Transcript BMC Automotive Materials - Bulk Molding Compounds, Inc.

AUTOMOTIVE
Complete
Composite
Solutions
BMC Offers High Performance with Low Cost
BMC materials have been used in the automotive sector for more than 30 years and never has the need
been greater for a high performance material that can meet the demands for BOTH cost and weight
reduction than in today's automotive market.
New demanding global fuel economy and tailpipe emissions regulations present severe challenges for
today’s automotive engineers. BMC brings a unique balance properties and physical characteristics that
help meet the challenge for current and future automotive applications.
High temperature resistance – Tg > 200C
Very high strength (fexural modulus greater than 18 GPA)
Low weight (30% lighter that equivalent aluminum parts)
Chemically resistant to most automotive fluids
Repeatable molded part dimensions (zero post mold shrink possible)
Excellent dimensional stability/tight tolerances (low CLTE)
Low warpage/excellent part flatness
Extremely high creep resistance (150C)
Excellent flammability resistance (UL94V-0)
Excellent electrical properties (insulating or conductive)
Low relative cost to alternative high performance materials
High temperature assembly possible (soldering, welding, etc.)
Wide Range of Materials/Properties
Bulk Molding Compounds Inc. is the worlds leading supplier of
unsaturated polyester and vinyl ester based thermoset
composite materials.
BMC composite compounds are composed of various raw
materials including resins, low profile additives, catalysts,
pigments, mould release agents, fillers and fiber
reinforcements.
At BMCI we work closely with our customers to custom
formulate our materials to deliver properties specific to each
applications unique requirements to insure the correct balance
of performance versus price.
HIGHLY ENGINEERED POLYESTER AND
VINYL ESTER THERMOSET COMPOSITES
BMCI Global Footprint
BMCI has 7 compounding facilities locating in North America, South America, Europe and Asia to serve the
global automotive market. Each of these markets are supported by local BMC sales and technical service
representatives.
•USA - Chicago, IL, Perrysburg OH,
•Mexico – Juarez, Mexico City
•Brazil – Sao Paulo,
•Germany – Hamburg,
•China- Dongguan
BMC Range of Properties
BMC’s unique blend of properties make them ideal for use in the extreme environments found in a wide
variety of automotive applications.
•Automotive Electrical and Lighting Systems
•Under the Hood/Powertrain
•Body Structures
•Exterior Trim
•Alternative Fuel Vehicles (Hybrid Electric/Fuel Cell)
Property
Density
Shrinkage
Out of Mold Shrinkage
Flexural Strength
Flexural Modulus
Impact Strength
Compressive Strength
Tensile Strength
Tensile Modulus
Elongation at Break
Thermal Coefficient of Linear
Expansion
Heat Deflection Temp HDT-A
Heat Deflection Temp HDT-C
Max Service Temperature
Thermal Conductivity
Flammability
Water Absorption
Surface Resistivity
Volume Resistivity
Standard
Units
Value
ISO 1183
ISO 2577
ISO 2577
ISO 178
ISO 178
ISO 1790
ISO 604
ISO 527
ISO 527
ISO 527
g/cm3
%
%
MPa
GPa
KJ/m2
MPa
MPa
GPa
%
1.5-2.5
0.3 - minus 0.1
< 0.05
75 - 150
9.0 - 20.0
10 - 50
140 - 180
30 - 70
10.0 - 15.0
0.2 - 0.5
VDE 0304/T.1
ISO 75
ISO 75
10-6/K-1
C
C
C
W/mk
class
mg (1d)
Ω
Ω cm
11 - 22
> 250
> 200
190 - 200
0.4 - 0.8
HB - V0/0.8mm
<30 (0.25%)
1012
1014
UL 94
ISO 62
IEC 60093
IEC 60093
BMC vs. High Performance Materials
BMC thermosets offer the most cost-effective
performance at elevated temperatures under load,
pressure, and chemical exposure in automotive
applications compared to metal and engineered
thermoplastics.
Bulk molding compounds specifically offer “the best
balance of physical properties at the lowest possible
cost when compared to engineering thermoplastics and
die cast metals.”
(Average Material Attribute Comparison)
BMC Range of Molding Processes
BMC materials are produced in multiple forms, shapes, and
sizes to meet each customers specific processing
requirements.
BMC materials can be processed by injection, compression,
injection-compression, or resin transfer molding depending
on the part size, shape, tolerancing, physical properties, and
production volumes
Tool life in most cases exceeds more than one million shots
making it a very economical process when compared to
metal die casting processes.
