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BASFs Automotive Innovation Pipeline

Bursa/ Turkey, 2011 October 13th

Dr. Christian Schmidt BASF R&D Verbund Automotive

Automotive Solutions Performance Passion Success

125th anniversary of the automobile

cars love chemistry


Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

Innovation Chains From Megatrends to Products


Market Pull Innovation Chain

Global Megatrends

Market Needs

Possible Solutions

Projects

Product Innovation

e.g. energy efficient mobility

e.g. light weight construction

e.g. CFRP for structural parts

e.g. development of new polymer matrices

e.g. new resin formulation

Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

Automotive Megatrends

Weight Reduction

Environment & Sustainability

Propulsion & Catalysts

Innovative Materials Comfort & Quality Energy Management

Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

Automotive Megatrends

Weight Reduction

Environment & Sustainability

Propulsion & Catalysts

Innovative Materials Comfort & Quality Energy Management

Bursa, October 13th 2011

Weight Reduction Automotive Solutions Performance Passion Success

European Legislation for CO2 Emission Options for Achievement


Average new car fleet emission [g CO2/km]

152 g/km
Combustion Engine Electric Mobility Current average/ Germany 150 Weight Reduction Catalysts & Fuel Additives Energy Management Energy Density Battery Lightweight 95 g/km Composites Heat Management

140

130

120 g/km
120

Goal 2012
110

100

90 2010 Bursa, October 13th 2011 2012 2014 2016 2018

Goal 2020
2020

2025: possibly 70 g/km

Weight Reduction Automotive Solutions Performance Passion Success

Current Light Weight Concepts: Weight Percentage of Plastics in Cars


Weight distribution of materials in a midsized car (1500 kg)
Steel Lightmetals Othermetals Thermoplastics Elastomers Thermosets Thermoplasticelastomers Fluids&Chemicals Glass&Ceramics Textiles&Fabrics Paints&Adhesives Electronics Others
kg

700 290 55 190 50 35 4 80 40 35 15 5 8

ca. 20 % polymer materials, ca. 15 % plastics

Ratio of plastics will increase further to save additional weight


Bursa, October 13th 2011

Weight Reduction Automotive Solutions Performance Passion Success

BASF Success Story AIM out of Ultramid From Simple to Multifunctional Modules
Porsche 3.2-liter 6-cyl. Boxer, SOP 1972 Ford 5.4-liter V8 SOP 2004

Largest AIM in North America (weight-wise)

Weight reduction: 40 - 50 %
Bursa, October 13th 2011

BMW 2-liter L4 DI Diesel SOP 1998


Status: commercial

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Ford Mustang GT 5.0-liter V8 SOP 2011

Weight Reduction Automotive Solutions Performance Passion Success

Short Fiber Reinforced Ultramid Applications Weight Savings max. 50 kg 5 g CO2/ km


Interior Powertrain
Weight reduction 50 % Ultramid engine mount Ultramid oil pan

Ultramid in car seats Weight reduction: 20 %

Ultramid transmission cross beam

Exterior

Structural

Ultramid TOP Weight reduction: 40 %


Bursa, October 13th 2011 Status: commercial

Ultramid structural inserts Weight reduction: 40%

Automotive Solutions Performance Passion Success

How can we save even more weight by an optimized design of short fiber reinforced thermoplastic parts?
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Bursa, October 13th 2011

Weight Reduction Automotive Solutions Performance Passion Success

Integrative Simulation Ultrasim for Short Fiber Reinforced Thermoplastics


Process Measurement

BASF Material model

Basic assumptions of modeling Anisotropic Nonlinear Strain-rate sensitive Tensile-compression asymmetric Failure modeling Temperature dependent
Bursa, October 13th 2011 Status: commercial

Part

Weight Reduction Automotive Solutions Performance Passion Success

Optimized Design with Ultramid CR and Ultrasim


Aluminum 100 % weight Ultramid CR 1st generation -35 % weight Ultramid CR 2nd generation -50 % weight

