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Slide 1 - Polymers in Automobiles Candace “Mustang” DeMarti Henry “Firebird” Antonovich Kevin “Camaro” Reinhart
Slide 2 - Overview Plastics vs. Metals Polymer Applications in Automobiles - Instrument Panels - Engine - Windows - Tires - Body Panels
Slide 3 - Why use plastics? Oil Embargo (1970’s) and Japanese Competition Compete with other materials based on: Weight savings Design flexibility Parts consolidation Ease of fabrication
Slide 4 - Show & Tell
Slide 5 - ppt slide no 5 content not found
Slide 6 - Instrument Panels (IP) Polycarbonate/ABS resins Introduction of airbags in IP design Injection Molding vs. Blow Molding
Slide 7 - Instrument Panels (IP)
Slide 8 - Engine ULTEM polyetherimide (PEI) resin to replace aluminum under the hood for 1st time High-performance amorphous resin from GE Complete air management modules can be made of thermoplastic Throttle Body
Slide 9 - Body Panels Plastic Body Panels - Chevy Corvette since 1953 Sheet Steel - still most commonly used for vehicle body structure Aluminum - weighs less but costs more Plastics - increasingly used for metals parts replacement
Slide 10 - Choosing a material: 1. Cost 2. Flexural Modulus 3. Coefficient of Thermal Expansion 4. Chemical Resistance 5. Impact Resistance 6. Heat Deflection Temperature (HDT)
Slide 11 - “On-line” vs. “Off-line” painting Better color match Incorporate in existing facilities Assembly line temperatures exceed 200oC Alloys: Polyphenylene ether/polyamide ABS/Polyesters ABS/Polycarbonates Larger choice in materials Additional steps take time More plastics will enter the market as assembly lines are redesigned
Slide 12 - Sheet Molding Compound (SMC) Highly cross-linked and highly filled Polymer component is polyester Suitable of compression molding Molded product combined high modulus with high strength Body panels (hoods and deck lids) More expensive than metal, but lower tooling cost
Slide 13 - Growth of applications - Body panels on GM’s Lumina, TransPort, and Silhouette - Structural components - valve covers, grille- opening reinforcements, fascia supports, etc. 250 million lbs. of SMC was used in 1997 Applications of SMC Bottom line benefits Tooling for SMC hood was 23% of steel Weight savings of 18%
Slide 14 - Composite front fenders and hood design for 1995 Lincoln Continental Result of need for lighter-weight and more cost efficiency integrated system SMC fenders and hood Bottom line benefits: SMC fender tooling was 40% of projected tooling for steel fenders Comparative weight saving was 33% Applications of SMC
Slide 15 - Solitary Bumper Beam For 1997 Saturn coupe Injection molded from GE Plastics’ Xenoy 1102 Single part that replaces functions of 17 parts on previous system To absorb impact, specially designed molded-in towers crush upon impact
Slide 16 - Windshields Toughened Safety Glass (TSG) - tempered glass Laminated Safety Glass (LSG) - two panes of glass bonded together using polyvinylbutyral
Slide 17 - Tire Components Tread Sidewall Bead-high tensile brass-plated steel coated with rubber Radial Ply-belts of rubber coated cord Innerliner Reinforcing Fillers-carbon black Chemicals-antidegradants, curitives
Slide 18 - Desirable Properties of Tire Components
Slide 19 - Elastomers in Tires Natural Rubber (NR) Polyisoprene Rubber (IR) Styrene Butadiene Rubber (SBR) - 1.89 billion lbs/yr (1993) Polybutadiene Rubber (BR) - 1.03 billion lbs/yr (1993)
Slide 20 - Natural Rubber (NR) 99.99% cis Polyisoprene Good low temperature flexibility. Low Tg (-65 C). Low heat buildup. 200,000 to 400,000 MW. Easy Processing. Has high tensile and tear properties. Stress crystallizes. Excellent dynamic fatigue Poor resistance to oxygen, ozone, hydrocarbon solvents and heat.
Slide 21 - Polyisoprene Rubber (IR) Same cis structure as NR, but also contains low levels of 3,4 and trans 1,4 polyisoprene. Above structures prevent stress crystallization and thus has lower tensile and tear properties. 300,000 to 500,000 MW. Other properties similar to NR .
Slide 22 - Polybutadiene Rubber (BR) Good low temperature flexibility. High abrasion resistance. Low heat buildup. Low tensile strength. Generally blended with SBR or NR. Improves aging resistance of NR.
Slide 23 - Styrene Butadiene Rubber (SBR) Dynamic properties determined by styrene, 1,4 and 1,2 butadiene levels. Improved strength, abrasion resistance, and blend compatibility over BR alone. Addition of styrene results in lower cost and contributes to the good wearing and bonding characteristics.
Slide 24 - Elastomers Used in Tire Components
 

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