Can we continue to lightweightvehicles using PP compounds?Workshop

Dr. Olaf Henschke | Technical Service and Development Transportation, Dow Europe GmbH, Horgen, SwitzerlandMrs. Marie Buy | Marketing Manager Transportation, Dow Europe GmbH, Horgen, SwitzerlandDr. Jeff Munro | Research and Development Transportation Elastomers, Dow USA, Lake Jackson, Texas Dow Packaging & Specialty Plastics

General Business

Outline

• Introduction of Dow Polyolefin Elastomers in Automotive• Light Vehicle Industry Trends and Impact• Design of Thermoplastic Olefin (TPO) Compounds• Dow Solutions Addressing Industry Trends – ENGAGE™ Polyolefin Elastomers• Manufacturing Efficiency• Enhanced Lightweighting• Interactive APP – Modeling and Idea Generation

General Business

Polypropylene modifier providing impact resistance and stiffness & flow property balance• in Talc-filled/rigid and soft TPO formulations• for interior and exterior body-molded parts

Automotive applications

General Business

Dow Evolves to Keep Pace with Automotive Needs

1970s

Average Vehicle Production

9.9MM

1.6MM

14.4MM

12.1MM

2.4MM

0.7MM

Source: Wikipedia

General Business

Dow Evolves to Keep Pace with Automotive Needs

1990s

Average Vehicle Production

8.4MM

1.6MM

16.6MM

12.8MM

1.0MM

1.4MM

Source: Wikipedia

Launch of INSITE™catalyst- based technologyLaunch of ENGAGE™POE 8000 series

Manufacturing

Technology

General Business

Dow Evolves to Keep Pace with Automotive Needs

2000 to 2010s

Average Vehicle Production

12 to 7.1MM

3.1 to 2.9MM

20.1 to 15.6 MM

24.2 to 35.1 MM

3.7 to 1.9 MM

5.0MM

Source: Wikipedia

Launch of ENGAGE™POE 7000 seriesLaunch of high meltstrength ENGAGE™ POE

Manufacturing

Technology

Launch of ENGAGE™XLT POE

General Business

Dow Evolves to Keep Pace with Automotive Needs

2019 and Beyond

Average Vehicle Production

Source: OAIC

Next generation…

Manufacturing

Technology

2020 Projected Global Production= 100 MM Cars

General Business

Light Vehicle Industry Trends and Impact

Sustainability Safety Consumer Behaviors ManufacturingEfficiencies

IMPACT ON LIGHT VEHICLE

IMPACT ON TPO

• Thin walling• Body panel replacement

• Airbags • Vehicle interior redesign• Diverse and tougher skins• Tailgate

• Ease of handling• Fewer manufacturing steps• Part integration

• Higher flow with improved performance, capable of maintaining stiffness / toughness balance

• Low coefficient linear thermal expansion (CLTE) to achieve tighter gaps in-between exterior body panels

• Fast crystallization for improved surface aesthetics duringdemoulding process

• Optimal low temperature impact performance

• Excellent scratch and chemical resistance

• Low gloss and excellent grain retention as well as good soft touch feel

• Development of TPO systems for tailgates

• Less rubber for same impact, or same rubber for higher impact

• Fast cooling, quick demoulding, shorter cycle time

• High temperature resistance, passes hot water jet test enabling stringent painting tests

• Reduce GHG Emissionsby lightweighting

• Electric Vehicles (EV)

• Passenger Safety • Ride Sharing• Autonomous Vehicles• SUVs

General Business

Design of Thermoplastic Olefin (TPO) Compounds

Polypropylene

TalcFiller

Polyolefin ElastomerTypically formulation DOEs are used to

determine the performance window

Polypropylene Matrix Material Homopolymer

or Impact CopolymerGood Processing and

Temperature Resistance

Mineral Filler Increase Stiffness, Control Shrinkage,

Nucleate

Elastomer Increase Toughness,Performance at Low

Temperature

General Business

Manufacturing Efficiency

Shorter cycle-time and improved rubber

efficiency

EnhancedLightweighting

Thinner walls

ENGAGE 8842ENGAGE 7467ENGAGE 8150/7ENGAGE XLT 8677

ENGAGE 8100/7

ENGAGE 8200/7

ENGAGE 8137

ENGAGE 7447

0

2

4

6

8

10

12

14

16

0.8560.8580.860.8620.8640.8660.8680.870.872

Mel

t ind

ex (g

/10

min

)

Density (g/cm3)

Dow Solutions Addressing Industry Trends

Higher Flow

Stiffness/ Toughness Balance

General Business

General Business

ENGAGE 8842ENGAGE 7467ENGAGE 8150/7ENGAGE XLT 8677

ENGAGE 8100/7

ENGAGE 8200/7

ENGAGE 8137

ENGAGE 11567

ENGAGE 11547

ENGAGE 11527

ENGAGE 7447

0

2

4

6

8

10

12

14

16

0.8560.8580.860.8620.8640.8660.8680.870.872

Mel

t ind

ex (g

/10

min

)

