On the road to eco-mobility:
Innovative solutions for lightweight vehicles
Jean-Claude Steinmetz
June, XXX 2012
A major player in chemicals with compelling strengths
2011 Proforma
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110
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GROUP PRESENTATION COPYRIGHT 2011 – SOLVAY SA NV
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An increased regulatory pressure to reduce CO2 emissions
g CO2 / km
200
2015
180
154 g CO2 / km
160
2016
140g CO2/km
140
2020
2015
120
130g CO2/km
95g CO2/km
100
80
2010
2012
2014
2016
2018
Jean-Claude Steinmetz
2020
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Meeting CO2 emission targets is a demanding challenge
for most OEMs
OEMs face
several billion of
euros penalties
 What will be the
repercussion on the
customer’s price?
2010, European Federation for Transport & Environment
Jean-Claude Steinmetz
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Innovation is the Key to limit penalties impact
Innovation regarding:
1- Car conception
Electrical vehicle
Hybrid vehicle
2- Powertrain performance
Engine downsizing
3- Car structure
Lightweight solutions
Jean-Claude Steinmetz
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Available technologies to meet 2015 CO2 emission target
More efficient power train
10% fuel consumption
  -15g CO2
+ 13 kg / year
Weight (kg)
Aerodynamics
SCx decrease of 5dm2
  -2g CO2
Average vehicles weight
Rolling resistance
- 10%   -2g CO2
Source: PSA Moveo june 2011
Auxiliaries
air conditioning / lightning
 from -2 to -10 g CO2
New Peugeot 208: -
110 kg vs 207
Aluminium, high-strength
steel & redesign
  -10g CO2
Plastic part weight savings
  -3g CO2
New Audi A3:
- 80 kg vs previous model
Jean-Claude Steinmetz
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New materials will allow breakthrough vehicle weight saving
Stake:
>100kg weight saving
Weight reduction
130g CO2/km
Target 95g
CO2/km
NON STRUCTURAL
SEMI STRUCTURAL
2010
2025
Thermoplastic
compounds
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STRUCTURAL
Thermoplastic
composites
Jean-Claude Steinmetz
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Required stakes to meet 2020 CO2 emission targets
WEIGHT
SAVING
TARGET:
CHALLENGES
VEHICLE RETHINK & REDESIGN
COST COMPETITIVENESS
-20%
= 200kg mass
reduction
MEANS TO SUCCEED
PARTNERSHIPS WITH OEMs
PROCESS
SAFETY
COLLABORATIVE R&D
PROGRAMS
RECYCLING
SUVENTIONS
Industry
Institutions
JOINT REGULATIONS
Jean-Claude Steinmetz
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Partnership & Collaborative programs: FastLite, the lightweight
program launched by french OEMs for Body-In-White applications
Objectives: build a B-Pillar composite demonstrator
•
•
•
Develop a glass or carbon reinforced Polyamide composite material
Develop part manufacturing and integration process to meet automotive cycle times
Validate structural crash performance
Partnership with:
TOMORROW
Body-in-White
TODAY
B-pilar
A first step to demonstrate the feasibility
of Polyamide composite solutions
on BIW structure
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Jean-Claude Steinmetz
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Process:
Lightweight seat structure developed with Faurecia
Partnership with:
2012
2016
2020
Metal solution
Polyamide solution
Composite inserts
Target:
20% weight saving
35% weight saving
Crash performance under validation
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Jean-Claude Steinmetz
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A complete Life Cycle Assessment
Chemist
+
Formulator
Tier 1
OEM
User
Non Recycled Technyl® production
Vehicle
Assemblage
assembling
du véhicule
Using
Utilisation
End
of vie
life
Fin de
Recycled Technyl® production
Injection of
Fan and Shroud Module
2 ACV because of different formulation
1 Unique ACV because of same design and weight
7 environmental indicators in this Life Cycle Assessment
Acidification
Eutrophisation (aquatic
environment disturbance)
Climate change
Non renewable ressources
(Greenhouse gas emissions)
selling out
Ozone layer diminution
Energy consumption
Photochemical
oxydation
A unique collaborative approach with a multi-criteria analysis
for the whole value chain
Jean-Claude Steinmetz
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Substantial reduction of environmental impact for all indicators
New
FSM
Recycled New
FSM
FSM
Recycled
FSM
New FSM Recycled New FSM Recycled New FSM Recycled New FSM Recycled New FSM Recycled
FSM
FSM
FSM
FSM
FSM
The introduction of a recycled polyamide reduces substantially
the part’s environmental impact during it whole life
(from -9% to – 28%). It has been demonstrated for all evaluated points.
Jean-Claude Steinmetz
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TARGETS ACHIEVABLE THROUGH COLLABORATIVE PROGRAMS
WEIGHT
SAVING
TARGET:
-20%
= 200kg mass
reduction
TIME to MARKET
Product Development
Process optimization
COLLABORATIVE R&D PROGRAMS
Pan European program support
JOINT REGULATIONS
Jean-Claude Steinmetz
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Solar Impulse, the “King partnership program”
Solvay: the first main partner of the “zero fuel” airplane
Over 6,000 parts made
from Solvay products are used
in this lightweight airplane
Rhodia will be on board
for the new generation
Solar Impulse with
engineering plastics and
high performance fibers
© Image Jean Revillard
2014: Round-the-world flight in stages
Jean-Claude Steinmetz
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