comparison
6
5.6
5.1
5
4
3
2.5
2
1
0
Nylon 50% RH
Celstran PPGF40-02
Celstran PPGF50-01
18
Celstran® LFRT
Tensile Strength Comparison
19,000
18,000
18,000
17,500
17,000
17,000
16000
Nylon 50% RH
Celstran PPGF40-02
Celstran PPGF50-01
19
Celstran® LFRT
Flexural Modulus Comparison
1,600,000
1,390,000
1,400,000
1,200,000
1,000,000
1,110,000
900,000
800,000
600,000
400,000
200,000
0
Nylon 50% RH
Celstran PPGF40-02
Celstran PPGF50-01
20
Celstran® LFRT
Plastic Door Carriers
Material Trends in Door Modules
Drivers for LFRT Polypropylene Door Carriers
► Very good impact strength combined
with high rigidity
and heat resistance
► Suitable for snap elements
► Chemical resistance
► Good moldability, short cycle times
► Sufficient mechanical properties
‒ Armrest load
‒ Forced entry
‒ Side impact
► Balanced properties
‒ -40°C to 80°C+
‒ No pre-drying
► Low creep
‒ Conventional handling
and processing equipment
► Low density – low part weight
► Good acoustic damping
► Colored visual surface
► No pre-drying
► Low emissions/odor
► Low mold temperature
► Low thermal expansion
► Thin walled design ~ 2.0 mm
‒ Low viscosity
LFRT PP: A Solution for These Drivers
22
Material Trends in Door Modules
Processing Drivers for LFRT PP Door Carriers
► Good moldability
‒ Wide processing window
► No pre-drying
► Low mold temperature
‒ 100°F to 150°F
► Conventional material handling
► Conventional processing equipment
‒ IM, ICM, ECM
LFRT PP: A Solution for These Drivers
23
Celstran® LFRT Acoustic Performance
► Celanese’s leadership position as a supplier to door modules
provided an opportunity to evaluate noise transmission through a
Celstran part
► Celstran fiber entanglement helps dampen sound waves, leading
to a quieter cabin
Jaguar XJ
24
Case Study – Material Selection
2007MY Jeep Wrangler
Why Celstran LFRT polypropylene was chosen:
► Best balance of properties (impact, creep, fatigue)
► Weight savings
► Ability to mold complex shapes
► Ease of integration
► Cost savings
25
Case Study – Modularization Selection
Stamped Steel
Composite
Cartridge
Composite Module
Plate
► Low level
► No integration
► High level of integration
of integration
► Greater OEM
assembly labor
► Supports window lift,
door lock and latch
hardware
► Higher cost
► OEM labor intensive
► Less OEM assembly
► Supports window lift,
door lock and latch
hardware
► Water shield required
► Highest cost
►
►
►
►
►
labor
Supports window lift,
door lock and latch
hardware
Integrated seal function
Lowest cost
Weight savings
Pre-validated
performance
26
Case Study – Design / Mfg. Integration
Wet Side
Dry Side
10
17
11
1
7
9
2
13
3
5
6
10
15
12
7
4
3
14
12
6
12
12
16
12
8
1 Cable Pass-Through
6 Assembly Locating Pins
12 Trim Attachment Clip Interface
2 Wire Harness Attachment
7 Window Regulator Guide Rail Mounts
13 Power Window Motor Mount
3 Arm Rest Structure/
8 Integrated Seal Channel/
(Insert Supports a Manual Version)
Support Bracket
4 Glass Anti-Slam
Bumper Attachment
5 Latch Presenter Attachment
Crush Limiting Rib
9 Power Regulator Drive Unit
14 Wire Harness Clips
15 Shipping Label Locator
(Twist Lock/Snap-Fit Interface)
10 Water Deflectors
16 Break Away Service Access Panel
11 Inside Handle Attachment
17 Inside Handle Cable Attachment
27
What Does This Mean For Your Future?
Structural Demands
Greater
Structural
Demand!!!
