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Plastics in Automotive
Department of Polymers, Faculty of Chemical Technology,
Institute of Chemical Technology, Prague
Lanxess Mobility Days
Prague, November 22 – 23, 2012
JAN RODA
2
Institute of Chemical Technology, Prague
INSTITUTE OF CHEMICAL TECHNOLOGY, PRAGUEFaculty of Chemical Technology, Department of Polymers
� metals
� ceramics
� glasses
� polymers – plastics, elastomers
�hybrids – composites, sandwiches, lattices, foams
Five broad families of materials
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Metals – rel. high moduli, soft, easily deformed, high-strength alloys
Ceramics – high moduli, brittle
low tolerance for stress concentration and for high contact – stresses,
stiff, hard, abrasive resistant (cutting tools)
Glasses – non-crystalline, amorphous
hard, brittle, vulnerable to stress concentrations
Plastics (thermo*, reacto* ) – low moduli, elastic deflection can be large,
creep, strength, properties depend on temperature strongly ,easy to shape
(in single operation), low coefficient of friction
Elastomers – service temperature above Tg
very low modulus, enormous elastic extension
Hybrids – combination of two or more materials in a predetermined configuration
and scale, fiber–reinforced composites – polymer matrix + fibres of glass,
carbon, polymer
Blends of materials
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polymer types
Thermoplastics
Thermosets (reactoplastics)
Fibres
<Elastomers>
Reinforced polymers, foams, blends, alloys
World polymer production
Plastics 70 %
Fibers
synthetic 13 %
regenerate 1.2 %
natural 8.5 %
Elastomerssynthetic 4.5 %
natural 2.8 %
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
15,0%
23,5%
5,0%5,0%
20,5%
6,5%
3,0%
21,5%
Rest of Asia
China
JapanLatin AmericaNAFTA
Europe
CIS
Middle East.
Africa
World Production 2010 - 264 Mt/a
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
39,0%
27,3%
7,5%
5,6%
20,6%
Packaging
Others
Building & Construction
Automotive
Electrical & Electronic
European Plastics Demand by Segments 2010
9FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Difference in mechanical properties of plastics and elastomers
Materials Weight (kg) Weight (%)
Regular steel 738 40.0
High and medium strength steel 237 12.9
Stainless steel 34 1.8
Other steels 15 0.8
Iron castings 136 7.4
Aluminum 143 7.7
Magnesium 5 0.3
Copper and brass 29 1.6
Lead 20 1.1
Zinc castings 5 0.2
Powder Metal 19 1.1
Other metals 2 0.1
Plastics/composites 155 8.4
Rubber 84 4.5
Coatings 13 0.7
Textiles 22 1.2
Fluids and lubricants 97 5.3
Glass 48 2.6
Other 41 2.2
Annual Breakdown of Materials Content in US Light Vehicles
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Various polymers are used in over 1 000 different parts of all shapes and sizes
in cars, from instrument panels and interior trim to bumpers and radiator
grilles, fuel tanks and engine parts. The material selection for a particular
application will depend primarily on the ability to meet the required
specification and also on polymer price and total systems cost. The total
systems cost includes the cost of the polymer, processing cost and tooling and
assembly cost, and is a prime consideration for cost-conscious car
manufacturers.
Commodity polymers, engineering polymers and high performance plastics
are used to manufacture more demanding applications in the car. The most
valued properties of engineering plastics for automotive applications are their
high heat resistance, dimensional stability, strength and resistance to a range of
chemicals. These properties have led to their replacement of traditional
materials such as metal and thermosets in motor vehicles.
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
28,0%
9,0%
11,0%12,0%
4,0%
11,0%
11,0%
1,0%
3,0%10,0% Polyolefins
Polyamides
PET, PBTPVC
PUR
Elastomers
OtherEng. resin blends
PC, ABS, and blends
POM
Plastics types in a typical mid-size Ford vehicle in 2010. Not including
tires.
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Usage of plastics in North American Light Vehicles in %
Polypropylene 24
Polyurethanes 16
Nylon 10
ABS 7
Polyvinyl chloride 8
Polyethylene 5
Polycarbonate 5
Polyvinyl butyral 2
Other 22
approx 150 kg plastics per vehicle ∼8 % of weight
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Plastics in modern automotive vehicles
� fundamental role in construction
in comfort
in ecological aspects
� use and selection of material is influenced
- global trends in cost
- fuel economy targets
- environmental factors
improved fuel economy (reduced
environ.footprint)
consumption, CO2 emission
fuel engine efficiency, vehicle weight,
aerodynamic drag
� legislation – reuse
recovery
recycling
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Plastics in modern automotive vehicles
� choice of material
mechanical and physical properties
ageing
surface properties
styling requirements
visual appearance
touch
� enviromental aspects
emission
recylability
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
28,0%
9,0%
11,0%12,0%
4,0%
11,0%
11,0%
1,0%
3,0%10,0% Polyolefins
Polyamides
PET, PBTPVC
PUR
Elastomers
OtherEng. resin blends
PC, ABS, and blends
POM
Breakdown of plastics types in a typical mid-size Ford vehicle in 2010.