Bursa, October 13th 2011

Status: commercial

Weight Reduction Automotive Solutions Performance Passion Success

Pedestrian Protection with Ultramid CR and Ultrasim - Lower Bumper Stiffener (LBS)
Process Material Part

Joint development with OEM


Combination of BASFs product and engineering know-how faster development and lower testing costs 40% savings in weight highest rating in lower leg impact test (5/5)

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Bursa, October 13th 2011

Status: commercial

Automotive Solutions Performance Passion Success

How can we further substitute metals by more thermally and dimensionally stable thermoplastics?
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Bursa, October 13th 2011

Weight Reduction Automotive Solutions Performance Passion Success

Modern Engine Concepts Need New Materials: Ultramid Endure


Heat aging at 220 C
Tensile strength [MPa]
250 200 150
5 4

Ultramid Endure PPS PPA PA 66/6 PA 66


0 500 1000 1500 2000 2500 3000 3500

100 50
1 2 3

time [h]
1 2 3

Resonator Charge-air lines Intercooler caps

4 5

Throttle valve Intake manifold

Bursa, October 13th 2011

Status: market launch

Weight Reduction Automotive Solutions Performance Passion Success

Ultramid Endure Innovative Stabilization Technology


PA 66
220 C / 1000 h 2 mm

Ultramid Endure
220 C / 3000 h 2 mm

500 m
Bursa, October 13th 2011

30 m

Automotive Solutions Performance Passion Success

How can we further substitute metals by new light weight constructions?


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Bursa, October 13th 2011

Weight Reduction Automotive Solutions Performance Passion Success

Relationship between Properties and Fibre Length in Reinforced Plastics


Standardized property [ - ]

Advanced composites

Stiffness Strength

Toughness
0,1 1 Fiber-length 10 100 [mm]

Short

Statistic long Injection molding

Oriented endless fibers Pressing, resin transfer molding

Bursa, October 13th 2011

Weight Reduction Automotive Solutions Performance Passion Success

Lightweight Composites - Long Glass Fiber Reinforced Ultramid Structure


polymer meltfeeding (twin screw extruder) pelletizer

heating

pultrusion die

cooling puller

Index Ultramid Structure = 100 %


Notched impact strength Inverse Creep elongation Warpage stability Ultramid Structure LF Reference*

Crash absorber

Incineration

Energy absorption

SGF
0 20 40 60 80 100 120
*Reference = Short glass fiber (SGF) Polyamide

LGF

Long glass fiber (LGF): More Performance through 3D network

Bursa, October 13th 2011

Status: market launch

Weight Reduction Automotive Solutions Performance Passion Success

The First Injection Molded Plastic Wheel Rim with Ultramid Structure
Designvorgabe

>> smart forvision in cooperation with BASF IAA 2011, Frankfurt

Weight savings: 3 kg/ wheel rim 12 kg/car 18 kg equivalent to sprung weight Bursa, October 13th 2011

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Weight Reduction Automotive Solutions Performance Passion Success

Polyurethanes for Long Fiber Injection LFI-PUR


Long fiber injection with Elastoflex E glass fiber content 20-50 weight% foamed duroplastic polyurethane high temperature stability, superior impact strength, high flexural modulus adhesion to thermoplastic sheets thermal expansion coefficient between steel and aluminum

cutting

transport wetting & mixing PU-components oscillating nozzle glass roving

mold

Bursa, October 13th 2011

Status: commercial

Weight Reduction Automotive Solutions Performance Passion Success

Concepts for the Future: Enter the Metal Core Domain for Further Weight Reduction
Challenge: Light weight substitution of metal chassis & frame
Weight /property 100%
-40%

Solution
Future light weight composite material concepts require Long / endless fibre reinforcement High fibre content 50% carbon or glass fibres Improved reactive systems Multi-material solutions Possible process technologies RTM / RIM Sandwich Pultrusion

-15% -20% -40%

Steel

~20 % of total weight

Weight reduction of 100 150 kg possible (10-15 g CO2/km)


Bursa, October 13th 2011

Alu

CFK (unidir.)