BMCI In-House Technical Support Capabilities
BMCI offers a range of application development support services to
help select and/or develop materials with the right balance of
properties and cost to meet requirements.
Customization of
formulations allows us to insure we are providing an optimized
solution for each application with correct balance of properties vs.
cost.
A breadth of in house material development, testing, design
engineering and prototyping enables us to help customers deliver
solutions to meet the most demanding deadlines and requirements.
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Material Selection
Material Formulation/Sampling
Full Service Materials Lab/Testing
Instron, Dynatup, Gas Chromatograph
FTIR, DSC, DMA, TGA
Engineering/Design
Materials/Product Training
Prototyping
Injection molding
Compression Molding
Rapid Prototyping
Full Service Tool Shop
Prototype and Production Tooling Fabrication
Conversion of Die Cast or Thermoplastic Molds for BMC Development
BMC Range of Automotive Applications
Spoilers, Air Vents
ECU Enclosures
Electric Motor Brush Holders,
Armatures, Housings
Capless Fuel
Filler
Engine Heat Shield/Beauty Covers
Fuel Pumps
Cylinder Head Covers
Electronic Throttle Bodies
Thermostat Housings
Head Lamp Reflectors
Vacuum Pump Housing
Engine Front/Rear Covers
Cooling Pump Housing
Oil Pump Housing
Oil Filter Housing
Under Body Heat
Shields
Body Structural Inserts
Transmission Sump Pan
Transmission Thrust Washers
Transmission Valve Body
Transmission Linkage
Starter End Cap
Oil Sump/Pan
Turbo Systems
BMC Automotive Materials
BMC materials used in Exterior, Lighting, Body Structure
Applications.
BMC Unsaturated Polyester Composites deliver excellent surface quality,
painting and metalizing capabilities, tight tolerances, and high strength
through temperatures in excess of 180°C, making them the logical
choice for headlamp reflectors, exterior painted surfaces, heat shield
shielding applications, and body structural supports.
Properties/Units
304
324
675
ASTM
Test Method
<.0008
<.001
.001-.003
D955
1.77-2.05
1.80-1.95
1.80-1.90
D792
Barcoal Hardness
40-55
50-60
50-60
D2583
Water Absorption, 24 hrs. %
.10-.20
.10-.30
.23-.27
D570
Flexural Strength, kpsi
11-24
11-16
11-14
D790
Flexural Modulus, Mpsi
1.5-2.2
1.5-1.8
1.8-2.0
D790
Tensile Strength kpsi
5-9
4-6
4-5
D638
Izod Impact, Notched, ft-lb/in
2-10
2-4
3-5
D256
Heat Deflection Temp., °F
>500
>400
>500
D648
Linear Shrinkage, in/in
Specific Gravity
BMC Automotive Materials
BMC materials used in high temperature under the hood applications.
BMC Polyester and Vinyl Ester Composites offer very high glass transition temperatures in excess of 175°C
making them a perfect fit for highly functional powertrain components that must maintain their properties and
dimensions across their operating range as well as exposure to high vibration loads and harsh fluids. This
makes them an excellent choice for engine sealing applications, electronic throttle bodies, pump housings,
and turbo systems.
Properties/Units
665
675
685
695
Dimension
X
ASTM
Test Method
.0015 .0025
.001-.003
.0015.0025
.0002.0020
.0000 .0006
D955
1.65-1.70
1.80-1.90
1.72-1.85
1.72-1.85
1.80-1.90
D792
Barcoal Hardness
40-50
50-60
50-65
50-65
50-60
D2583
Water Absorption, 24 hrs.
%
0.1-0.3
.23-.27
0.1-0.2
0.1-0.2
0.15-0.25
D570
Flexural Strength, kpsi
11-14
11-14
24-30
24-30
22-24
D790
Flexural Modulus, Mpsi
1.3-1.6
1.8-2.0
1.7-1.9
1.7-2.0
2.1-2.3
D790
Tensile Strength kpsi
4-5
4-5
8-11
8-11
8.5-9.5
D638
Izod Impact, Notched, ftlb/in
3-5
3-5
11-17
10-17
15-17
D256
>500
>500
>500
>500
>500
D648
Linear Shrinkage, in/in
Specific Gravity
Heat Deflection Temp.,
°F
BMC materials
Applications.
used
in
Conductive
and
Specialty
As automotive systems and technologies evolve to meet new
regulations, improve fuel economy, reduce environmental
impacts and meet consumer demands, BMC’s flexibility in
formulation enables high value material solutions in the most
unique applications. From highly conductive composites for use
in PEM Fuel Cell Bipolar Plates to very high strength composite
materials with long term creep resistance meeting the extreme
requirements in fuel cell stack end plates.
