CAR BODY REINFORCEMENT WITH SIKA GALM BIRMINGHAM APRIL Denis SOUVAY - Global Product MarkeFng Manager Reinforcer

Transcription

1 CAR BODY REINFORCEMENT WITH SIKA GALM BIRMINGHAM APRIL 2017 Denis SOUVAY - Global Product MarkeFng Manager Reinforcer

2 TABLE OF CONTENTS 1. SIKA AUTOMOTIVE: WHO WE ARE AND WHAT WE DO 2. HIGH STRENGHT BONDING: SIKAREINFORCER AND SIKAPOWER 3. DVD PADS BONDING: SIKAFLEX - ULM 4. EXISTING APPLICATIONS 2 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

3 WHAT WE DO BUILDING TRUST SIKA IS A SPECIALTY CHEMICALS COMPANY WITH A LEADING POSITION IN THE DEVELOPMENT AND PRODUCTION OF SYSTEMS AND PRODUCTS FOR BONDING, SEALING, DAMPING, REINFORCING, AND PROTECTING IN THE BUILDING SECTOR AND THE MOTOR VEHICLE INDUSTRY. SIKA AT A GLANCE 17,000+ TEAM MEMBERS 90+ COUNTRIES 170+ FACTORIES WORLDWIDE 9 NEW FACTORIES IN NEW PATENTS IN ACQUISITIONS IN BN NET SALES (CHF) IN 2015 WE ARE THERE Our products might not always be visible but the results they achieve are clear to see. 3 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

4 SIKA AG TARGET MARKETS CONCRETE WATERPROOFING ROOFING FLOORING SEALING AND BONDING REFURBISHMENT INDUSTRY AND AUTOMOTIVE 4 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

5 SIKA AUTOMOTIVE TECHNOLOGY SEGMENTS BIW STRUCTURL INSERTS ACOUSTIC SYSTEMS BODY SHOP ADHESIVES TRIM AND ASSEMBLY AHESIVES INTERIOR AND EXTERIOR ADHESIVE PAINT SHOP (LATIN AMERICA) 5 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

6 SIKA AUTOMOTIVE GLOBAL REACH LOCAL PRESENCE Our products for BONDING, SEALING, DAMPING ans STRENGTHENING proudly serve ALL major global and local OEM s, OES and Fer component suppliers in their regions 6 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

7 STRUCTURAL REINFORCEMENT WITH SIKAREINFORCER WEIGHT REDUCTION WHILE KEEPING NVH AND CRASH PERFORMANCE 7 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

8 SIKAREINFORCER AND SIKASTRUCTURE CONCEPT Light- weight, 3- dimensional design solufon. CombinaFon of a structural carrier SikaStructure and an expandable heat reacfve SikaReinforcer. both materials are injected. Reinforcer Foam (SikaReinforcer ): Bonds the structure to car body Structural Carrier (SikaStructure ): SFffens car body 8 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

9 SIKAREINFORCER EXAMPLE OF NVH PACKAGE VOLVO S90 High performance Extensive use of UHSS to increase crash performance of body structure results in loss of NVH performance à Foamed reinforcers placed at structural nodes increase torsional and bending frequency Design freedom InjecFon molded parts show very high freedom of design to fulfil all customer requirements 9 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

10 SIKAREINFORCER PERFORMANCE SIKAREINFORCER VS STEEL REINFORCEMENTS Performance (kn/deg) PREFERED AREA = plasfc reinforcers Steel parts High performance higher potenfal per weight 3-6 x higher effecfvity Lightweight soluqon Weight (g) 10 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

11 SIKA HIGH STRENGTH BONDING CONCEPT 11 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

12 SIKA HIGH STRENGTH BONDING BENEFIT SikaPower (structural adhesive) PERFORMANCE +50% SikaReinforcer (structural foam) 12 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

13 SIKA HIGH STRENGTH BONDING APPLICATION CONCEPT Step 1 Apply thick beads of SikaPower adhesive. Step 2 Insert SikaStructure element (plasfc carrier); adhesive beads compressed. Step 3 Apply second SikaPower bead (if necessary). Step 4 Cover plate compresses second bead. Aner the cathodic coafng dip, SikaPower cures in the E- coat oven. 13 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