CFK (quasi)

Mg

Weight Reduction Automotive Solutions Performance Passion Success

Resin Transfer Molding (RTM) and Reaction Injection Molding (RIM)


component component

A
pumps

Viscosity [mPas] 1500

Polyamide-RIM PU-RTM

mixing
1000
BMW i3 life module

press

500

Endless fiber reinforcement preform


50
Bursa, October 13th 2011
* Source: Fraunhofer ICT

Epoxy-RTM (Baxxodur)

100

150

[sec]

Status: pilot

Weight Reduction Automotive Solutions Performance Passion Success

Light Weight Composites Sandwich Structures

core

Faces with thickness t

Solid Constant thickness of the faces, t Stiffness Strength Weight


Bursa, October 13th 2011

+ core 2t

+ core 6t

100% 100% 100%

600% 250% 102%

3600 % 820% 106%

Weight Reduction Automotive Solutions Performance Passion Success

Light Weight Composites PU Based Honeycomb Structures


Elastoflex E3532 No dripping Excellent edge wetting Lower processing temperature under development

Audi A4

MB M-class

Paper based core material Low density structure with good NVH properties Weight reduction 50-75% Sun shade, spare wheel cover, etc.
Bursa, October 13th 2011

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VW Tiguan Jaguar XK8

Status: commercial

Automotive Solutions Performance Passion Success

Automotive Megatrends

Weight Reduction

Environment & Sustainability

Propulsion & Catalysts

Innovative Materials Comfort & Quality Energy Management

Bursa, October 13th 2011

Propulsion & Catalysts Automotive Solutions Performance Passion Success

Optimized Catalysts for Improved Propulsion Efficiency


Alternative fuels Diesel 10 % Modern propulsion concepts Gasoline direct injection Lean burn engines Downsized engines 10-20 % Hybrid cars 20-30 %

Compressed natural gas (CNG)

20 %
Fiat

Biofuels (biodiesel B30, bioethanol E85) 25-75 %

potential for efficiency improvement & CO2 reduction

Find the perfect fit: Optimization of the catalyst system by BASF Catalysts

Bursa, October 13th 2011

Propulsion & Catalysts Automotive Solutions Performance Passion Success

Catalyst Systems for Diesel Passenger Cars to Meet EU Emission Legislation


NOx [g/km] 0.3 1.0

EURO5 EURO4 EURO2 EURO1 EURO3 EURO6

DOC
CSF Soot Filter

Diesel Oxidation Catalyst

HC+NOx [g/km] 0.3 1.0 0.05 0.1

Soot [g/km]

Catalysed Soot Filter

Selective Catalytic Reduction 1.0 2.0 or

LNT
CO [g/km]
Bursa, October 13th 2011 Status: commercial

Lean NOx Trap Catalyst

Propulsion & Catalysts Automotive Solutions Performance Passion Success

KEROPUR Gasoline Performance Packages


Effective deposit control ensures a clean intake system Friction modifiers reduce friction between cylinder walls (blue) and piston rings (red) of the engine Corrosion protection of metal surfaces

Deposits on Intake Valve

KEROPUR ensures clean Intake Valve

Without Keropur

With Keropur

Potential of 2 % fuel savings (3 g CO2/km)


Bursa, October 13th 2011 Status: commercial

Propulsion & Catalysts Automotive Solutions Performance Passion Success

Status and Future Innovations of Li-Ion Batteries by BASF


100000

10000

Li-Ion Li-Ion high voltage


LFP, LVP

power density / W/kg

1000

Ni-Cd Ni-MH Pb/acid

Li-S
LNCMO

100

10

BASF commercial activities: cathode materials, electrolytes

BASF R&D activities: improved materials, new battery concepts

1 0 25 50 75 100 125 150 175 200 250 300

Pilot, production 2012 2500 t/a, USA


Bursa, October 13th 2011

standardised range in km

Propulsion & Catalysts Automotive Solutions Performance Passion Success

Overall CO2 Emission Balance of Mobility


Average CO2 emissions (g/km)
Current German new car fleet average
Indirect emissions from production and electricity generation Direct emissions from car