Not including tires.
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polypropylene (PP)
E= 0.8 – 1.1 – 2.5 GPa /reinf.
Tm = 170 °C
Tg = -10 °C
UUT = 90 °C
isotactic
semicrystalline
variety of application
Application:
unreinforced interior trim, storage bins, instrument panels
chalk-reinforced bumper fascia
glass fiber-reinforced battery trays
rubbery modified polymer
CH CH2
CH3n
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyethylene (PE)
E= 0.2 – 0.4 – 0.7 – 1.4 GPa
Tm = 110-130 °C
Tg = -80 °C
UUT = 70 °C
semicrystalline
different types – LDPE, LLDPE, HDPE
Application:
trim duct – works
reservoirs for fluids
multilayer fuel tanks
CH2 CH2
n
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyethylene terephthalate (PET)
E = 2,5-3,1 GPa
Tm = 265 °C
Tg = 75°C
UUT= 70-100°C
semicrystalline
low cost material
Application:
fibers for carpeting application
fabrics, seat covering , floor mats
films
n
O C CH2 CH2 O C
O O
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polybutylene terephthalate (PBT)
Et = 2,5-10(filled)GPa
Tm = 225 °C
Tg = 65°C
UUT= 130 – 150 °C
semicrystalline, similar to PET
Perfect mechanical ant thermal properties, good dimensional stability,
moisture absorption, chem.resistance
glass fiber reinforced ( 15/30%) or unreinforced
Application:
electric systems, plug collectors, fuse boxes, etc.
underhood components,
housing and brackets, handles, mirror housing
C O CH2 CH2 CH2 CH2 O C
O
O n
• Pocan PBT Typical application
.
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polycarbonate (PC)(from Bisphenol A and COCl2)
E = 2.2 – 2.5 GPa
Tf = 230°C
Tg = 150°C
UUT= 125 °C
amorphous polymer
excellent optical clarity and toughness
blends – improved toughness
Application:
lenses, glazing
Blends of PC with ABS and PBT
C
CH3
O
CH3
O C
O n
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Acrylonitrile-butadiene-styrene copolymer (ABS)
Tg = 105°C
UUT= 90°C
amorphous
good impact
excellent balance of properties – impact strength, stiffness, thermal
stability, can be painted or chromed
Application:
chromed trim
interior and exterior trim components
CH2 C
CH3
CN n
CH CH2
m
E = 2,2-2,9 GPa
CH2 C
CH3
CN
n
CH2 CH CH CH2
o
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyvinyl chloride (PVC)
E = var GPa
Tg = 80 °C
UUT= 60°C
amorphous
good toughness, flexibility
Application:
vinyl trim for leather, wear resistant coatings, cable insulations, wiring,
roof rack coverings, grips, moulded plugs,
dashboard , sun visors
CH CH2
Cl n
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polymethylmethacrylate (PMMA)
E = 2,9GPa
Tg = 115 °C
UUT= 60-80°C
amorphous
clear, tough, perfect weatherability,scratch resistance
Application:
glazings
lenses
CH2 C
CH3
C
O
CH3
O n
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyurethanes
� different structures
(diversity in composition and application)
� basic structural unit – chemical bond
and different form of polymer → diverse
applications
Application:
bumpers, gaskets
fascias, instrument panels
heating, ventilation, air conditioning seals
air filter, headliner foam
seatings, adhesives
sound isolation
NH C O
O
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Different processing methods
RIM polyurethane
formation of complex shapes
� bumpers, fascias, spoilers – energy absorption
Structural RIM and reinforced RIM
glass fibres or mica -RRIM
glass fibre mesh-SRIM
� body panels
Thermoplastic PUR elastomers (TPU)
� bulk products, adhesives, coatings
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
― noise, vibration, harshness reduction
― seating comfort
― sealing application
� lightweight, flexibility in design, resiliency
PUR foams
(a) flexible, (b) semiflexible, (c) rigid
- (seat) cushions, seat backs, armrest, head-rest, steering wheel,
instrument panels
- sound, noise, vibration reduction
- (density 30 - 50 kg/m3)
Thermoplastic foams
– expanded PP, PE
– energy management, insulation
Foam for automotive
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyamide 6 (PA 6)
unreinforced E = 3 GPa
glass fiber reinforced E = 9 GPa
Tm = 220 °C
Tg = 50 °C
UUT= 150 °C
semicrystalline
Application:
engine covers
handles
fans
shrouds
fibres - carpeting
NH (CH2)5 C
O n
Coolant Circuit
OilCircuit
StructuralParts
Others (electric / electronic, covers, ...)
