Plastics & Fiber Reinforced Plastics For Modern Automobiles

Special Presentation for 4TH Plasto 2006 Avinash Arankalle Sr.Assistant Director, The Automotive Research Association of India, Pune

Automotive Plastics

Thermosets

Thermoplastics

Fiber Reinforced Plastics

Semi-crystalline

Amorphous

Thermosets

Thermoplastics

Fibers

Semi-crystalline Vs Amorphous Plastics

Semi-crystalline Plastics Sharp Melting Point Usually Opaque Amorphous Plastics Broad Softening Range Usually Transparent

High Shrinkage
Solvent Resistant Fatigue / Wear Resistant

Low Shrinkage
Solvent Sensitive Poor Fatigue / Wear

Examples of Thermoplastics
Semi-crystalline Plastics
Acetal (POM) Polyester (PETP, PBTP) Polyamide(Nylon)(PA) Fluorocarbons(PTFE) Polyethylene (PE) Polypropylene (PP)

Amorphous Plastics
Acrylonitrile-butadiene-Styrene (ABS) Acrylic(PMMA) Polycarbonate (PC) Modified Polyphenylene Oxide (PPO) Polystyrene (PS) Polyvinyl Chloride (PVC)

PE, PP,PS and PVC are known as Commodity Plastics, while all others are known as Engineering Plastics.

Global Demand for Major Plastics

250 200 150 MMTA 100 50 0 1995 2000 2005 2010

Per Capita Polymer Consumption

25 21.5 20 15 11.7 10 5 0 India Europe China World 3.8 15.1 Kg

Low per Capita Polymer Consumption a pointer to promising demand growth in Future. Per Capita Consumption of FR is 0.2kg whcih very low and expected to grow at 20% growth rate in India

Table-1 Material contents in A Typical Passenger Car

Present

Future
Aluminium Intensive vehicles Net Wt. lb 336 99 469 458 30 215 543 2150 1000 % 16 5 22 21 1 10 25 100 Composite intensive vehicles Net Wt. lb 313 93 32 430 358 108 534 1870 1280 % 17 5 2 23 19 6 29 100

Baseline 1988
Material Weight lb Steels Cast Iron Wrought Aluminium Cast aluminium Reinforced Plastics Unreinforced Plastics Others Total Weight reduction 1727 412 32 145 30 215 590 3150 -% 55 13 1 5 1 7 18 100 --

32

40

Materials Usage in Avg. Vehicle

Steel sheets: 41% Non-ferrous: 2% Glass: 2.9%

Plain Steels: 18% Plastics: 9.3% Textiles: 0.9%

Cast iron: 6.4% Rubber: 5.6% Fluids:0.9%

Aluminium: 8% Adhesives: 3.0% Misc.: 2%

Plastics In Car

Bumpers: 9.5% Interior Trim: 19% Upholstery: 8%

Dashboard: 14.2% Seats: 12.3% Others: 37%

History of Automotive Plastics

In 2000 : More than 1.8 Million Tones of Various Types of Plastics were used in Automotive in about 1000 different parts.

Use of Plastics in Automobiles

Use of Light Weight Materials : International Scenario

Top 10 Plastics in Automotives

4.0% 3.9% 20.8%

PU PP PVC PE TPO Nylon ABS Unsat PE PC Sat PE

8.9% 7.4%

6.4%

20.0% 9.0%

9.1%

10.4%

Plastics in Automotive
Material
PVC PU PP ABS Nylon Polyesters Phenolics PE PC Mod. PPO Acetal RIM PU

1980
12.5 11.2 8.0 6.4 2.75 1.5 7.0 2.5 0.3 0.3 0.8 --

1985
11.0 15.0 11.0 6.4 3.5 5.5 5.0 4.0 3.0 3.0 2.0 1.2

1990
8.0 20.0 15.4 6.5 5.8 11.0 3.5 11.6 5.3 4.1 5.85 2.4

PBT
Cellulose Acrylics Others

-0.2 1.2 0.02

0.5
0.15 1.0 2.5

1.0
-0.7 3.6

TOTAL

54.8

74.25

104.35

Why Plastics so Important to the Automotive Industry ?

Light Weight Functional Design Economics Integrated Systems Styling Potential New Effects Recyclability

Improved Safety Reduced Noise & Vibrations Reduced aerodynamic drag coefficient Legislative Requirements Corrosion & Chemical Resistance Resource Efficiency

Weight Reduction

In the USA the legislation of Fuel Economy was brought in force in 1985, which is known comonly as Corporate Average Fuel Economy (CAF). According to this legislative requirement, every car sold in the market by the vehicle manufacturer should have average 29 miles to the US gallon (m.p.g.) of petrol (11km/lit.)