20

132

152

Potential for improved ICE

20

90

110

EV - electricity based on fossil fuels only

162 107

EV - electricity based on current German energy mix

EV - electricity based on renewable sources only

Electricity based on CO2 neutral sources is crucial for sustainable mobility


Bursa, October 13th 2011

Propulsion & Catalysts Automotive Solutions Performance Passion Success

Renewable Resources Wind Power Complex Structure of a Rotor Blade


Protective coating WindCoat Contour & Finish, OLDODUR BladeProtect & BladeCoat

Hull materials Baxxodur epoxy adhesives and infusion & lamination systems

PET foam BALSA PVC foam

Complex hybrid structures Light weight structure

Extrusion foams: Styrodur C

Chemistry enables sustainable energy sources for tomorrows mobility


Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

Automotive Megatrends

Weight Reduction

Environment & Sustainability

Propulsion & Catalysts

Innovative Materials Comfort & Quality Energy Management

Bursa, October 13th 2011

Propulsion & Catalysts Automotive Solutions Performance Passion Success

Three Pillars of Electromobility

Battery (Materials)

Light Weight Construction

Heat Management
Higher energy efficiency for heating & cooling less energy used for heating & cooling reduced seasonal variation of range, increased range in summer & winter

Higher storage capacity of batteries Higher driving range of vehicle

Lower weight lower energy consumption for driving overall increased range

Bursa, October 13th 2011

Energy Management Automotive Solutions Performance Passion Success

Automotive Heat Management: Definition

Improve the energy efficiency of a cars climatisation system (heating & cooling) to increase thermal comfort of passengers reduce seasonal variation of driving range, esp. in electric cars
*: In a wider sense also heat management for battery system (to maintain optimal operation temperature of 20-25 C)
Bursa, October 13th 2011

Energy Management Automotive Solutions Performance Passion Success

Driving Range Dependence of Electric Cars as Function of Ambient Temperature


100

e.g. 150 km
seasonal reduction of range

maximal range (%)

Psychological threshold: range of 100 km

90 80 70 60 50

> 100 km
40 -20 -10 0 10 ambient T / C
schematic representation - urban drive situation (< 50 km/h average speed; start and stop) - for T > +30 C: 1000 W/m solar irradiation assumed Bursa, October 13th 2011

20

30

40

Energy Management Automotive Solutions Performance Passion Success

Driving Range Dependence of Electric Cars as Function of Ambient Temperature


100
Improvement potential when range reduction is lowered by 20, 30 or 50 %

90 80 70 60 50 40

maximal range (%) -20

-10

10 ambient T / C

20

30

40

schematic representation - urban drive situation (< 50 km/h average speed; start and stop) - for T > +30 C: 1000 W/m solar irradiation assumed Bursa, October 13th 2011

Energy Management Automotive Solutions Performance Passion Success

Overview on BASFs Automotive Heat Management Technologies


Polymer foams for thermal insulation IR reflective pigments for coatings IR reflective pigments for interior surfaces IR reflective films for glazing
Solar heat management IR reflective pigments for coatings and interior

Other technologies (electrochromic systems, self-switching IR absorbers, latent heat storages) Simulation and system analysis
IR reflective film for glazing
reflective film glazing
ol

Status: commercial

Insulation foams and High performance foams

co

NIR Vis

outside

inside

Status: pilot Bursa, October 13th 2011

Status: commercial/ pilot

Energy Management Automotive Solutions Performance Passion Success

Simulation and System Analysis Summer Case for Mid-Sized Electric Car
Electric car: Summer conditions
Outside: +30C & sunny at noon Inside: +20C Windows ~ 70% Chassis ~ 30%

Effect of heat management measures


energy consumption / rel. % 100 80 60 40 20 0

-45 %

Total cooling requirement: 3.0 kW


Average energy requirement for driving: ~ 3kW @ 20 km/h, ~10 kW @ 60 km/h, ~16 kW @ 100 km/h

Status quo

combined Thermal Insulated IR IR Insulation Windows reflective reflective potential coating windows

Saving potential ~ 45 % by combination of all measures in summer case


Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

How can we improve energy management for combustion engine cars?