Integration
Integration is Driving the Need for LFRT PP
28
Celstran® LFRT
Front End Performance
Front End Modular Design Components
Pre-assembly simplifies vehicle production
and offers validation opportunities
30
Ford Fusion, Mercury Milan
The challenges:
► Higher tensile loads
► Impact behavior
► High stiffness at elevated
temperatures
► Low creep and CTE
► Good crash behavior
The innovation:
► Ticona formulated a new grade
of high performance LFRT-PP
with 20-30% better properties
Early Involvement Enabled a New Product Formulation
Optimized for the Application
31
Celstran® LFRT Integration
Ford Fusion
7 Primary and Secondary Hood Latch Mounting
1
2
8 Hood Latch Support Bracket Mounting
9 Crash Sensor Mounting
2
5
8
5
7
Optimized Component Attachment Using
10 Inserted Threaded-nuts
10
8
4
4
9
Front Apron Adds Stiffness for
1 Compressive Loads
6
2 Headlight Mounting and Support
6
3 Wire Loom Support
4 Radiator Mounting Through Snapfit
3
5 Transmission Cooler Mounting
6 Fan Shroud and Cooling Fan Mounting
Front End Carriers Save Money by the Integration
of Many Metal Components Into One Plastic Part
32
Dodge Nitro FEM
Celstran PP-GF40
2
1
2
3
5 Wire Loom Support
8 Crash Sensor Mounting
6 Fan Shroud and
9 Optimized Component
Cooling Fan Mounting
7 Wiper Fluid
Attachment Using
Inserted, Threaded-nuts
Reservoir Mounting
5
7
4
5
4
1 Primary and Secondary Hood Latch Mounting
2 Headlight Mounting and Support
8
5
6
3 Front Grille and Trim Mounting
4 Radiator Mounting
9
Celstran is Perfect for Integrating Metal Components
33
Celstran® LFRT
Structural Automotive Carriers Also Use Nylon
LFRT-PA66 Front End Jaguar XJ
Celstran LFRT-PA withstands vehicle temps as high as 180°C and
air temperatures up to 200°C during almost five hours of thermal cycling
34
Celstran® LFRT
Instrument Panel Substrates
Celstran® LFRT
Celstran is the Right Choice for IP and Console Applications
Because…
► Superior structural performance allows greater design freedom and
integration than talc-PP
► Fiber matrix provides quieter cabins than talc-PP and SMA-based
systems
► Low-emission and ESD grades are already available to support a global
market
► Celanese’s world-class service and support available locally
► Innovation projects are continuously underway to reduce overall system
cost
36
Celstran® PP-GF30 05
in Comparison with SMA
Wall thickness: ~2.2 mm, cut from molded IP
70
Impact Strength (kJ/m2)
60
50
40
30
20
10
0
No Heat-Age
Heat-Aged
500h/140°C
Celstran PP-GF30 05 01 P10/13
Heat-Aged
1000h/140°C
SMA
37
Celstran® PP-GF30 05
in Comparison with PC-ABS GF10
Penetration test ISO 6603-2 fracture energy (J)
Celstran
Fracture Energy (J)
PC-ABS
Wall Thickness 2 mm
Wall Thickness 3 mm
Wall Thickness 4 mm
Test-Behavior at -40°C, RT, +85°C and 120°C
38
Celstran® PP GF30-05 vs.
PC-ABS and SMA
100
Yield point > 2.5% toughness area
90
SMA GF16
Pulse 630GF
Celstran PP-GF30-05
Tensile Strength MPa
80
70
60
50
SMA with
40
brittle breakage
30
20
10
0
0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
Elongation
Superior Toughness Behavior
39
Source: Kunststoffe
3/2003
Celstran® LFRT – Part Integration and
Cost Reduction for Instrument Panels
Potential for
Foam
Integration Adhesion
Mech.
Properties
IM
Process
Handling
+
+
0
+ (3)
--
+
+
0
+ (3)
++
+ (1)
+ (2)
++
++
Material
Weight
Price
PC-ABS
+
--
-
SMA
+
-
LFT-PP
++
++
Ranking
++ best
+
acceptable
(1) Requires flame pre-treatment
-
bad
(2) Best crash characteristics @ – 35°C
- - worse
(3) Brittle material; part handling critical;
parts damaged during shipping and handling
Best Cost-to-Performance Ratio
40
Celstran® PP-GF30-05
Injection Molding vs. SMA-G15
Injection Molding Feasibility Study
SMA-G15
Part
Celstran PP-GF30
Instrument Panel
Weight about 3600 g
T Cyl. 230-250°C
Cycle about 60 s
Weight about 3900 g
T Cyl. 250-280°C
Cycle about 60 s
Air Duct Panel
Weight about 950 g
T Cyl. 230-250°C
Cycle about 60 s
Weight about 1000 g
T Cyl. 250-280°C
Cycle about 60 s
Fan Housing
( Duct Panel )
Weight about 350 g
T Cyl. 230-250°C
Cycle about 34 s
Weight about 380 g
T Cyl. 250-280°C
Cycle about >34 s
Reinforcement
Part
Weight about 490 g
T Cyl. 230-250°C
Cycle about 45 s
Weight about 520 g
T Cyl. 250-280°C
Cycle about 45 s
Material has to be dried
Delivers Lower Energy Utilization and Lower Part Weight
41
Celstran+ PP LFRT
Advantages vs. SMA and PC-ABS
► Weight and cost savings
► Optimal mechanical performance
► Improved creep resistance
► Improved impact performance
► Improved notched impact strength
► Superior tensile strength
► Greater load bearing capacity
► Increased sound dampening properties
► Low carbon emission
► Energy efficiency in processing
Best Cost-to-Performance Ratio
42
Celstran® LFRT
Cadillac SRX Crossover
Manufacturer:
DAA Draexlmeier
End User: GM
Material:
Celstran PP-GF30
Benefits:
► Improved integration over
previous materials
► Low odor grade for global
markets
► Superior cold temperature
impact for PAB deployment
43
Instrument Panel VW Golf Plus
Material:
► Celstran PP-GF20
► Concentrate technology
Requirements and Benefits:
► Improved part stiffness
► Best melt flow characteristics
► Homogeneous fiber matrix
distribution
► High impact
► Low C-emission
► Passenger airbag function
-35°C / +85°C
Celstran Instrument Panels are Stronger,
Lighter and Offer New Design Possibilities
44
What are Additional Applications
for Celstran® LFRT?
