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The 3rd living space:Materials & surfaces for the passenger comfort and
wellbeing of tomorrow
In-vehicle Air Quality Summit 2016Beijing, 09-10.11.2016, Mark Chatwood & Stefan Buri
Table of content
Stahl´s role in car interiors
Market trends
Technology trends
Next gen automotive interior surfaces
Conclusion
Who is Stahl?
Stahl´s multiple touchpoints in premium carinteriors
Stahl: the leading car interior materials surfaces expert.
23 11
60038
> 1.800
Plants
Countries
People worldwide
Application Labs
Salestechnicians
9
R&D Centers
Operational Excellence
Tier 3: Surface Technology / Chemistry
Tier 2: Materials Manufacturers
Tier 1: Component / Systems Integrators
OEM / Assembly
+Know-How
Technology
Steering wheel DashboardSun visorMiddle consoleGlovebox
Seat coversHeadrest
Gear shift
Other applications
Door trimsEPDM profiles
PVC
PU
TPO
Leather
EPDM
Fabric
Why premium OEMs and all major manufacturers co-operate with Stahl§ World-market leader in its
segments§ Best-in-class surface
Know-How§ Off the shelf OEM solutions§ Technology- & innovation§ leadership§ Global footprint§ Quality consistency &
interior harmony
Stahl business model along the supply chain
Stahlrootstrength
Market trends
Premium car interior materials.
Stahls core proposition for car interior builders
End-to-end leather solutions
Synthetic trim materials
Auto Leather crust Auto Leather finish
Manufacturing units: 56
Manufacturing units: 85 Manufacturing units: 63
Inte
rior
har
mon
y
Global Automotive interior materials supply chains
Interior Trends
§ Importance of car interior is growing.
§ OEMs upgrading its models by choosing more premium interior materials. More soft-touch materials, dynamic volume growth of material classes.
§ Interior materials and A-surfaces play a vital role to comfort, perceived quality and luxurious appeal.
§ Trend towards light interior colors
§ Multiple migration / substitution effects of interior material classes (upgrading / de-contenting).
§ Growing demand for more sustainable materials and technologies (e.g. water-based, low-emission, green technologies)
§ China: transformation of market on back of new regulations and raising consumer awareness.
§ Leather and coated synthetic trims are the materials of choice for premium car buyers worldwide.
Automotive interior materials market
35 1510
300
70 60
190
Hardplastics & decorative
surfaces***
Fabrics PVC Slush PU spray moulding - Recticel
Microfibre In mould coating -IMC
Coated synthetic trim - PVC
Coated synthetic trim - TPO
Coated synthetic trim - PU
Genuine Leather trim (Auto)
0
50
100
150
200
250
300
350
Mio m2 / year
Stahl surface & substrate expertise
6-20% CAGR**
3% CAGR*
*Source: LV production forecast, IHS ; **Source: CAGR% segment assessment, Stahl; *** e.g. PP, ABS, Chrome, Wood, coated hard-plastics (e.g. piano black), screens, foot mats etc.
Stahl team assessment
OEMmodelupgrading
De-contenting
China: a transforming marketInterior Air Quality: Consumer awareness raising, regulations increasing.
Interior Air Quality Consumer awareness raising, (China) regulations increasing
§ Formaldehyde
§ NMP / NEP
§ Acetaldehyde
§ Hydrocarbons
§ Toluene
§ Amines
§ Ketones
§ Esters
The desirable “new car smell”:
“Interior Air Quality as emerging differentiating factor to premium OEMs.” Enabler: low VOC technology range for interior materials
The chemical emissions from materials are responsible for it
Innovation leadership securing Stahl´s position as the global industry reference.
Stahl is founded. Worldwide expansion from 1945 onwards.
The launch of automotive water-based leather finish systems.
The development and launch of Polymatte® technology.
Introducing co-solvent free (NMP/NEP) finish systems.
193019921998
2004
Stahl leading the way towards clean & green car interior materials.
Stahl introducing water-based anti-squeak / high abrasion finish system based on Polymatte®. - BMW first to market. - 2005 ff. European OEM adopting: M-B, Peugeot, JLR, Porsche, Audi, VW Group.- 2008 ff. US OEM adopting seeking premium positioning, like Lincoln, Ford, Chrysler, GM.- 2008 ff. Asian OEM: Lexus adopting, followed by several other ones.- Stahl technology setting new industry benchmark worldwide.
Introducing water-borne anti-squeak finish systems for Leather and Synthetic trim materials.
(PVC, PU, TPO, coated fabrics).
2004 ff.
2005
Leather Wet-End chemicals optimized for low-VOC and smell: introducing NPEO-free product range,
launch of patented automotive fat-polymer technology.
Stahl EVO: introduction VOC-free product range that is ahead of legislations.
Stahl introducing Stay Clean chemistry for protecting pale colored car interior materials.
Renewable and bio-based raw material sources
2006 ff.
2012
20132014 ff.
China: transition from lower-grade to high-quality water-based surface technology for Synthetic trim materials.
Stahl global business line sales record: Last twelve months (LTM), in mio EUR
China VOC regulations and raising customer awareness a key driver of transition
VOC & Smell
Premium car interior materials.
Green & clean
Smart
Appeal
Taste
Sight
Hearing Smell
Touch
The customer experience –engaging with the 5 senses
The future car interior
VOC & Smell in car interior materials: root causes
VOC&Smellisacomplexandmultifacetedtopic.Foremost,it´sachemicalsubject.Rootcausesandsolutionpathsinthedifferentstagesofprocessesandsupplychains.
