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.