BASF-Automotive Innovation Pipeline

BASFs Automotive Innovation Pipeline
Bursa/ Turkey, 2011 October 13th
Dr. Christian Schmidt BASF R&D Verbund Automotive
Automotive Solutions Performance Passion Success
125th anniversary of the automobile
cars love chemistry

Bursa, October 13th 2011
Innovation Chains From Megatrends to Products

Market Pull Innovation Chain
Global Megatrends
Market Needs
Possible Solutions
Projects
Product Innovation
e.g. energy efficient mobility
e.g. light weight construction
e.g. CFRP for structural parts
e.g. development of new polymer matrices
e.g. new resin formulation
Automotive Megatrends
Weight Reduction
Environment & Sustainability
Propulsion & Catalysts
Innovative Materials Comfort & Quality Energy Management
Weight Reduction
Weight Reduction Automotive Solutions Performance Passion Success
European Legislation for CO2 Emission Options for Achievement

Average new car fleet emission [g CO2/km]
152 g/km
Combustion Engine Electric Mobility Current average/ Germany 150 Weight Reduction Catalysts & Fuel Additives Energy Management Energy Density Battery Lightweight 95 g/km Composites Heat Management
140
130
120 g/km
120
Goal 2012
110
100
90 2010 Bursa, October 13th 2011 2012 2014 2016 2018
Goal 2020
2020
2025: possibly 70 g/km
Current Light Weight Concepts: Weight Percentage of Plastics in Cars

Weight distribution of materials in a midsized car (1500 kg)
Steel Lightmetals Othermetals Thermoplastics Elastomers Thermosets Thermoplasticelastomers Fluids&Chemicals Glass&Ceramics Textiles&Fabrics Paints&Adhesives Electronics Others
kg
700 290 55 190 50 35 4 80 40 35 15 5 8
ca. 20 % polymer materials, ca. 15 % plastics
Ratio of plastics will increase further to save additional weight

BASF Success Story AIM out of Ultramid From Simple to Multifunctional Modules
Porsche 3.2-liter 6-cyl. Boxer, SOP 1972 Ford 5.4-liter V8 SOP 2004
Largest AIM in North America (weight-wise)
Weight reduction: 40 - 50 %
BMW 2-liter L4 DI Diesel SOP 1998

Status: commercial
8
Ford Mustang GT 5.0-liter V8 SOP 2011
Short Fiber Reinforced Ultramid Applications Weight Savings max. 50 kg 5 g CO2/ km

Interior Powertrain
Weight reduction 50 % Ultramid engine mount Ultramid oil pan
Ultramid in car seats Weight reduction: 20 %
Ultramid transmission cross beam
Exterior
Structural
Ultramid TOP Weight reduction: 40 %

Bursa, October 13th 2011 Status: commercial
Ultramid structural inserts Weight reduction: 40%
How can we save even more weight by an optimized design of short fiber reinforced thermoplastic parts?
10
Integrative Simulation Ultrasim for Short Fiber Reinforced Thermoplastics

Process Measurement
BASF Material model
Basic assumptions of modeling Anisotropic Nonlinear Strain-rate sensitive Tensile-compression asymmetric Failure modeling Temperature dependent
Part
Optimized Design with Ultramid CR and Ultrasim

Aluminum 100 % weight Ultramid CR 1st generation -35 % weight Ultramid CR 2nd generation -50 % weight
Status: commercial
Pedestrian Protection with Ultramid CR and Ultrasim - Lower Bumper Stiffener (LBS)
Process Material Part
Joint development with OEM

Combination of BASFs product and engineering know-how faster development and lower testing costs 40% savings in weight highest rating in lower leg impact test (5/5)
13
Status: commercial
How can we further substitute metals by more thermally and dimensionally stable thermoplastics?
14
Modern Engine Concepts Need New Materials: Ultramid Endure

Heat aging at 220 C
Tensile strength [MPa]
250 200 150
5 4
Ultramid Endure PPS PPA PA 66/6 PA 66

0 500 1000 1500 2000 2500 3000 3500
100 50
1 2 3
time [h]
1 2 3
Resonator Charge-air lines Intercooler caps
4 5
Throttle valve Intake manifold
Status: market launch
Ultramid Endure Innovative Stabilization Technology

PA 66
220 C / 1000 h 2 mm
Ultramid Endure
220 C / 3000 h 2 mm
500 m
30 m
How can we further substitute metals by new light weight constructions?

