Bright solutions for the automotive market

Transcription

1 Bright solutions for the automotive market

2 The primary focus in the automotive industry is to reduce CO2 emissions Michael Koch Business Unit Director Europe

3 DSM supports the changing automotive market The automotive industry has faced a challenging period since As the global community has increased its focus on climate change, more stringent emission regulations have been introduced to actively work toward reducing environmental impact. With approximately one billion cars on the road today and 60 to 70 million more coming off the global production lines each year, all eyes are on the automotive industry to improve vehicle fuel efficiency and reduce harmful emissions, without compromising on the safety and comfort features that drivers have come to depend on. In addition to the main trend of improving vehicle efficiency and fuel economy, the industry is also looking to reduce system costs, and reduce environmental impact by using innovative materials with a better ecological footprint. Improving efficiency The primary focus in the automotive industry is to reduce CO2 emissions by reducing weight and friction, while increasing the level of electrification, says Michael Koch, Business Unit Director Europe at DSM Engineering Plastics. This is why there is growing attention to metal-toplastic conversion, as well as hybrid and electrical cars. DSM provides new, eco-efficient application developments in various high-performance materials for all three of these areas. Reducing system costs DSM provides materials that enable savings on both material and process costs. Our high flow capability materials can be molded into parts with thinner walls at lower injection molding temperatures, saving on both material and energy costs. At the same time, high crystallization rates ensure faster production cycles. By producing our materials globally, we also reduce the validation costs of new solutions for our global partners. Securing safety DSM is the market leader in both airbag containers and brake booster body valves. In order to support our customers through the full design cycle, we have developed high-speed simulation capabilities to test component performance, for example with airbag deployment. Minimizing environmental impact Our portfolio includes bio-based and recyclebased materials, as well as durable materials with a longer useable lifespan, all of which contribute to better lifecycle analyses than the plastics or metals they replace. We also offer a complete line of halogen-free flame retardants, and we re working to expand our portfolio of materials free from hazardous substances.

4 Driving automotive innovations DSM partners with the complete automotive business chain to introduce new, innovative and sustainable solutions. Since the automotive industry is so focused on reducing emissions, this drives the majority of innovation in the market, says Bert Havenith, Business & Innovation Manager Automotive at DSM Engineering Plastics. A single vehicle contains anywhere from 20 to 40 kilograms of engineering plastics, primarily around the engine where improved heat performance is required. Under-the-hood temperatures have risen with the use of turbocharged engines that maximize performance while minimizing engine size. DSM s Diablo grades of Akulon and Stanyl are ideal for these applications.

5 DSM s portfolio of products supports the current and future needs of the automotive industry: Less weight, fewer emissions With close to 30,000 parts in a single vehicle, mass reduction has a cumulative effective where every little bit contributes toward the goal. That s why we offer a variety of materials suitable for metal-to-plastic conversion that reduce weight by up to 50 percent for improved fuel consumption and reduced emission levels. Using materials from our growing portfolio of Eco+ solutions will also substantially reduce penalties for CO2 emissions as governments put new legislation into place, such as the stringent limits that will take effect in Europe in Less friction for 1% fuel reduction The Stanyl Timing Chain Tensioner has been successfully used in the automotive industry for almost 20 years due to its excellent wear performance. It has also been proven to reduce fuel consumption by one percent and CO2 emissions up to two grams per kilometer. We ve spent extensive time in research and development to create a competitive portfolio of solutions for the automotive industry. Fulfilling electrical needs We co-develop applications for starters, alternators, batteries and electro-motors for hybrid and electric vehicles. Yet even with the big push toward electric vehicles, they will only represent between two and 10 percent of the market by That s why we also provide innovative materials for the electrical systems in petrol-powered vehicles, focusing on mass reduction for cost savings, miniaturization while maintaining high mechanical performance and insulation capabilities, and design flexibility. Improving carbon and eco footprints DSM develops bio-based and recycle-based plastics, including Arnitel Eco, EcoPaXX, Palapreg ECO and Akulon RC. EcoPaXX is 100 percent carbon neutral from cradle to gate, Arnitel Eco contains up to 53 percent renewable materials, Palapreg ECO is a bio-based plastic, and Akulon RC is made from post-industrial recycled materials. Using materials from our growing portfolio of Eco+ solutions will substantially reduce the carbon and eco footprints of automotive components.

6 Partnering for a brighter future DSM places customer needs at the center of our business In order to be an active supplier in the automotive industry, you must be global, offer the right portfolio of performance materials, provide a guaranteed stock supply, and offer in-depth customer support. These are must-haves, says Joost d Hooghe, Sales Manager Automotive Europe at DSM Engineering Plastics. What differentiates DSM from the pack is our people, and the way we interact with customers. The company has an open structure and a low emphasis on hierarchy, so we re quick at connecting the right people to find a solution to our customers needs. Global programs, global products DSM has a strong global presence both in established markets and in the growth economies, with a leading position in Europe, the US and China. In 2010, we acquired the Novamid polyamide business from Mitsubishi Chemical Corporation in Japan to provide our customers substantial new opportunities in the Japanese market where innovation and sustainability continue to drive growth. We have also collaborated in a joint venture in the first half of 2011 to produce polyamides in Russia via KuibyshevAzot, creating a better position from which to serve the Russian market. We ve spent extensive time in research and development to create a competitive portfolio of solutions for the automotive industry. Guaranteed supply DSM has production facilities on three continents to guarantee a steady supply of materials. In addition to this, we have research facilities and sales and marketing offices around the globe to create a solid network that includes research and technology support and account management within the regions. Customer support At DSM, we believe that good relationships make good business. That s why our brightest minds from scientists to sales and marketing professionals are all keenly focused on our customers. We support all elements in the automotive chain, from OEMs to Tier 3 customers. Drawing on the knowledge of the clever and creative people in our Innovation Centers and Global Virtual Lab, we seek to find the best solution possible for every customer need. Drawing on the knowledge of the clever and creative people in our Innovation Centers and Global Virtual Lab, we seek to find the best solution possible for every customer need

