Post on 09-Mar-2018
SABIC AUTOMOTIVE
STAMAX™ PP AUTOMOTIVE STRUCTURES
CESAR MARELLIA.D.EAMÉRICA DO SUL
No. 1
Sustainability
is a design challenge…
…SABIC’s materials
contribute to the
solution.
RECYCLE
MORE
MAKE THINGS
LAST LONGERMAKE THINGS MORE
EFFICIENTLY
USE FUEL +ENERGY
MORE EFFICIENTLY
•Recycled resin
•Bio-based reins
•Eco-FR resins
•Thin-wall design
•Yield improvement
•Process elimination
•Fuel economy
•Energy efficiency
•Solar, LED, EV
•Durability
•Upgradeability
•Reusability
•Close the loop
•Design for Recycle
•Fewer materials
THINK BIGGER: SUSTAINABILITY + DESIGN
IMPROVE
MATERIALS
Our challenge: We must educate our
customers both to think about sustainability
more broadly, AND, to think SABIC for an
integrated solution. To achieve this, WE
have to think about sustainability more
broadly and inclusively!
Adapted from the UNEP D4S Manual and the IDSA Okala Design Guide
No. 2
BRAIN STORM – INTRODUCTION
MAKE THINGS
MORE EFFICIENTLY
USE FUEL +ENERGY
MORE EFFICIENTLY•Thin-wall design
•Yield improvement
•Process elimination
•Fuel economy
•Energy efficiency
•Solar, LED, EV
+
No. 3
SABIC® PP AUTOMOTIVE PORTFOLIO
SABIC PP random copolymer4935
STAMAX™ resin: long glass fiber PP20-30-40-60 YM and YK series
• Stiffness, tensile strength, creep, heat distortion, aesthetics
• Front end modules, door modules, IP carriers
SABIC PP compound:• impact modified PP, aka TPO
• mineral filled PP
• glass filled PP
5000-6000-7000-8000-9000 series
G32XX and 15T10XX, 37T10XX series
• Stiffness, impact, flow, CLTE, aesthetics
• Bumpers, body panels, interiors, HVAC, structures
SABIC PP super high impact copolymer86MF97-108MF97
Impacto, a aderência da tinta, resistência aos raios UV,
Bumpers
SABIC PP high crystalline copolymerCX02-CX03-CX04
Rigidez, densidade, impacto, Flow, painéis de porta
SABIC PP copolymerPHC31
PP
resin
sC
om
po
un
ded
PP
No. 4
STAMAX™ RESIN – GRANULATE LONG GLASS FIBER PP
Glass filament
Thermoplastic coating
PP matrix
+ additives
Glass coating
Glass Roving
No. 5
A LONG HISTORY IN LONG GLASS FIBER MATERIALS
• Pultrusion Process for Granulate Long Fiber Technology (G-LFT)
DSM production 1953 – 1997
• Direct Long Fiber Technology (D-LFT)
DSM investigated 1993 – 1997
• Micro Impregnation for Granulate Long Fiber Technology (G-LFT)
DSM 1997- 2002 / SABIC acquires in 2002
• Acquisition of RheMax Product Line
SABIC expands wirecoating to North America in 2009
• Expanded capacity in Americas to support global demand
BSL, Mississippi in 2011
No. 6
STAMAX™ RESIN - GRADE PORTFOLIO
Long fiber provides:
Excellent stiffness and strength
Good creep and fatigue behavior
Excellent impact resistance over a broad temperature range
Dimensional stability (comp. low warpage)
Standard pellet length: 15 mm
Color: general purpose black
Currently in production in USA, Belgium, China
Grades
PP - Homopolymer 20YM240 30YM240 40YM240 60YM240
PP - Copolymer 20YK270 30YK270 40YK270 60YK270
Base Polymer 20 30 4060
(for dilution)
No. 7
STAMAX™ RESIN - FOCUS APPLICATIONS
Instrument panels• Structures
• Center stacks
Interiors
• Door modules
• Seating
• Hatch back
Front Ends• FEMs
MATERIAL PROPERTIES
STAMAX™ RESIN
No. 9
MECHANICAL PROPERTIES - OTHER PLASTICS VS. PP G-LFT
mSMA PC/ABS PC/ABS STAMAX™ RESIN
Filler content (%) 12 0 10 20
Density (kg/m3) 1150 1150 1200 1050
Tensile strength (Mpa) 56 48 63 81
E-modulus (Mpa) 4700 2300 3900 4800
Izod notched impact 23C [kJ/m2] 8 48 11 15
Izod notched impact -30C [kJ/m2] 7 38 9 20
HDT 1.8 (C) 115 127 130 157
Spiral flow at 2 mm [mm] 230 345 300 650
CLTE [10-6/K] 55 75 55 45
No. 10
EFFECT LENGTH ON FIBER ORIENTATION AND SHRINKAGE
Short glass: highly aligned orientation
Long glass: more isotropic orientation
High width
shrinkage
Low width
shrinkage
No. 11
GLASS FILLED PP SENSITIVITY TO WARP
Short glass materials show approximately 2 times higher warp
• Shorter fibers orient more easily in flow direction (highly anisotropic materials)
30% Long glass 30% Short glass
MATERIALS CHARACTERIZATION, DESIGN AND SIMULATION
STAMAX™ RESIN
No. 13
MATERIALS CHARACTERIZATION, DESIGN AND SIMULATION
No. 14
FIBER ORIENTATION PREDICTION IS CRITICAL
Default result of Moldflow:
Correct long fiber result:
50% error
in modulus
Validated
correct
results at
SABIC
Short glass: highly aligned orientation
Long glass: more isotropic orientation
High width
shrinkage
Low width
shrinkage
Effect of Fiber Orientation
on Shrinkage
Result of Fiber Orientation
Prediction on Modulus
LGF material knowledge leads to more accurate material model and application success!