17
Relationship between Properties and Fibre Length in Reinforced Plastics

Standardized property [ - ]
Advanced composites
Stiffness Strength
Toughness
0,1 1 Fiber-length 10 100 [mm]
Short
Statistic long Injection molding
Oriented endless fibers Pressing, resin transfer molding
Lightweight Composites - Long Glass Fiber Reinforced Ultramid Structure

polymer meltfeeding (twin screw extruder) pelletizer
heating
pultrusion die
cooling puller
Index Ultramid Structure = 100 %

Notched impact strength Inverse Creep elongation Warpage stability Ultramid Structure LF Reference*
Crash absorber
Incineration
Energy absorption
SGF
0 20 40 60 80 100 120
*Reference = Short glass fiber (SGF) Polyamide
LGF
Long glass fiber (LGF): More Performance through 3D network
Status: market launch
The First Injection Molded Plastic Wheel Rim with Ultramid Structure
Designvorgabe
>> smart forvision in cooperation with BASF IAA 2011, Frankfurt
Weight savings: 3 kg/ wheel rim 12 kg/car 18 kg equivalent to sprung weight Bursa, October 13th 2011
20
Polyurethanes for Long Fiber Injection LFI-PUR

Long fiber injection with Elastoflex E glass fiber content 20-50 weight% foamed duroplastic polyurethane high temperature stability, superior impact strength, high flexural modulus adhesion to thermoplastic sheets thermal expansion coefficient between steel and aluminum
cutting
transport wetting & mixing PU-components oscillating nozzle glass roving
mold
Status: commercial
Concepts for the Future: Enter the Metal Core Domain for Further Weight Reduction
Challenge: Light weight substitution of metal chassis & frame
Weight /property 100%
-40%
Solution
Future light weight composite material concepts require Long / endless fibre reinforcement High fibre content 50% carbon or glass fibres Improved reactive systems Multi-material solutions Possible process technologies RTM / RIM Sandwich Pultrusion
-15% -20% -40%
Steel
~20 % of total weight
Weight reduction of 100 150 kg possible (10-15 g CO2/km)

Alu
CFK (unidir.)
CFK (quasi)
Mg
Resin Transfer Molding (RTM) and Reaction Injection Molding (RIM)

component component
A
pumps
Viscosity [mPas] 1500
Polyamide-RIM PU-RTM
mixing
1000
BMW i3 life module
press
500
Endless fiber reinforcement preform

50
* Source: Fraunhofer ICT
Epoxy-RTM (Baxxodur)
100
150
[sec]
Status: pilot
Light Weight Composites Sandwich Structures
core
Faces with thickness t
Solid Constant thickness of the faces, t Stiffness Strength Weight

+ core 2t
+ core 6t
100% 100% 100%
600% 250% 102%
3600 % 820% 106%
Light Weight Composites PU Based Honeycomb Structures

Elastoflex E3532 No dripping Excellent edge wetting Lower processing temperature under development
Audi A4
MB M-class
Paper based core material Low density structure with good NVH properties Weight reduction 50-75% Sun shade, spare wheel cover, etc.
25
VW Tiguan Jaguar XK8
Status: commercial
Weight Reduction
Propulsion & Catalysts Automotive Solutions Performance Passion Success
Optimized Catalysts for Improved Propulsion Efficiency

Alternative fuels Diesel 10 % Modern propulsion concepts Gasoline direct injection Lean burn engines Downsized engines 10-20 % Hybrid cars 20-30 %
Compressed natural gas (CNG)
20 %
Fiat
Biofuels (biodiesel B30, bioethanol E85) 25-75 %
potential for efficiency improvement & CO2 reduction
Find the perfect fit: Optimization of the catalyst system by BASF Catalysts
Catalyst Systems for Diesel Passenger Cars to Meet EU Emission Legislation

NOx [g/km] 0.3 1.0
EURO5 EURO4 EURO2 EURO1 EURO3 EURO6
DOC
CSF Soot Filter
Diesel Oxidation Catalyst
HC+NOx [g/km] 0.3 1.0 0.05 0.1
Soot [g/km]
Catalysed Soot Filter
Selective Catalytic Reduction 1.0 2.0 or
LNT
CO [g/km]
Lean NOx Trap Catalyst
KEROPUR Gasoline Performance Packages

