Enabling Economical Vehicle Light Weighting Through New Glass

Reinforcement SolutionsHANS VAN DER STEEN, OWENS CORNING,

Global Business Development Leader, Structural Composites

October 13-16, 2014 Orange County Convention Center

Orlando, FL

Copyright © 2014 Owens Corning. All Rights Reserved. Image copyright: © Misha - Fotolia.com, © istock.com

Source: Owens Corning Marketing Intelligence

The Drivers for Composites in Transportation

Need for light, less pollutant vehicles50% of automotive sales from BRICIncreased comfort demands

Improve fuel efficienciesNew OEM & market concentrationIncreased vehicle functionality

Advanced composites solutionsAdvanced polymersHigh strength metalsNew battery materials & chemicals

Lower CO2 emissionsUrbanizationGlobalization

Mega Trends

AutomotiveIndustry Trends

TransportationTrends

Impact forMaterials

and Chemicals

2000 2005 2010 2015 2020 202520

25

30

35

40

45

50

55

60

65

9

11

13

15

17

19

21

23

25

27

Canada 2025: 56.2

Brazil 2017[3]: 40.9S. Korea 2015: 39.3

China 2020[1]: 50.1

Japan 2020: 55.1

EU 2021: 60.6

Mexico 2016 : 35.1

US 2025[2]: 56.2

US

Canada

Mexico

EU

Japan

China

S. Korea

India

Brazil

US km/lMiles p

er

gasoline g

allon n

orm

alize

d t

o

CA

FE t

est

cycl

e

km/l

Regulations, the key driver for Light Weighting

Source : International Council of Clean Transportation ( ICCT), May 2014http://www.theicct.org/info-tools/global-passenger-vehicle-standards.

Solid lines : historical performanceDashed lines : enacted targetsDotted lines : proposed targets

In Europe, the legal target of 130g/km set for 2015, is met two years in advance. 2013 CO2 emissions for new cars sold, fell 4% to an average 127grams/km.Source: European Environment Agency April 2014

The 95 gr/km cap on CO2 emissions in the EU will be fully implemented by 2021, and no longer 2020 as initially foreseen.Source: European Commission report Feb 2014

The Chinese government revealed a new mandate requiring at least 30 percent of all automobiles purchased by the government to be electric or “new energy” vehicles by 2016Source: China’s Ministry of Industry and Information Technology July 14

Region

Enforcement scheme

Fiscal: Penalty for excess emissions

Non-fiscal:Revoke type-approval

certificate

Non-fiscal: publish name of

manufacturer

US x x  EU x    Japan x   xCanada x x  China   x xS-Korea x    

The Trigger for Light Weighting, Regional Regulations

Source: International Council of Clean Transportation ( ICCT), May 2014

Dependent on weight

36%

Independent of weight

64%

Fuel consumption breakdown

Efficient Diesel Engines

Smart Gasoline Engines

Alternative Power Train Designs

Alternative Transmission Systems

Use Of Bio Fuels And Bio Diesel

Light Weighting With The Use Of Composite

Ways to reach emissions & Fuel efficiency targets

-100Kg -0.35 l/100km -9.0 g/km

Pie data source: Owens Corning estimate, September 2014

Structural Composites,the applications

Cross member

Pillars

Seat structures

Back seat floor

Central floor system

Roof structure

Door structure(crash beam)

Battery housing

Suspension

Bumper beams(crash cans)

Steel vs. Aluminum vs.Steel Composites vs. Steel

Weight Reduction ↓ ↓↓

Process Complexity ↑ ↑Raw Mat. Cost ↑ ↑↑

Design Freedom = ↑Function Integration = ↑

Source: Owens Corning estimate, September 2014

Structural Composites,Competitive Solutions

Approximately200kg of weight

reduction per vehicle will be required

to address OEMsCO2 gap

Short term Aluminum will displace

steel for one onone replacement,

With pure focus on weight out.

Medium-long term Composites allow for

enhanced function integration,

But requiresre-engineering ofthe car modules.

Vehicle production expected to

exceed 100MM units* by 2020

Potential ofweight out due to

composites is estimated at ~100 kg

by 2022 (20-25kg of

reinforcementsper car)

Source: Owens Corning estimate, September 2014The graph excludes the amount of non structural composites used in vehicles today

2015 2016 2017 2018 2019 2020 2021 20220.00

5.00

10.00

15.00

20.00

25.00

30.00

Kg

Co

mp

os

ite

s/ V

eh

icu

le

HighlyStructural

(300Kt)

Structural(200Kt)

Semi-Structural

(300Kt)

The Oportunity for Reinforcements in Structural Composites,

Source: Owens Corning estimate, September 2014

Why SMC forstructural composites

Steel vs. SMC versus Steel SMC versus Aluminum

Weight Reduction ↓↓ =

Function Integration ↑ ↑↑

Investments ↓↓ ↓↓

Raw Mat. Cost ↑↑ ↑

Design Freedom ↑ ↑↑

Process Complexity ↓ ↓

Cycle times ↑ ↑

Carbon Footprint ↓ ↓↓

FAST IMPREGNATION

CO2 EMISSION REGULATIONS

ME 1510 ROVING

VEHICLE LIGHT WEIGHTING

EXCELLENT PROCESSABILITY

LOW VOC EMISSIONS

DESIGNED FOR NEW EPOXY SMC

TECHNOLOGY

ME1510 MULTI-END ROVING

Designed for use with Epoxy SMC

Fast impregnation

Excellent process-ability

Good surface appearance

Designed for SMC low VOC3 emissions

Up to 25%2 part weight reduction

vs. steel

(1) Owens Corning lab, Besana, It, Nov.2012, Epoxy material system (2) Owens Corning SMC Technical Cost Modelling analysis, 2013(3) Volatile Organic Compound

Improved mechanical properties vs. standard

SMC materials

ME1510 MULTI-END ROVINGProduct Benefits

Up to 63%1

glass loading achievable

UP TO 25% PART WEIGHT

REDUCTION VS. STEEL

Improved mechanical

properties vs standard SMC

SUPERIOR STRENGTH AND FLEXURAL MODULUS+ 20% compared to Owens Corning ref. product+ 23% compared to competitor

SMC molded laminates, Owens Corning Besana pilot line, Summer 2013 Pictures courtesy BASF, Germany

Flexu

ral St

rength

[Mpa]

Flexu

ral M

odulus [Gpa *

10]

Tensile

Stre

ngth [M

pa]

Impact

Charpy [

KJ/m²]

050

100150200250300350400450500

OC_ME1510OC_P204Competition

Good bonding

Weak bonding

Up to 63%1

glass loading achievable

ME1510 MULTI-END ROVINGProduct Benefits

Automotive Light Weighting will be one of the drivers for composites growth in the next decade.

SMC is an attractive Process Technology for Structural Composites

Epoxy SMC = no VOC emissions & good fatigue

Owens Corning ME1510 allows for high glass loading which results in better mechanical properties.

Summary