7 We have production facilities on three continents to guarantee a steady supply of materials. Bert Havenith Automotive Innovation & Business Manager

8 Our products support the future needs of the automotive industry Oil sump in Akulon Decreased friction Chains are used to synchronize the timing of the movement of the pistons with the timing of the actuation of inlet and outlet valves. To provide the appropriate chain tension, guides are used, a key component of which is the slide shoe that is usually made from non-reinforced PA66. Stanyl PA46 yields 22 percent less friction than PA66, leading to two grams per kilometer less CO2 emissions, and a total vehicle fuel reduction of one percent. To achieve the same fuel savings using metal-to-plastic conversion, you would need to replace 20 kilograms of material. Stanyl also offers best-in-class wear performance, extending the life of the component by a factor of four to seven. Reduced weight The main method of weight reduction is via metal-to-plastic conversion, which generally saves up to 50 percent. Even in high temperature applications this can be realized by using Stanyl Diablo and Akulon Diablo. For components where good dimensional stability is key to production and use, such as EPS housings and pump components, Arnite PET offers considerable weight reduction. This product also has a long track record in brake boosters. Stanyl Diablo and Akulon Diablo are 50 percent lighter than metal, while saving up to 25 percent on system costs Increased electrification The drive for vehicle efficiency plays an even bigger role in hybrid and electric vehicles than it does in petrol-powered cars. Electrical components made of Stanyl and Stanyl ForTii deliver high temperature resistance, high mechanical performance, good electrical insulation, longer life spans and improved flow and processing capabilities for a reduction in system costs of up to 25 percent. Thermoconductive materials for LED lighting have improved performance with a high dimensional stability for less beam vibration and low outgassing. Our solutions for automotive electrical systems can sustain the higher processing temperatures of surface mount soldering techniques, and have successfully demonstrated a 33 percent reduction in wall thickness for vehicle control modules while improving flexibility. Improved Cost efficiency DSM s automotive solutions can have a significant effect on your bottom line. For example, brake tubes made from Arnitel are 75 percent lighter than rubber with a 50 percent reduction in cost, while also being a plasticizer-free solution. Gears made from Stanyl have optimal performance characterized by extremely high abrasion resistance, high temperature resistance and longterm durability with significantly lower production costs. Akulon Ultraflow achieves up to 25 percent cost reduction through thin-wall molding and faster

9 Making the case for DSM s solutions Timing chain guide and tensioner in Stanyl. It has been proven to reduce fuel consumption by one percent and CO2 emissions up to two grams per kilometer. cycle times for air inlet manifolds, engine covers, airbag containers and seat components. Decreased footprint Our bio-based solutions have smaller ecological footprints than traditional plastic materials. EcoPaXX is 70 percent bio-based while being completely carbon neutral from cradle to gate. Arnitel Eco is between 20 and 50 percent bio-based, while reducing greenhouse gas emissions by 50 percent. Turbo resonator in Stanyl Diablo Fog lamp housing in Arnite

10 Driving innovation Innovation is a key determining factor for DSM s success, and is often focused on sustainability. In many of the market segments our customers serve, consumers expect continuous product innovation that improves functionality and performance. In other segments, innovation is driven by the need to reduce costs or improve efficacy. By increasing the speed to market and success rate of our innovation process, we continue to deliver value to our customers. DSM in Automotive: smarter, lighter, greener, brighter. Overview applications in Automotive DSM s product portfolio: Akulon PA6/PA66 Chassis and Structural Parts Powertrain Air and Fuel Safety Arnitel TPC Structural Timing systems Air inlet manifolds Airbag containers Arnite PET en PBT Arnitel Eco EcoPaXX PA410 Novamid PA6/PA66 Stanyl PA46 Stanyl ForTii PA4T reinforcements Front end module carrier Body plugs Structural parts Oil sump and CHC Bearing cages FEAD systems MTD & DMF Crankshaft covers Turbo resonators Clean air ducts Charge air cooler end caps Hot & cold charge air ducts Turbo compressor Airbag covers Airbag inflators and igniters Brake booster valve bodies Brake tubes housing

11 Partnering for success DSM actively supports the full chain of automotive manufacturing from Original Equipment Manufacturers (OEMs) through tier one, two and three customers. Our established automotive presence includes global OEM account management and research and technology support in all of the regions. We operate manufacturing facilities on three continents, offering guaranteed supply of our materials across the globe. Finally, we back all of our material sales with a collaborative partnership that harnesses the power of our bright minds and bright science to lead the future innovations of the automotive industry. Sustainability is one of our key pillars for success. Manufacturers increasingly seek out high performance materials to reduce the carbon footprint of vehicles over the course of their life cycle. DSM offers Eco+ solutions that reduce weight and friction to reduce CO2 emissions, as well as bio-based and recycle-based materials. We also offer a full range of halogen-free flame retardant solutions that maintain high safety performance. Lighting Electrical and Electronics Interior Exterior Drivetrain AFL & DBL frames Coils and E-Motors Air vanes Outdoor rearview CVJ boots Bulb & sockets LED components Connectors Fuseboxes Door handle systems Seat components mirrors Roof racks EPS components Reflectors Sensors Pedal systems Wire & cable Door handles Gear shift consoles

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