StyLightNew material solution for lightweight design

ACCE September 6-8, 2017John Fialka, Business Development Manager

Contents

PROCESSING OF STYLIGHT

DOOR PANEL DEMONSTRATOR

CHARACTERISTIC PROPERTIES OF STYLIGHT

AUTOMOTIVE FOCUS ON LIGHTWEIGHTING

KEY APPLICATIONS FOR STYLIGHT

DRIVERS FOR LIGHTWEIGHTING IN AUTOMOTIVE

Slide 3

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2016 2019 2022 2025

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Model Yearmiles per gallon grams CO2 emissions per mile

Fuel Efficiency – US CAFÉ standards trend

Slide 4

Same message around the world…

� Growing global concern to reduce greenhouse gas emissions

Slide 5

Automotive OEM’s Focus on Lightweight Material Solutions to meet CAFÉ & Emission Targets

•10% reduction in vehicle

weight can result in 8% fuel

economy improvement

•Target 4.5 MPG reduction

requires 25% weight reduction

(900lbs)

•Light weight solutions also

provide safety benefits

� American Chemistry Council issued “roadmap” to accelerate use of Plastics

JEC Composite Show 2017 Highlights

•Growth in TPC Automotive Applications – Wiper tub

– Seat Frame

– Oil Pans

•Growth in Carbon Fiber Applications– Growing commercial applications in Automotive i.e. Ford Super

GT, GM Corvette hood & BMW I3 Electric car & 7 Series

– Aesthetic applications for high end vehicles

STYLIGHT - INNOVATION WITH THERMOPLASTIC COMPOSITES

Slide 8

• Semi-finished product (plate/sheets)

• Thermoplastic matrix = Thermoformable = no chemical reaction = short cycle time

• Reinforced with fabrics or non-crimp fabrics– Glass– Carbon

• No trapped air = no voids

• Fully impregnated

• Integration in the injection molding process possible (back molding with all styrenics possible)

Endless fiber reinforced materials

The sheet manufacturing process

StyLight Processing

CHARACTERISTIC PROPERTIES OF STYLIGHT

Test Method and Materials

Name Stylight G290-1 PA6 [dry] TPC PC TPC

Matrix mod. SAN PA6 [dry] PC

Fiber E-Glass E-Glass E-Glass

Reinforcement 8 x balanced glass fabric [2/2]

290 g/m²

4 x balanced glass fabric [2/2]

600 g/m²

8 x balanced glass fabric [2/2]

290 g/m²

Thickness 2,0mm 2,0mm 2,0mm

Fiber content 45% 47% 45%

35mm

F

Test speed: 5 mm/minPre-load: 15 MPa

0

100

200

300

400

500

600

700

800

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Flexural Test DIN EN ISO 14125

StyLight G290-1

PC TPC

PA6 TPC [dry]

Mechanical Properties

F

MPa

% deflection

Increases the stiffness by 15% and the strength up to 40% versus conventionalThermoplastic Composites available commercially

Values are measured with balanced woven fabric 50/50, thickness 2mm, 8 layers at RT and dry, fiber volume content 45% to 47%

Temperature dependence modulus (SAN vs. PA6)

16400.00

16600.00

16800.00

17000.00

17200.00

17400.00

17600.00

17800.00

18000.00

18200.00

-50 -30 -10 10 30 50 70 90

Te

nsi

le m

od

ulu

s [M

Pa

]

Temperature [°C]

Theoretical Modulus Composite

SAN (358N)

PA6 dry (B3S)

PA6 cond. (B3S)

Assumptions: Tensile Modulus Glass Fiber: 73000 MPa; FVR: 45%; Ideal adhesion fiber/matrix; Micromechanics approach:

( )ϕϕ −⋅+⋅= 1MatrixIIFaserII

EEE

Mechanical Properties

0

50

100

150

200

250

PA6 TPC PC TPC StyLight

HDT A 1,8 MPa DIN EN ISO 75 [°C]

Impact Properties (Puncture impact Energy absorbtion)

Despite a relative brittle matrix StyLight laminate provide a high impact resistance

*Values are measured with 300 g/m2 fabric and 4 layers (Thickness 1 mm) at room temperature and ambient humidity.

