Amirkabir

A
i k bi university
i
it
Color and polymer research institute

Polymotive
y
(Polymer in the Automotive Industry)
Zahed Ahmadi

IIntroduction
d i
Technical
Environmental
Special Topics
Conclusion

Outline

Material & Process Technology:

basis for choice

Amirkabir
A
i k bi university
i
it
Color and polymer research institute

Performance

Weight

Cost

Environmental
v o e a
aspects

Automotive
Engineering

Economy
Amirkabir
A
i k bi university
i
it
Color and polymer research institute

Environmental

Technical (Mobility)

Automotive industry

T h i l
Technical

Main Challenge in body design

Afforrdability off weight redu

uction

Multi-Material Concepts
Multi
Material
Concept
p

Advanced
LM-Spaceframe
Steel
Spaceframe
Al-Spaceframe
Al
Spaceframe
Coil-coated
shell
High strength
Steels

Steel
Unibody

Steel thin wall

casting
Composites

Approach

Advanced
Steel body

Stainless Steel
Spaceframe

Advanced
Composites
(FRP)

Design

Materials
> 2012

Processes

Amirkabir university
Color and polymer
research institute

Preliminary SLC body concepts

Steel intensive
Weight reduction:

40 kg
(14 %)*

ULBC

SLBC

Multi-Material, economic

Multi-Material, advanced

Weight reduction:

62 kg
(22 %)*

Weight reduction:

114 kg
(41 %)

Additional part

Additional part

Additional part

Highlights:
Strut tower in FeMn-Steel
Tunnel in hot-formed steel
(Usibor 1500)
Body side and B-pillar in
dualphase-steel
Roof in Quietsteel
Fender in Steel polymer
composite

Highlights:
Longitudinal rail in FeMn
tailored welded blanks
Suspension-strut mount as Aldiecast
Tunnel in FeMn-blank
Rear wheelhouse in Al-diecast
Inner B-pillar
B pillar in Al-diecast
Al diecast
Roof in Al-blank

Highlights:
Longitudinal rail in HSS
tailored welded blanks
Strut tower in Mg-diecast
Floor panel in Al- and Mg-blank
Wheelhouse and rear
longitudinal rail in Al-blank
Inner B-pillar
B pillar in hot formd steel
Roof in Mg-blank

Key properties

Thermal and dimensional stability

High and low operating temperatures
Potential for weight reduction
Mechanical stiffness and strength
Freedom of design

Polymers in car

Development of materials in a car

Amirkabir
A
i k bi university
i
it
Color and polymer research institute

Various Polymers
y
Used in Automotive

Examples

Amirkabir
A
i k bi university
i
it
Color and polymer research institute

Plastics

Polyurethane
P
l
th
Offers Multiple Solutions

Amirkabir
A
i k bi university
i
it
Color and polymer research institute

Applications From Bumpers to Seats or Headliners

Replacing Steel With Polyurethane

Horizontal Composites for Exterior
Parts

Composite
Structure of Mercedes with Advanced SMC

Amirkabir
A
i k bi university
i
it
Color and polymer research institute

Environmental
Amirkabir
A
i k bi university
i
it
Color and polymer research institute

Recycling Process Reclaims More

Usable Materials from
End-of-Life Vehicles

Recycling Process Reclaims

Recycle

Materials recovered from can be

used to manufacture new vehicle
parts and other
plastic
l ti products
d t

Special Topics

Body Parts Replacement

Bumper

PP / EPDM / Talc
(Import from POLIKEMI,
POLIKEMI 5000 MT/Year)

Polyurethane Foam Seat

Recycling
Weight reducing
Flame
l
retarding
di
Cost

Polyurethane Foam Recycling

Polyurethane foam material import
20 000 kg/day seat foam

Polyurethane Foam Recycling

Mechanical Recycling (Grinding)

Polyurethane Foam Recycling

Polyol Recovery

Polyurethane Foam Recycling

Continuous Recycling

Dashboard skin

Plastics in dashboards
Year 2000
IM
23,2%

Year 2010

SM TPO/TPU
0,0%
, SM TPO/TPU
IM
23,2%

SM TPO/TPU
0 2%
0.2%

SM PVC
25,3%SM PVC
25,3%

SM PVC
34.0%

SC PUR
4,0% SC PUR

Other
50.8%

4,0%
TF PVC
26,3% TF PVC
26 3%
26,3%

TF TPO/ASA
21 2%
21,2%
TF TPO/ASA
21,2%

TF = Thermo Forming;

SM = Slush Moulding;

SC PUR
15.0%

IM = Injection Moulding; SC = Spray Coating

Advantages of PVC-Slush Technology

versus
Thermoforming

Residual Stress Free

Cost / Performance
Design Freedom

Esthetics (color, aspect, soft touch, grain)

Scratch Resistance
Easy Processing
y tailor made color
Available in any
Perception of quality in car

Slush molding

Dashboard Slush Material Import

Dashboards No
= 1500
Dashboard Weight = 2.700
Material
i l Price
i
= 5
Total weight
Total price

/day
kg
Euro/kg
/k

= 4000
kg/day
= 20 000 Euro/day

Fuel Tank

Multilayer Structure:
PE-PA-PVDF-EVOH-Ionomer

LPG Tank

Conclusion
Recycle
Car Bumper
p
Dashboard skin
Bodyy composites
p
Polyurethane foam
Fuel tank (Gasoline tank , Gas tank)

Thank
You