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Copyright © 2014 Owens Corning. All Rights Reserved. Images © istockphoto.com
LONG FIBER REINFORCED THERMOPLASTICS ENABLING ECONOMICAL VEHICLE LIGHT WEIGHTING THROUGH NEW GLASS REINFORCEMENT SOLUTIONS
© Misha - Fotolia.com, © istock.com
COREY MELVIN, OWENS CORNING, Global Product Manager, Long Fiber Thermoplastics
Market Drivers for Long Fiber Thermoplastics Long Fiber Thermoplastic Advantages Owens Corning’s new Performax® SE4849 roving for LFT PP
TOPICS FOR TODAY’S TALK
WE’LL TOUCH ON…
Need for light, less pollutant vehicles 50% of automotive sales from BRIC Increased comfort demands
Improve fuel efficiencies New OEM & market concentration Increased vehicle functionality
Advanced composites solutions Advanced polymers High strength metals New battery materials & chemicals
Mega Trends
Automotive Industry Trends
Transportation Trends
Impact for Materials and Chemicals
Lower CO2 emissions Urbanization Globalization
Source: Owens Corning Marketing Intelligence
CO2 EMISSION REGULATIONS ON THE 3 CONTINENTS KEY DRIVERS FOR WEIGHT OUT INITIATIVES IN AUTOMOTIVE
Efficient Diesel Engines
Smart Gasoline Engines
Alternative Power Train Designs
Alternative Transmission Systems
Use Of Bio Fuels And Bio Diesel
Light Weighting With The Use Of Composite
REACHING EMISSIONS & FUEL EFFICIENCY TARGETS
-100 Kg -0.35 l/100km -9.0 g/km
by 2015: 130 g CO2/km
by 2020: 95 g CO2/km
THE MARKET DRIVER FOR LONG FIBER THERMOPLASTICS LEADING EUROPE CO2 EMISSIONS REGULATIONS
Tailp
ipe
emiss
ions
, g C
O2/
km
Average CO2 emissions from new passenger cars 180
160
140
120
100
80
60 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025
The 2012 EEA report indicates
OEM’s will achieve the 2015 C02
emission targets
CHALLENGE Reach the
2020 target of 95g C02 /km
by 2025: 75 g CO2/km
Source: database 2012 - Tailpipe Emissions, g CO2/km
Source: database 2012
THE MARKET DRIVER FOR LONG FIBER THERMOPLASTICS LIGHT WEIGHTING
C02 emissions are linked to vehicle mass
Light weighting is essential to C02 emission reductions
Short term Aluminum will displace
steel for one on one replacement, With pure focus on
weight out.
Medium-long term Composites allow
for enhanced function integration, But requires
re-engineering of the car modules.
LIGHT WEIGHTING COMPETITORS COMPOSITES ARE ONE OF THE SOLUTIONS
Approximately 200kg of weight
reduction per vehicle will be required
to address OEMs CO2 gap
Steel vs. Steel vs. Aluminum Steel vs. Composites
Process Complexity = ↓
Weight Reduction ↓ ↓↓
Raw Mat. Cost ↑ ↑↑
Design Freedom = ↑
Function Integration = ↑
Highly Structural
(300Kt)
GLASS REINFORCED COMPOSITE OPPORTUNITIES IN AUTOMOTIVE
30,0
25,0
20,0
15,0
10,0
5,0
0
2015 2016 2017 2018 2019 2020
Kg C
ompo
site
s/Ve
hicl
e
Vehicle production expected to
exceed 100MM units*
by 2020
Potential of weight out due to
composites is estimated at ~100 kg by 2020
(20-25kg of reinforcements
per car)
½ Structural
Structural
Highly Structural
Semi- Structural
(300Kt)
Structural (200Kt)
Source: Owens Corning estimate, 2013. *: IIHS Global Insights and CSM Auto Forecast December2011 The graph excludes the amount of non structural composites used in vehicles today
Highly Structural
(300Kt)
Copyright © 2014 Owens Corning. All Rights Reserved. Images © istockphoto.com
LONG FIBER REINFORCED THERMOPLASTICS ADVANTAGES OF LONG FIBER THERMOPLASTICS
Source: Owens Corning
WHY LONG FIBER THERMOPLASTICS?
Short Glass <1mm
Long Glass >1mm
Advantages versus Short Fiber
Significant lower warpage vs short glass fibers
Much lower CTEs and higher isotropy than short glass fibers
Improved impact performance (especially Low temp.)
Improved creep resistance (better than PA short glass fiber)
Improved long and short term heat resistance
Advantages versus Metal
Lower weight
Parts consolidation leading to lower cost
Source: Ticona
THE LONG FIBER ADVANTAGE
Stress is transferred to the fibers The structural members of the composite
Long glass fibers create a “skeletal
structure” within the molded article Resists distortion and provides unmatched
strength, toughness and overall performance
Source: Owens Corning – J. Thomason
LFT Technology boosts material property profile: Dry-as-molded as well as Creep and Heat Resistance
Source: Owens Corning – J. Thomason
LONG FIBER VS. SHORT FIBER GLASS REINFORCED LFT
GLASS REINFORCED LFT SNAPSHOT
Growth Rate: 11-13% CAGR for the period 2013-2017
Glass Reinforcements: >140Kt/yr
LFT Process: 64% LFTP Compounding, 21% DLFT, 15% CFRT (Tapes)
Polymer: 80% PP, 13%PA, 7% Other
Market Segmentation: 81% Automotive, 7% Furniture, 5% EE, 7% Other
Source: Owens Corning Marketing Intelligence- Total LFT industry glass volume demand.
