Transcript High performance TPE in Automotive ?

High performance TPE in
Automotive?
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Trends in Automotive Technology
• Yesteryears
“You can have any colour as long as it is black”
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Trends in Automotive Technology
• Today
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Use of Polymer in Cars
11.2% (142Kg) of total weight, (excluding tires).
5.80%
10.80%
51.10%
Body
31.90%
Interior
Drive
Source: BMW
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10.40%
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Chassis
E&E
Facts and Figures
• Over 2 millions tonnes of Plastics in Europe
alone.
• The most widely specified material.
• More than 1000 plastics parts.
• On average, 100kg of plastics replaces 200300Kg of conventional materials. E.g. 4.2Kg
lighter in Engine cover and 5Kg in Fuel tanks.
• Cuts oil consumption by 12 million tonnes
and reduce CO2 emissions by 30 millions
tonnes/p.a. just in Western Europe.
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Trends in Automotive Technology
• The future
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Trends in Automotive Technology
•
•
•
•
•
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Reduce exhaust emissions.
Better fuel economy.
Improved safety.
Increase comfort and convenience.
Reduce weight Vs functionality.
Reduce COST!!!!
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Trends in Automotive Technology
European Union Directive 2000/53/EC
“End of Life Vehicle”
8 to 9 million tonnes of waste every year.
Design and Manufacture for Re-use,
Re-cycle and Re-covery.
Reduction and Control of Hazardous
substances.
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Trends in Automotive Technology
Noticeable shift from:
• Thermosets to Thermoplastics.
• Amorphous to Crystalline polymers.
• Moderate to High temperature materials.
• Approx. 25% increase in volume of
Plastics.
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What is a TPE or TPR?
Stiffness Vs. Temperature
E-modulus
Thermoset
Thermoplastic
Thermoset Elastomer
Thermoplastic Elastomer
Room temperature
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Scales
Rubbers
Plastics
50
5
70
90 100 110 120 130 140 150
50
70
90 100 110 120 130 140 150
80
20
30
40
50
60
70
80
Rockwell R
Rockwell R
95
90
95
Polypropylene
Shore A
Elastic Band
30
40
50
60
70
80
Shore D
10
100
Flexural Modulus (MPa)
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1000
Sarlink* from DSM
• PP + Crossed linked
EPDM rubber.
• Shore 40A to 50D.
• Low density.
• Fluid resistance
comparable to GP
polychloroprene rubber.
• Excellent fogging
properties with low
VOCs emission.
• Easy to colour.
• Two-shots with
Polyolefins.
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Hydraulic engine mount heat shield
Bellows & Dust covers
Alcryn* from APA
• Melt process-able rubber.
• Shore 55 to 80A.
• Outstanding UV and
Ozone resistance.
• Oil, Grease and Fuel
resistance.
• Elastic properties of nature
rubber.
• Two-shots with PVC, ABS,
PC.
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Tail light housing
Corner mouldings
Elastollan* from Elastogran
• Thermoplastic
Polyurethane.
• Shore 55A to 74D.
• Polyester & Polyether
types.
• UL94-VO:Halogen free.
• Transparent grades.
• Two-shots with ABS, PA,
PBT, PC.
• New Aliphatic TPU with
improved hydrolysis and
UV resistance.
Cable connection
Gear lever noise &
vibration damping
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Hytrel* from Du Pont
• Thermoplastic Polyester
Copolymer Ether Ester.
• Shore 30 to 82D.
• Excellent flex fatigue.
• Noise & vibration
damping.
• High tensile & tear
strengths.
• Heat resistance.
• Two-shot with PBT,
ETPV*.
Combustion Air Swirl Generator
Trucks Auxiliary Springs
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Two-shots Bond strength?
