Upload
others
View
6
Download
0
Embed Size (px)
Citation preview
1
Celstran® LFRTStructure meets
Appearance
September 2010
2
Overview
Trends
LFRT for Structural
LFRT for Appearance
Synergies of combining Structure and
Appearance
Future Activities
3
Trends with LFRT
Time
STRUCTURAL
APPEARANCE
4
Glass CarbonAramid Stainless Steel
PEEK
PPS
TPU
PA6 & 66
PBT/PET
POM
PPO
PC/ABS
PP
PE
Perf
orm
an
ce
Fiber Price
PPS
TPU
PA6 & 66
POM
PEEK
PPS
TPU
PA6 & 66
PPS
PA6 & 66
POM
PPO
PC/ABS
STRUCTURAL CONDUCTIVE
Celstran refers to a wide variety of Long Fiber
Reinforced Thermoplastic materials
Celstran® LFRTs Product Range
5
Celstran® PP:
Structures the right automotive applications
Stiff, tough and light – even in
cold temperatures
Good dimensional stability
Excellent pellet integrity –
suitable for bulk handling
Static dissipative grades are
available
Helps consolidate the recycle
stream
High quality pellets make high quality parts
6
Celstran® LFRT Mechanical Properties
Talc-PP
(20%)
LFRT-PP
(20%)
LFRT-PP
(30%)
LFRT-PP
(40%)
Density 1.1 1.03 1.12 1.21
Tensile Strength 23MPa 65 85MPa 145MPa
Modulus 2350MPa 3980MPa 6000MPa 9000MPa
Notched Izod (23C) 4.9 ft-lb/in 5.1 ft-lb/in 6.1 ft-lb/in 7.2 ft-lb/in
Hard IP, trim
or console
Soft IP,
Door
Module or
Console
FEM
Celstran Mechanical Performance Is Better
7
Property Performance: Creep
0
0.2
0.4
0.6
0.8
1
0 500 1000 1500 2000
Hours
Str
ain
(%
@ 2
50
°F
& 2
00
0 p
si)
Predictable Part Performance a
Necessity and LFT PP Delivers
8
Celstran is tough, even at cold temperatures
Celstran
PC-ABS
Fra
ctu
re e
ne
rgy [
J ]
Penetration test ISO 6603-2 Short-glass Trend
Versus
Temperature
Long-glass Trend
Versus
Temperature
Impact behavior at -40°C, RT, +85°C and 120°C
Tested at three different wall thicknesses
Celstran® PP-GF30 versus PC-ABS GF10
wall thickness
2 mm
wall thickness
3 mm
wall thickness
4 mm20
15
10
5
0
9
Material Weight PricePotential for
Integration
Foam
Adhesion
Mech.
Properties
IM
ProcessHandling
PC-ABS + - - - + + 0 + (3)
SMA + - - - + + 0 + (3)
LFT-PP ++ ++ ++ + (1) + (2) ++ ++
Ranking
++ best
+ acceptable
- bad
- - worse
(1) Requires flame pre-treatment
(2) Best crash characteristics @ – 35°C
(3) Brittle material; part handling critical;
parts damaged during shipping and handling
Celstran® LFRT – Part Integration and
Cost Reduction for Instrument Panels
Best Cost-to-Performance Ratio
10
Celstran® PP: Adds appearance to
the right automotive applications
Excellent pellet integrity –
suitable for bulk handling
Colorability – excellent surface
aesthetics
Low c-emission grades are
available
Helps consolidate the recycle
stream
High quality pellets make high quality parts
11
Celstran Performs Like Other PP Materials
Celstran PP-GF20
Talc-PP
Overhead Bin After Scratch Testing
Common Interior Testing
Low C Emission (VDA 277)
– Measured < 50 µg C/g
– Target < 100 µg C/g
Fogging (VW PV 3015)
– Measured 1 mg
– Target < 2 mg
Low Odor (GM Method)
– Measured 3
– Target 3-4
Scratch and Mar (Ford Load)
– Measured No Visible Whitening
– Target No Visible Whitening
12
Celstran® PP
Combining Structure and Appearance
Reduction of extra aesthetic trim parts or paint
Flexibility to design thinner wall structures
(10 – 15%)
First surface class ‘A’ interior combined with
structural integrity
Cost savings (up to $6/vehicle)
13
Long-Glass PP for
A-Surface Overhead Console
OEM: 2009MY Ford Motor Co. Ford® Flex™ CUV
System Supplier: Grupo Antolin
Material Processor: Grupo Antolin
Material Supplier: Ticona
Resin: PP-GF20
Tooling Supplier: N/A
Unique use of injection-molded long-glass fiber-PP materials in– above-the-beltline
– Class A interior part
– light texturing and in light colors
– replaced a talc-filled TPO material that had insufficient thermal stability
– A special UV-protection package helps stabilize the colorant; components are sonically welded to the bin door.
