F2008-04-002
Advances in Automotive Plastics
The automotive industry, a large user of thermoplastics and thermosets polymers, is influenced by a number of societal needs. The dynamics involved in offering cost effective, appealing and safe vehicles globally results in constant change for the OEMs and the suppliers. Some of the driving forces currently influencing product design are: design modularity, increasing safety regulations, weight reduction, noise/vibration control, manufacturability/styling, corrosion resistance, recycle content (End of Life for Vehicle - ELV), design for disassembly, increased use of renewable resources, and emission reduction. These, of course, must be met at a cost that ensures customer access. The success of plastics in this industry is a result of constant innovation. This paper will focus on linking technology enabled advancements in polymer systems to vehicle performance. Some of the subjects to be discussed will be:
o Engineered polymers with advanced aesthetics and weather resistance New technologies are emerging in which level of grained mold replication exceeds what was possible before. Also, new molding resins for interior uppers that survive solar and thermal impact with excellent modulus retention will be presented. o Durability improvements in polypropylene compounds PP compounds are very versatile materials but can show mar and scratches in high wear portions of the vehicle. Mechanistic understanding has been advanced, guiding product developments such as INSPiRE* TF8000ES TPO. o Breakthroughs for interior plastics in odor reduction For many reasons, auto consumers are increasingly interested in a lower odor interior environment. Material suppliers are responding with new technologies such as VORANOL* VORACTIVE* polyols and lower VOC ABS and PP resins that enable this standard to be met. o New, cost effective PP blends produced at the molder's machine Previously with compounds, mixing had to be accomplished in a separate step prior to injection molding. Advancements in the blend components and better screw designs now allow nearly all performance classes can be achieved by direct addition to the presses. o Structural applications and long glass fiber reinforced resins PP/glass pulltrusion techniques result in reinforced resins that can replace steel structures with proper engineering. Properties and application examples will be discussed.
The authors will discuss each of these advancements in the context of enabling new or more effective application development at the Tier and OEM customer. Recommendations will be made on how best to apply these innovative technologies to advance future part and vehicle performance.
* INSPIRE, VORANOL and VORACTIVE are trademarks of The Dow Chemical Company
Poster presentation: Body design for passenger cars, trucks and buses