Trends in Automotive Technology • Yesteryears “You can have any colour as long as it is black”
Trends in Automotive Technology • Today
10.40% 10.80% 5.80% 51.10% 31.90% Body Interior Drive Chassis E&E Use of Polymer in Cars 11.2% (142Kg) of total weight, (excluding tires). Source: BMW
Facts and Figures • Over 2 millions tonnes of Plastics in Europe alone. • The most widely specified material. • More than 1000 plastics parts. • On average, 100kg of plastics replaces 200-300Kg of conventional materials. E.g. 4.2Kg lighter in Engine cover and 5Kg in Fuel tanks. • Cuts oil consumption by 12 million tonnes and reduce CO2 emissions by30 millions tonnes/p.a. just in Western Europe.
Trends in Automotive Technology • The future
Trends in Automotive Technology • Reduce exhaust emissions. • Better fuel economy. • Improved safety. • Increase comfort and convenience. • Reduce weight Vs functionality. • Reduce COST!!!!
Trends in Automotive Technology European Union Directive 2000/53/EC “End of Life Vehicle” 8 to 9 million tonnes of waste every year. • Design and Manufacture for Re-use, Re-cycle and Re-covery. • Reduction and Control of Hazardous substances.
Trends in Automotive Technology Noticeable shift from: • Thermosets to Thermoplastics. • Amorphous to Crystalline polymers. • Moderate to High temperature materials. • Approx. 25% increase in volume of Plastics.
Thermoset Thermoplastic E-modulus Thermoset Elastomer Thermoplastic Elastomer Room temperature What is a TPE or TPR? Stiffness Vs. Temperature
50 5 70 70 90 90 100 100 110 110 120 120 130 130 140 140 150 150 50 70 90 100 110 120 130 140 150 Rockwell R Rockwell R Rockwell R 80 80 95 95 20 30 40 50 60 70 80 90 95 Polypropylene Shore A Elastic Band 30 40 50 60 70 80 Shore D 10 100 1000 Flexural Modulus (MPa) Scales Rubbers Plastics
Sarlink* from DSM • PP + Crossed linked EPDM rubber. • Shore 40A to 50D. • Low density. • Fluid resistance comparable to GP polychloroprene rubber. • Excellent fogging properties with low VOCs emission. • Easy to colour. • Two-shots with Polyolefins. Hydraulic engine mount heat shield Bellows & Dust covers
Tail light housing Corner mouldings Alcryn* from APA • Melt process-able rubber. • Shore 55 to 80A. • Outstanding UV and Ozone resistance. • Oil, Grease and Fuel resistance. • Elastic properties of nature rubber. • Two-shots with PVC, ABS, PC.
Cable connection Gear lever noise & vibration damping Elastollan* from Elastogran • Thermoplastic Polyurethane. • Shore 55A to 74D. • Polyester & Polyether types. • UL94-VO:Halogen free. • Transparent grades. • Two-shots with ABS, PA, PBT, PC. • New Aliphatic TPU with improved hydrolysis and UV resistance.
Combustion Air Swirl Generator Trucks Auxiliary Springs Hytrel* from Du Pont • Thermoplastic Polyester Copolymer Ether Ester. • Shore 30 to 82D. • Excellent flex fatigue. • Noise & vibration damping. • High tensile & tear strengths. • Heat resistance. • Two-shot with PBT, ETPV*.
Two-shots Bond strength? Tensile Adhesive Strength (MPA) Alcryn* 2160 Elastollan* 1180A ETPV* 90A01 Nylon 1.45 7 3.3 PBT 1.2 7 6.8 30% GR PET No data No data 6.6 TPC-ET No data 8 7.1 PC 4.12 7 No data PC/ABS 4.72 4 No data ABS 5.48 7 No data
DuPont™ ETPV engineering thermoplastic vulcanizates Description: a high performance cross-linked elastomer dispersed in: a high performance thermoplastic elastomer Recycling code (ISO 11469): > AEM + TPC - ET < AEM = ethylene acrylic elastomer TPC - ET = thermoplastic ether ester elastomer Finally introducing…….
The cross-linked elastomer brings: • Heat resistance • Low hardness • Creep- and compression set resistance The thermoplastic elastomer brings: • Excellent oil and grease resistance • Excellent flexural resistance • Allows usage on standard thermoplastic processing equipment The combination of these materials brings: • Significant cost savings versus cross-linked rubber • Excellent oil and heat resistance • Recyclability DuPont™ ETPV is a thermoplastic elastomer in the shore A range that resists >150oC in air for 3.000 hours (retains >50% of elongation at break & tensile strength) in combination with good oil resistance. ETPV*
Tensile strength after ageing in air at 150ºC 18 0h 16 1000h 2000h 14 3000h 12 10 Tensile strength (MPa) 8 6 4 2 0 DuPont™ ETPV DuPont™ ETPV DuPont™ ETPV DuPont™ ETPV 60A01L NC010 60A01HSL BK001 90A01 NC010 90A01HS BK001 ETPV*
Kalrez® 300°C Viton® J 275°C H Silicone 250°C Silicone (HS) Fluorosilicone G 225°C Vamac® F DuPont™ ETPV 200°C Heat Resistance EPDM Polyacrylate (ACM) HNBR E EVA (high VA) Hypalon 175°C Hytrel® Epichlorohydrine (ECO) Olefinic TPE D Alcryn Ethylene-propylene 150°C Geolast Neoprene Sarlink C Nitrile (NBR) Butyl 125°C B 100°C SBR & NR A 75°C Class 50°C Type Oil Resistance (% swell in ASTM #3 Oil) No req. 140% 120% 100% 80% 50% 30% 20% 10% ASTM D2000 / SAE J200 Specifications. N.b. The purpose of this chart is to give a general overview. Formulation may affect compound performance. A B C D E F G H I ETPV*
Better Fuel Vent Tubes Automotive body plugs with excellent resistance to heat and chemicals Ignition Coil boot Formed to fit, this fuel vent tube is scheduled for production in a 2005 model North American car. Zytel® 70G30 DuPont™ ETPV 90A01 NC010 Oil reservoir cover with integrated seal Applications
What about? Part weight Rubber PA 15% GR ~1kg Conventional design ~0.5 kg Rubber Opportunity for DuPont™ ETPV New design Hard segments may be made in Hytrel® BM6574 BK316 Automotive air ducts with excellent flexibility, oil and Chemical resistance, and performance at 150ºC
Fast Thermoplastic processing. Standard thermoplastics equipments. No post mould curing of parts. Supplied in form ready to use . No plasticizers. Lower density. Often lower material price Vs. high performance rubbers. Recyclable. Lower production costs. Thermoplastic processors to enter new markets. Higher productivity. Higher quality consistency. Performance not change by migration & no contamination. Lighter components. Lower production costs. Use of regrinds. Meets environmental requirements. Benefits Vs Rubber
Trends in Automotive Technology • The future