AutomotiveLeather
VDA277(Static)
VDA278(Dynamic)
VDA275(Formaldehyde)
Fogging VDA270(Smell)
Substrate - - - - -
TanningAgents + + +++ ++ +++
Fatliquors +++ ++++ - ++++ +++
Colors - - - - -
Finishsystem +++ ++ + ++ +
SyntheticSeat&Trim
VOC Smell
Substrate
FinishsystemSubstrate-specific
Source:FILK,Freiberg- Noinfluenceto++++verystronginfluence
Successfactorsfirsttomarket:- CommunicationOEM-T1-T2-T3- Integratedapproach- Complementarycompetenciestosametable
(OEM,manufacturer,Stahl)
Smellissue
VOCissue
- Globallogistics- Fragmentedsupplychains- Regionalshift(Crustvs.Finishingproduction)
Technology trends
Premium car interior materials.
OEM requirements on interior material surfaces
A balancing act tailored to OEMs individual needs
Interior HarmonyQuality consistency of class A surfaces
independent of car interior component and substrate used (Leather, PVC, PU, PVC,
TPO, fabrics etc.)
Design / StylingSensorial Experience:
natural appearance, color, low-gloss (not burnish), haptics, softness, smell etc.
Sustainability / EmissionsFogging, VOC, smell, sustainability criteria
Physical performanceAbrasion, rub fastness, moisture resistance, bally flex, UV resistance, heat resistance, anti-squeak,
anti-soil, anti-stain (dye ingress)
Stay Clean technology
Premium car interior materials.
And demand for surface protection is increasing
Vision: lotus-effect
Pale colours in car interiors have come to stay
Stahl 3rd generation Stay Clean technology
And it’s easy to See why
And it´s easy to see why.
Soiling: It´s a major pain to all customers in the world
23
To protect light surfaces against typical stains, we developed Stay Clean.
Stay Clean
24
VOC & Smell:The Future
Premium car interior materials.
Interior Air Quality Consumer awareness raising, (China) regulations increasing
§ Formaldehyde
§ NMP / NEP
§ Acetaldehyde
§ Hydrocarbons
§ Toluene
§ Amines
§ Ketones
§ Esters
The desirable “new car smell”:
“Interior Air Quality as emerging differentiating factor to premium OEMs.” Enabler: low VOC technology range for interior materials
The chemical emissions from materials are responsible for it
What Drives us ?
Chineseregulation
Reachbecomingglobal
TOSCA
GADSLRSLMRSLLWGZDHC
STAHLRSL.ThisisourFuture.
Latest Challenges.
BTXFreeSilicone.Realeased forsalenewproductsD4- Octamethylcyclotetrasiloxane <0.1.
Acetaldehyde.Scavengers.
Smell.GoldenSampleistheresuchathing
VOC.TestMethod.Continuousimprovementprogram.
Next steps for Stahl
Smell/Odour roomGuangzhouChinaCOE
Understandthedifferencebetweenregions
DoweneeddifferentsolutionsinAsiavsEurope.
RoundRobin.Stahl andpartners.
OEMconsolidationoftestprocedure.
Build up of Emission lab in Waalwijk
■ Investment for micro chamber & bag emission tests
■ 1 dedicated FTE for testing hired■ Build up of own testing know how■ Timing
■ Jan: Start testing■ Jan – Apr: Feasibility & Cross check
■ Later extension with 1 m3 chamber (BMW, furniture) possible
SMELL vrs VOC ???????
IsthereCorrelation?Yes/No
TestMethods?Manyvariedandnotrepeatable.
OEMMethodsoftest?Isittimeforharmonisation?
Stahl Sustainability Roadmap
100 % Petrochemical
VOC containing
100% Renewable
volatiles
Carbon Source
VOC free
Stahl Sustainability Roadmap
100 % Petrochemical
VOC containing
100% Renewable
volatiles
Carbon Source
STAHL EVOCurrent Portfolio
Vision Green & Clean
- Compliancy, - Detox - Low-VOC
Step 1:
-B
io-b
ased
pro
duct
s-
Reu
se/r
ecyc
le-
Env
iron
men
t P
&L
Ste
p 2:
VOC free
XX
XX
XX
XX
XX
XX
Performance & VOC
Premium car interior materials.
XX
XX
XX
XX
From biomass to bio-based finish systems
Stahl’sBio-basedPolyMatte:
Natural touch & feel / performance / sustainability credentials
XX
XX
Automotive Center of Excellence for OEMs, Tiers and business partners.
Partnerships
The 3rd living space of the FutureRinspeed Oasis: World premiere Jan/2017@CES Las Vegas.
Interior materials of the Future:
Solvent-basedFrom toxic to non-toxic
Water-basedFrom NMP/NEP to co-solvent-free
Bio-basedFrom crude oil to biomass
We create responsible partnerships that spark innovation and open up endless possibilities
Stahl Automotive Center of Excellence
Inaugurated Sept 2015, Waalwijk, The Netherlands
Automotive Center of Excellence (CoE):
- OEM, T1, customers& partners
- CoE in all key auto regions (EU, MX, CN)
- Interior Harmony
Stahl Automotive: the car interior surfaces expert – root strengths
Auto & Non-Auto
market trends
Business model & partnerships
Know-how (application formulation, chemistry)
Global footprint
Best-in-classsTechnology
Interior Harmony