No. 15
FIBER ORIENTATION PREDICTION IS CRITICAL
No. 16
WHY RUN SIMULATIONS IN PP-LGF?
• Shorter development time
• Greater cost pressure
• Reduced/no prototypes
• Virtual prototyping
• Doing it right the first time
65mm
Moldflow code and process enables accurate prediction of fiber orientation, warp, and mechanicals
No. 17
PROPER PREDICTIVE MODELLING CAPABILITYSAVES MASS & COST
Optimized for weight &
performance
2.85 KgInitially released package 3.60 Kg
Fiber orientation core layer E-modulus distribution
20% mass savings realized using LGF design, process and materials knowledge
No. 18
STAMAX™ RESIN DESIGN
No. 19
DIMENSIONAL
Dimensional accurancy
No major changes to production tool
• Only some insert positions changes, ca. up to 1.0 mm resulting in all dimensions within ± 1.0mm.
• No adjustments needed between mid and side parts.
Low warpage part
AN ALL-PLASTIC, DESIGN-OPTIMIZED SABIC SOLUTION
STAMAX™ RESIN
No. 21
BIG BENEFITS
• Minimize weight
• Maximize design flexibility
• Styling differentiation
No. 22
ANIMATION
No. 23
TRADITIONAL APPROACH VS. SABIC’S
TRADITIONAL SABIC
No change in design of the full
tailgate or its components
Plastics simply replace
conventional materials
Minimal to no reduction in weight
or cost with lower performance
Optimize the design
of the full tailgate
High performance SABIC
materials backed by design
and engineering support
Significant weight reduction,
maximized design freedom,
equal or improved performance
and no cost penalty
No. 24
STAMAX™ RESIN SUPPORT
TIER
MATERIALS
PROCESS
DESIGN
&
STYLING
PREDICTIVE
ENGINEERING
DEVELOPMENT
TEAM
No. 25
CONCEPTUAL GOALS & OBJECTIVES
• 30% lighter vs. conventional tailgate
• Equal or better performance vs. conventional tailgate
• Tailgate as an offline module
• Class A surface for inner structure (only some additional service panels)
• Integrate the hinge in the inner structure
• Glazing, lighting and spoiler integrated in backlite
• Exterior bottom part fixed mechanically; no gluing to ensure serviceability, repairability and
flexibility on process (paint) and design (license plate)
• Use standard components (gas strut, lock, wiper motor)
No. 26
MATERIAL SOLUTIONS
BACKLITE / REAR WINDSHIELD
• LEXAN™ GLX143 resin (transparent)
• CYCOLOY™ XCM830 resin (blackout)
• EXATEC™ resin plasma coating
CARRIER
• STAMAX™ 40YM240 resin (in-coloured)
REAR LIGHTING
• LEXAN LS1 / LS2 resin (lenses)
• LEXAN HF1110R resin (reflectors)
EXTERIOR PANEL
• SABIC® PPc 8900 (for offline painting)
• NORYL GTX™ 985 resin (for online painting)
No. 27
SIGNIFICANT WEIGHT REDUCTION
30% or 12.5 kg vs. conventional tailgate materials (i.e., steel, glass)
COMPONENTS
PROCESS
ASSEMBLY
STAMAX™ RESIN
No. 29
THE LAST SIX INCHES – COMPONENTS
© IAV · 08/2013 · VB-S63 29
No. 30
THE LAST SIX INCHES – COMPONENTS
© IAV · 08/2013 · VB-S63 30
Stuctural part
Bracket
latch
Reinforcement
part
Crash cable
Harness and hoseGlue
Backlite
Tail
lamp
upper
Tail lamp
middle
Tail lamp
lower
Wiper motor
Latch
Outer panel
3rd brake light
Handle
License
plate
lamp
Sealing
Covers
Wiper
HingesGas strut
In SABIC Materials
No. 31
PROCESS MAP – 1ST HIGH LEVEL DRAFT
MOLDINGSECONDARY OPERATIONS
COMPONENT ASSEMBLY
FINAL ASSEMBLY
STAMAX™ resin inner structure
2K-LEXAN™ resin backlite with CYCOLOY™ resin blackout
