ALBIS GROUP
Albis Plastics Corporation
Higher Temperature PP-Based
Composite Provides Nylon/PALevel Performance at Lower
Weight and Economic Feasibility
Society of Plastic Engineers
Automotive Composites Conference & Exhibition
September 13, 2012
Agenda
ALBIS GROUP
Albis Plastics Corporation
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2
ALBIS Group
Mega-Trends and Market Drivers
Performance PA GF / PP GF / PP LFRT
next PP- NewTechnology
next PP - Development Process
Performance of next PP GF 35
next PP GF 35 - Aging Tests
Drop-in solution / Warpage
Target Applications
Current Status Test
Summary
jim.keeler@albis.com / (248) 410-9015
ALBIS Group
Facts & Figures
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3
ALBIS GROUP
Albis Plastics Corporation
OTTO KRAHN GmbH & Co. KG
Holding
1961
Foundation
649/733 Mio. EUR
Turnover 2010/2011
approx. 10.000
Customers
923
Employees
16
Subsidiaries
3
Compounding Sites
130.000 t/p.a.
Compounding Capacity
42
Compounding Lines
1995 / 2005
Certification ISO-9001 / ISO-TS 16949
jim.keeler@albis.com / (248) 410-9015
ALBIS Group
Global Network
4
jim.keeler@albis.com / (248) 410-9015
ALBIS GROUP
Albis Plastics Corporation
Mega-Trends and Market Drivers
Motivation for Material Substitution
ALBIS GROUP
Albis Plastics Corporation
 Weight reduction
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Lower density  Lightweighting  Improved fuel efficiency
Vehicle Fuel efficiency  CO2 emission reduction and higher MPG
 Economic feasibility
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Avoidance of Penalties (excess CO2 emissions)
Material cost reduction (PP is lower cost base resin vs PA)
Processing cost reduction with PP vs. PA
−
−
No pre-drying necessary
Lower processing temperatures use less energy and faster cycling
 Material Availability
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5
Broad supplier base for PP feedstock
Better global availability of PP vs. PA
jim.keeler@albis.com / (248) 410-9015
Mega-Trends and Market Drivers
Vehicle Emission Standards
ALBIS GROUP
Albis Plastics Corporation
European Union-Emission Standards (EC)443/2009:
Target of 130g CO2/km for 2012
phase-in basis between 2012 & 2015
2012 65%
2013 75%
2014 80%
2015 100%
Penalties
effective 2015:
+1g – 5,-Euro/car
+2g – 10,- Euro/car
+3g – 45,- Euro/car
+4g – 155,- Euro/car
+5g – 240,- Euro/car…
effective 2019:
+1g – 95,- Euro/car…
Target of 95g CO2/km for 2020
(to be reviewed in 2013)
Source: Broschure „Worldwide Emission Standards and Related Regulations“, Continental Automotive GmbH, 3-2012
 New emission standards drive weight reduction.
6
jim.keeler@albis.com / (248) 410-9015
Mega-Trends and Market Drivers
Emission Standards Penalties
ALBIS GROUP
Albis Plastics Corporation
Source: Report „How clean are Europe´s cars?“, European Federation for Transport and Environment (T&E), 9-2011
 If Daimler, Volvo, BMW are not fulfilling Emission
Standards they could face severe penalties as of 2015,
i.e. +15g @Daimler would result in ca. 1,000,000,000 Euro
7
jim.keeler@albis.com / (248) 410-9015
Mega-Trends and Market Drivers
Emissions Reduction Impacts Design
ALBIS GROUP
Albis Plastics Corporation
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Weight reduction
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Electrification „Supercredits“ (<50g cars, equal 3,5cars)
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Electrical performance, „high voltage“
Downsizing, i.e. smaller, powerful engines
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Metal replacement
Lower density polymers/ fillers (e.g. PA=>PP, hollow glass)
Carbon fibre technology
Foaming, gas-injection, etc.
Mechanics
Heat / creep resistance
„Aggressive“ liquids, i.e. fuels, lubes, etc.
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Chemical resistance
Biofuel resistance (E10, E85)
 Market Driven vs. Customising.
8
jim.keeler@albis.com / (248) 410-9015
New Product Designs
What does all this mean for Car Manufacturers / Suppliers?
