Lightweight structures with new car...

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Lightweight structures with new car technologies Julian Haspel Application Development, LANXESS Business Unit Semi-Crystalline Products Automotive Days Poland October 27-28, 2011

Transcript of Lightweight structures with new car...

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Lightweight structures with new car technologies Julian HaspelApplication Development,LANXESS Business Unit Semi-Crystalline Products

Automotive Days Poland October 27-28, 2011

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LANXESS – A premium supplier of high-tech plastics for demanding technical applications

LANXESS provides premium high-tech plastics

Main industries of LANXESS’ high-tech plastics are automotive (>50%) and electro / electronics (>20%)LANXESS’ leading high-tech plastic brands: Durethan®, Pocan®

- Recognized as intelligent system solutions - Combining mechanical strength with resistance to heat,

oils and abrasionNew service brand HiAnt®- Tailored international customer service and in-depth

know-how in product, application, process and technology development

Main Business Unit: Semi-Crystalline-Products (SCP) belonging to Performance Polymers Segment

Sources: JD Powers 08/2010; LANXESS own estimates

Automotive

E & E

Sport / leisureConstruction

OthersPackaging

High-tech plastics

100%

50%

0%

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More than 20 years of experience in compound technology

Inventor of the hybrid technology

Innovative materials and concepts for new application fields in automotive and motorcycle manufacturing

Well acquainted with various demands by the automotive industry

Valuable expertise from other industries (e.g. electro)

Important contribution to future E-mobility, alternative fuels and flame protection

LANXESS – A leading development partner for the automotive industry

Valuable experience and focus on innovation for the future of mobility

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Share of materials in automotive production [%]

Global production of light vehicles [mn units]

Growing car production and trend of weight reduction drive demand for high-tech plastics

Innovations in high-tech plastics enable future mobility

Global car production with annual growth of ~3.3%Increased usage of high-tech plastics per car drives growth of 7% p.a.Global production of light vehicles will increase by 30% within 5 years Current high-tech plastic share in Western cars 15-17%Chinese vehicles only consist of about 7% plastic components Growth potentialE-mobility further pushes high-tech plastics

Total share of plastic expected to exceed 25%

Sources: JD Powers 08/2010; Polymotive; Plastics Europe 2010; LANXESS own estimates; Handelsblatt.com (Oct. 21, 2010),

~+30%

2010 2015e

50

100

2005

~+10%

72 65 59 52 50

2123 27 31 32

12 14 17 187

High-tech plasticsOther materialsFerrous metals

2010 2015e1980 1990 2000

0

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Comparison of different fuel economy standards worldwide

Comparison of actual and projected fuel economy for new passengers vehicles

Sources: AN, F., and A. Sauer. 2004. Comparison of Passenger Vehicle Fuel Economy and GHG Emission Standards Around the World. Pew Center on Global Climate Change, Washington, DC; Updated data obtained from “Passenger Vehicle Greenhouse Gas and Fuel Economy Standards: A Global Update“, The International Council for Clean Transportation, retrieved from there, July 2010

Fuel

eco

nom

y (m

iles

per g

allo

n)

2002 2004 2006 2008 2010 2012 2014 2016 2018 2020

Solid points and lines: actual dataHollow dots and dashed lines: nearest targets enactedSmaller Hollow dots and dotted lines: proposed targets

20.00

25.00

35.00

30.00

40.00

45.00

50.00

55.00

60.00

65.00

70.00

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Thermoplastic in automobiles

Increased use of high-tech plastics as basis for automotive innovation

Thermoplastic in trucks

Innovative materials lead to weight and cost reduction, greater safety and comfort

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What is “Plastic/Metal Hybrid” (PMH)?