Test Method
Properties/Units
940
955
945
Application Use Temperature,
°C
< 120
< 200
< 150
0.0002 –
0.002
0.003
.0002.0010
D955
1.75-1.95
D792
Linear Shrinkage, after
postbake , in/in
Specific Gravity
1.78 – 1.83 1.78-1.82
Bulk Resistivity, Ohm-cm
0.02 – 0.04
0.02
ESD
Range
USFCC
Thermal Conductivity, inplane W/m°C
45
45
<1
E1461-92
Flexural Strength, kpsi
6.5
6.5-7.5
12-14
D790
Flexural Modulus, Mpsi
2.0
1.7
1.8-2.0
D790
Compressive Creep ,1000 hr
@200PSI, %
< 0.003
< 0.0002
NA
D695
Izod Impact, Notched, ft-lb/in
0.20
0.15
3-6
D256
Glass Transition
Temperature, °C
190
> 250
150 - 160
D4065
BMC Sustainable Material Solutions
The major environmental and social impacts of products throughout their life cycle along with the materials
from which they are produced, is increasingly being recognized by customers across all market sectors. Many
companies have embraced the importance of product sustainability, driven by environmental objectives and
increased demand and prices of energy and resources.
BMC materials offer immediate solutions to this demand with core products that offer one
of the lowest energy content and cost solutions in light weight/high performance materials.
BMCI has further responded to the demand for renewable materials by
developing a line of bio-based BMC composites that employ the use of
vegetable oils based resins, recycled fillers, and natural and organic fiber
reinforcements.
Green BMC
Green BMC is manufactured using
100% soy based resin an doffers
properties comparable to standard to
standard grades at competitive costs.
Green BMC also provides a solution to
thermoset reprocessing but using
pulverized molded BMC as 10% of its
filler content.
Forward Lighting
Headlamp design is one of key components vehicle designers depend on to give vehicles their soul and identity.
BMC composites have been the materials of choice for automotive headlamp manufacturers worldwide for more
than 20 years, due to their superior performance, low cost and flexibility in design.
BMC headlamp materials offer high temperature resistance combined with dimensional stability, and low
coefficient of thermal expansion allowing for highly complex shapes and tight tolerances to be produced and
maintained throughout their operational life.
Process: Injection Molding
Material: BMC 304, 324 No Base Coat
Benefits of BMC:
 Lowest Cost vs. Performance Material
 No Machining Operations
 Direct Metalized
 No Base Coat
 Low Fogging
 Component Integration/Design Flexibility
 High precision parts
 Very good dimensional stability
 Excellent rigidity
Typical application requirements
• Temp : -40C to 180C
• Tight tolerances and dimensional stability over
operating range/Low CLTE
• High stiffness up to 180C
• Long term creep resistance
BMC Composites have demonstrated more than 20 years
of success in replacing die cast metals in engine sealing
applications. BMC’s high strength, and ability to maintain
the required properties under long term exposure to high
temperatures and hot engine oil make it the perfect choice
to reduce cost and weight in applications such as cylinder
head covers, oil pans, engine front and rear covers.
The stiffness of the material allows for less ribbing and total
material use compared to Polyamide thermoplastics. Its
inherent creep resistance allows for larger bolt spans,
improved multi-planar sealing and/or added safety factor in
maintaining constant surface pressures on the sealing
flange preventing oil leakage and potential engine fires.
Typical application requirements
• Temp : -40C to 130C
• Tight tolerances and dimensional
stability over operating range
• Flexural creep resistance to maintain
seal
• Chemical resistance to under hood fluids
• Long term exposure to hot engine oil
Engine Sealing
Process: Injection or Compression Molding
Material: BMC 675, 685, 695, 695HT
Polyester and Vinyl Ester Composites
Benefits of BMC over Al, Mg:
 Piece Price Savings: 30-40%
 Tooling Cost Reduction
 Weight Savings: 25-30%
 Improved NVH/Damping Properties
Benefits of BMC over PA66
 Higher temperature capabilities
 Improved flatness of sealing flange
 Dimensional stability and creep
resistance
 Ease of coloring/aesthetics
 Supports larger bolts spans
 Excellent Flame Resistance (UL94 V-0)
Heat Shields/Engine Covers
BMC materials are specified as thermal barriers based on the high temperature properties to protect and/or insure
the proper long term function for fuel pumps, tanks, injectors as well as other components located close to
exhaust systems such as spare tires.
