Transcript Slide 1

High Value Metal Replacement in
Automotive Powertrain Applications
New Opportunities with Thermosets Under the Hood
Jim Cederstrom
Automotive Business Development Manager
Bulk Molding Compounds, Inc
Sept 16, 2009
SPE – Automotive Composites Conference & Exhibition
Past Drivers for Plastics
Market Share (%)
Lbs
(Vehicle Weight Gain)
*Source: U.S. Environmental Protection Agency, Light-Duty Automotive Technology and Fuel Economy Trends: 1975 Through 2008
Past Drivers for Plastics
(Vehicle Weight Gain)
• Consumer Preference
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High displacement engines (Fun to Drive)
4 wheel drives
Advanced climate control systems
NVH improvements
Infotainment systems
• Advanced Safety Systems
– Anti-lock brakes, Stability/Traction Control,
Airbags
• Emissions Systems
– Fed Tier II and CARB LEV requirements
• Negative impact on cost/weight/CAFE
Plastics Growth in Vehicles
(Weight reduction)
• 250 lbs of Plastics/Composites
• 331 lbs of Plastics/Composites
• More than 30% increase
• Average 150 lbs vehicle weight
reduction
• UTH last to grow
*Source: American Chemistry Council
Typical Application Requirements
• Temperature Resistance: -40C to 130C
• Chemical Resistance:
– Coolant, Brake Fluid, Fuels, Solvents, NaCl, Humidity, Hot
Engine Oil
• Vibration/Impact Resistant
• Structural Rigidity
• Creep Resistance
• Long Term Dimensional Stability
Progression of Plastics Under the Hood
PP, PA66, PBT
BMC, SMC, PA66,
PA6, PA66
PPA, PPS, PA4,6, BMC,
Phenolic
18 lbs
9 lbs
1985
1995
2005
What’s Next for Composites Under the Hood?
(Market Drivers)
RESULT
MARKET DRIVERS
• Dramatically increased
emissions and fuel economy
regulations
– US CAFE - 35 mpg
– US Emissions Fed Tier 2 and
CARB LEVII (CO2, NOx)
– EURO 5 and EURO 6 Emissions
• Rising fuel prices
• Extended warranties
• Consumer sentiment towards
greener vehicles
• Drive toward energy
independence
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Vehicle Downsizing
Engine Downsizing
More Efficient Powertrains
Complex Powertrain Controls
Alternative Fuels/Energy
• More extreme requirements
• Renewed and aggressive focus
on lightweight materials and
cost reductions
New and more demanding applications
RESULT
TECHNOLGY TRENDS
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GDI and diesel engines
Turbo/super charging
Highly active intake systems
Electronically controlled valve
actuation/timing
Drive by wire systems
Cylinder deactivation
EGR
Alternative/bio fuels
Engine start/stop systems
Hybrid Electric Powertrains
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More complex systems
Tighter packaging space
Higher heat
Higher pressures
More corrosive fluids
Added Cost
“Higher Performance Polymers”
• Existing composite apps
• New hydraulic/mechatronic systems
Future Growth in Plastics Under the Hood
(New Requirements for PT Composites)
• Higher Temperature Resistance: -40C to 150C (>200C)
• Mechanical Strength and Impact Resistance Across a Wider Range
of Temperatures
• Chemical Resistance (New more aggressive fluids):
– Long Life Engine Coolants: OAT, HOAT
– Alternative fuels: Flex fuels, Diesel Fuel, BioDiesel Fuels
– EGR gases
• Long Term Dimensional Stability
– Tighter tolerance requirements
– Across wider temperature range
• Creep Resistance (high temp)
• Longer Warranty Periods
Bulk Molding Compound (BMC) Composite Materials
• Long history of BMC composites in
demanding automotive applications
• More than 90% of all automotive
headlamp reflectors are produced in
BMC
• Very high temperature resistance, high
precision parts, low system cost.
BMC Composite Material Composition
(Wide Range of Materials/Properties)
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Composite Cost Comparison
On a cost / unit volume basis thermosets offer significantly higher value
compared to many High Performance Thermoplastics.
PERFORMANCE
BMC vs. High Performance Thermoplastics
PEI
Phenolic
PEBMC
VEBMC
LCP,
PEEK
PPS
PPA,
PA4,6
PA66, 6,
PBT, PET
Thermosets offer a much higher
Performance vs. Price ratio
PP
PRICE
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BMC vs. High Performance Materials
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BMC Precision Net Shape Molding
BMC composites provide the tightest tolerance and dimensional stability over
any other high performance composite material
Material
Aluminum
Mold
Moisture
CLTE (μm/m°C)
Shrinkage (%) RT to 150°C
Absorption (%)
0
0.70
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BMC Dimension X
0.00
18
0.15
PPS (50% GF)
0.33
58
0.03
PEI (30% GF)
0.30
48
0.25
PA6,6 (30% GF)
0.25
61
>1.0
Key Factors Driving Dimensional Improvements
in BMC
• Normally lower shrinkage BMC’s result in higher CTLE, and less
compressive creep resistance
• Optimization of the low profile additives, resin cross-linking density,
filler system, and fiber have resulted in a new BMC composite
systems that provide the maximum creep resistance, lowest possible
CTLE and smallest possible molded part tolerances
• These breakthroughs can now being translated in to various high
precision powertrain applications.