Effective deposit control ensures a clean intake system Friction modifiers reduce friction between cylinder walls (blue) and piston rings (red) of the engine Corrosion protection of metal surfaces
Deposits on Intake Valve
KEROPUR ensures clean Intake Valve
Without Keropur
With Keropur
Potential of 2 % fuel savings (3 g CO2/km)

Status and Future Innovations of Li-Ion Batteries by BASF

100000
10000
Li-Ion Li-Ion high voltage

LFP, LVP
power density / W/kg
1000
Ni-Cd Ni-MH Pb/acid
Li-S
LNCMO
100
10
BASF commercial activities: cathode materials, electrolytes
BASF R&D activities: improved materials, new battery concepts
1 0 25 50 75 100 125 150 175 200 250 300
Pilot, production 2012 2500 t/a, USA

standardised range in km
Overall CO2 Emission Balance of Mobility

Average CO2 emissions (g/km)
Current German new car fleet average
Indirect emissions from production and electricity generation Direct emissions from car
20
132
152
Potential for improved ICE
20
90
110
EV - electricity based on fossil fuels only
162 107
EV - electricity based on current German energy mix
EV - electricity based on renewable sources only
Electricity based on CO2 neutral sources is crucial for sustainable mobility

Renewable Resources Wind Power Complex Structure of a Rotor Blade

Protective coating WindCoat Contour & Finish, OLDODUR BladeProtect & BladeCoat
Hull materials Baxxodur epoxy adhesives and infusion & lamination systems
PET foam BALSA PVC foam
Complex hybrid structures Light weight structure
Extrusion foams: Styrodur C
Chemistry enables sustainable energy sources for tomorrows mobility

Weight Reduction
Three Pillars of Electromobility
Battery (Materials)
Light Weight Construction
Heat Management
Higher energy efficiency for heating & cooling less energy used for heating & cooling reduced seasonal variation of range, increased range in summer & winter
Higher storage capacity of batteries Higher driving range of vehicle
Lower weight lower energy consumption for driving overall increased range
Energy Management Automotive Solutions Performance Passion Success
Automotive Heat Management: Definition
Improve the energy efficiency of a cars climatisation system (heating & cooling) to increase thermal comfort of passengers reduce seasonal variation of driving range, esp. in electric cars
*: In a wider sense also heat management for battery system (to maintain optimal operation temperature of 20-25 C)
Driving Range Dependence of Electric Cars as Function of Ambient Temperature

100
e.g. 150 km
seasonal reduction of range
maximal range (%)
Psychological threshold: range of 100 km
90 80 70 60 50
> 100 km
40 -20 -10 0 10 ambient T / C
schematic representation - urban drive situation (< 50 km/h average speed; start and stop) - for T > +30 C: 1000 W/m solar irradiation assumed Bursa, October 13th 2011
20
30
40
Driving Range Dependence of Electric Cars as Function of Ambient Temperature

100
Improvement potential when range reduction is lowered by 20, 30 or 50 %
90 80 70 60 50 40
maximal range (%) -20
-10
10 ambient T / C
20
30
40
schematic representation - urban drive situation (< 50 km/h average speed; start and stop) - for T > +30 C: 1000 W/m solar irradiation assumed Bursa, October 13th 2011
Overview on BASFs Automotive Heat Management Technologies

Polymer foams for thermal insulation IR reflective pigments for coatings IR reflective pigments for interior surfaces IR reflective films for glazing
Solar heat management IR reflective pigments for coatings and interior
Other technologies (electrochromic systems, self-switching IR absorbers, latent heat storages) Simulation and system analysis
IR reflective film for glazing
reflective film glazing
ol
Status: commercial
Insulation foams and High performance foams
co
NIR Vis
outside
inside
Status: pilot Bursa, October 13th 2011
Status: commercial/ pilot
Simulation and System Analysis Summer Case for Mid-Sized Electric Car
Electric car: Summer conditions
Outside: +30C & sunny at noon Inside: +20C Windows ~ 70% Chassis ~ 30%
Effect of heat management measures

energy consumption / rel. % 100 80 60 40 20 0
-45 %
Total cooling requirement: 3.0 kW

Average energy requirement for driving: ~ 3kW @ 20 km/h, ~10 kW @ 60 km/h, ~16 kW @ 100 km/h
Status quo
combined Thermal Insulated IR IR Insulation Windows reflective reflective potential coating windows
Saving potential ~ 45 % by combination of all measures in summer case

How can we improve energy management for combustion engine cars?

