Auto Electronics Affect on Demand for Plastics

Auto Electronics Affect on Demand for Plastics

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Description: Key trends in the automotive industry are moving towards increased safety and the reduction of CO2 emissions. There is an above average growth in the automotive electronics/electrics segment demand when compared with vehicle production. Plastics in the automotive electronics/electrics segments are growing at an increased rate of 4.8% per year.

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Author: Dipl.-Ing. Ralf Jantz (Fellow) | Visits: 2266 | Page Views: 2374
Domain:  High Tech Category: Business Subcategory: Economics 
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Short URL: https://www.wesrch.com/electronics/pdfEL1GP9E0KRLYB
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Save the date: 2016 World Stem Cell Summit & RegMed Capital Conference, Dec. 6-9 Palm Beach County Convention Center, West Palm Beach, Florida.
 
Contents:
Demands made on plastics in automotive electrics/electronics

Plastics in E&E applications � Fusebox meets dryer June 5 � 6, 2008 Marienberg Fortress, W�rzburg Dipl.-Ing. Ralf Jantz

Agenda
Trends Market overview Applications Demands on the materials Summary

Key development topics in the automotive industry
Increased safety Parking assistant (automatic parking) Pedestrian safety Recognition of passing vehicles Lane departure warning assistant / lane changing assistant Distance control (ACC - Adaptive Cruise Control) Recognition of traffic signs Warning to driver when danger is imminent Cornering light (intelligent lighting) Night view systems Increased crash safety (active and passive) LEDs for front and rear lamps (Day-time lamps to become compulsory in Europe) Reduction of CO2 emissions Lightweight construction More efficient engines Alternative propulsion systems (hybrid, electric engine) Alternative fuels (methanol, ethanol, natural gas, ...)

Above-average growth in the automotive E/E segment

Automotive EE applications

Many innovative developments with EE systems. Above-average growth of EE applications compared with vehicle production.

Car production

Growth in Europe
Plastics in automotive EE
500
kt
4.8 % a year

400 300 200 100 0 2007 2008 2009 2010 2011

Growth automotive EE world: 7.5 % a year up to 2011

Plastics in cars 2007 (Europe)
Engineering plastics in cars as a whole: ~ 3,500 kt
Others: 860 PA: 350

~ 11 %

Automotive EE: ~ 385 kt

PU: 300

Others: 175

PA: 120

PBT: 90 PP: 1900

PBT: 90

Figures in 1,000 t

Base: 23.3 million new vehicles in Europe (2007)

Applications in automotive EE
Plugs, connectors Sensors, actuators Fuse box ECU (electrical control unit) Closure/locking systems

Adjusting mechanism for headlamps Lamp sockets Pitman arm Servo-motor Generator Bezel

Specifications
Part specifications Low wall thicknesses, miniaturization High stiffness Reliability Dimensional accuracy Material specifications Easy-flow materials

High-modulus materials Hydrolysis resistance Isotropic shrinkage low warpage

Specifications
Part specifications Low wall thicknesses, miniaturization High stiffness Reliability Dimensional accuracy Material specifications Easy-flow materials

High-modulus materials Hydrolysis resistance Isotropic shrinkage low warpage

Easy-flow materials Distribution box interlayer
Requirements: Low wall thicknesses Low warpage

Advantages of using an easy-flow material: Low filling pressure Reduced cycle time

Material: Pocan DP 1105 (PBT unreinforced)

Advantages of easy-flow materials
Low filling pressure Low locking forces Low deformation of cores due to lower pressures Cycle time reduction Reduced mold maintenance costs Thin walls Improved surface appearance Improved weld line quality

Longer flow paths with same injection pressure

+ 106 %

+ 30 %

PA 6 GF 30

PA 6 GF 30 easy flow

PBT GF 30

PBT GF 30 easy flow

Property profile of easy-flow materials
200
%

150

Flow spiral length Flexural modulus Izod 1U Injection pressure

100

50

0

PA 6 GF 30

PA 6 GF 30 easy flow

Flow characteristics of various Durethan grades
1400
BKV30 EF

1200 1000 Flow length, mm 800 600 400 200 0 0

DP BKV30 XF BKV35 EF BKV50 EF DP BKV60 EF BKV30

1

2

3

4

5

Wall thickness, mm

Intelligent formulations for new applications
Easy-flow materials High-rigidity EE boxes

Development of highly filled grades

High load-bearing properties

High-modulus materials for automotive EE applications

Specifications
Part specifications Low wall thicknesses, Miniaturization High stiffness Reliability Dimensional stability Material specifications Easy-flow materials

High-modulus materials Hydrolysis resistance� Isotropic shrinkage low warpage

Stiffness Electric distribution box
The electric distribution box is positioned between the truck driver's cab and the engine compartment. Requirements: High stiffness High dynamic load-bearing capacity Heat resistance up to 70 �C Good dimensional stability

Implementation: Material with high filler content; made possible by new formulation (easy flow) Material: Pocan T 7391 (PBT+PET) GF 45

High elasticity modulus at elevated temperatures based on the example of PA 6
25000

Elasticity modulus, MPa

20000

Durethan� BKV 60 EF (PA 6 GF 60) Durethan� BKV 30 (PA 6 GF 30)

� High service temperatures of 170� C and above � High heat conduction (60 % GF) and faster demolding due to high stiffness result in shorter cycle times.