Mega-Trends and Market Drivers
Growth of Plastics Usage
ALBIS GROUP
Albis Plastics Corporation
Growth of plastics usage in cars
[kg]
300
250
235 kg
190 kg
200
150
134 kg
12 %
15 %
16 %
20 %
93 kg
14 %
50
129 kg
12 %
100
250 kg
1974
1983
1991
1997
2003
2008
Golf I
Golf II
Golf III
Golf IV
Golf V
Golf VI
0
Source: VDI - Plastics in Automotive Engineering, Mannheim, 21.-22.03.2012
 Weight and cost reduction drive increased use of plastics.
9
jim.keeler@albis.com / (248) 410-9015
Mega-Trends and Market Drivers
Inter-Polymer Competition
 Substitution chain in the plastics industry
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Current status
 next PP close the gap
10
jim.keeler@albis.com / (248) 410-9015
ALBIS GROUP
Albis Plastics Corporation
Performance PA GF / PP GF / PP LFRT
Current Status
Properties
Albis Plastics Corporation
PA6 GF30 PP LFRT 30
Density [g/cm³]
1,12
1,36
1,12
ISO 1183
tensile strength [MPa] 23°C
E-Modul [MPa] 23°C
elongation at break [%] 23°C
E-Modul [MPa] 75°C
E-Modul [MPa] 120°C
55
5500
2
3200
1750
110*
5500*
5*
4500*
3800*
110
6300
2,3
4600
3500
DIN EN ISO 527
HDT A [°C]
138
>200
156
DIN EN ISO 75
Flexural strength [MPa]
75
175*
147
DIN EN ISO 178
DIN EN ISO 527
DIN EN ISO 527
DIN EN ISO 527
DIN EN ISO 527
Charpy unnotched [kJ/m²] 23°C
12
70*
52
Charpy notched [kJ/m²] 23°C
5
11*
19
DIN EN ISO
179/1eU
DIN EN ISO
179/1eA
750
650
550
ALBIS Norm
Flow spiral [mm]
* conditioned
11
PP-H GF30
ALBIS GROUP
jim.keeler@albis.com / (248) 410-9015
next PP - New Technology
ALBIS GROUP
Albis Plastics Corporation
 A technical alternative to PA6 and PP LFRT compound
 Based on low cost, approved Polypropylene matrix
 New innovative technology
 Closing the gap between commodities and engineering resins
12
jim.keeler@albis.com / (248) 410-9015
next PP - Development Process
ALBIS GROUP
Albis Plastics Corporation
 15 months development time
 Approx. 190 production runs on laboratory extruder in R+D
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Formulation development
Processing development
Determination of mechanical properties through internal and external
laboratory
 9 Production trials
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Scale up
Processing development
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−
−
13
Optimazation dosing position and units
Optimazation screw design
Maximization throughput
jim.keeler@albis.com / (248) 410-9015
ALBIS GROUP
E-Modul [MPa]
Performance of next PP GF 35
E-Modulus vs. Temperature
8000
Albis Plastics Corporation
PA6 GF30 (cond.)
7000
next PP GF35
6000
PP-H GF30
PP LFRT 30
5000
4000
3000
2000
1000
20
40
60
80
100
120
Temperatur [°C]
 Up to 110° C very similar to Nylon and PP LFRT 30
14
jim.keeler@albis.com / (248) 410-9015
ALBIS GROUP
Performance of next PP GF 35
Benchmark I
Properties
Albis Plastics Corporation
PP-H GF30 PA6 GF30 PP LFRT 30 next PP GF 35
Density [g/cm³]
1,12
1,36
1,12
1,18
ISO 1183
tensile strength [MPa] 23°C
E-Modul [MPa] 23°C
elongation at break [%] 23°C
E-Modul [MPa] 75°C
E-Modul [MPa] 120°C
55
5500
2
3200
1750
110*
5500*
5*
4500*
3800*
110
6300
2,3
4600
3500
100
8300
3
4900
3000
DIN EN ISO 527
HDT A [°C]
138
>200
156
154
DIN EN ISO 75
Flexural strength [MPa]
75
175*
147
140
DIN EN ISO 178
Charpy unnotched [kJ/m²] 23°C
12
70
52
50
Charpy notched [kJ/m²] 23°C
5
11
19
10
DIN EN ISO
179/1eU
DIN EN ISO
179/1eA
750
650
550
940
ALBIS Norm
Flow spiral [mm]
* conditioned
15
jim.keeler@albis.com / (248) 410-9015
DIN EN ISO 527
DIN EN ISO 527
DIN EN ISO 527
DIN EN ISO 527
Performance of next PP GF 35
Benchmark Il
E-Modul 23°C
200%
Flow spiral
180%
160%
E-Modul 75°C
140%
120%
ALBIS GROUP
Albis Plastics Corporation
next PP 30
PP LFRT 30
PA 6 GF 30 con.