Weight Reduction

Weight reduction of 30% improves fuel economy by 6 m.p.g. or 2.1 km/lit. It is estimated that, on average, 100kg of plastics replaces 200 300 kg of conventional material, reducing the fuel consumption by 750 liters over the life span of 1,50,000 km running of a car. Globally, this would save over 21 million barrels of petrol per year. Additional calculations suggest that it would reduce CO2 emissions by 50 million tones per year

Functionality

Design Freedom Component consolidation Balance Mechanical Properties along with rigidity, impact strength and ductility, tactile properties such as soft touch Innovative Polymers play roles e.g. Fule Tank, Tailgate, engine manifold, etc.

Economy
Total number of parts Cost of sub assembly

Assembly line cost

Tailgate in Polypropylene Tailgate in Steel, kg Finished part weight, Kg Total Cost in Rs. 6.42 725

Double Skirt Part 4.3

1060

Single Skirt Part 2.6

535

Styling potential

Plastics possess unlimited shaping potential & aesthetic appearance to provide various aerodynamic shapes desired by the modern vehicles integrated along with the functional requirements e.g. door mounted mirror, exterior panels, bumpers, etc.

New Effects

It includes wide range of characteristics such as sound dampening, thermal and electrical insulation, energy absorption, colour, gloss, texture etc. The safety standards of the modern vehicle, with improvements designed for passenger protection derive from these characteristics of plastics. So does the level of comfort and passenger-friendliness of car interiors

Corrosion resistance

The traditional sheet steel used require corrosion protection, however, none of the plastics is susceptible to factors like acid rain, sea spray and road salt. The corrosion resistance provided by plastics ways out to extensive automotive applications. Due to distinctive chemical nature owned by each polymer, selection of engineering plastics should be critically accessed for each application. This because, some of the plastics get affected by fuels and lubricants, others are attacked by battery acid and all are affected to some degree by weathering

Development of Markets for Plastics in Automotive

Main Application Areas

Interior

Electricals
Component Housings, Switches & Sockets, Connectors, Lighting Systems, Circuit Boards & Wiring Harnesses, Battery Boxes, Ignition, etc.

Seats, Door Panels, Upholstery, Instrument Panels, Steering Wheels, Roof-liners, Interior Trim, Climatic Control / Air Ducts, Air Bags, Seat Belts, Pedals.

Exterior

Bumpers & Fascia System, Body Panels, Exterior Trim, Weather Strip Seals, Head lamps, Tail lamps & Reflectors, Window Glasses, Door sill panels

Main Application Areas

Power-train
Transmissions, Driveshaft, Bearings, Flywheels, CV Joints & U Joints

Engine
Air Intake Systems, Fuel Intake Systems, Engine Components, Cooling Systems

Chassis

Fuels

Structures, Supports, Suspension, Brakes

Fuel Tanks, Fuel Lines, Vapour Recovery System, Fuel Filter Pipes, Fuel pumps, Fuel Modules, Fuel Rails

Automotive Applications of Plastics

Component Bumper Main Plastics Type PP, ABS, PC, RIM PU Weight in Kg / Avg. Car 10.0

Seats
Dashboard Fuel Systems

PUR, PP, PVC, ABS, PA

PP, ABS, PA, PC, PE PE, POM, PA, PP

13.0
15.0 7.0 6.0

Body (including body panels0 PP,PPE, UP

Under the Bonet Components

Interior trim Electrical Components Exterior Frame Lighting Upholstery Reservoirs TOTAL

PA, PP, PBT

PP,ABS, PET, POM, PVC PP,PE, PBT, PA, PVC ABS, PA, PBT, ASA, PP PP,PC, ABS, PMMA, UP PVC, PUR, PP, PE PP,PE,PA

9.0
20.0 7.0 4.0 5.0 8.0 1.0 105.0

Exterior Plastic Body Panels

New Construction Principles New Manufacturing Processes New Production Sites

Exterior Plastic Body Panels

Example : Conductive Fender

Design Flexibility Functionality Hybrid Construction Light Weight

Exterior Competitive Automotive Markets Foster Flexibility

One Brand delivers numerous products and models which differ in car type, equipment, colour, etc.

Same Parts concepts Modular Construction Platform Strategy Small Edition

Plastic provide cost efficient solutions

Exterior Light Weight and Cost

Cars will stay a multi material application but Plastics Body Panels can provide:

Weight Reduction Reduction of Fuel Consumption (CO2 emissions) Design Freedom Cost Efficient Production for Small Editions Integration of various functions

Exterior Applications

Automotive Bumpers
Moulded from RIP-PU or or elastomer modified thermoplastic PBT. Withstands impact test at -200C and temperatures as high as 1800C Polymer pigment coatings on surfaces improves gloss finish, aesthetic appearance and colour stability, weather resistance and resistance to yellowing & chalking.

Headlamps & Reflectors

Made up from PC resins weigh far less than glass lenses. Offers greater freedom of design. Withstands temperatures as high as 2050C.

Provides Optimum optical properties.

Exterior Applications

Door handle

Radiator Grill

Door Panel

Air Ducts

Interior Applications

Instrument Panel
Made up of ABS, ABS / PC alloys, PC, PP, modified PPE and SMA resins. Complex design possible in items such as airbag housings, center stacks for the instrument panels, and large integrated instrument panel pieces. Helps to eliminate need for a steel support beams, and allows manufacturers to save cost and weight.