40
Energy Management PUR Thermal Engine Encapsulation

Thermal Engine Encapsulation Benefits
Engine reaches operating temperature faster, i.e. less cold starts Reduced CO2-emission 6-9 g/km Additional sound insulation No application in conventional cars yet
Future potentials
Start stop mode Hybrid on/off engine mode Down sizing
Status: pilot
Energy Management Thermoelectric Effect

cold
Technology: Conversion of a temperature difference into electric energy
_
Efficiency [Z T] 1,2 1,0 0,8 0,6 0,4 0,2 p-PbTe 0,0 0 p-Bi2Te3 p-SiGe n-Bi2Te3 n-PbTe
Key application: Recovery of waste heat from exhaust gas stream Thermoelectric material and module integration determine performance Challenge: Transfer material improvement into module performance Material potential >10% efficiency Potential savings: up to 3 g CO2/km
hot
+
n-SiGe
100 200 300 400 500 600 700 800 900 1000 1100 T [C]
Status: lab phase
First Transparent Solar Roof and Transparent OLED

Transparent organic photovoltaics cells Also work with diffuse light
OPV
Transparent organic LED Efficient area lighting Adjustable colours
OLED
43
Bursa, October 13th 2011 Status: lab/ pilot phase
Weight Reduction
How can we improve scratch resistance of car coatings?
45
Comfort & Quality Automotive Solutions Performance Passion Success
Improved Scratch Resistance by iGloss Hybrid Material with Nano Hard Phase
TEM Elastic polymer prevents plastic scratch
20 nm
Hard phase prevents abrasive scratch
Hybrid material coating: Elastic polymer + in situ formed nano hard phase High toughness + excellent scratch resistance
Bursa, October 13th 2011 Status: market launch
Improved Scratch Resistance by iGloss Hybrid Material with Nano Hard Phase
Multiple crockmeter testing 10, 50 & 100 times Hard phase in bulk, not only in top layer Outstanding and enduring dry scratch resistance
47
How can we create surfaces that combine individual design and high performance?
48
New Weathering Resistant Luran S SPF30

Gloss retention (ISO4892-2A)
Luran S (ASA)
Weathering resistant, impact modified SAN based engineering plastic Especially suited for exterior applications New SPF stabilization technology for even higher weathering resistance
outdoor weathering simulation 100 90 80 Gloss level (%) 70 60 50 40 30 20 10 0 0
ABS ABS UV ASA ASA UV Luran S SPF30

200 400 600 800 1000 1200 1400 1600 1800 2000
hours of testing
retention of gloss, colour and impact properties even after prolonged UV exposure
Luran HH-120 SPF Piano Black

Greyscale ISO 4892-2A
Luran HH-120 Standard Stablization 5 4 3 2 1 0 500 1000 1500 Test time (hr) 2000 2500 Luran HH-120 SPF Stablization
Luran HH-120 (AMSAN) Excellent high gloss for decorative parts Intense color deepness (Piano Black) Easy processing Vicat B > 120 C
examples of high gloss Luran S (above) & Luran HH (right) automotive applications Bursa, October 13th 2011 Status: market launch
Application of new SPF stabilization technology 50 allows substitution of PMMA in exterior applications
Elastoskin In Mold Coated PUR Spray Elastomer
Release agent
IMC
PU Skin
High surface quality soft touch Multicolored surfaces in one step Lowest emissions
51
Extreme freedom of design
Steron Technology Process and Properties

structuring
textured mold
spraying
Steron coating
adhesion
lamination
strip off
product
soft touch structure

air permeable pores

Status: pilot phase/ market launch
Steron Technology New Options for Individual Surface Design

Steron Coating carrier:
textiles, leather, paper, foam, plastics, wood, metal...
dash board surface
Status: pilot phase/ market launch
How can we create ceramic or metal surfaces with the design freedom of thermoplastics?
54
Catamold Molding Metals and Ceramics like Plastics

Benefits of metal or ceramic injection molding (MIM/ CIM) Production of complex, small parts - ease of automation, low specific production costs High product quality
Original design
~200C
~100C
~1400C
MIM
Granulate
Green part
Brown part
Sintered part
50% weight reduction
Status: commercial
Catamold High Class Surfaces

