Plastics in Automotive
JAN RODA
Department of Polymers, Faculty of Chemical Technology,
Institute of Chemical Technology, Prague
Lanxess Mobility Days
Prague, November 22 – 23, 2012
INSTITUTE OF CHEMICAL TECHNOLOGY, PRAGUE
Faculty of Chemical Technology, Department of Polymers
Institute of Chemical Technology, Prague
2
Five broad families of materials
metals
ceramics
glasses
polymers – plastics, elastomers
hybrids – composites, sandwiches, lattices, foams
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
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
World polymer production
Plastics
Fibers
Elastomers
70 %
synthetic
13 %
regenerate
1.2 %
natural
8.5 %
synthetic
4.5 %
natural
2.8 %
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Europe
21,5%
Rest of Asia
15,0%
CIS
3,0%
China
23,5%
Middle East.
Africa
6,5%
NAFTA
20,5%
World
Japan
5,0%
Latin America
5,0%
Production 2010 - 264 Mt/a
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Building & Construction
20,6%
Packaging
39,0%
Electrical & Electronic
5,6%
Automotive
7,5%
Others
27,3%
European Plastics Demand by Segments 2010
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Difference in mechanical properties of plastics and elastomers
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS 9
Annual Breakdown of Materials Content in US Light Vehicles
Materials
Regular steel
High and medium strength steel
Stainless steel
Other steels
Iron castings
Aluminum
Magnesium
Copper and brass
Lead
Zinc castings
Powder Metal
Other metals
Plastics/composites
Rubber
Coatings
Textiles
Fluids and lubricants
Glass
Other
Weight (kg)
738
237
34
15
136
143
5
29
20
5
19
2
155
84
13
22
97
48
41
Weight (%)
40.0
12.9
1.8
0.8
7.4
7.7
0.3
1.6
1.1
0.2
1.1
0.1
8.4
4.5
0.7
1.2
5.3
2.6
2.2
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
Eng. resin blends
3,0%
POM 1,0%
Other
10,0%
Polyolefins
28,0%
Elastomers
11,0%
PUR
11,0%
Polyamides
9,0%
PVC
4,0%
PC, ABS, and blends
12,0%
PET, PBT
11,0%
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
Polyethylene
5
Polyurethanes
16
Polycarbonate
5
Nylon
10
Polyvinyl butyral
2
ABS
7
Polyvinyl chloride
8
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
Eng. resin blends
3,0%
POM 1,0%
Other
10,0%
Polyolefins
28,0%
Elastomers
11,0%
PUR
11,0%
Polyamides
9,0%
PVC
4,0%
PC, ABS, and blends
12,0%
PET, PBT
11,0%
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)
CH CH2
CH3
Tm = 170 °C
Tg = -10 °C
UUT = 90 °C
n
E= 0.8 – 1.1 – 2.5 GPa /reinf.
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
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyethylene (PE)
CH2 CH2
n
Tm = 110-130 °C
Tg = -80 °C
UUT = 70 °C
E= 0.2 – 0.4 – 0.7 – 1.4 GPa
semicrystalline
different types – LDPE, LLDPE, HDPE
Application:
trim duct – works
reservoirs for fluids
multilayer fuel tanks
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyethylene terephthalate (PET)
O CH2 CH2 O C
Tm = 265 °C
Tg =
75°C
UUT= 70-100°C
O
C
O n
E = 2,5-3,1 GPa
semicrystalline
low cost material
Application:
fibers for carpeting application
fabrics, seat covering , floor mats
films
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polybutylene terephthalate (PBT)
Tm = 225 °C
Tg =
65°C
UUT= 130 – 150 °C
O CH2 CH2 CH2 CH2 O C
O
C
O n
Et = 2,5-10(filled)GPa
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
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
• Pocan PBT Typical application
.
Polycarbonate (PC)
(from Bisphenol A and COCl2)
Tf =
230°C
Tg = 150°C
UUT= 125 °C
CH3
O
C
CH3
O C
O n
E = 2.2 – 2.5 GPa
amorphous polymer
excellent optical clarity and toughness
blends – improved toughness
Application:
lenses, glazing
Blends of PC with ABS and PBT
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Acrylonitrile-butadiene-styrene copolymer (ABS)
H3C
CH2 CH CH CH2
CH2 C
Tg = 105°C
UUT= 90°C
N C n
o
H3C
CH2 C
CH CH2
N C n
m
amorphous
E = 2,2-2,9 GPa
good impact
excellent balance of properties – impact strength, stiffness, thermal
stability, can be painted or chromed
Application:
chromed trim
interior and exterior trim components
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyvinyl chloride (PVC)
CH CH 2
Cl
n
Tg = 80 °C
UUT= 60°C
E = var GPa
amorphous
good toughness, flexibility
Application:
vinyl trim for leather, wear resistant coatings, cable insulations, wiring,
roof rack coverings, grips, moulded plugs,
dashboard , sun visors
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
CH3
Polymethylmethacrylate (PMMA)
CH2 C
O C
n
O
Tg = 115 °C
UUT= 60-80°C
E = 2,9GPa
CH3
amorphous
clear, tough, perfect weatherability,scratch resistance
Application:
glazings
lenses
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyurethanes
different structures
(diversity in composition and application)
basic structural unit – chemical bond
NH C
O
O
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
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
Foam for automotive
― 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
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyamide 6 (PA 6)
NH
(CH2)5 C
O n
Tm = 220 °C
Tg = 50 °C
UUT= 150 °C
unreinforced
E = 3 GPa
glass fiber reinforced E = 9 GPa
semicrystalline
Application:
engine covers
handles
fans
shrouds
fibres - carpeting
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Durethan® – Typical automotive applications under the hood
Fuel Delivery
System
Coolant Circuit
Air
System
Oil
Circuit
Others
(electric / electronic, covers, ...)
Structural
Parts
Polyamide 66 (PA 66)
Tm = 260 °C
Tg = 50 °C
UUT= 170 °C
NH (CH2)6 NH C (CH2)4 C
O
O n
unreinforced
E = 3 GPa
glass fiber reinforced E = 9 GPa
semicrystalline
Application:
air intake manifold, carpeting, under hood
PA 6 + PA 66 properties depends on moisture absorption – water = softness
PA 11 + PA 12 low moisture absorption - fuel lines
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyamide engineering plastic
> 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
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS
Polyamide engineering plastic
• 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
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
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 housing
ABS
-- 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
Plastics in Fuel Systems
fuel tank (the largest plastic component)
HDPE or multilayer construction – HDPE plus EVOH copolymer
FACULTY OF CHEMICAL TECHNOLOGY
DEPARTMENT OF POLYMERS