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High performance TPE in Automotive?. 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.

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trends in automotive technology
Trends in Automotive Technology
  • Yesteryears

“You can have any colour as long as it is black”

use of polymer in cars

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
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 technology3
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 technology4
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 technology5
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.
slide10

Thermoset

Thermoplastic

E-modulus

Thermoset Elastomer

Thermoplastic Elastomer

Room temperature

What is a TPE or TPR?

Stiffness Vs. Temperature

slide11

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
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

alcryn from apa

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.
elastollan from elastogran

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.
hytrel from du pont

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
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

finally introducing

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…….
slide18

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*

slide19

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*

slide20

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*

slide21

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

slide22

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

benefits vs rubber
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