Use of Polymers in automobiles
-
Upload
nk-babul -
Category
Technology
-
view
2.832 -
download
4
description
Transcript of Use of Polymers in automobiles
PRESENTATION BYNAWAL KISHORE BABUL
100109034
Plastics vs. Metals Polymer Applications in Automobiles
- Instrument Panels- Engine- Windows- Tires- Body Panels
Compete with other materials based on:◦ Weight savings◦ Design flexibility◦ Parts consolidation◦ Ease of fabrication
Car Part Polymer
Trim Panels (3) Polypropylene (PP)
Impact Absorber Thermoplastic Olefin (TPO)
Radio Housing ABS/Polycarbonate(PC)
Door Outer Panel ABS/Polycarbonate(PC)
Handle Polypropylene (PP)
Fog Light Cover Thermoplastic ElastomericOlefin (TEO)
Tire Elastomers
Application Material Processing MethodLoad-Bearing- bumper beams
Glass-fiber reinforced polyester resins
Pressing of resincompounds
Moldings/covers- front apron- spoiler- wheel-well liners- radiator grill- hood- fenders- trunk
PolyurathanePolypropylenePolyethleneAcrylonitrile-butadiene- styrene (ABS)Polycarbonate
Injection Molding
ProtectiveMoldings
Polyvinyl chlorideEthylene-PropyleneTerpolymers
Injection Molding/Extrusion
EnergyAbsorbing Foam
Polyurethane Liquid ReactionFoaming
Polycarbonate/ABS resins Introduction of airbags in IP design Injection Molding vs. Blow Molding
ULTEM polyetherimide (PEI) resin to replace aluminum under the hood for 1st time
• High-performance amorphous resin from GE
• Complete air management modules can be made of thermoplastic
Throttle Body
Plastic Body Panels - Chevy Corvette since 1953
Sheet Steel - still most commonly used for vehicle
body structureAluminum - weighs less but costs morePlastics - increasingly used for metals parts
replacement
1. Cost2. Flexural Modulus3. Coefficient of Thermal Expansion4. Chemical Resistance5. Impact Resistance6. Heat Deflection Temperature (HDT)
• Better color match• Incorporate in existing facilities• Assembly line temperatures exceed 200oC
Alloys:Polyphenylene ether/polyamide ABS/PolyestersABS/Polycarbonates
• Larger choice in materials• Additional steps take time• More plastics will enter the market as assembly lines are redesigned
Advantage of plastics
Highly cross-linked and highly filled Polymer component is polyester Suitable of compression molding Molded product combined high modulus with high
strength Body panels (hoods and deck lids) More expensive than metal, but lower tooling cost
• Growth of applications- Body panels on GM’s Lumina, TransPort, and Silhouette- Structural components - valve covers, grille- opening reinforcements, fascia supports, etc.
• 250 million lbs. of SMC was used in 1997
Bottom line benefits◦ Tooling for SMC hood was 23% of steel◦ Weight savings of 18%
Composite front fenders and hood design for 1995 Lincoln Continental
Result of need for lighter-weight and more cost efficiency integrated system
SMC fenders and hood Bottom line benefits:
◦ SMC fender tooling was 40% of projected tooling for steel fenders
◦ Comparative weight saving was 33%
Toughened Safety Glass (TSG)- tempered glass
Laminated Safety Glass (LSG)- two panes of glass bonded together using polyvinylbutyral
SGL Group and car company BMW
JV by SGL Group and car company BMW carbon fiber-reinforced plastics (CFRP) Costs around $100m
THANK YOU