Function Integration and Lightweight Design – Offerings of a Chemical Company Peter Weinmar, Dr. Andreas Bischoff, Tokumi Toyota Tokyo, November 2011 Outline 1. Trends in Automobile Industry 2. Function Integration Example 4. Leightweight Design Examples 5. Conclusion / Outlook 2 Function Integration and Lightweight Design – Offerings of a Chemical Company Trends in Automobile Industry Growing production of cars world wide Weight reduction of components Operating temperatures in engine compartment still increasing Lifetime extension of assembled parts Less failures - less cost of replacements 3 Function Integration and Lightweight Design – Offerings of a Chemical Company Growing car production and trend of weight reduction drive demand for high-tech plastics Global car production annual growth of ~3.3% Global production of light vehicles [mn units] Increased usage of high-tech plastics per car drive growth of 7% p.a. Global production of light vehicles will increase by 30% in the next 5 years Current high-tech plastic share in Western cars 15-17% Chinese vehicles only consist of about 7% plastic components growth potential E-mobility further pushes high-tech plastics total share of plastic expected to exceed 25% ~ +30% ~ +10% 100 50 0 2015e Share of materials in automotive production [%] 7 21 72 Innovation in high-tech plastics enable future mobility 2010e 2005 1980 12 14 23 27 65 1990 59 17 18 31 32 High-tech plastics Other materials Ferrous metals 52 50 2000 2010e 2015e Sources: JD Powers 08/2010; Polymotive; Plastics Europe 2010; LXS own estimates; Handelsblatt.com (Oct. 21, 2010), 4 Function Integration and Lightweight Design – Offerings of a Chemical Company Requests from customers & development targets Enviromental Issues Reduce CO2, High Oil Price Direction of Technology Technical Needs to Elastomers Reduce Weight Replace metal by plastic Low hardness material Reduced Fuel Consumption Hybrid engines, emobility High heat resistant and high purity Polymers High Transmission Efficiency Low viscosity oil Oil additive resistance Reduce ozon layer attack Replacement of CFC CO2 resistance Higher fuel Layered composites of rubber and impermeability thermoplastic Consolidate materials Balanced in heat resistance, oil resistance and low temperature Properties Long service life Long term heat resistance, UV resistance, oil resistance, low compression set Improved processability Easy and robust forming of parts Clean Emission Reduce hydrocarbon exhaust Recycling economy 5 Reduce material consumption Function Integration and Lightweight Design – Offerings of a Chemical Company Examples of Automotive Parts for Under the Hood Application by Lanxess Brackets Cooling Circuit Beauty Cover Air System Timing Belt Oil Curcuit Torsion vibration damper 6 Function Integration and Lightweight Design – Offerings of a Chemical Company Goals in function integration 1. Change from 2 step process to 2 component injection moulding using Durethan and Therban for under the hood applications (Parts for the oil and cooling circuit) 2. Simplification of the production process, less process steps, less control tests needed, higher level of integrated functionality 3. More freedom for design 7 Function Integration and Lightweight Design – Offerings of a Chemical Company Specification Profiles Thermoplast and Rubber Good Bonding Properties Good Bonding Properties Service Temperature from -40°C to 150°C Service Temperature from -40°C to 150°C Resistance against chemicals (Oil, Glycol) Resistance against chemicals (Oil, Glycol) Aging resistance Aging resistance Good mechanical properties Good mechanical properties Tensile Tensile Stiffness Stiffness Damping Damping Rheology Flow Behavior Vulcanization properties High service temperature achieved with highly filled Durethan® and Therban® AT 8 Function Integration and Lightweight Design – Offerings of a Chemical Company Application Example 2K-Media Box Injection points Flow connections 9 Function Integration and Lightweight Design – Offerings of a Chemical Company Challenge Tool Temperature Control Determination of the cycle time 10 Function Integration and Lightweight Design – Offerings of a Chemical Company Thermal Analyses Optimization of the Cycle Time After optimization of the whole thermal tool environment: Reduced cycle time of 60 to 70 seconds (dependent of the elastomer) 11 Function Integration and Lightweight Design – Offerings of a Chemical Company Lightweight Design Replacement of metal by engineering thermoplastics and plastic/metal-hybrids Integrating functions of parts into one assembly via the thermoplastic component Lighter structures using thermoplastic composite sheets in hybrid structures Integrating formerly seperated manufacturing processes Composite sheet lower beam in the frontend of the new Audi A8 (TEPEX® PA6/Glas). 