14 SIKA HIGH STRENGTH BONDING EXAMPLE OF IMPLEMENTATION IN VW GOLF 7 ApplicaQon target Side crash of electro Golf derivafve with 300 kg addifonal weight (Baperies) Global reducfon of sheet metal thickness in roof frame Lightweight soluqon : Weight reducfon (vs steel solufon) > 2.5 kg Design freedom : InjecFon molded parts show very high freedom of design to fulfil all customer requirements 14 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

15 ANTI- FLUTTER APPLICATION WITH SIKASEAL AND SIKAFLEX ULTIMATE WEIGHT REDUCTION ACHIEVED WITHOUT READ- THROUGH ISSUES 15 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

16 ADHESIVE SOLUTIONS SIKAFLEX - ULM ROOT CAUSE OF READ- THROUGH Inadequate Design Thermal condifons Δ α Light- weight (Substrate thickness) Assessment / PrevenFon 16 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017 Improper applicafon Wrong adhesive (mechanical properfes)

17 ANTI- FLUTTER SOLUTIONS SIKAFLEX ULM BONDING OF DVD PADS PURPOSE AND BENEFITS Provide sfffness in roof area despite significant roof thickness reducfon ReducFon of weight (roof panels / roof structures) Side benefit: sound damping effect 17 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

18 BONDING OF DVD PADS SIMULATION ROOF STIFFNESS Results of Finite Elements CalculaFons 0.75 mm roof Reference 0.75 mm roof + DVD 0.55 mm roof + DVD Z- displacement [mm] for given force Normalized sfffness [%] Weight change [kg] ref Analyzing deformafon of roof panel under load with different roof set- ups: Clear sfffening / weight saving effect with bonded DVD in roof panel Weight reducfon of nearly 2 kg is possible on a standard size roof. 18 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

19 REQUIREMENTS FOR BONDING OF DVD PADS REDUCE READ- THROUGH EFFECT SIKAFLEX - ULM SIKAFLEX LM- 1 SIKAFLEX LM- 2 SIKAFLEX LM C - 5 C REFERENCE Best performance 19 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017

20 SIKAFLEX - ULM TECHNOLOGY SOUND DAMPING measurement on Steel measurement on absorbent side 20 APRIL, 2017 DENIS SOUVAY - LIGHTER VEHICLE STARTS WITH SIKA / GALM 2017 Best solufon for sfffening and sound dampening

21 LIGHTER VEHICLE STARTS WITH SIKA APPLICATIONS FROM THE FIELD

22 VW GOLF MORE THAN 30 SIKA PRODUCTS INSIDE MEGATREND: SAFETY AND E/HYBRID VEHICLES ApplicaQon Highlight Improving crash safety, bond- line read through, weight reducfon CHALLENGE Lightweight materials and E design required specialized applicafon technology SOLUTION High- strength bonding, SikaPower, and Sikaflex ULM enhance safety, plus 35 kg weight savings Main Content: STRUCTURAL ADHESIVES SikaPower 150 meters bond line steel to steel REINFORCERS & ACOUSTICS SikaReinforcer plus high- strength bonding for side crash safety SikaBaffle - 36 baffles ASSEMBLY ADHESIVES Sikaflex plus SikaBooster accelerated system glass bonding Sikaflex - ULM for DVD bonding (Dachverstärkungsdämpfung- roof sfffening/damping) LAMINATION ADHESIVES SikaMelt interior door panels

23 MERCEDES S- CLASS NVH AND LOCAL STIFFENING NVH PACKAGE FOR MIXED BONDING ApplicaQon Highlight Solving NVH (Noise, VibraFon, Harshness) and vehicle dynamics - extensive light weighfng with UHSS (Ultra- High Strength Steel) CHALLENGE Strengthening with design freedom and joining where welding is not possible SOLUTION 16 SikaReinforcer parts at strategic nodes, dynamics improved, 10 kg weight savings Main Content: STRUCTURAL ADHESIVES SikaPower 217 meters bond line aluminum to steel REINFORCERS 16 parts contribufng strength at strategic locafons throughout the vehicle ASSEMBLY ADHESIVES Sikaflex Glass bonding, mixed material panorama roof, Sikaflex UHM mixed material roof (aluminum/steel) Sikaflex ULM for DVD bonding INTERIOR & EXTERIOR BONDING SikaMelt sun visors, parcel shelf, headliner, pillars SikaTherm leather/texfle / foil/ ABS consoles, panels

24 BETTER VEHICLES START WITH SIKA LIGHTER STRONGER SAFER QUIETER GREENER