Lightweight structures with new
car technologies
Julian Haspel
Application Development,
LANXESS Business Unit Semi-Crystalline Products
Automotive Days Poland
LANXESS – A premium supplier of high-tech plastics for
demanding technical applications
LANXESS provides premium high-tech plastics
Main industries of LANXESS’ high-tech plastics are automotive (>50%) and electro / electronics (>20%)
LANXESS’ leading high-tech plastic brands: Durethan®, Pocan®
- Recognized as intelligent system solutions
- Combining mechanical strength with resistance to heat, oils and abrasion
New service brand HiAnt®
- Tailored international customer service and in-depth
know-how in product, application, process and technology development
Main Business Unit: Semi-Crystalline-Products (SCP)
belonging to Performance Polymers Segment Automotive
E & E Sport / leisure Construction Others Packaging High-tech plastics 100% 50% 0%
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More than 20 years of experience in compound technology
Inventor of the hybrid technology
Innovative materials and concepts for new application fields in automotive and motorcycle manufacturing
Well acquainted with various demands by the automotive industry
Valuable expertise from other industries (e.g. electro)
Important contribution to future E-mobility, alternative fuels and flame protection
LANXESS – A leading development partner for the automotive
industry
Valuable experience and focus on innovation for the future of mobility
Share of materials in automotive production [%]
Global production of light vehicles [mn units]
Growing car production and trend of weight reduction drive
demand for high-tech plastics
Innovations in high-tech plastics enable future mobility
Global car production with annual growth of ~3.3%
Increased usage of high-tech plastics per car drives growth of 7% p.a.
Global production of light vehicles will increase by 30% within 5 years
Current high-tech plastic share in Western cars 15-17%
Chinese vehicles only consist of about 7% plastic components Æ Growth potential
E-mobility further pushes high-tech plastics
Æ Total share of plastic expected to exceed 25%
~+30% 2010 2015e 50 100 2005 ~+10% 72 65 59 52 50 21 23 27 31 32 12 14 17 18 7 High-tech plastics Other materials Ferrous metals 2010 2015e 1980 1990 2000 0
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Comparison of different fuel economy standards worldwide
Comparison of actual and projected fuel economy for new passengers vehicles
Sources: AN, F., and A. Sauer. 2004. Comparison of Passenger Vehicle Fuel Economy and GHG Emission Standards Around the
World. Pew Center on Global Climate Change, Washington, DC; Updated data obtained from “Passenger Vehicle Greenhouse Gas and Fuel Economy Standards: A Global Update“, The International Council for Clean Transportation, retrieved from there, July 2010
Fuel econo my (miles p e r gallon) 2002 2004 2006 2008 2010 2012 2014 2016 2018 2020
Solid points and lines: actual data
Hollow dots and dashed lines: nearest targets enacted Smaller Hollow dots and dotted lines: proposed targets
20.00 25.00 35.00 30.00 40.00 45.00 50.00 55.00 60.00 65.00 70.00
Thermoplastic in automobiles
Increased use of high-tech plastics as basis for automotive
innovation
Thermoplastic in trucks
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What is “Plastic/Metal Hybrid” (PMH)?
Metal sheet
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Production process (2/3) – Injection molding
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Deformation under bending load
Force F [kN]
Deformation f [mm]
50
Plastic/metal composite profile
340
f F
Closed sheet steel profile
Cross-section of a plastic/metal hybrid structure
Over-molded edge
Sheet metal profile Molded „button“ Plastic rib structure Molded „button“ Over-molded edge
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Examples of Plastic/Metal Hybrid front ends out of Durethan
®More than 70 models in mass-production Far more than 50 mn parts on the road
Audi A4 – 2000 Ford Focus – 1998 Ford Fiesta – 2001 Renault Megane – 2002 Mazda Demio – 2002 Hyundai Getz – 2002 Kia Spectra – 2003
Audi Q7 V12 – 2008
Mercedes Benz A – 2004 Chrysler 300C – 2004 VW Polo – 2001 Nissan Quest – 2003 BMW X3 – 2003 BMW 1er – 2004 BMW 3er – 2005 Mercedes Benz Vito – ‘03
Ford Galaxy – 2006 Ford S-Max – 2006 Audi TT – 2006 Hyundai Avant – 2006 Hyundai Veracruz – 2006 Hyundai Santa Fe – 2006 Kia Carens – 2006 Kia Lotze – 2006
Ford Mondeo – 2007 Audi A5 – 2007 Audi A4 – 2007 Hyundai i30 – 2007 Hyundai Starex – 2007 Audi Q5 – 2008 Ford Kuga – 2008 Hyundai Genesis – 2008
Audi A3 – 2008 Audi A7 – 2010 Audi A1 – 2010 Audi A8 – 2010 Audi A6 – 1998
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Worldwide first pedal box with PMH
Material Durethan BKV 30 H2.0
10% cost and weight advantages compared to conventional design
Integration of numerous functions
Ductile crash behavior
Plastic/Metal Hybrid – Pedal box
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State-of-the-art technology for aircrafts
Challenge: cost optimized and ready for mass production alternatives for the automotive industry
High-tech plastics with glass, carbon, aramid or mixture
2D semi-finished product (panel) based on a thermoplastic matrix
Easy alteration to 3D shape
Fabrics or uni-directional fabric made of continuous filaments
Complete impregnation
Continuous fiber reinforced thermoplastic composites (CFT) –
Overview
Advantages
Low weight – high strength
Excellent crash performance
No corrosion and easier recycling Integration of functions Possibility of complex designs Low investment Challenges Influence of temperature and water absorption
Continuous fiber reinforced thermoplastic composites (CFT) –
Advantages and challenges
High performance systems for greater safety, efficiency and sustainability
Hybrid steel sheet
W e igh t re la ted force / [N /g ] Deflection / [mm]
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Door impact beam
Continuous fiber reinforced thermoplastic composites (CFT) –
Examples
Steering column
Innovative high-tech plastics for the future of mobility
LANXESS Semi-Crystalline Products –
High-tech plastics key for future sustainable mobility
Expertise in customer-oriented R&D and
cutting edge product properties
Cost and performance optimized solutions ready
for mass production
High-tech plastics material leadership and
engineering know-how
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This presentation contains certain forward-looking statements, including assumptions, opinions and views of the company or cited from third party sources. Various known and unknown risks, uncertainties and other factors could cause the actual results, financial position, development or performance of the company to differ materially from the estimations expressed or implied herein. The company does not guarantee that the assumptions underlying such forward looking
statements are free from errors nor do they accept any responsibility for the future accuracy of the opinions expressed in this presentation or the actual occurrence of the forecasted
developments.
No representation or warranty (express or implied) is made as to, and no reliance should be placed on, any information, including projections, estimates, targets and opinions, contained herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements contained herein, and, accordingly, none of the company or any of its parent or subsidiary undertakings or any of such person’s officers, directors or employees accepts any liability whatsoever arising directly or indirectly from the use of this document.
