Light Weight Automotive TPOs with Improved Aesthetics, an additive approach

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1 Light Weight Automotive TPOs with Improved Aesthetics, an additive approach Wim Van de Velde, Director of Marketing, Plastic Additives May 2014, Wards Interior Automotive conference, Dearborn,MI 1

2 Agenda Milliken & Company Hyperform HPR-803i: What is it? How does it perform? Commercial interior case studies 2013 Milliken & Company 2

3 Milliken & Company Milliken, Private &

4 Milliken & Company Founded in Headquartered in Spartanburg, SC, USA 7,000+ associates Global presence- 45 facilities around the world H Technical Innovation Community of innovators More than patents H Headquarter Technical center 2014 Milliken & Company

linens, office interiors, labels, and much more Floor Covering Beautifying offices, hotels, airports, homes, and commercial environments

5 Milliken & Company Performance Materials Custom-engineered textiles for a variety of industrial markets including automotive (hoses, airbags, interlinings, tires) Apparel & Specialty Fabrics Fabrics for industrial applications such as healthcare, hospitality, table linens, office interiors, labels, and much more Floor Covering Beautifying offices, hotels, airports, homes, and commercial environments around the world 2014 Milliken & Company Performance Solutions Assisting organizations to become safer and more competitive in the marketplace

Clarifying agent Performance plastic additives R & D projects Hyperform HPN Nucleating agent Stiffness/impact

6 Milliken Chemical: innovation Colorants for Clear PP Colorants for PU Silicone Polymeric bound chemistry Silicone chemistry Colorants for detergents Performance plastic additives Hyperform HPR Reinforcing agent Millad NX 8000 Clarifying agent Performance plastic additives R & D projects Hyperform HPN Nucleating agent Stiffness/impact balance Crystallization speed Barrier Scratch resistance Crystallization orientation 2014 Milliken & Company Opticals

7 Hyperform HPR-803i: what is it? Milliken, Private &

Hyperform HPR-803i is a synthetic mineral-based reinforcing additive Fiber length = 20 microns Fiber diameter = 0.

8 HPR-803i Technology Reinforcing Agent for Automotive PP Compounds HPR offers a drop-in solution for OEM s to light weight vehicle PP; low-cost, low-hanging fruit solution. Brings additional scratch resistance and colorability value. Hyperform HPR-803i is a synthetic mineral-based reinforcing additive Fiber length = 20 microns Fiber diameter = 0.5 micron Mohs hardness = 2.5 (Talc = 1.0 ; glass fiber = 6 to 7) Density = 2.3 (Talc = 2.7; glass fiber = 2.6) Testing performed in 35MFR interior grade Medium impact copolymer Milliken & Company 8

9 Hyperform HPR-803i: how does it perform? Milliken, Private &

Hyperform HPR-803i reinforced PP Easy-to-implement reinforcing technology HPR-803i in the Market 5 to 15 % Weight reduction Scratch improvement Runs on

10 Hyperform HPR-803i reinforced PP Easy-to-implement reinforcing technology HPR-803i in the Market 5 to 15 % Weight reduction Scratch improvement Runs on conventional IM equipment Easier to process compounds Recycled PP performance booster Meeting increasing lightweight demands in automotive 2013 Milliken & Company 10

Reinforcing efficiency Modulus Different filler types for PP with class A surface finish Fine talcs Coarse talcs Calciumcarbonate Hyperform HPR 803i Talc CaCO3 Filler loading Ratio Exposed

11 Reinforcing efficiency Modulus Different filler types for PP with class A surface finish Fine talcs Coarse talcs Calciumcarbonate Hyperform HPR 803i Talc CaCO3 Filler loading Ratio Exposed Surface / Volume x 3,5 x 2 Molders and compounders can realize high-performance, reduced density materials and parts with HPR-803i in filled PP and TPO applications 2013 Milliken & Company 11

12 Weight and density reduction Using HPR-803i hybrids for interior and exterior parts HPR-803i hybrid Talc filled Part density between 0.95 and 0.99 Kg/dm3 Part density > 1.0 Kg/dm Milliken & Company 12

Talc 13% HPR- 803i/talc Flow length 9% HPR-803i/talc 7% HPR-803i Higher weld line strength

13 Ease of processing Filling length (mm) Lower compound viscosity enables easier processing 360 Flow length 350 Spiral flow sample ( = injection point) % Talc 13% HPR- 803i/talc Flow length 9% HPR-803i/talc 7% HPR-803i Higher weld line strength Faster cycle time Lower extrusion temperature Easier filling of the mold 2013 Milliken & Company 13

Talc HPR-803i Talc HPR-803i 4 3.62 3 2 1 2.27 1.17 1.