Metal sheet

Polyamid 6 GR

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Production process (1/3) – Deep-drawn metal sheet

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Production process (2/3) – Injection molding

Open injection mold tool Pre-positioned metal insert Finished composite

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Production process (3/3) – Finished product

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Deformation under bending load

Forc

e F

[kN

]

Deformation f [mm]

50

Plastic/metal composite profile

340

f

F

Closed sheet steel profile

Open sheet steel profile

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Cross-section of a plastic/metal hybrid structure

Over-molded edge

Sheet metal profile Molded „button“

Plastic rib structure

Molded „button“

Over-molded edge

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Typical application of Plastic/Metal Hybrid: front ends

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Examples of Plastic/Metal Hybrid front ends out of Durethan®

More than 70 models in mass-productionFar more than 50 mn parts on the road

Audi A4 – 2000 Ford Focus – 1998 Ford Fiesta – 2001 Renault Megane – 2002 Mazda Demio – 2002 Hyundai Getz – 2002 Kia Spectra – 2003

Audi Q7 V12 – 2008

Mercedes Benz A – 2004 Chrysler 300C – 2004 VW Polo – 2001 Nissan Quest – 2003 BMW X3 – 2003 BMW 1er – 2004 BMW 3er – 2005 Mercedes Benz Vito – ‘03

Ford Galaxy – 2006 Ford S-Max – 2006 Audi TT – 2006 Hyundai Avant – 2006 Hyundai Veracruz – 2006 Hyundai Santa Fe – 2006 Kia Carens – 2006 Kia Lotze – 2006

Ford Mondeo – 2007 Audi A5 – 2007 Audi A4 – 2007 Hyundai i30 – 2007 Hyundai Starex – 2007 Audi Q5 – 2008 Ford Kuga – 2008 Hyundai Genesis – 2008

Audi A3 – 2008 Audi A7 – 2010 Audi A1 – 2010 Audi A8 – 2010

Audi A6 – 1998

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Plastic/Metal Hybrid – Part of the body structure

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Worldwide first pedal box with PMH

Material Durethan BKV 30 H2.0

10% cost and weight advantages compared to conventional design

Integration of numerous functions

Ductile crash behavior

Plastic/Metal Hybrid – Pedal box

Shift gear Automatic gear

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State-of-the-art technology for aircrafts

Challenge: cost optimized and ready for mass production alternatives for the automotive industry

High-tech plastics with glass, carbon, aramid or mixture

2D semi-finished product (panel) based on a thermoplastic matrix

Easy alteration to 3D shape

Fabrics or uni-directional fabric made of continuous filaments

Complete impregnation

Continuous fiber reinforced thermoplastic composites (CFT) –Overview

CFT for demanding mobility solutions

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AdvantagesLow weight – high strengthExcellent crash performanceNo corrosion and easier recyclingIntegration of functionsPossibility of complex designsLow investment

ChallengesInfluence of temperature and water absorption

Continuous fiber reinforced thermoplastic composites (CFT) –Advantages and challenges

High performance systems for greater safety, efficiency and sustainability

Hybrid steel sheet

Wei

ght r

elat

ed fo

rce

/ [N

/g]

Deflection / [mm]

Hybrid PA composite sheet

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Door impact beam

Continuous fiber reinforced thermoplastic composites (CFT) –Examples

Steering column

One shot molding process

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Innovative high-tech plastics for the future of mobility

LANXESS Semi-Crystalline Products –High-tech plastics key for future sustainable mobility

Expertise in customer-oriented R&D and cutting edge product properties

Cost and performance optimized solutions ready for mass production

High-tech plastics material leadership and engineering know-how

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This presentation contains certain forward-looking statements, including assumptions, opinions and views of the company or cited from third party sources. Various known and unknown risks, uncertainties and other factors could cause the actual results, financial position, development or performance of the company to differ materially from the estimations expressed or implied herein. The company does not guarantee that the assumptions underlying such forward looking statements are free from errors nor do they accept any responsibility for the future accuracy of the opinions expressed in this presentation or the actual occurrence of the forecasted developments.No representation or warranty (express or implied) is made as to, and no reliance should be placed on, any information, including projections, estimates, targets and opinions, contained herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements contained herein, and, accordingly, none of the company or any of its parent or subsidiary undertakings or any of such person’s officers, directors or employees accepts any liability whatsoever arising directly or indirectly from the use of this document.

Safe harbour statement