Decorative interior parts made of black zirconia
BMW i-drive rotary knob BMW gear shift lever
56
BASF Global Competence Team Seating Design Safety Light Weight Comfort
BASF product portfolio for seats
Excellent design with Steron, Catamold Humidity control with Luquafleece Smart textiles for flat heating Multi rigidity foams: PUR (Elastoflex) Structural parts in Ultramid Crash management with Neopolen (EPP) Cathodic e-coat Cathoguard
e.g. >> smart forvision
Unique network of cross divisional material experts for excellent haptics and design, crash management, weight reduction and comfort in automotive seating
Weight Reduction
Ultramid S Balance PA 6.10 from Renewable Resources

Ricinus communis L. Castor oil
Ricinoleic acid
Bursa, October 13 2011
63% biobased Long-chain polyamide Low water uptake Lower density High media resistance th
Sebacic acid
Status: commercial
PA 6.10
Halogen Free Flame Retardants in Ultradur and Ultramid

Ultradur
halogen free FR
PBT
halogenated
Recycling Smoke density Fire behavior Density Electrical Property Mechanics Costs
Halogen free flame retardance light colour, high design freedom ideal for E&E applications
Bursa, October 13th 2011 Status: market launch/ commercial
Cross-divisional Competencies Combined: Concept Cars in Cooperation with BASF
Hyundai i-flow
>> smart forvision
http://www.automotive.basf.com
We help our customers to be more successful !

62

BASF-Automotive Innovation Pipeline

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BASF-Automotive Innovation Pipeline

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BASFs Automotive Innovation Pipeline

Bursa/ Turkey, 2011 October 13th

Dr. Christian Schmidt BASF R&D Verbund Automotive

Automotive Solutions Performance Passion Success

125th anniversary of the automobile

cars love chemistry

Automotive Solutions Performance Passion Success

Innovation Chains From Megatrends to Products

e.g. energy efficient mobility

e.g. light weight construction

e.g. CFRP for structural parts

e.g. development of new polymer matrices

e.g. new resin formulation

Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

Environment & Sustainability

Propulsion & Catalysts

Innovative Materials Comfort & Quality Energy Management

Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

Environment & Sustainability

Propulsion & Catalysts

Innovative Materials Comfort & Quality Energy Management

Bursa, October 13th 2011

Weight Reduction Automotive Solutions Performance Passion Success

European Legislation for CO2 Emission Options for Achievement

90 2010 Bursa, October 13th 2011 2012 2014 2016 2018

2025: possibly 70 g/km

Weight Reduction Automotive Solutions Performance Passion Success

Current Light Weight Concepts: Weight Percentage of Plastics in Cars

700 290 55 190 50 35 4 80 40 35 15 5 8

ca. 20 % polymer materials, ca. 15 % plastics

Ratio of plastics will increase further to save additional weight

Weight Reduction Automotive Solutions Performance Passion Success

Largest AIM in North America (weight-wise)

BMW 2-liter L4 DI Diesel SOP 1998

Weight Reduction Automotive Solutions Performance Passion Success

Short Fiber Reinforced Ultramid Applications Weight Savings max. 50 kg 5 g CO2/ km

Ultramid in car seats Weight reduction: 20 %

Ultramid transmission cross beam

Ultramid TOP Weight reduction: 40 %

Ultramid structural inserts Weight reduction: 40%

Automotive Solutions Performance Passion Success

Weight Reduction Automotive Solutions Performance Passion Success

Integrative Simulation Ultrasim for Short Fiber Reinforced Thermoplastics

BASF Material model

Weight Reduction Automotive Solutions Performance Passion Success

Optimized Design with Ultramid CR and Ultrasim

Bursa, October 13th 2011

Weight Reduction Automotive Solutions Performance Passion Success

Joint development with OEM

Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

Weight Reduction Automotive Solutions Performance Passion Success

Modern Engine Concepts Need New Materials: Ultramid Endure

Ultramid Endure PPS PPA PA 66/6 PA 66

Resonator Charge-air lines Intercooler caps

Throttle valve Intake manifold

Bursa, October 13th 2011

Status: market launch

Weight Reduction Automotive Solutions Performance Passion Success

Ultramid Endure Innovative Stabilization Technology

Automotive Solutions Performance Passion Success

How can we further substitute metals by new light weight constructions?