EXATEC™ Coating
Defroster
Applique in SABIC® PPc
Cleaning
Flaming
Painting in body color
Applique in NORYL GTX™ resin
On-line painting
OR
Machining
Flaming/activation for gluing
Riveting and preassembling components on inner structure
Assembling (gluing) backliteon structure
Assembling last components
Positioning and assembling on car, fixing connect functions to car
Assembling applique
No. 32
ANIMATION
No. 33
5.1 Hinge to
BIW4.1 Covers (6x)
© IAV · 08/2013 · VB-S63 33
THE LAST SIX INCHES – ASSEMBLY SEQUENCE
1.1 Structure part + inserts
1.2 Bracket latch
1.3 Reinforcement part
1.4 Crash cable
1.5 Harness and hose
1.6 Glue
1.7 Glazing
1.8 Tail lamp upper
1.9 Tail lamp middle
1.10 Tail lamp lower
1.11 Latch + wiper motor
2.1 Outer panel
2.2 3rd break light
2.3 Handle + license plate lamp
2.4 Sealing
1
2
3 4
4.2 Bump stops
4.3 Ball screws
4.4 Wiper
Assembly
to BIW
4.5 Hinge
5
5.2 gas strut
SOME EXAMPLES OF PERFORMANCE DATA
ALL-PLASTIC TAILGATE
No. 35
STIFFNESS – MEETS ALL REQUIREMENTS UP TO 80°C
300 N Gravity
267 N
224 N
600 N
0.01 N/mm2
Bending
Torsion
Slam
a = 100 m/s2
Vertical
stability
Gas struts
Seal
112 N
500 N
Pull
Lateral
stability
QUESTIONS?
0800 772 2864
latin.america@sabic-ip.com
No. 37
THANK YOU!
No. 38
No. 39
DISCLAIMER
DISCLAIMER: THE MATERIALS, PRODUCTS AND SERVICES OF SAUDI BASIC INDUSTRIES CORPORATION
(SABIC) OR ITS SUBSIDIARIES OR AFFILIATES (“SELLER”) ARE SOLD SUBJECT TO SELLER’S STANDARD
CONDITIONS OF SALE, WHICH ARE AVAILABLE UPON REQUEST. INFORMATION AND RECOMMENDATIONS
CONTAINED IN THIS DOCUMENT ARE GIVEN IN GOOD FAITH. HOWEVER, SELLER MAKES NO EXPRESS OR
IMPLIED REPRESENTATION, WARRANTY OR GUARANTEE (i) THAT ANY RESULTS DESCRIBED IN THIS
DOCUMENT WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY
OF ANY DESIGN OR APPLICATION INCORPORATING SELLER’S MATERIALS, PRODUCTS, SERVICES OR
RECOMMENDATIONS. UNLESS OTHERWISE PROVIDED IN SELLER’S STANDARD CONDITIONS OF SALE, SELLER
SHALL NOT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS MATERIALS, PRODUCTS,
SERVICES OR RECOMMENDATIONS DESCRIBED IN THIS DOCUMENT. Each user is responsible for making its own
determination as to the suitability of Seller’s materials, products, services or recommendations for the user’s particular use
through appropriate end-use and other testing and analysis. Nothing in any document or oral statement shall be deemed to
alter or waive any provision of Seller’s Standard Conditions of Sale or this Disclaimer, unless it is specifically agreed to in a
writing signed by Seller. Statements by Seller concerning a possible use of any material, product, service or design do not,
are not intended to, and should not be construed to grant any license under any patent or other intellectual property right of
Seller or as a recommendation for the use of any material, product, service or design in a manner that infringes any patent
or other intellectual property right.
SABIC and brands marked with ™ are trademarks of SABIC or its subsidiaries or affiliates.
© 2014 Saudi Basic Industries Corporation (SABIC). All Rights Reserved.
† Any brands, products or services of other companies referenced in this document are the trademarks, service marks
and/or trade names of their respective holders.