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Bursa, October 13th 2011

Energy Management Automotive Solutions Performance Passion Success

Energy Management PUR Thermal Engine Encapsulation


Thermal Engine Encapsulation Benefits
Engine reaches operating temperature faster, i.e. less cold starts Reduced CO2-emission 6-9 g/km Additional sound insulation No application in conventional cars yet

Future potentials
Start stop mode Hybrid on/off engine mode Down sizing

Bursa, October 13th 2011

Status: pilot

Energy Management Automotive Solutions Performance Passion Success

Energy Management Thermoelectric Effect


cold

Technology: Conversion of a temperature difference into electric energy

_
Efficiency [Z T] 1,2 1,0 0,8 0,6 0,4 0,2 p-PbTe 0,0 0 p-Bi2Te3 p-SiGe n-Bi2Te3 n-PbTe

Key application: Recovery of waste heat from exhaust gas stream Thermoelectric material and module integration determine performance Challenge: Transfer material improvement into module performance Material potential >10% efficiency Potential savings: up to 3 g CO2/km

hot

+
n-SiGe

100 200 300 400 500 600 700 800 900 1000 1100 T [C]

Bursa, October 13th 2011

Status: lab phase

Energy Management Automotive Solutions Performance Passion Success

First Transparent Solar Roof and Transparent OLED


Transparent organic photovoltaics cells Also work with diffuse light
OPV

Transparent organic LED Efficient area lighting Adjustable colours

OLED

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Bursa, October 13th 2011 Status: lab/ pilot phase

Automotive Solutions Performance Passion Success

Automotive Megatrends

Weight Reduction

Environment & Sustainability

Propulsion & Catalysts

Innovative Materials Comfort & Quality Energy Management

Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

How can we improve scratch resistance of car coatings?

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Bursa, October 13th 2011

Comfort & Quality Automotive Solutions Performance Passion Success

Improved Scratch Resistance by iGloss Hybrid Material with Nano Hard Phase
TEM Elastic polymer prevents plastic scratch

20 nm

Hard phase prevents abrasive scratch

Hybrid material coating: Elastic polymer + in situ formed nano hard phase High toughness + excellent scratch resistance
Bursa, October 13th 2011 Status: market launch

Comfort & Quality Automotive Solutions Performance Passion Success

Improved Scratch Resistance by iGloss Hybrid Material with Nano Hard Phase
Multiple crockmeter testing 10, 50 & 100 times Hard phase in bulk, not only in top layer Outstanding and enduring dry scratch resistance

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Bursa, October 13th 2011 Status: market launch

Automotive Solutions Performance Passion Success

How can we create surfaces that combine individual design and high performance?
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Bursa, October 13th 2011

Comfort & Quality Automotive Solutions Performance Passion Success

New Weathering Resistant Luran S SPF30


Gloss retention (ISO4892-2A)

Luran S (ASA)
Weathering resistant, impact modified SAN based engineering plastic Especially suited for exterior applications New SPF stabilization technology for even higher weathering resistance

outdoor weathering simulation 100 90 80 Gloss level (%) 70 60 50 40 30 20 10 0 0

ABS ABS UV ASA ASA UV Luran S SPF30


200 400 600 800 1000 1200 1400 1600 1800 2000

hours of testing

retention of gloss, colour and impact properties even after prolonged UV exposure
Bursa, October 13th 2011 Status: market launch

Comfort & Quality Automotive Solutions Performance Passion Success

Luran HH-120 SPF Piano Black


Greyscale ISO 4892-2A
Luran HH-120 Standard Stablization 5 4 3 2 1 0 500 1000 1500 Test time (hr) 2000 2500 Luran HH-120 SPF Stablization