Density (g/cm3)

Dow Solutions Addressing Industry Trends

ENGAGE™ 11567Melt Index at 190°C/2.16 kg (g/10 min)

1Density(g/cm3)

0.866

ENGAGE™ 11547 Melt Index at 190°C/2.16 kg (g/10 min)

5Density(g/cm3)

0.866

ENGAGE™ 11527Melt Index at 190°C/2.16 kg (g/10 min)

15Density(g/cm3)

0.866

General Business

Offer Broad Range of Benefits

Property Features Value ImprovementLow Glass TransitionTemperature

Less rubber for same impact, or same rubber for higher impact

Cost/ Performance Optimization: Improved impact or higher rubber efficiency

10% less rubber for sameimpact performance

Fast Crystallization Fast cooling, Quick demoulding, Shorter cycle time

Cost Optimization: Shorter cycle times and improved aesthetics

>15% cooling time reduction

High Melting Point High temperature resistance, Passes hot water jet testenabling stringent painting tests

Cost/ Performance Optimization: Improved paintability

Enables 2 coat paint systems(vs current 3 coat)

High Flow whileRetaining Impact

Thinner walls yet, meet mechanical property targets in addition to improved CLTE (Thinwalling for complex parts)

Performance Optimization: Lightweighting/ fuel economy and shorter cycle time

10% improvement on MFRand 10% thinner = 16% faster cooling

Data based on tests and research conducted by Dow. Users should confirm results by their own tests.

Manufacturing Efficiency

Enhanced Lightweighting

General Business

Interactive Modeling Session

Output TPO Properties Input Variables

Flow MFR 230°C, 2.16 kg Level of

Polyolefin ElastomerStiffness

Flexural Modulus

ToughnessNotched Charpy Impact Resistance at 23°C

Level ofTalc FillerNotched Charpy Impact

Resistance at - 30°C

Instrumented Dart Impact Resistance at - 40°C

Melt Index (Flow)of Polyolefin Elastomer

Thermal ExpansionCoefficient of LinearThermal Expansion

General Business

Enable Cost / Performance Optimization

0

2

4

6

8

10

12

14

16

18

20

22

24

0

250

500

750

1000

1250

1500

ENGAGE™ 8100 15 %

ENGAGE™ 11567 15 %

ENGAGE™ 8200 15 %

ENGAGE™ 11547 15 %

ENGAGE™ 8137 15 %

ENGAGE™ 11527 15 %

Flexural Modulus (MPa) MFR 230 °C, 2.16 kg Charpy Impact - 30 °C (kJ/m²)

Low glass transition temperature High rubber efficiency

Flex

ural

Mod

ulus

MFR

, Notched C

harpy at –30 °C

These are typical properties, not to be construed as specifications.

Melt Index 1 Melt Index 5 Melt Index 15

General Business

Enable Cost / Performance Optimization

0

2

4

6

8

10

12

14

16

18

20

22

24

0

250

500

750

1000

1250

1500

ENGAGE™ 8100 15 %

ENGAGE™ 11567 13,5 %

ENGAGE™ 8200 15 %

ENGAGE™ 11547 13,5 %

ENGAGE™ 8137 15 %

ENGAGE™ 11527 13,5 %

Flexural Modulus (MPa) MFR 230 °C, 2.16 kg Charpy Impact - 30 °C (kJ/m²)

Low glass transition temperature High rubber efficiency

Flex

ural

Mod

ulus

MFR

, Notched C

harpy at –30 °C

These are typical properties, not to be construed as specifications.

Melt Index 1 Melt Index 5 Melt Index 15

General Business

Enable Cost / Performance Optimization

Hard TPO

15% ENGAGETM 8200

13.5% ENGAGETM 11527reduced to

Soft TPO

39% ENGAGETM 8842

36% ENGAGETM 11567reduced to

General Business

Enable Cost / Performance Optimization

0

2

4

6

8

10

12

14

16

18

20

22

24

0

250

500

750

1000

1250

1500

ENGAGE™ 8150 15 %

ENGAGE™ 11567 13,5 %

ENGAGE™ 8100 15 %

ENGAGE™ 11547 13,5 %

ENGAGE™ 8200 15 %

ENGAGE™ 11527 13,5 %

Flexural Modulus (MPa) MFR 230 °C, 2.16 kg Charpy Impact - 30 °C (kJ/m²)

Low glass transition temperature High rubber efficiency

Flex

ural

Mod

ulus

MFR

, Notched C

harpy at –30 °C

These are typical properties, not to be construed as specifications.