Optimal Processing conditions ensure no glass read-through for excellent aesthetics.
Improved craftsmanship and appearance come at a slight cost reduction as well.
14
Long-Glass-PP
First-Surface Console Side Panels
OEM: 2010MY Ford Motor Co.: Lincoln® MKT CUV
System Supplier: Automotive Components Holdings
Material Processor: Automotive Components Holdings
Material Supplier: Ticona Engineering Polymers
Resin: Celstran® PP-GF20
Tooling Supplier: Not Available
This is the largest molded-in-color, 20% long-glass PP part
Class A surface out of the tool for a premium vehicle
Precolored and textured part– 100% color-matched
– no glass read-through
– offers higher stiffness than talc-filled PP ( By xxxx)
– lower cost than ABS (By XXX)
– eliminated the need for squeak & rattle countermeasures
Saving = $6.00 USD/vehicle
15
Not only materials
Material development
Part design – meet end requirements
Processing optimization (proprietary…)
Concentrate approach (economic benefits)
16
Early Development Assistance
Material Selection
MoldFlow CAE:
– Gate location assistance
– Feedsystem design/balancing
– Filling analysis, incl sequential
– Warpage predictions
CAE Structural: review or perform
Tooling consultations, such as design
recommendation for attachment-point adjustability
Supply test panels or standard parts
Processing assistance at trials
Engineering support for OEM or Tier Product
Development meetings
Ticona offers much more than just material selection
17
Optional available for the air management in the area of
“under the hood”
Optional available for the air management in the
area of “under the hood”
Celstran®+ for IP Applications
Concentrate Technology
40-60% reinforcement available
PP-GF40-04CN15/10 (concentrate to let-down to GF20)
PP-GF45-05X551-1X (concentrate to let-down to GF20)
Grades to Meet Application Requirements
Celstran+ PP-GF20 Celstran+ PP-GF30 Celstran+ PP-GF40
GF20 Blend(Concentrate Technology)
Instrument Panels Fan Housings Instrument PanelsP-Airbag Chute Channel
Fan Housings
GF30-05CN01/10Concentrate Technology*
GF40-04CN03/10GF30-04CN02/10
*Optional: Concentrate Technology
45-60% reinforcement available
PP-GF45-05X551-1X (concentrate to let-down to GF30)
PP (+) GF60-04 (concentrate to let-down to GF30)
18
Innovative SolutionsCelstran LFRT - Superior Properties for Automotive Applications
5-Finger Scratch and Mar Celstran® LFRT 20% vs. Talc-PP
Head-to-Head Testing Conducted
System: Ford Corporate O/H Console
Part Submitted: Sunglasses Holder
Tested by: Detroit Test Labs, Inc.
Test Standards: Ford loads used
Result: No visible whitening
Results – No Visible Whitening
19
Innovative SolutionsCelstran LFRT - Superior Properties for Automotive Applications
PP-20% Talc Filled
Scratch Rating @ 2N = 2
Scratch Rating @ 13N = 4
Evidence of whitening
Celstran® PPGF20
Scratch Rating @ 2N = 1
Scratch Rating @ 13N = 3
No whitening
20
Innovative SolutionsCelstran® LFRT - Superior Properties for Automotive Applications
Better scratch and mar compared to talc PP
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
21
Celstran®+ PP LFRT
vs. SMA for Instrument
Panel Applications
For More Information:
Americas
Hansel Ramathal
(859) 372-3195
Europe
Olaf Herd
+49 (6107) 772 1648