12 Function Integration and Lightweight Design – Offerings of a Chemical Company Hybrid-technology – „Plastic keeps metal in shape“ Lightweight structures (thin wall thickness) preference for denting or buckling The structure can be supported with small forces, that are carried by the plastic ribs → → F2 F1 sheet metal → Fplastic support 13 → Fplastic → → F2 >> F1 Function Integration and Lightweight Design – Offerings of a Chemical Company What is a Plastic/Metal Hybrid? Metal Sheet Injection molded Plastic/Metal Hybrid Polyamid 6 GR 14 Function Integration and Lightweight Design – Offerings of a Chemical Company Comparison of Steel and Plastic/Metal Hybrid Profiles under Bending Load 4,0 force F [kN] 3,5 3,0 Plastic/metal hybrid profile 2,5 Closed metal profile 2,0 1,5 Open metal profile 0,5 F 0 0 2 4 6 8 10 12 14 16 18 20 deformation f [mm] 15 Function Integration and Lightweight Design – Offerings of a Chemical Company f 340 Typical Application of Plastic/Metal-Hybrids: Frontends Description Durethan BKV 30 H2.0 EF PA 6 + GF30 Hybrid technology with steel inserts Advantages Weight reduction: 10 – 50 % vs. steel construction Cost reduction: 10 – 40 % vs. steel construction High functional integration Higher precision and better quality High performance 16 Function Integration and Lightweight Design – Offerings of a Chemical Company Examples of Plastic/Metal-Hybrid Frontends out of Durethan Audi A6 – 1998 Audi A4 – 2000 Mercedes Benz A – 2004 Ford Galaxy – 2006 Chrysler 300C – 2004 Ford S-Max – 2006 Ford Focus – 1998 Ford Fiesta – 2001 VW Polo – 2001 Nissan Quest – 2003 BMW X3 – 2003 Audi TT – 2006 Hyundai Avant– 2006 Hyundai Veracruz– 2006 Hyundai i30 – 2007 Hyundai Starex– 2007 Audi A1 – 2010 Audi A8 - 2010 Ford Mondeo – 2007 Audi A5 - 2007 Audi A4 - 2007 Audi Q7 V12 – 2008 Audi A3 – 2008 Audi A7 – 2010 Renault Megane – 2002 Mazda Demio – 2002 Hyundai Getz – 2002 Kia Spectra – 2003 BMW 1er – 2004 BMW 3er – 2005 Mercedes Benz Vito – 2003 Hyundai Santa Fe – 2006 Audi Q5 – 2008 Kia Carens – 2006 Kia Lotze – 2006 Ford Kuga – 2008 Hyundai Genesis - 08 More than 70 models in mass-production Far more than 50 Mio parts on the road 17 Function Integration and Lightweight Design – Offerings of a Chemical Company Continuous fiber reinforced thermoplastic composites (CFT) State of the art technology for aircrafts Challenge: Cost optimized and ready for mass production alternatives for the automotive industry High-tech plastics with glass, carbon, aramid or mixture 2D semi-finished product (panel) based on a thermoplastic matrix Easy alteration to 3D shape Fabrics or uni-directional fabric made of continuous filaments Complete impregnation For demanding mobility solutions 18 Function Integration and Lightweight Design – Offerings of a Chemical Company Continuous fiber reinforced thermoplastic composites (CFT) Advantages Excellent crash performance No corrosion and easier recycling Integration of functions Possibility of complex designs Weight related force / [N/g] Low weight – high strength Hybrid PA composite sheet Hybrid steel sheet Low investment Deflection / [mm] Challenges Influence of temperature and water absorption 19 High performance systems for greater safety, efficiency and sustainability Function Integration and Lightweight Design – Offerings of a Chemical Company Advanced processing of CFT „In Mold Forming Process“ Heating up above melting point IR heater Shaping during the closing of injection molding tool… Demolding …and subsequent injection molding of rib pattern usual cycletimes between 45s und 90s only one tool necessary → low invest repeatable, secure process 20 Function Integration and Lightweight Design – Offerings of a Chemical Company Examples for CFT parts Door Impact Beam Steering column One shot molding process 21 Function Integration and Lightweight Design – Offerings of a Chemical Company Conclusion Lanxess offers to Tier1 and OEM customers unique solution In Function Integration By joining hard thermoplastics with soft rubbers and saving weight In Hybrid Technology Development By stabilizing metal with thermoplastics and maintaining strength In Lightweight Design By allowing new material solutions and keeping end part properties 22 Function Integration and Lightweight Design – Offerings of a Chemical Company Thank you very much for your attention. Contacts at LANXESS in Japan: Motohiko Kato Head of Business Unit Semicrystalline Products (Polyamides, PBT) in Japan: LANXESS K.K. 1-6-5 Marunouchi Chiyoda-ku, Tokyo 100-8215 www.lanxess.co.jp [email protected] Tel.: 03-5293-8025 Yoichi Tajima Head of Business Unit Technical Rubber Products in Japan [email protected] Tel.: 03-5293-8028 25 Function Integration and Lightweight Design – Offerings of a Chemical Company This information and our technical advice - whether verbal, in writing or by way of trials - are given in good faith but without warranty and this also applies where proprietary rights of third parties are involved. Our advice does not release you from the obligation to verify the information currently provided - especially that contained in our safety data and technical information sheets - and to test our products as to their suitability for the intended processes and uses. The application, use and processing of our products and the products manufactured by you on the basis of our technical advice are beyond our control and, therefore, entirely your own responsibility. Our products are sold in accordance with the current version of our General Conditions of Sale and Delivery. (C) 2010 LANXESS Deutschland GmbH. All rights reserved. 26 Function Integration and Lightweight Design – Offerings of a Chemical Company
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