Automotive Seats
Materials used are RIM-PU, PC-ABS, PA-6.
Provides comfort and safety to drivers and passengers. Ensures ergonomical designs, good vibration dampening properties. Foaming material yiel automatically correct seat positioning improving lateral stability to support drivers in all positions

Under the Hood - Integration

Example : Engine

Design Flexibility Functionality Hybrid Construction Light weight

Under the Hood Thermal Resistance

Example : Air Intake Manifold

Thermal Properties Mechanical Properties Process Cost Fuel Efficiency

Engine Applications

Engine Manifold

Throttle Body

Cooling System

Fuel Tank

Under the Hood Compatibility with Electronics

Example : Gear Box Control

Durability (1400C) Comfort Fuel Efficiency Hybrid Electronics / Plastics

Automotive Plastics and Safety

Federal Motor Safety Standards (FMVSS) provide the Challenges and Opportunities for Plastics e.g.

Plastic Fuel Tank Bumpers Automotive Seats

: : :

Flammability Test :

Regulations ECE R34, FMVSS 301 ECR R42, EEC 74 / 483 ECE R17, R21, & 25 FMVSS 201, 202, 207 FMVSS 302, ISO 3795

Safety Active Devices

Example : Anti Blocking System (ABS), Electronic Stabilization Program (ESP)

Hybrid Engineering Electrical / Electronic / Magnetic Properties

Safety Plastic Connectors

Plastic connects various materials and devices

Hybrid Systems Electrical Systems Glass Fiber Systems

Threats to Plastics in Automotive

Aluminium Alloys High Strength Low Alloy Steels (HSLA) Magnesium Alloys Engineering Ceramics Plastic Scrap & Recycling

Bus Body Applications

WHY FOR CITY TRANSPORT BUSES?

Consumption of diesel for over 6.0 lakhs of registered buses in the country is more than 25,00,000 kiloliters and fuel bills are roaring over10,000 million rupees. Any attempt to improve fuel efficiency and conserve the depleting fuel resources & energy is the need of tomorrow. Bus Code Practice as per AIS 052 shall be in force from 2006 which will mandate bus builders to meet specifications.

WHY FOR CITY TRANSPORT BUSES?

Better riding comforts, reduced noise & vibration levels, ergonomic seats and aesthetic appearance are needs of bus passengers traveling from city to city.
Mandates on End of Life of Vehicles (ELV) leading to issues of recycling of materials are expected in future

What Are the possible Advantages to use for Buses?

Weight reduction to 35-40% leads to 10% improvement in fuel efficiency Composite sandwich structures possess better dampening coefficient and shall reduce noise & vibration levels when used for floor, roof and side panels Aerodynamic designs shall improve drag coefficient to make fuel efficient vehicle

International Scenario & Technology Gaps

In India use of Plastics & composites in Auto industry is less than 4%. Use of Plastics & Composites in the developed countries is increasing in the automotive sector to achieve fuel economy, safety and comforts The material of construction is dictated in India perticularly by the collaborators. The existing standards and regulations like CAFE standards, limits on gvw, crashworthiness, NVH are not enforce and restrict technology of use of light weight materials. Lack in Joint venture and collaborative programs between various sectors as seen elsewhere e.g. Intercity Bus Weight Reduction Program between Transport Development Center; Martec Ltd; Prvost Car; Virtual Prototype Technologies Inc; Canada North American Bus Industries (NABI) and TPI Composites; USA Advance Technology Transit Bus (ATTB) Program with Los Angeles County Metropolitan Transportation Authority (LACMTA) and Metropolitan Transportation Authority of Harris County, Texas (Houston Metro); USA GKN Composites; UK

International Scenario : Light Weight Bus Models

Scania Irizar PB Coach:2004

MAN Lions International Coach:2004

Marcopolos 49 Passenger, 12.9 meter, Three-axle Scolaris Vacanza 13 two-axle Andare

13 meter, two-axle Van Hool 916TL

International Scenario : Light Weight Bus Body Components

Computer Aided Engineering and aerodynamic design of Bus

Interiors, Dashboard and Luggage Compartment of Bus

International Scenario : Light Weight Bus PHASE II Components

Engine Manifold

FRP Leaf Spring & Propeller shaft

New Innovative Technology in Applications of Plastics and Composites in Automotives

Automotive Applications of Nano-composites

Definitions

Flame-retardant Polyolefins

Definitions

Applications of Non-woven Jute Fibers

Applications of Non-woven Jute Fibers

Jute Fiber Applications

Jute Fiber Applications

Conclusions

For the future generation of vehicles Automotive Plastics are emerging materials due to economics, functionality, fuel economy & safety legislations NVH requirements also may find potential applications for the plastics Sustainable Developments is foreseen in the Plastics for the future of automotives One of the need for its penetration in market is overcome Scrap & Recycling problem

Thank You . . .