Thermoplastic Solutions for Lightweight Structures

Thermoplastic Solutions for Lightweight Structures

Dr.-Ing. Martin Wanders

Head of Global Application Development

Business Unit High Performance Materials

Stainz, May 24th 2013

2

Introduction

Plastic / Metal Hybrid Technology – principle and history

Innovative developments

High modulus grades

Adhesive bond technology

Composite technology

Application fields

Agenda

3

Specialty chemicals company

Spin-off from Bayer in 2004

Focus on: Plastics, Rubber, Specialty chemicals, Intermediates

Global success story

17,200 employees in 31 countries

48 production sites worldwide

2012 sales of EUR 9.094 billion

Strategy of targeted innovation

Vital role in LANXESS´growth

Focus on process and products innovation

LANXESS – Global player in the specialty chemicals industry

4

LANXESS – Based on three powerful segments

Advanced Intermediates

Saltigo

Advanced Industrial Intermediates

Sales 2012: 1.7 Billion €

Inorganic Pigments

Functional Chemicals

Material Protection Products

Leather

Rhein Chemie

Rubber Chemicals

Ion Exchange Resins

Performance Chemicals


Performance Polymers

Performance Butadiene Rubbers

Butyl Rubber

High Performance Materials


Keltan Elastomers

High Performance Elastomers

Customer Day Kiev – Dr. Martin Wanders – Technology and Innovation for the Plastics Industry 5

Facts

Part of: Performance Polymers Segment

Employees: ~ 1,500

Market position: Among global top 5

Applications

Products and Brands

Products: Intermediates – Caprolactam, Glass Fibers High-tech plastics – based on Polyamide (PA) Polybutylenterephtalate (PBT), Monofilaments

Brands: ~ 1,500

High Performance Materials – Leading supplier of high-tech plastics

6

High Performance Materials – Strong setup to serve global demand

Global compounding

network guarantees

market and customer

proximity

Security of supply

guaranteed by

in-depth upstream

integration into key

intermediates

New downstream

integration due to

Bond Laminates

acquisition

A reliable partner –

worldwide

* under construction

Krefeld-Uerdingen, DE

Wuxi, CN

Antwerp, BE

Jhagadia, IN

Gastonia, US

Hamm-Uentrop, DE

Porto Feliz, BR*

Today 2005

SCP global compounding network Site for upstream integration

Brilon, DE

Site for downstream integration

7

Global product and application development (GPAD) to drive innovation

Tailored development activities

and services

Globally positioned and

networked

Head count (2013): 130

Departments

- Product development

- R&D testing center

- Application development

- Customer engineering services

GPAD profile

Wuxi, CN

Hong Kong, CN

Dormagen, DE

São Paulo, BR

Pittsburgh, US

Mumbai, IN

Product and application development center

8

Lightweight design – a key technology for sustainable mobility

Lightweight design compensates for the negative

consequences of new drive concepts (e.g. heavy

battery in electric cars) – without lightweight design

modern mobility is unthinkable

Lighter cars increase fuel efficiency, reduce CO2

emissions in road traffic, thereby contributing to

“Greener Mobility”

Increasing demands for comfort and safety cause the

weight to spiral upwards – lightweight design

ensures that cars remain economical

9

Introduction



High modulus grades



Application fields

Agenda

10

F1

→

Denting or buckling of

lightweight structures

due to the thin wall

F2 F1

→ → >>

F1

→

F2

→ F2

→

Strengthening the structure

with small forces carried

by plastic ribs

Sheet metal

Support

High-tech plastics keep metal “in shape”

Metal

Polymer

Mechanical fixing

+

Plastic / Metal Hybrid Technology (PMH) enables lightweight

construction

11

Weight reduction vs. 2nd generation: ?

Weight reduction vs. steel: ~30%

Weight reduction vs. 1st generation: ~15%

Steel sheet: 1.5mm thickness

Single steel sheet supported and

functionalized by overmolded

high-tech plastics

Glass fiber content in plastics: 30%*

Aluminum / steel sheet: 1.2 / 0.8mm

thickness

Several smaller sheets are mounted

with overmolded high-tech plastics


System carrier: 1997 In-mold assembly: 2005

Frontend 1st generation Frontend 2nd generation Frontend 3rd generation

Our high-tech plastics developments contribute to weight

reduction in cars

? … … …

* Weight percentage

12

Agenda

Introduction

Plastic / Metal Hybrid Technology – principle and History


High modulus grades



Application fields

13

Highly reinforced PA or PBT

compounds

High modulus (HM)

High strength

Low viscosity resins allow

incorporation of high fiber amounts

Ideal solution for lightweight applications

Product characteristics development

Flowability

Stiffness

Tensile

strength

0

150

%

200

100

50

250

BKV30

PA6 GF30

BKV30 EF

PA6 GF30

DP BKV60EF

PA6 GF60

Product development for lightweight solutions – Easy Flow

enables high modulus (HM) grades

14

Weight reduction vs. 2nd generation: ~15%

Weight reduction vs. steel: ~30%

Weight reduction vs. 1st generation: ~15%

Steel sheet: 1.5mm thickness

Single steel sheet supported and

functionalized by overmolded

high-tech plastics



thickness

Several smaller sheets are mounted

with overmolded high-tech plastics



thickness

Sheets are overmolded with less but

extremely stiff high-tech plastics


System carrier: 1997 In-mold assembly: 2005 High-modulus materials: since 2012 in serial production

