Lightweighting: How Adhesive Tapes Contribute to Weight Reduction in Automotive Production Processes

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1 Lightweighting: How Adhesive Tapes Contribute to Weight Reduction in Automotive Production Processes Presented by: Amy Kaus Senior Applications Solution Engineer tesa tape, inc.

2 Every Gram Counts The lightweighting trend is here to stay Ford: 2015 F-150 with aluminum body General Motors: Scalloped edges around sheet metal panels on Cadillac Nissan: Thermoplastic liftgate on Rogue Audi: 2015 A3 with aluminum hood and tailgate BMW: New i3 battery car body constructed of carbon fibre Land Rover: 800 pound reduction in Range Rover Sport General Motors: Carbon fibre-reinforced plastic on hood and roof of Corvette Stingray Mazda: Reducing mass of lug nuts

3 CAFE Standards Corporate Average Fuel Economy (CAFE) standard was first enacted by Congress in 1975 Purpose to reduce energy consumption by increasing the fuel economy of cars and light trucks Obama Administration established two additional guidelines for passenger cars and light truck fuel efficiency standards 1 Model Years at 35.5 mpg Model years by 2025 at 54.5 mpg Improve fuel economy and reduce greenhouse gas emissions Save consumers more than $1.7 trillion at the gas pump and reduce U.S. oil consumption by 12 billion barrels 1

4 Fuel Efficiency and Trend toward Lightweighting Fuel efficiency dependent on vehicle weight, design, engine size, fuel type, driving cycles, driving habits EPA estimates a 1% - 2% fuel economy increase for every 100 pounds removed from vehicle Vehicle weight reduction by using lighter, stronger, different materials Non-traditional production materials under consideration, and already in use by some OEMs 2015 Ford F-150 combination of mixed metals and aluminum alloys is 700 pounds lighter than predecessor 2 Ricardo-Study.pdf 2

5 Lightweighting with Adhesive Tapes Adhesive tapes are designed to replace traditionally used rubber and plastic plugs, and butyl patches, as a hole sealing solution Permanent sealing against humidity, dirt Puncture-resistance against mechanical impacts Maximum flexibility for uneven surfaces Applicable for interior and exterior locations 85% weight reduction can be achieved based on covering average 72 holes per vehicle

6 Lightweighting with Adhesive Tapes Adhesive tapes with aggressive acrylic adhesive are used in lieu of hot melt Secure attachment of cables and small harnesses throughout vehicle body Anti-squeak and rattle properties prevent unwanted noises for vehicle lifetime Weight savings can average 73% to 87% depending on adhesive tape solution

7 Lightweighting with Adhesive Tapes Laser-engraved self-adhesive films replace traditional metal tags for vehicle identification Durable against thermal, chemical and physical influences Data is permanently engraved in surface Compliant with legal and manufacturer-specific regulations of auto industry Weight savings as much as 95%

8 Lightweighting with Adhesive Tapes PET fleece and cloth backings are proven solutions for harness coverings in engine and passenger compartments Backings offer flexibility, temperature resistance, abrasion protection, and noise damping properties Wire harness diameters increasing in size due to growing amount of electric components in vehicles Adhesive cloth tapes could provide as much as 10% of component weight savings versus the use of tradition harness coverings such as convoluted tubing

9 Lightweighting with Structural Adhesives Structural adhesives are used to replace mechanical fastening and welding Structural adhesive can join materials that are lighter weight but cannot be joined by mechanical methods Joining of dissimilar metals with the added protection from galvanic corrosion Joining of plastics and composites to metal Improved component performance through load distribution over larger area and increase stiffness Component weight reduction of over 50% for material changes allowed by adhesives

10 Lightweighting: How Adhesive Tapes Contribute to Weight Reduction in Automotive Production Processes Presented by: Amy Kaus Senior Applications Solution Engineer tesa tape, inc.

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