Melt Index 0.5 to 1 Melt Index 1 to 5 Melt Index 5 to 15

General Business

Manufacturing Efficiency

General Business

Product Name Melt Index

at 190°C/2.16 kg (g/10 min)

Density(g/cm3)

Maximum Flow at 220°C (mm)

ENGAGE™ 1156713.5 % 1 0.866 434

Reference ENGAGE™ 820015 % 5 0.870 454

ENGAGE™ 1154713.5 % 5 0.866 457

ENGAGE™ 1152713.5 % 15 0.866 480

Enable Processing Optimization

General Business

ENGAGE™ 8200

ENGAGE™ 11547

Soft TPO formulation with 39 % POE

-80 -60 -40 40 60 80 100 120 140 160 °C

Low Glass Transition

High Melting Point

Enable Improved Temperature Resistance

General Business

-80 -60 -40 0 20 40 60 80 100 120 140 160 °C

ENGAGE™ 8200ENGAGE™ 11547

Soft TPO formulation with 39% POE

Fast Crystallization

Enable Processing Optimization

General Business

ENGAGETM 11000 Series – Cycle Time Study

Part Dimensions:920 x 80 x 45 mm

Wall thickness: 2 mm

Part Weight: 730 g

Maximum Flow Path: 580 mm

Melt Temperature: 220 °C

Initial Cycle Time: 47 seconds

Enable Processing Optimization

General Business

Enable Cycle Time Reduction

SampleCooling time

15 secondsCooling time

13 secondsCooling time

11 secondsCooling time

9 secondsCooling time

7 seconds

ENGAGE™11567

ENGAGE™8200

ENGAGE™11547

ENGAGE™11527

General Business

Enable Cycle Time Reduction

Cooling Time15 13 11 11 9 7

Total Cycle Time44 42 40 41 40 36

ENGAGETM 8200 15% ENGAGETM 11527 13.5%

General Business

Better Compatibility and Particle Size Distribution

Hard TPO Morphology

15% ENGAGE™ 8100

13.5% ENGAGE™ 11567reduced to

ENGAGE™ 8100 ENGAGE™ 11567

General Business

Void

Paint

TPO

5 µm

Paint-TPOInterfaceIs Intact

Heat Resistance Is Key

Data per tests conducted by Dow. Additional information available upon request. Properties shown are typical, not to be construed as specifications. Users should confirm results by their own tests.

-3500

-3000

-2500

-2000

-1500

-1000

-500

0

500

30 50 70 90 110 130 150 170

Dim

ensi

onal

Cha

nge,

µm

Temperature, °C

TMA Indentation

ENGAGE XLT 8677

ENGAGE 8842

Water jet temp.

Traditional Polyolefin Elastomers

Enable Improved Paint Adhesion

High-melting ENGAGETM

Polyolefin Elastomers

General Business

Enhanced Lightweighting

General Business

Enable Part Downgauging for Future Car Design

General Business

Lower DensityT20 → T15 → T10

Metal Replacement

TPO Opportunities in Metal Replacement

General Business

Component wt% wt%

35 MFR ICP 72.9 62.5

Elastomer 17.1 27.5

Talc 10 10

Melt Index 1 Melt Index 5 Melt Index 15

Enable Lower Thermal Expansion in TPO Compounds

General Business

30 MFR hPP/30 wt% POE

≤ 0.864 g/cc

0.870 g/cc

0.885 g/cc

0.902 g/cc

ENGAGE™ 115X7

Experimental POE1

Enable Lower Thermal Expansion in TPO Compounds

General Business

Metal Replacement Example

Objective –Reduce CLTE < 3 x 10-5 m/m/°C T20 T25 HAR

Talc

Exp. POE + HAR Talc

POE EG8200 EG8200 EG8200 Exp. POE1

POE wt% 20 20 20 20PP wt% 60 55 55 55

Standard Talc wt% 20 25 0 0

HAR Talc wt% 0 0 25 25

MFR, dg/min 28 26 23 25

Flex Mod, MPa 1550 1700 2100 2000

0 °C Charpy, kJ/m2 7.2 8.0 9.2 12.5

-20 °C Charpy, kJ/m2 4.1 4.0 4.2 6.1

-20 °C Dart Total Energy, J 38 37 24 28

CLTE in MD, 10-5 m/m/°C (-40 to 100 °C) 4.5 4.0 3.4 2.8

Minimize CLTE with combination of HAR talc and Exp. POE with good stiffness/impact/flow.

CLTE

General Business

Interactive Modeling Session

Output TPO Properties Input Variables

Flow MFR 230°C, 2.16 kg Level of

Polyolefin ElastomerStiffness

Flexural Modulus

ToughnessNotched Charpy Impact Resistance at 23°C

Level ofTalc FillerNotched Charpy Impact

Resistance at - 30°C

Instrumented Dart Impact Resistance at - 40°C

Melt Index (Flow)of Polyolefin Elastomer

Thermal ExpansionCoefficient of LinearThermal Expansion

General Business

General BusinessForm number: 777-095-01-ED

Let’s meet and talkDr. Olaf Henschkeohhenschke@dow.com

Marie Buymbuy@dow.com

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