15000

10000

5000

0 23 80
Temperature, �C

120

170

High-performance thermoplastics
300 PA 66 GF 50 PPS GF30 PA12 GF50 250 PA 6 GF 50 PPS GF+Min 65 Breaking stress, MPa 200
PPS GF30 PA 66 GF 50 PBT GF 45 PA 6 GF 60 EF PA 6 GF 50 PA12 GF50 PSU GF 30 PEI GF 45 PBT GF 60 PA4.6 GF60

LCP GF 50
LCP GF30 PPS GF+Min 65 LCP GF 50

PA 6 GF 60 EF PBT GF 45 PEI GF 45 PBT GF 60 PSU GF30 LCP GF30 PA4.6 GF60

150

100

50

0 0 5000 10000 15000 Elasticity modulus, MPa 20000 25000

Highly filled PA 6 Low warpage, high dimensional stability
Lower shrinkage difference lower warpage
2,5 2

1 0,8

Lower water absorption high dimensional stability

0,6

Water absorption, %

Shrinkage, %

0,55 % 0,34 %

1,5 1

0,4 0,2 0
PA 6 GF 30

0,5 0

PA 6 GF 60 EF

PA 6 GF 30

PA 6 GF 60 EF

Molding shrinkage

Post-shrinkage
23 �C, 50 % r. F.

Specifications
Part specifications Low wall thicknesses, miniaturization High stiffness Reliability Dimensional accuracy Material specifications Easy-flow materials

High-modulus materials Hydrolysis resistance Isotropic shrinkage low warpage

Hydrolysis resistance Connector plug
Application in power-assisted steering.

Requirements: Resistance to moisture and temperature fluctuations No failure during the service life of the vehicle

Material: Pocan DP 7139 PBT GF 30, hydrolysis-stabilized

Advantages of hydrolysis stabilization
Improved aging resistance particularly in moist and hot climates Smaller reduction in mechanical properties Higher resistance to fracture Higher impact resistance / toughness

Hydrolysis-stabilized PBT Safety reserves in a humid climate
120 100

Flexural strength

Property change, %

80 60 40 20 0 0 2 4 6 8 10 Pocan DP 7139 Pocan B 3235

Exposure conditions: 100 �C and 100 % r.h.

Exposure period (days)
120 100

Izod impact resistance
Pocan DP 7139 Pocan B 3235

Much lower deterioration of properties at the end of the exposure period.

Property change, %

80 60 40 20 0 0 2 4 6

8

10

Exposure period (days)

USCAR test
70 60 50 40 30 20 10 0 Initial value USCAR 2 USCAR 4
DP 7139 GF 30 HR PBT GF 30 hydrolysis-stabilized

Iz o d im p a c t re s is ta n c e , k J /m �

B 3235 GF 30 PBT GF 30 Standard

-40 �C to max. 110 �C -40 �C to max. 150 �C In each case 40 cycles of 9 hours

Specifications
Part specifications Low wall thicknesses, miniaturization High stiffness Reliability Dimensional accuracy Material specifications Easy-flow materials

High-modulus materials Hydrolysis resistance Isotropic shrinkage low warpage

Low warpage Integrated central electrics*
Requirements: Very low warpage tendency High dimensional stability High stiffness

Implementation: Material with low, isotropic shrinkage. Material: Pocan B 7616 (PBT+PC) GF 15

* combines load distribution function with vehicle electronics functions

Low-warpage blends of polyester
PBT GF
- Relatively high, anisotropic shrinkage Tendency to warpage - Normal GF surface + Outstanding mechanical properties - Reduced mechanical properties - Only moderate flow properties

(PBT+PC) GF
+ Low, isotropic shrinkage Very low warpage + Very good surface quality

(PBT+ASA) GF

ASA: Acrylonitrile Styrene Acrylic

New low-warpage grades
PBT GF 30

(PBT+ASA) GF 30 POCAN B 3235

(PBT+PC) GF 30 POCAN A 3130

POCAN KU-1 7635

Properties
PBT GF (PBT+ASA) GF (PBT+PC) GF

Flow properties

++ ++ ++ ++ o o ++ ++

++ ++ ++ + ++ ++ + +

o o o o + ++ ++ o o
Low warpage Good surface

Mechanical requirements
Toughness

Strength / Stiffness

Heat resistance

Warpage

Surface quality

Weather stability

Resistance
Chemical resistance

Fields of application
Complex part design (very low warpage)
PBT+PC

High demands on surface quality

PBT+ASA

Complex part design (low warpage) High demands on surface quality Good chemical resistance Good weather resistance

High mechanical requirements
PBT

High chemical resistance

Outlook
Further trends LED/technology Material requirements Close tolerances, temperature resistance Resistant to: CaCl2, caustic soda solution, AdBlue Laser transmission welding Numerous FR grades are already in service in many EE applications Know-how transfer

Chemical resistance

Secure connection technology Flame retardance

Summary
Auto EE market is growing at an above-average rate Growth is being driven by new developments Technology-driven raw material manufacturers are accompanying this growth with specific material developments. Required property profile: - easy flow - high stiffness - hydrolysis-resistant - low warpage - high temperature resistance (short-term peak temperatures in the engine compartment of up to 200 �C) - chemical-resistant (new fillers)

Thank you for your attention
Further information: www.durethan.de www.pocan.de
Ralf Jantz LXS-SCP-BLAM-PAD-AD Phone: +49 2133 - 51 29901 Mobile: +49 175 - 31 29901 Mail: ralf.jantz@lanxess.com