Tensile Adhesive Strength (MPA)
Nylon
PBT
30% GR PET
TPC-ET
PC
PC/ABS
ABS
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Alcryn* 2160
1.45
1.2
No data
No data
4.12
4.72
5.48
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Elastollan* 1180A
7
7
No data
8
7
4
7
ETPV* 90A01
3.3
6.8
6.6
7.1
No data
No data
No data
Finally introducing…….
DuPont ETPV
™
engineering thermoplastic vulcanizates
Description: a high performance
cross-linked elastomer
dispersed in:
a high performance
thermoplastic elastomer
Recycling code (ISO 11469): > AEM + TPC - ET <
AEM = ethylene acrylic elastomer
TPC - ET = thermoplastic ether ester elastomer
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ETPV*
The cross-linked elastomer brings:
• Heat resistance
• Low hardness
• Creep- and compression set resistance
The thermoplastic elastomer brings:
• Excellent oil and grease resistance
• Excellent flexural resistance
• Allows usage on standard thermoplastic processing equipment
The combination of these materials brings:
• Significant cost savings versus cross-linked rubber
• Excellent oil and heat resistance
• Recyclability
DuPont™ ETPV is a thermoplastic elastomer in the shore A
range that resists >150oC in air for 3.000 hours (retains
>50% of elongation at break & tensile strength) in
combination with good oil resistance.
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ETPV*
Tensile strength after ageing in air at 150ºC
18
0h
1000h
2000h
3000h
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Tensile strength (MPa)
14
12
10
8
6
4
2
0
DuPont™ ETPV
60A01L NC010
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DuPont™ ETPV
60A01HSL BK001
DuPont™ ETPV
90A01 NC010
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DuPont™ ETPV
90A01HS BK001
ETPV*
Kalrez®
300°C
J 275°C
H 250°C
Viton®
Heat Resistance
G
225°
C
F
200°C
E
D
C
Silicone
Silicone (HS)
Fluorosilicone
Vamac®
175°C
DuPont™ ETPV
EPDM
150°C
125°C
B 100°C
A
Type
75°C
50°C
EVA
(high VA)
Ethylene-propylene
Sarlink
Butyl
Hypalon
Olefinic TPE
Geolast
Neoprene
Polyacrylate (ACM)
HNBR
Hytrel®
Epichlorohydrine (ECO)
Alcryn
Nitrile (NBR)
SBR & NR
No req.
140%
120%
100%
80%
50%
30%
20%
10%
A
B
C
D
E
F
G
H
I
Class
Oil Resistance
(% swell in ASTM #3 Oil)
ASTM D2000 / SAE J200 Specifications.
N.b. The purpose of this chart is to give a general overview. Formulation may affect compound performance.
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Applications
Better Fuel Vent Tubes
Formed to fit, this fuel
vent tube is scheduled
for production in a 2005
model North American
car.
Automotive body plugs with excellent
resistance to heat and chemicals
Ignition Coil boot
Zytel® 70G30
Oil reservoir cover with
integrated seal
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DuPont™ ETPV
90A01 NC010
What about?
PA 15% GR
Rubber
Part weight
~1kg
~0.5 kg
Conventional design
Rubber
Opportunity for
DuPont™ ETPV
New design
Hard segments may be made
in Hytrel® BM6574 BK316
Automotive air ducts with excellent flexibility, oil and
Chemical resistance, and performance at 150ºC
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What about?
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Benefits Vs Rubber
• Fast Thermoplastic processing.
• Standard thermoplastics
equipments.
• No post mould curing of parts.
• Supplied in form ready to use .
• No plasticizers.
• Lower density.
• Often lower material price Vs.
high performance rubbers.
• Recyclable.
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 Lower production costs.
 Thermoplastic processors to
enter new markets.
 Higher productivity.
 Higher quality consistency.
 Performance not change by
migration & no contamination.
 Lighter components.
 Lower production costs.
 Use of regrinds.
 Meets environmental
requirements.
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Trends in Automotive Technology
• The future
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A Polymer for Every
Application
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