100%
Charpy notched
E-Modul 120°c
80%
60%
40%
tensile strength
23°C
Charpy unnotched
Flexural strength
HDT A
 next PP shows comparable properties with better
flowability
16
jim.keeler@albis.com / (248) 410-9015
ALBIS GROUP
next PP GF 35 - Aging Tests
Thermal Storage Tests
Hot air storage
(Ofen storage)
E-Modul
0h / 23°C
[MPa]
DIN EN ISO 527
tensile strength
[MPa]
DIN EN ISO 527
elongation at break
[%]
DIN EN ISO 527
Flexural modulus
[MPa]
DIN EN ISO 178
Charpy unnotched
[kJ/m²]
DIN EN ISO 179/1eU
Charpy notched
DIN EN ISO 179/1eA
[kJ/m²]
Albis Plastics Corporation
1000h /
130°C
0h / 23°C
1000h /
150°C
7920
8290
8255
8100
98
106
109
105
3,0
3,0
2,7
2,6
6941
7684
7360
7570
55
55
52
48
10
10
11
11
 No reduction of the properties after thermal storage
17
jim.keeler@albis.com / (248) 410-9015
next PP GF 35 - Aging Tests
Oil aging test
ALBIS GROUP
Albis Plastics Corporation
 Oil aging 100h @ 90°C
Tensile Strength
120%
100%
80%
next PP GF 35
PA GF 30
VWRequirement
60%
Un. Charpy (23°C)
40%
E-Modul 23°C
20%
0%
Flexural Modulus
18
jim.keeler@albis.com / (248) 410-9015
Flexural Strength
next PP GF 35 - Aging Tests
Glycol aging test
 Glycol aging 100h @ 90°C
Tensile Strength
120%
ALBIS GROUP
Albis Plastics Corporation
PA GF 30
next PP GF 35
VW Requirement
100%
80%
60%
Un. Charpy (23°C)
40%
E-Modul
20%
0%
Flexural Modulus
19
jim.keeler@albis.com / (248) 410-9015
Flexural Strength
next PP GF 35
Drop-in solution / Warpage
ALBIS GROUP
Albis Plastics Corporation
shrinkage
PA 6 GF 30
next PP GF 35
longitudinal
0,16
0,4
transverse
0,82
0,6
averaged
0,49
0,5
 Drop-in solution, due to comparable shrinkage
 Less warpage, due to smaller difference between
longitudinal and transverse shrinkage
20
jim.keeler@albis.com / (248) 410-9015
next PP GF35
Targets / Applications
Main focus areas:
1. Automotive
►
Under the hood
−
engine cover, fan frame, fuse box,
air intake manifold, etc.
2. E&E
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Power tools
Appliances
3. General industries
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21
Furniture
Other existing PA6 GF applications
jim.keeler@albis.com / (248) 410-9015
ALBIS GROUP
Albis Plastics Corporation
ALBIS GROUP
next PP GF 35
Current Status Tests
Albis Plastics Corporation
 FMVSS 302 (flambility test)
passed
 Shrinkage 60x60x2 mm3 (parallel / transverse)
0,3-0,4 / 0,5-0,6
 Glow wire test/ 650°C @ 1 mm - 4 mm
passed
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GWFI
IEC 60695-2-12
 Emissions
not finished
 Media storage
not finished
 Scratch resistance test
not finished
22
jim.keeler@albis.com / (248) 410-9015
next PP GF 35
Summary
ALBIS GROUP
Albis Plastics Corporation
 Weight reduction (ca. -18% vs. PA)
 Economic feasibility
 Excellent HDT performance (HDT A = 154°C);
PP GF 140°C, PP LFRT 156°C, PA GF > 200°C
 High stiffness (> 8000 MPa @ 23°C)
 Good aging properties
 Drop-in solution / Warpage
 Processing advantages (Flow spiral approx. 94 cm)
 Outstanding surface properties
23
jim.keeler@albis.com / (248) 410-9015
ALBIS GROUP
Albis Plastics Corporation
Thank you for your attention!
Jim Keeler,
Albis Plastics Corporation
jim.keeler@albis.com