With the proliferation of turbo chargers in more consumer transportation applications, engine covers are being
employed to protect consumers from the hot turbo and/or EGR components located near the top of engines.
These localized high temperatures exceed the capability of traditional engineering thermoplastic materials.
Process: Injection Molding or Compression Molding
Material: BMC 304 Polyester, BMC 675, 695 Vinyl Ester
Composite
Benefits of BMC over PA, PPA:
 Piece Price Savings: 15-60%
 Higher Long Term Temperature Resistance Tg.> 200C
 Very Low Warpage
 No dimensional change with moisture absorption
 Ease of coloring/aesthetics
 Excellent Flame Resistance (UL94 V-0)
Benefits of BMC over SMC:
 Piece Price Savings
 Less processing steps
 Flexibility of processing (injection or compression)
 Design Flexibility/Functional Integration
Electronic Throttle Body/Air Control Valve
The potential benefits of plastic throttle bodies over die cast aluminum are many, but
the integrated functions, very tight air flow specifications and hence dimensional
requirements combined with an extreme operational environment make realizing these
benefits a tremendous challenge.
BMCI has answered that challenge with the material innovation “Dimension X” a zero
shrink polyester composite with very low CLTE that meets both long term durability and
dimensional stability required in electronic throttle valves. In production since 2005
BMC Dimension X provides a high value material solution to meet the growing
demands for cost and weight reduction while simultaneously delivering additional
technical benefits over traditional aluminum parts.
Process: Injection Molding
Material: BMC Dimension X, BMC L420 Polyester
Composite
Benefits of BMC over Aluminum:
 Piece Price Savings: 30-40%
 Tooling Cost Reduction
 Weight Savings: 25-30%
 Improved icing / no heating
 Eliminates coking performance issues
 Equivalent or better dimensional tolerances
 Print Tolerance: +/- 0.05mm flatness/roundness
 Improved safety during crash
 Reduced manifold dynamic loading
Electronic Throttle Body/Air Control Valve
Typical application requirements
• Temp : -40C to 150C
• Very tight tolerances
• Dimensional stability for concentricity of
bore diameter over operating range
• Creep resistance
• Chemical resistance to under hood fluids
Benefits of BMC over High Performance
ETP
 Piece Price Savings: 30-75%
 Zero out of mold shrinkage
 Lower CLTE/better dimensional stability
 Larger bores possible
Electric Motor Components
The number of electric motors in automobiles continues to grow at a rapid pace as vehicle technologies evolve to
meet new market demands. From small motors including starter motors, windshield wiper motors, pump motors,
window lift motors, power steering motor, fan motors, compressor motors, and actuator motors to larger motors
such as traction motors found in electric vehicles.
BMC offers customers a full range of high-performance composite solutions for motor coil forms, insulators, end
caps, armature shaft insulators, brush holders, housings, stator encapsulations, etc. BMC materials offer
properties such high heat resistance, arc resistance, flame resistance, moisture resistance, and electrical
insulation required in these demanding applications.
Process: Injection Molding
Material: BMC 600, 604, 605, 620, 3001H, 1901
Polyester Composites
Benefits of BMC vs. High Performance
Thermoplastics:
 Piece Price Savings: 40-50%
 Improved dimensional stability
 Better Creep Resistance
 Improved property retention over service life
 Reduced noise
 Higher Dielectric Strengths
 Lower Moisture Absorption
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Typical application requirements
Tight tolerances and dimensional stability over
operating range
150°C continuous use temperature
High mechanical strength/stiffness
Chemical resistance
Good Resistivity/High dielectric strength
Flammability resistance (UL94V-0) and Arc
Resistance
BULK MOLDING COMPOUNDS, INC.
“Complete Composite Solutions”
Contact:
Jim Cederstrom,
Automotive Business Development
Phone: 248.766.7111
Email: [email protected]
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forward lighting
airbag control
unit housing
transmission stator
Electronic
throttle control
housing
motor armatur
valve cover
starter motor
electrical motor housing
Fluid impeller
BMC Automotive Components
gear shift linkage