Frontend 2nd generation Frontend 3rd generation

Our high-tech plastics developments contribute to weight

reduction in cars

* Weight percentage

Frontend 1st generation

15

Automotive – Structural parts with high modulus grades

Durethan® DP BKV 60 H2.0 EF

(PA 6 + GF60)

• High modulus

• Easy flowing

Advantages

• Cost and weight reduction compared to

SMC* or metal design

• Enables high function integration

• Glued into the BIW** contributing to the

stability of the car

PMH with aluminum and GIT

Shot weight: 12 kg

Part weight: 9 kg Superior to pure metal designs

*Sheet Mold Compound **Body in White

Audi A8 - spare wheel well

16

Carbon reinforcement offers additional opportunities

PA6-GF 60 EF

PA6-CF30

High modulus next generation – weight specific comparison of

glass fiber and carbon PA6

* Dry as molded, at 23°C

PA6-GF 60 EF

PA6-CF30

17

Joint research project funded

by the German government

(Federal Ministry of Education

and Research)

New bonding technology targets higher

performance level to gain further weight reduction

Project objective: ~30% weight reduction

compared to standard hybrid components

Application areas: components that require

stiffness

Research project: Adhesive bond technology

Metal Polymer Mechanical fixing +

New adhesive bond technology

Polymer

Primer / glue

Metal

Current technology

Innovation – new bond technology for plastic / metal hybrid

components

18

Frontend Audi A8

Composite sheet

Thermoplastic matrix materials reinforced with woven fabrics

Glass, carbon or aramid fibers (also hybrid)

Continuous fibers (fiber length = part length)

Advantages of hybrid composite parts

Low weight (density e.g., 1.8 kg/dm³)

High stiffness, strength and energy absorption

No corrosion, simple recycling

No investment for additional tools

Full-plastic composite parts as alternative to plastic-metal structures

Further development – hybrid technology with composite

sheets and plastic/plastic hybrid

19

IR heater

Heating up above

melting point

Shaping during the closing of

injection molding tool

Subsequent injection molding of rib

pattern

Demolding

Integration of composite sheet into the hybrid composite

part through “in-mold forming”

20

Co-operation with ZF Friedrichshafen, a leading

automobile supplier for drive technology and

chassis

New brake pedal with ~50% weight reduction

compared to standard steel pedal

Additional benefits include:

Function integration

Reduction of process steps

No corrosion protection needed

Easy recycling

Development project: brake pedal Evolution of brake pedals

Mounted pedal block

Steel:

794g

Plastic metal hybrid:

526g

Composite sheet:

355g

Innovation – first brake pedal with composite sheet

21

Series production airbag container

Prototype container with composite sheets

Weight: 550 g

Weight: 360 g

Partnership with Takata AG, Aschaffenburg –

a leading producer of occupant-safety-systems

Successful development of new passenger airbag

housings with composite sheets

First thermoplastic composite airbag housing to be

used for passenger cars

35 % weight reduction compared to series part

Joint development of a passenger airbag container based on

composite sheet technology

22

Simulation is a must –

Airbag housing (1/2)

anisotropy

non-linearity

strain rate dependency

failure / Breakage

rotation of fiber directions / non-

orthogonal fiber directions

temperature dependency

…

Most relevant criteria

for simulation

Series-production

status

thin insert

thick insert

/U. Gaumann (Takata), J. Haspel (Lanxess), VDI Tagung Kunststoffe im Automobil, Mannheim, 2013/

23

Simulation is a must –

Airbag housing (2/2)

anisotropy

non-linearity

strain rate dependency

failure / Breakage

rotation of fiber directions / non-

orthogonal fiber directions

temperature dependency

…

Most relevant criteria

for simulation

Series-production

status

thin insert

thick insert

/U. Gaumann (Takata), J. Haspel (Lanxess), VDI Tagung Kunststoffe im Automobil, Mannheim, 2013/

24

Agenda

Introduction



High modulus grades



Application fields

25

Car area Components with LANXESS contribution

Drivetrain

Chassis

Interior

Cross car beam Frontend

Cylinder head cover

Bracket

Steering rod

Engine oil pan

Airbag housing

Roof frame Spare wheel well

Seat pan

Gas tank liner

Structural insert

Pedal / pedal bracket

Gearbox oil pan

High-tech plastics for lightweight applications

Car body

26

LANXESS has built up extensive know-how in

lightweight solutions

Contributing to innovations with new technologies

and high-performance materials

Self-developed top-notch simulation tools

Ongoing improvement of ready for mass

production lightweight technologies

Prototype

Passenger airbag housing

Takata AG

Prototype

Brake pedal

ZF Friedrichshafen AG

LANXESS – partner for innovative lightweight solutions

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Documents

Thermoplastic Solutions for Lightweight Structures