Intake Systems
Pump Housings
Transmission
Systems
BMC Dimensional Change/Fluid Exposure
• Part dimensions can also be affected by the absorption of various
automotive fluids.
• BMC demonstrate very low dimensional change to most automotive
fluids.
Dimensional Change (%) After Exposure to
Various Automotive Fluids (2000 hours)
Fluid
BMC Composite (%
dim change)
Dexcool (93°C)
0.05
Used Engine Oil (150°C)
0.00
ATF (150°C)
0.01
Gasoline (24°C)
0.03
Power Steering Fluid (150°C)
0.01
Brake Fluid (150°C)
0.14
BMC Electronic Throttle Valves
• BMC Dimension X Polyester Composite
• Cost savings: 20 - 35%
• Weight savings: 25-30% (≈ 0.5lb)
• Zero mold shrinkage
• Tight/repeatable tolerances
– +0.03/-0.06mm, 90mm bore
– +/- 0.015 MM ,20mm bore
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Reduced manifold dynamic loading
Improved icing / no heating
Possible electric motor down sizing
Improves safety during crash
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BMC in Engine Oil Applications
(Engine Sealing)
• BMC 665, 675, 695
• Excellent Track Record
– >60 MM parts w/o failure
• Strong/Rigid Parts at High Temps
• Excellent Flatness/Tolerances
– Excellent Creep Resistance
Engine front/timing covers
Pressurized Engine Lubrication Circuit
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BMC Thermal Mechanical Performance
BMC composites offer very high glass transition temperatures and exceptional
stiffness enabling metal replacement in dimensionally critical applications
with constant mechanical loading under long term high temperature exposure
Material
Tg (°C)
Aluminum
Flexural Modulus
23°C (GPa)
Flexural Strength
23°C (Mpa)
68.9
BMC Composite
200
13.2
154
PPA (33% GF)
125
10
200
PPS (40% GF)
90
11.1
225
PA 6,6 (33% GF)
55
6.4
180
Rigidity at Elevated Temperature
(BMC vs. Engineering Thermoplastics)
BMC High Pressure Engine Oil Applications
(Oil Pump and Filter Housings)
• BMC TDV584, BMC 665, BMC 695
• Piece price savings: 30-50%
• Weight savings: 25-30%
– 0.25 -1 lb
• Strong/rigid material at high temps (150°C)
• Withstands high oil pressure/cycling
– > 15bar
– Low deflection
• Self lubricating formulation for low wear
• Tight/repeatable print tolerances
• Very low creep/CTE
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BMC Property Retention vs. Fluid Aging
150°C 2000hr Engine Oil Exposure
150°C 2000hr ATF Exposure
120°C 2000hr Long Life Coolant Exposure
BMC Pump Applications
(Electric Pump Housings)
BMC TDV584, BMC 665, BMC 695
• Electric engine oil pumps
• Electric auxiliary CVT pumps
• Electric/auxiliary coolant pumps
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ICE thermal efficiency control
Charge-air cooling
Battery cooling for electric vehicles
Electronics cooling for electric vehicles
• Vacuum pumps for braking
• Electric fuel pump inlet/outlet
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BMC High Temperature Exposure
(Engine Covers/Heat Shields)
• Higher engine compartment temps >150°C
• BMC low cost/high temp solution for
covers/heat shields
• Continuous use temps > 220°C
• Low S.G. 1.5-1.6
• Class A surface
• Excellent flatness
• Low thermal conductivity
200°C 2000hr Air Exposure
– 0.5 W/mK
• Easily painted, colored, coated
• Inherently flame retardant
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BMC Alternative Powertrain Systems
(Hydrogen Fuel Cell)
• Low cost/high performance material solution for
proton exchange membrane (PEM) “Bi-Polar”
plates
• Excellent balance of conductivity, moldability and
physical properties
• Excellent resistance to aggressive fuel cell stack
environment
• Very flat and dimensionally stable plates
• Very thin plates to 1mm (web thickness as low as
0.3mm)
• Innovative conductive adhesive/sealant for anodecathode bonding – 50% stack height reduction
• Successful Automotive OEM Pilot Programs
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BMC Alternative Powertrain Systems
(Electric Vehicles)
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Long history high voltage applications
High Dielectric Strengths (>15 kv/mm)
High UL Relative Temp. Index (RTI) rating (160˚C)
High volume resistivity retention with humidity
exposure (1E+14 Ωcm)
• High Comparative Tracking Index to prevent
carbon tracking (>600 Volts )
• Inherently flame resistant (UL-94-HB/V0)
• Low CTE – Excellent for overmolding and
insulating metal components
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BMC Alternative Powertrain Systems
(Hybrid Electric Vehicles)
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Power distribution module boxes
Inverter/converter boxes/frames
Battery pack frames
Thermal management system components
Overmolded electrical lead frames/bus bars
High voltage connectors
Low cost/high temp solution for heat
shielding/thermal barriers
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Summary
• Molding parts to the correct dimensions, with very tight tolerances, and a
wide processing window, has never been easier than with BMC.
• BMC composites maintain tighter print tolerances out of mold and at
elevated temperatures as compared to higher cost high performance
thermoplastics...and are highly suited for metal replacement in powertrain
applications
• 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.
• BMC materials are suited for metal replacement in hybrid vehicle
powertrains, from highly conductive solutions to high dielectrics
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