14 Delta L value Scratch resistance Reducing the filler content and a harder surface result in better scratch 7 10N Erichsen scratch 6 5 Talc HPR-803i Talc HPR-803i Fine grain (VW K31) 15% Talc 6% HPR-803i Coarse grain (VW K3A) 2013 Milliken & Company 14

15 Hyperform HPR-803i Applications for HPR-803i containing PP compounds 2013 Milliken & Company 15

16 Commercial interior case studies Milliken, Private &

17 Lightweighting & foaming Milliken, Private &

foamed application Mechanical foaming material 20% 2µ talc filled Chemical foaming material 20%

18 Case Study foamed parts Lightweight foamed parts Challenge evaluate the performance of Hyperform HPR-803i in chemical and mechanical (gas inject) foaming applications Engine cover - typical foamed application Mechanical foaming material 20% 2µ talc filled Chemical foaming material 20% 1µ talc filled Reduce part weight Evaluate stiffness Evaluate impact Targets 2014 Milliken & Company

Case Study foamed parts Lightweight Foam Technology Mechanical Foam Chemical Foam Special equipment incorporates the gas into polymer Chemical foaming agent added to polymer N 2 or CO 2 added to

19 Case Study foamed parts Lightweight Foam Technology Mechanical Foam Chemical Foam Special equipment incorporates the gas into polymer Chemical foaming agent added to polymer N 2 or CO 2 added to polymer Creates small, uniform voids Gas displaces polymer Equipment changes necessary Foaming agent added to polymer Creates small, uniform voids Gas displaces polymer May leave residual chemicals 2014 Milliken & Company 19

Part weight (g) Case Study foamed parts No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i Stiffness loss with foaming Mechanical

20 Part weight (g) Case Study foamed parts No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i Stiffness loss with foaming Mechanical foaming Gas foaming allowed for 11% weight reduction over control, and HPR-803i allows another 7% weight reduction over talc HPR-803i maintains higher stiffness than talc 60 11% 7% 14% % 10% 8% 6% 4% 12% 10 2% 3% 0 Un-foamed Foamed 0% Talc HPR-803i Materials: 35 mfr impact coploymer, 2µ talc 2014 Milliken & Company 20

21 Part weight (g) Case Study No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i No filler 20% talc filled 10% talc + 3% HPR 10% HPR-803i Stiffness loss with foaming Chemical foaming Chemical foaming allows for 12% weight reduction over control, and HPR-803i allows another 9% weight reduction over talc HPR-803i maintains higher stiffness than talc % 9% 14% % 10% 8% 6% 4% 2% 13% 4% 0 Un-foamed Foamed 0% Talc HPR-803i Materials: 18 mfr medium impact coploymer, 2µ talc 2014 Milliken & Company 21

Case Study Impact loss with foaming Impact loss with foaming Foaming and Impact Strenght Mechanical Foam Chemical Foam 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 2014 Milliken & Company 84% Talc 52% 35%

22 Case Study Impact loss with foaming Impact loss with foaming Foaming and Impact Strenght Mechanical Foam Chemical Foam 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 2014 Milliken & Company 84% Talc 52% 35% 30% 25% 20% 5% 0% 32% Foaming is known to negatively affect 15% impact strength. However in some interior applications this is not of major 10% concern. HPR-803i Talc 25% HPR-803i Multi-Axial Impact, 23 C, 2.2 m/s Notched Charpy impact, 23 C Materials: 35 mfr impact coploymer, 2µ talc Materials: 18 mfr medium ICP, 1µ talc 22

23 Case Study - foaming Outcome Hyperform HPR-803i allowed for additional weight reduction with reduced filler content and lower density More tests needed to understand the effect of HPR- 803i particle size on the formation of foam structure using either technologies Part weight reduced ~8% Stiffness & impact requirement met Targets 2014 Milliken & Company 23

