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 requirements of OEM s Future trends 1
Material-use in cars Year 1998 Metals 75.4% Others (glass, paints, fluids, etc) 9.7% Rubber 5.6% Plastics 9.3% ABS 1.7% PE 0.6% PMMA 0.2% PVC 1.1% PP 3.7% PA 0.7% Acetal 0.2% PC 0.4% PPO 0.2% PC + PBT 0.1% Other plastics 0.6% Source: APME By weight-percentage; average weight of car = 1120kg Material-use in cars Year 2000 Year 2005 Others (glass, paints, fluids, etc) 9% Rubber 6% Plastics 11% Others (glass, paints, fluids, etc) 9% Rubber 6% Plastics 15% Metals 74% Metals 70% Source: APME By weight-percentage 2
PVC-use in cars Interior dashboard skins, carpets, door panels, consoles, arm rests, grips, interior seals, sun visors, seat coverings, luggage compartment covers Exterior body trim, window encapsulation, bumper spoiler, door steps, roof rack coverings Others underbody coating, battery separation plates, fuel line protection Electrical wiring cable insulation, moulded plugs Summary Introduction The evolution of PVC-slush: past & present How PVC meets the increasingly stringent requirements of OEM s Future trends 3
Plastics in dashboards Year 2000 Year 2003 IM 23.2% SM TPO/TPU 0.0% SM PVC 25.3% SM TPO/TPU 0.2% SM PVC 34.0% SC PUR 4.0% Other 50.8% TF PVC 26.3% TF TPO/ASA 21.2% SC PUR 15.0% TF = Thermo Forming; SM = Slush Moulding; IM = Injection Moulding; SC = Spray Coating Market evolution: PVC-slush Tons 16000 14000 12000 10000 8000 6000 4000 2000 0 1995 1997 1999 2001 2003 Total estimated European volume 4
Models with PVC-slush Models with PVC-slush 5
Summary Introduction The evolution of PVC-slush: past & present How PVC meets the increasingly stringent requirements of OEM s Future trends - Material & process technology: basis for choice Performance Weight Cost Environmental aspects 6
Material & process technology: basis for choice Performance: Styling requirements Visual appearance Touch (Haptik) Mechanical & physical properties Surface properties Ageing Environmental aspects: Emissions Recyclability Design freedom Costs (material, tool, investment) TPO foam sheet PVC foam sheet TPO compact sheet ABS/PVC compact sheet PUR casting PUR Spray skin TPU slush PVC slush Styling requirements Source: VDI; plastics in Automotive engineering (Mannheim, 2003) 7
Advantages of PVC-Slush Technology Cost / Performance Design Freedom Stress Free Esthetics (color, aspect, soft touch, grain) Scratch Resistance Easy Processing Available in any tailor made color Low fogging Perception of quality in car Summary Introduction The evolution of PVC-slush: past & present How PVC meets the increasingly stringent requirements of OEM s Future trends 8
Market evolution: PVC-slush 16000 Forecast 14000 12000 Tons 10000 8000 6000 4000 2000 0 1998 2000 2002 2004 2006 Total estimated European volume Reasons for future growth All classes of vehicles Other interior applications of PVC-slush (design uniformity) Door panels Other car manufacturers 9
Mechanical recycling of PVC automotive waste Summary General Case study: instrument panels Re-use of recyclate 10
GENERAL Depending on source and quality of the waste Conventional and dissolution Critical success factors: Easy collectable High volume Separation of materials Origin (production or ELV waste) GENERAL Examples of collection and recycling in practice Autovinyle (France) WIPAG Eco-care Chaize Vinyloop 11
Case study: Instrument panels Production waste Origin is known Practically no ageing Easy collectable Types of waste: Rejected skins Trimscrap type I (PVC + PUR) Trimscrap type II (PVC + PUR + carrier) Rejected dashboards Case study: Instrument panels Recycling process: Schreddering PVC recyclate Other applications Delamination Separation Cryogrinding or dissolution PUR Carrier PUR 12
Case study: Instrument panels Cryogrinding: Free flowing powder 97-99% pure Dissolution See further Re-use of PVC recyclate Requirements Constant good quality Constant supply Possible applications Dashboards (double slush) Door panels (double slush) Flooring, 13
Double slush technology Principle: Virgin material Recyclate PUR Carrier Top skin: colour, touch, stability, Second skin: barrier function, recyclate Double slush technology Double slush technology is used for Audi A2 and A4 (2000) Technology works Developments are ongoing with use of recyclate Tests have been done with 25% of recyclate in second layer of dashboard on industrial installations No major problems have been encountered 14
Conclusions Experience mainly gathered with production waste Re-use in automotive is feasible Double slush technology (second layer) Constant supply and good quality ELV-waste Acceptable to re-use? (ageing, composition, ) 15