Lightweight structures with new car technologies

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1 Lightweight structures with new car technologies Julian Haspel Application Development, LANXESS Business Unit Semi-Crystalline Products Automotive Days Poland October 27-28, 2011

2 LANXESS A premium supplier of high-tech plastics for demanding technical applications 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 100% 50% Others Packaging Sport / leisure Construction E & E Automotive LANXESS provides premium high-tech plastics 0% High-tech plastics Sources: JD Powers 08/2010; LANXESS own estimates 2

3 LANXESS A leading development partner for the automotive industry 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 Valuable experience and focus on innovation for the future of mobility 3

4 Growing car production and trend of weight reduction drive demand for high-tech plastics 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 Growth potential E-mobility further pushes high-tech plastics Total share of plastic expected to exceed 25% Innovations in high-tech plastics enable future mobility Global production of light vehicles [mn units] 2005 ~+10% ~+30% e Share of materials in automotive production [%] e High-tech plastics Other materials Ferrous metals Sources: JD Powers 08/2010; Polymotive; Plastics Europe 2010; LANXESS own estimates; Handelsblatt.com (Oct. 21, 2010), 4

5 Comparison of different fuel economy standards worldwide Comparison of actual and projected fuel economy for new passengers vehicles Solid points and lines: actual data Hollow dots and dashed lines: nearest targets enacted Smaller Hollow dots and dotted lines: proposed targets Fuel economy (miles per gallon) Sources: AN, F., and A. Sauer Comparison of Passenger Vehicle Fuel Economy and GHG Emission Standards Around the World. 5 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

6 Increased use of high-tech plastics as basis for automotive innovation Thermoplastic in automobiles Thermoplastic in trucks Innovative materials lead to weight and cost reduction, greater safety and comfort 6

7 What is Plastic/Metal Hybrid (PMH)? Metal sheet Polyamid 6 GR 7

8 Production process (1/3) Deep-drawn metal sheet 8

9 Production process (2/3) Injection molding Open injection mold tool Pre-positioned metal insert Finished composite 9

10 Production process (3/3) Finished product 10

11 Deformation under bending load 50 Plastic/metal composite profile Force F [kn] Closed sheet steel profile Open sheet steel profile F Deformation f [mm] f

12 Cross-section of a plastic/metal hybrid structure Over-molded edge Over-molded edge Sheet metal profile Molded button Plastic rib structure Molded button 12

13 Typical application of Plastic/Metal Hybrid: front ends 13

14 Examples of Plastic/Metal Hybrid front ends out of Durethan Audi A Audi A Ford Focus 1998 Ford Fiesta 2001 Renault Megane 2002 Mazda Demio 2002 Hyundai Getz 2002 Kia Spectra 2003 Mercedes Benz A 2004 Chrysler 300C 2004 VW Polo 2001 Nissan Quest 2003 BMW X 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 A Audi A Hyundai i Hyundai Starex 2007 Audi Q Ford Kuga 2008 Hyundai Genesis 2008 Audi Q7 V Audi A Audi A Audi A Audi A More than 70 models in mass-production Far more than 50 mn parts on the road 14

15 Plastic/Metal Hybrid Part of the body structure 15

16 Plastic/Metal Hybrid Pedal box 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 Shift gear Automatic gear 16

17 Continuous fiber reinforced thermoplastic composites (CFT) Overview 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 CFT for demanding mobility solutions 17

18 Continuous fiber reinforced thermoplastic composites (CFT) Advantages and challenges Advantages Low weight high strength Excellent crash performance No corrosion and easier recycling Integration of functions Possibility of complex designs Low investment Weight related force / [N/g] Hybrid steel sheet Hybrid PA composite sheet Challenges Influence of temperature and water absorption Deflection / [mm] High performance systems for greater safety, efficiency and sustainability 18

19 Continuous fiber reinforced thermoplastic composites (CFT) Examples Door impact beam Steering column One shot molding process 19

20 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 20

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22 Safe harbour statement 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. 22