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Market Needs
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Automotive Megatrends
Weight Reduction
Automotive Megatrends
Weight Reduction
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
Goal 2020
2020
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
Weight reduction: 40 - 50 %
Bursa, October 13th 2011
8
Ford Mustang GT 5.0-liter V8 SOP 2011
Exterior
Structural
How can we save even more weight by an optimized design of short fiber reinforced thermoplastic parts?
10
Bursa, October 13th 2011
Basic assumptions of modeling Anisotropic Nonlinear Strain-rate sensitive Tensile-compression asymmetric Failure modeling Temperature dependent
Bursa, October 13th 2011 Status: commercial
Part
Status: commercial
Pedestrian Protection with Ultramid CR and Ultrasim - Lower Bumper Stiffener (LBS)
Process Material Part
13
Status: commercial
How can we further substitute metals by more thermally and dimensionally stable thermoplastics?
14
Bursa, October 13th 2011
100 50
1 2 3
time [h]
1 2 3
4 5
Ultramid Endure
220 C / 3000 h 2 mm
500 m
Bursa, October 13th 2011
30 m
Advanced composites
Stiffness Strength
Toughness
0,1 1 Fiber-length 10 100 [mm]
Short
heating
pultrusion die
cooling puller
Crash absorber
Incineration
Energy absorption
SGF
0 20 40 60 80 100 120
*Reference = Short glass fiber (SGF) Polyamide
LGF
The First Injection Molded Plastic Wheel Rim with Ultramid Structure
Designvorgabe
Weight savings: 3 kg/ wheel rim 12 kg/car 18 kg equivalent to sprung weight Bursa, October 13th 2011
20
cutting
mold
Status: commercial
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
Steel
Alu
CFK (unidir.)
CFK (quasi)
Mg
A
pumps
Polyamide-RIM PU-RTM
mixing
1000
BMW i3 life module
press
500
Epoxy-RTM (Baxxodur)
100
150
[sec]
Status: pilot
core
+ core 2t
+ core 6t
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
25
VW Tiguan Jaguar XK8
Status: commercial
Automotive Megatrends
Weight Reduction
20 %
Fiat
Find the perfect fit: Optimization of the catalyst system by BASF Catalysts
DOC
CSF Soot Filter
Soot [g/km]
LNT
CO [g/km]
Bursa, October 13th 2011 Status: commercial
Without Keropur
With Keropur
10000
1000
Li-S
LNCMO
100
10
standardised range in km
20
132
152
20
90
110
162 107
Hull materials Baxxodur epoxy adhesives and infusion & lamination systems
Automotive Megatrends
Weight Reduction
Battery (Materials)
Heat Management
Higher energy efficiency for heating & cooling less energy used for heating & cooling reduced seasonal variation of range, increased range in summer & winter
Lower weight lower energy consumption for driving overall increased range
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
e.g. 150 km
seasonal reduction of range
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
90 80 70 60 50 40
-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
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
co
NIR Vis
outside
inside
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%
-45 %
Status quo
combined Thermal Insulated IR IR Insulation Windows reflective reflective potential coating windows
Future potentials
Start stop mode Hybrid on/off engine mode Down sizing
Status: pilot
_
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]
OLED
43
Bursa, October 13th 2011 Status: lab/ pilot phase
Automotive Megatrends
Weight Reduction
45
Bursa, October 13th 2011
Improved Scratch Resistance by iGloss Hybrid Material with Nano Hard Phase
TEM Elastic polymer prevents plastic scratch
20 nm
Hybrid material coating: Elastic polymer + in situ formed nano hard phase High toughness + excellent scratch resistance
Bursa, October 13th 2011 Status: market launch
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
47
Bursa, October 13th 2011 Status: market launch
How can we create surfaces that combine individual design and high performance?
48
Bursa, October 13th 2011
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
hours of testing
retention of gloss, colour and impact properties even after prolonged UV exposure
Bursa, October 13th 2011 Status: market launch
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
Release agent
IMC
PU Skin
High surface quality soft touch Multicolored surfaces in one step Lowest emissions
Bursa, October 13th 2011 Status: commercial
51
spraying
Steron coating
adhesion
lamination
strip off
product
How can we create ceramic or metal surfaces with the design freedom of thermoplastics?
54
Bursa, October 13th 2011
Original design
~200C
~100C
~1400C
MIM
Granulate
Green part
Brown part
Sintered part
50% weight reduction
Status: commercial
56
Bursa, October 13th 2011 Status: commercial
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
Automotive Megatrends
Weight Reduction
Ricinoleic acid
63% biobased Long-chain polyamide Low water uptake Lower density High media resistance th
Sebacic acid
Status: commercial
PA 6.10
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
Hyundai i-flow
Bursa, October 13th 2011
http://www.automotive.basf.com