Copyright © 2014 Owens Corning. All Rights Reserved. Images © istockphoto.com
LONG FIBER REINFORCED THERMOPLASTICS PERFORMAX® SE4849 ROVING
Provides outstanding glass processing and wet out
Enables up to a 30% increase in compounding line speed
Opens new applications through high glass loading
Inner door module application example
Owens Corning internal tests - Pict. Copyright Leonello Calvetti / shutterstock.com
SE4849 ROVING REDEFINING LFTP PP & CFRT PP COMPOUND PERFORMANCE
DELIVERING UP TO 40%
IMPROVED PROCESSING AND WET-OUT
UP TO 30% INCREASE IN
COMPOUNDING LINE SPEED
HIGHER GLASS LOADING
POTENTIAL
UP TO 20% INCREASED MODULUS
ENABLING
DELIVERING
PROVIDING
Improved resistance to fuzz generation for easier processing Reduced strand stiffness for easier splaying Increased lubricity for lower strand tension Improved splice tensile strength enhancing
line efficiencies Improved LOI consistency for uniform
compounding Outstanding compatibility with PP for
better wet-out and dispersion Optimized adhesion to PP to meet all
mechanical performance needs Exceptional Color
SE4849 ROVING BENEFITS
Owens Corning internal tests
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
SE4121 SE4805 SE4849 Comp 1 Comp 2 Comp 3
FUZZ generation 50%-83% better than competitors
FUZZ is an accumulation of short broken or untangled glass filaments that collect at a strand contact point.
Impregnation Die Nozzle Fuzz Level (mg)
Good
Average
Poor
Trial 60%GC
SE4849 ROVING EXCELLENT RESISTANCE TO FUZZ ENABLING SUPERIOR GLASS PROCESSING
Owens Corning internal tests - Ibaraki Q4 2013
Outstanding Fuzz Resistance
(along with Dispersion) enables up to
20% increase in glass
loading
Std 50%GC
PERFORMAX® SE4849 ROVING EXCELLENT GLASS DISPERSION ENHANCING MECHANICAL PROPERTIES DELIVERING HIGHER GLASS LOADING POTENTIAL
Owens Corning internal tests (Ratio [%] of GC50) - Granville and Ibaraki Q4 2013
DISPERSION 21% better than OC standard product DISPERSION UP TO 40% better than some competitors
DISPERSION refers to the ability of the reinforcements to flow and scatter evenly within the polymer matrix thereby providing uniform fiber-polymer adhesion and load transfer.
SE4849 ROVING EXCELLENT GLASS DISPERSION DELIVERING HIGHER GLASS LOADING and FASTER LINE SPEED POTENTIAL
Physical count of undispersed glass on twenty
89mm x 89mm x 2mm low shear injection
molded plates
Undispersed Glass Count C
ount
of w
hite
spo
ts
Outstanding dispersion
(and Fuzz resistance) enables up to
30% increase in LFTP
line speed
75% line speed increase realized on the lab line while up to 30% achieved on Industrial lines
35m/min Maximum mimic Line Speed with acceptable dispersion
20m/min Historic Maximum Speed
0
2
4
6
8
10
12
14
16
18
20
SE4121 SE4849 Comp1 Comp2 Comp3
1st Col
2nd Col
SE4849 ROVING EXCELLENT SPLICE STRENGTH FOR EFFICIENT PROCESSING
46% better than OC standard products UP TO 38% better than some competitors
Owens Corning internal tests - Ibaraki Q4 2013 *Kilogram-force
Air splicer
Spliced strands Air splicer: JOINTAIR 116 by MESDAN Test conditions: Air pressure 0.7MPa, L6, T6 ,Chamber 127M
0
5
10
15
20
SE4121 SE4805 SE4849 Comp 1 Comp 2 Comp 3
Tensile Strength of Air Spliced Roving Strands (Kgf*)
Poor
Acceptable
Good
SE4849 ROVING TOMORROW’S PROCESSING CHARACTERISTICS COUPLED WITH MECHANICAL PROPERTY PERFORMANCE TO MEET TODAY’S DEMANDS
Owens Corning internal tests - Granville and Ibaraki Q4 2013
0
20
40
60
80
100
120 TENSILE
0
20
40
60
80
100
120 FLEX
Competitors Average
Competitors Average
SE4121 at 100% for reference
Owens Corning internal tests - Granville and Ibaraki Q4 2013
0
20
40
60
80
100
120 NOTCHED IMPACT
0
20
40
60
80
100
120 UNNOTCHED IMPACT
SE4121 at 100% for reference
Competitors Average
Competitors Average
SE4849 ROVING TOMORROW’S PROCESSING CHARACTERISTICS COUPLED WITH MECHANICAL PROPERTY PERFORMANCE TO MEET TODAY’S DEMANDS
Market Growth for LFT looks bright Automotive Light Weighting will drive growth Glass Reinforced LFT is one of the most economical solutions Owens Corning Performax® SE4849 will help improve the overall economics
SUMMARY