24 Decreasing Weight, Increasing Recycled PP, and Improving Scratch Resistance Luxus/Nissan Case Study Milliken, Private &

25 The Strength of Partnership Development of PP compounds containing new reinforcing agent Reinforcing fiber supplier Validation of the PP compounds and trims 2013 Milliken & Company 25

PP Weight Reduction and Recycled Content Weight (g) (%) 700 600 500 Molded Part component split (g) 645 g 568 g -77g 12% weight reduction 161 57 100 90 80 70 Material recipe component split (% in

26 PP Weight Reduction and Recycled Content Weight (g) (%) Molded Part component split (g) 645 g 568 g -77g 12% weight reduction Material recipe component split (% in weight) Filler Virgin PP & Additives Recycled PP % increased recycled PP 49 0 Talc Talc/HPR Hybrid 0 Talc Talc/HPR Hybrid 12% lighter part combined with increased recycled PP content 2013 Milliken & Company 26

27 Luxus TDS Door panel application 12% weight reduction 2013 Milliken & Company 27

Delta L value Scratch Resistance 7.0 10N Erichsen scratch 6.0 5.80 5.0 4.0 3.0 HPR/Talc 2.0 1.4 1.0 0.

28 Delta L value Scratch Resistance N Erichsen scratch HPR/Talc % Talc Talc-HPR Improved scratch resistance AND higher recycled PP Talc 2013 Milliken & Company 28

29 Dimensional Properties New compound on existing moulds : Dimensions within specifications 2013 Milliken & Company 29

30 Weight Reduction & Scratch Resistance Improvement Grupo Antolin Door Panel Case Study Milliken, Private &

31 Case study HPR-803i Delta L Weight (g) Doorpanel Grupo Antolin Weight reduction % Talc 9 % mineral filler (HPR/Talc hybrid) Scratch resistance 16 % Talc 9 % mineral filler (HPR/Talc hybrid) Fine grain (K31) Coarse grain (K3A) Polypropylene compound with Hyperform HPR-803i enables 6% weight reduction and scratch improvement 2013 Milliken & Company

32 Case study HPR-803i Weight Reduction C02 emission reduction Doorpanel Grupo Antolin 52 g saved per car for 2 rear doors 462 g CO 2 /car saved 7,8 tons/y less material ( 1 ) 111 tons CO 2 /y saved( 2 ) (1) For production of cars/year (2) Average single car mileage of km per car Polypropylene compound with Hyperform HPR-803i enables 6% weight reduction and CO 2 emission reduction 2013 Milliken & Company

33 Lighter weight, improved scratch, reduced color, improved flow, and improved weld strength compound Inno-Comp Case Study Milliken, Private &

Composition by weight, % Case study on HPR-803i Weight (g) Compound reformulation 100 80 60 290 270 281 40 20 250 262 0 20% talc 13% mineral filler (HPR/Talc Hybrid) 230 20% Talc 13% mineral filler

34 Composition by weight, % Case study on HPR-803i Weight (g) Compound reformulation % talc 13% mineral filler (HPR/Talc Hybrid) % Talc 13% mineral filler (HPR/Talc Hybrid) PP Total filler Stiffness = meets OEM specs Impact = meets OEM specs Density = >1.0 g/cc Stiffness = meets OEM specs Impact = meets OEM specs Density = <1.0 g/cc OEMs get lightweight parts Improved scratch performance Reduced color loading Improved flow properties Improved weld-line strength 2013 Milliken & Company 34

35 Inno-Comp TDS Application in B-pillar 7% weight reduction 2013 Milliken & Company 35

36 Weight and density reduction Using HPR-803i hybrids for interior and exterior parts HPR-803i hybrid Talc filled Part density between 0.95 and 0.99 Kg/dm3 Part density > 1.0 Kg/dm Milliken & Company 36

37 3 Thank you! Questions? Wim Van de Velde Marketing Director, Plastic Additives Milliken & Company 920 Milliken Road M-209 Spartanburg,SC T / C wim.vandevelde@milliken.com

PVC in automotive. Examining the trends and drivers behind the growth of PVC for dashboard applications

PVC in automotive. Examining the trends and drivers behind the growth of PVC for dashboard applications PVC in automotive Examining the trends and drivers behind the growth of PVC for dashboard applications Summary Introduction The evolution of PVC-slush: past & present How PVC meets the increasingly stringent