AirSystem
Fuel DeliverySystem
Durethan® – Typical automotive applications under the hood
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyamide 66 (PA 66)
unreinforced E = 3 GPa
glass fiber reinforced E = 9 GPa
Tm = 260 °C
Tg = 50 °C
UUT= 170 °C
semicrystalline
Application:
air intake manifold, carpeting, under hood
n
NH (CH2)6 NH C (CH2)4 C
O O
PA 6 + PA 66 properties depends on moisture absorption – water = softness
PA 11 + PA 12 low moisture absorption - fuel lines
� > 90 % of polyamide use - PA 6 and PA 66
+ other nylons - PA 46, PA 612, semiaromatic types
� characterization
• semicrystalline materials - Tm
crystalline regions – stiffness, strength, chem. resistance, thermal stability
amorphous regions – impact resistance, elongation
• Tm determined by density of H bonds resp. amide bonds
PA66 - nylon 66 Tm ~ 260 °C
PA 6 – nylon 6 Tm ~ 220 °C
- slower crystallization rate
- lower crystallinity, higher H2O sorption
• water absorption – in amorphous region regulated by frequency of NHCO
bonds, Tg decreases with H2O concentration
Polyamide engineering plastic
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
• mechanical properties - determined by PA type, mol. weight, temperature,
moisture content, additives, copolymerization
- PA are notch sensitive - impact modifiers, moisture
- PA + glass resp. carbon fibers - increase of stiffness and strength (also
notched impack strength)
- PA66 > PA 6 fatigue resistance
- perfect abrasion resistance and coefficient of friction (improvement by
graphite or MoS2)
- hydrolysis of PA real, but hydrolysis resistance good
- good thermal stability (melt is sensitive), acceptable oxidation stability
- excellent chemical resistance
• additives: lubricants, nucleation agents, stabilizers, (oxidation, heat), impact
modifiers, plasticizer, reinforcement, glass fibers, nanofillers etc.
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyamide engineering plastic
Polyamides in automotive
� the largest sector for PA, 34 % of world market
� successfully and continually replacing metals
� lower weight, cost and better functionality
- under the bonnet (hood) application ,air intake manifold (65 %), air and cooling
system, peripherals, throttle body housing, head cover, water-glycol circuit,
tubing of fuel system (major role in el. equipment), exterior part mirror housing,
door handless, wind screen wiper parts, roof frames, lock covers, wheel trims,
fuel filler caps, skirts, grilles
key lock system, rear mirror, push buttons, steering lock casings, ashtrays
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
PA6 Air Inlet Manifolds
Key performances:
•Long term temperature
resistance
•Pressure resistance
•Processability
•The best price/ performance
ratio
Comparison of the total cost of a 4 cylinders
air intake manifold made from aluminum vs PA6
Typical plan of an airbag
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Plastics in the Interior of the Vehicle
� the largest share of plastics in cars
� the passenger compartment is dominated by plastics
� instrument panels – complex design
� a key application for plastics
(reduction of cost and weight, improvement of
aesthetics)
�instrument and airbag housingABS -- general purpose, high flow,blow molding
low gloss
PC-ABS blends -- unique combination of properties
PP modified by (thermoplastic) elastomer or glass reinforced PP
occupy the same application space
high stiffness
high toughness
economical engineering material
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
� dashmat panel – sound barrier
� headliner – functional parts below roof
� seat backs – steel vs. plastic (PC/ABS)
� seat base – more demanding
∼ long term creep resistance, reclining system, heating
� door handle, door module
� steering wheel
� levers, switches, bearings
� airbag and airbag covers
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Plastics in Horizontal and Vertical Body Panels
� door panel, roof, floor, fender, hood, back panels
- the entry of plastics has been difficult
-fenders filled PC/ABS, nylon/PPO, filled thermosets
Plastics in the Exterior of the Vehicle
� bumpers (front, rear)
modified PP, ABS, PC/ABS
� underbody shields
glass – filled PP, ABS
� door handles
PC, PBT, nylon
� exterior mirror housing
many solutions – ABS, PC/ABS, nylon, EPDM
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Plastics in the Powertrain
� after a long period the plastics succeeded under the hood
- the wiring (connector, insulation, power plugs, switches and
controls)
- radiator grill
Blends PA/PBT, modified PBT , PA
- heating and AC ducts and consoles
- air intake manifold
- different shields
� fuel tank (the largest plastic component)
HDPE or multilayer construction – HDPE plus EVOH copolymer
Plastics in Fuel Systems