45
Spare Tire Tray – Honda Ridgeline
Manufacturer:
► Decoma (Ventra Plastics)
End User:
► Honda Motors
Material:
Features and Benefits:
► Cold temperature toughness
(-30°C) to withstand full size
spare tire drop
► Chemical resistance to
automotive fluids
► Good surface aesthetics
46
Celstran® LFRT
Roof and Sunroof Modules and Components
End User:
► Mercedes Benz
Market Segment:
► Automotive
Material:
temperatures, low creep
► Favorable acoustic
dampening, dimensional
stability
Low C-Emission Grade is Best for Sunroofs
47
Celstran® LFRT
Performs for Smaller Applications, Too!
End User:
► Renault Twingo
Market Segment:
► Exterior mirrors – Celstran PPGF25
► Battery tray – Celstran PP-GF40
► Power Distributor Box
– Celstran PP-GF40
temperatures
► Low creep under loads
► Good acoustic dampening
► Excellent dimensional stability
► Excellent low temperature impact
Exceptional As-Molded Surface Appearance
EH 32700©
2013 Celanese LFRT-007 AM 10/13
48
Celstran® LFRT
Heavy Truck Interior – Gear Shift Lever
End User:
► Mercedes / VW
Market Segment:
► Automotive
Material:
► Manufactured using gas assist
technology, low warpage
► Good surface finish, weight
and cost reduction vs. PA66
SG35
This Appearance Can Also be Achieved in
Combination with Gas Assist Molding
49
Celstran® LFRT
Assorted Other Components
Citroën C3 Roller Blind
Market Segment: Sun roof systems
Material: Celstran PP-GF50
Ford Focus Battery Tray
Market Segment: Auto Underhood
Material: Celstran LFRT-PP
Porsche Rear Trim Frame
Market Segment: Auto Exterior
Material: Celstran PA66
The Unique Blend of Celstran LFRT Structure
and Appearance Enables Innovation
50
Celstran® LFRT
Automotive HVAC Vanes – LFRT PA6-GF60
The challenge:
The innovation:
► High modulus in
► High modulus in thin
very thin sections
► “Robust feel”
► Good surface finish
1.84 mm cross section
► Class “A”, molded in color, without
secondary finishing
GM – Corvette
Nissan – Quest
Cadillac – STS
51
Celstran® LFRT
Cadillac STS
Nissan Quest
► Unsupported 145 mm span
► Unsupported 150 mm span
► Premium, elegant appearance
► Color matched to three interior colors
► LFT-PA and LFT-PBT
Other Parts Include Scuff Plates, Overhead Consoles, Hard Instrument
Panel, Center Stack/Center Console, Pillar Cladding…
52
Technical
Support Capabilities
Celanese Laboratories and Technical
Service Capabilities Focus On:
► Developing new polymers that expand
your design space
► Providing technical data and problemsolving tools that enable you to
optimize the performance
of Celanese polymers in
your application
Performance Driven Solutions
54
Technical Service
Application Development Support
► Technical support from concept through
commercialization
► Design / Computer Aided Engineering (CAE)
‒ Design reviews
‒ Mold filling analyses
‒ Structural analyses
‒ Gear analyses
► Part and tool design, gating and
material suggestions
► Material and testing laboratories
► Development molding laboratory
for molding trials
Valuable Technical Support During Product Development
55
Product Development Support
Accelerates Your New Product Introductions
New Product
Prototype
Opportunity
Generation
Part Design
Testing
Modeling & Simulation
Part Validation
Material and Application Expertise
Helps Optimize Design and Performance
56
Performance Driven Solutions
Performance: Ticona Engineering Polymers deliver the right mix of
properties focused on your application requirements.
Driven: A passion to achieve the highest level of Customer
Satisfaction.
Solutions: More than a bag of Pellets™, Ticona brings 50+ years of
design and processing innovation to bring your product vision to
reality.
57
Thank you.
Contact Information
Disclaimer
This publication was printed on 1 October, 2013 based on
Celanese’s present state of knowledge, and Celanese
undertakes no obligation to update it. Because conditions of
product use are outside Celanese’s control, Celanese makes
no warranties, express or implied, and assumes no liability in
connection with any use of this information. Nothing herein is
intended as a license to operate under or a recommendation
to infringe any patents.
Copyright © 2013 Celanese or its affiliates.
All rights reserved.
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