Luran HH-120 (AMSAN) Excellent high gloss for decorative parts Intense color deepness (Piano Black) Easy processing Vicat B > 120 C

examples of high gloss Luran S (above) & Luran HH (right) automotive applications Bursa, October 13th 2011 Status: market launch

Application of new SPF stabilization technology 50 allows substitution of PMMA in exterior applications

Comfort & Quality Automotive Solutions Performance Passion Success

Elastoskin In Mold Coated PUR Spray Elastomer

Release agent

IMC

PU Skin

High surface quality soft touch Multicolored surfaces in one step Lowest emissions
Bursa, October 13th 2011 Status: commercial

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Extreme freedom of design

Comfort & Quality Automotive Solutions Performance Passion Success

Steron Technology Process and Properties


structuring
textured mold

spraying
Steron coating

adhesion
lamination

strip off
product

soft touch structure


Bursa, October 13th 2011

air permeable pores


Status: pilot phase/ market launch

Comfort & Quality Automotive Solutions Performance Passion Success

Steron Technology New Options for Individual Surface Design


Steron Coating carrier:
textiles, leather, paper, foam, plastics, wood, metal...

Bursa, October 13th 2011

dash board surface

Status: pilot phase/ market launch

Automotive Solutions Performance Passion Success

How can we create ceramic or metal surfaces with the design freedom of thermoplastics?
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Bursa, October 13th 2011

Comfort & Quality Automotive Solutions Performance Passion Success

Catamold Molding Metals and Ceramics like Plastics


Benefits of metal or ceramic injection molding (MIM/ CIM) Production of complex, small parts - ease of automation, low specific production costs High product quality

Original design

~200C

~100C

~1400C

MIM

Granulate

Green part

Brown part

Sintered part
50% weight reduction

Bursa, October 13th 2011

Status: commercial

Comfort & Quality Automotive Solutions Performance Passion Success

Catamold High Class Surfaces


Decorative interior parts made of black zirconia
BMW i-drive rotary knob BMW gear shift lever

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Bursa, October 13th 2011 Status: commercial

Comfort & Quality Automotive Solutions Performance Passion Success

BASF Global Competence Team Seating Design Safety Light Weight Comfort
BASF product portfolio for seats
Excellent design with Steron, Catamold Humidity control with Luquafleece Smart textiles for flat heating Multi rigidity foams: PUR (Elastoflex) Structural parts in Ultramid Crash management with Neopolen (EPP) Cathodic e-coat Cathoguard
e.g. >> smart forvision

Unique network of cross divisional material experts for excellent haptics and design, crash management, weight reduction and comfort in automotive seating

Bursa, October 13th 2011

Automotive Solutions Performance Passion Success

Automotive Megatrends

Weight Reduction

Environment & Sustainability

Propulsion & Catalysts

Innovative Materials Comfort & Quality Energy Management

Bursa, October 13th 2011

Environment & Sustainability

Automotive Solutions Performance Passion Success

Ultramid S Balance PA 6.10 from Renewable Resources


Ricinus communis L. Castor oil

Ricinoleic acid

Bursa, October 13 2011

63% biobased Long-chain polyamide Low water uptake Lower density High media resistance th

Sebacic acid

Status: commercial

PA 6.10

Environment & Sustainability

Automotive Solutions Performance Passion Success

Halogen Free Flame Retardants in Ultradur and Ultramid


Ultradur
halogen free FR

PBT
halogenated

Recycling Smoke density Fire behavior Density Electrical Property Mechanics Costs

Halogen free flame retardance light colour, high design freedom ideal for E&E applications
Bursa, October 13th 2011 Status: market launch/ commercial

Automotive Solutions Performance Passion Success

Cross-divisional Competencies Combined: Concept Cars in Cooperation with BASF

Hyundai i-flow
Bursa, October 13th 2011

>> smart forvision

http://www.automotive.basf.com

Automotive Solutions Performance Passion Success

Bursa, October 13th 2011

We help our customers to be more successful !


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