0

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4

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PA6 TPC PC TPC Stylight

Impact resistance Ep DIN EN ISO 6603-2[J]

Flexural Stiffness vs Strength

Stylight C200-1

PA6/GF

PC/ GFStylight G290-1

ABS GF16

PA6 GF30

PA6/CF

AlSi1.2Mg0.4

SMC

Epoxy / GF

(RTM)

0

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40

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80

0 100 200 300 400 500 600 700 800

Sti

ffn

ess

[G

Pa

]

Strength [MPa]

Glass fibers weave 50/50 *

Carbon fiber weave 50/50*

*Values are measured according to ISO 14125, balanced woven fabric 50/50, at room temp and dry, fiber volume content 45% to 47%

Mechanical Properties

GF-PA6 GF-SAN

Fiber pull out = poor fiber matrix adhesionFiber pull out = poor fiber matrix adhesion

Sharp broken fibers (cutting edge) = good fiber matrix adhesion

Test Method: Laser Scanning Microscope

Representativemeasuring point

Measurementpicture

With appliedfilter

Measured lines

0

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PP TPC PA6 TPC PC TPC Stylight

Waviness LSM (laser scanning microscope) [µm]

Surface appearance

SAN based sheets provide reduced surface waviness compared to semi-crystalline matrices and even in relation to high flow PC � SAN most suitable matrix for aesthetic applications

SAN TPC

Different Surface Appearances

Black GF StyLight painted / clear coat Black GF StyLight + foil

Carbon StyLight withclear coat

GF StyLight with clear coat

Black GF StyLightdecorated with a foil

Black GF StyLightdecorated with a foil

Comparison chart

PC TPU StyLight PA PP

Properties Aesthetic applications Structural applications

Mechanical performance ++ + +++ ++ +

Impact strength +++ +++ ++ ++ +++

Processability* - +++ +++ + +++

Secondary operation** ++ +++ +++ + -

Heat resistance above 100°C + + +/- ++ +

Chemical resistance - +++ ++ +++ +++

Dimensional stability ++ ++ +++ - -

Surface waviness ++ ++ +++ - -

Low water uptake + + +++ - +++

* Includes formability, processing temp., drapability

** includes painting, gluing, foil decoration,…

Product Portfolio

DEMONSTRATOR

Optimization of Lay-up

Total Thickness 1,2 mm(+/-0,1 mm)

random glass 50 g/m² 4 layersglass woven fabrictwill 2/2, 290 g/m²

extra polymer surface layer

The StyLight Demonstrator

MoldedSurface Design

Foil

Organosheetwith grainedsurface

Organosheetwith high glosssurface

KEY APPLICATIONS FOR STYLIGHT

Key Applications for StyLight

Automotive

� Seat structures� Front end module� Door carrier� Firewall� Center console� Body panels� Interior trims� Parts with carbon fiber look

STYLIGHT - VIDEO

Slide 30

STYLIGHT – CONCEPT DEVELOPMENTS

Slide 31

Center Console – StyLight Concept

� Benefits: weight reduction, improved packaging, function integration

• Weight savings through part reduction– Combining basic structure with outer panel (integral design)

• High stiffness– Big cross section– Good mechanical properties of StyLight organo sheets

• Increased installation space due to integrated basic structure– Reduced wall thickness– Smaller design possible

• Simple geometries– Low tooling costs

• State-of-the art production technology at high volume– Thermoforming + Injection moulding (1 tool per part)

• StyLight sheets provide…

–Very high strength/stiffness compared to PA6 or PC based sheets.

–Impact resistance similar to PA6 composite or PC composite.

–Reduction of surface waviness compared to semi-crystalline

matrices and even compared to high flow PC

–Dimensional stability and chemical resistance

–Surface suitable for aesthetic applications (painted or decorated)

–Easy processability with compression / injection molding

–Possible weight reduction of up to 50%

Conclusion

� StyLight - A new and promising solution for LightWeight design

For more information visit www.ineos-styrolution.com

John Fialka, Business Development Manager

Mobil: 248-320-7230

E-Mail: john.fialka@styrolution.com