A. Schulman COMPOUNDING YOUR SUCCESS. A. Schulman. Lighter Safer Plastic Interiors trough materials and processings. Thilo Stier

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1 A. Schulman Lighter Safer Plastic Interiors trough materials and processings Thilo Stier

2 Table of Content Common Aims Advantages and Properties of POLYFORT (PP) POLYMAN (ABS) SCHULADUR (PCR) SCHULAMID (PA), Nylaforce, IXEF, SK1000 SCHULABLEND (Polymer blends) Potential of special Processes 2-K moulding Laser marking and welding Gas and water Injection Metal Substitution

3 Common Aims Design freedom Impact Resistance Surface Aspect, Scratch resistance Weatherability (UV) Low Emission and low Fogging Environmental aspects (Recycling) Accoustical behavior Cost efficiency

4 Polypropylene + Advantages Inexpensive Easy to process Ease of compounding - Disadvantages Low Heat Resistance Low Scratch resistance Warping

5 POLYFORT FIPP 15 M-HSR K1693 / FIPP 15 M-HSR K1757 PP Copolymer with 15% Mineral, very good Impact strength, Scratch resistance Low Emission Low Warpage UV stabilised Scratch resistance of Plastics Cardholder BMW

6 scratch test Erichsen Model 430P

7 POLYFORT HSR Polyfort FIPP 20 T standard Polyfort FIPP 15 M HSR 3329 grey Polyman ABS M/HI W grey

8 Scratch test Opel GME Delta L ABS M/HIW grey PP-Copo-20T grey standard POLYFORT FIPP 15 M HSR K1693 GREY POLYFORT FIPP 15 M HSR 3329 GREY shiny surface matt surface fine graining surface rough graining

9 PP COPO 20 T grey standard 19.3µm 16.0µm 28.8µm Scratch 9

10 POLYFORT FIPP 15 M HSR 3329 grey 9.5 µm 7.7 µm 13.0 µm Scratch 4

11 FIPP 20M-HSR

12 Properties and advantages of POLYMAN (ABS) + Advantages Economical Higher Scratch resistance than PP Less warpage, Higher heat stability Higher Impact strength and Creep Resistance - Disadvantages No UV stability High Gloss therefore mostly painted Difficulty in producing Low Emission grades

13 POLYMAN (ABS) M/AQ LE Our LE range conforms with OEM low emission requirements Handbrake handle Audi A3

14 SCHULADUR PCR GF30 SCHULADUR PCR(Post Consumer Recycled) PBT and recycled PET Blend Help to comply with recycling targets (2000 EG 53) More than 25%of recycled made of PET bottles Properties as good as virgin PBT Processing possible on PBT Molds Attractive price

15 SPE AWARD with Bosch and SCHULADUR PCR GF30 The Housing contains electrical connectors cable loop The cover holds the motor and the rear lock Peugeot 206 SW, rear screen wiper

16 SCHULAMID MKF Series Product Performance compounds with a glass fibers/mineral mix high mechanical and thermal performance Processing low warpage Applications fans & shrouds engine covers wheel covers A. Schulman

17 SCHULAMID MKF Series Commercial Applications Daimler Chrysler, Volkswagen, Opel, Audi, BMW, Renault, PSA, Ford etc. in Europe and America

18 SCHULAMID MKF Series rheological mould lay out (doubleclick on image) A. Schulman

19 SCHULAMID MKF Series thermal mould lay out A. Schulman Ejector side C

20 SCHULAMID MKF Series A. Schulman Grades SCHULAMID MKF3010(10GF 20Mineral) SCHULAMID MKF4015(15GF 25Mineral) Services Long lasting experience in FEM support (flow, warpage, mechanical) mould and gating lay out thermal spectroscopy processing support international presence

21 SCHULAMID SK1000 Loud speaker grids used to be Acetal Easyflow POM is brittle which raise safety concerns for impacts Limited UV-Stability Emission of Formaldehyd SCHULAMID SK1000 K1770 Specially modified for an easy flow Excellent impact strength Very low Emission Available in colours

22 Schulamid SK1000 Commercial Applications with Johnson Controls, Faurecia, Daimler-Chrysler

23 NYLAFORCE High performance Compounds in PA66 or PA6 with up to 70% Glass fibers Special Compounding technology and innovative Material modification Team project von A. Schulman and LEIS- Polytechnik Exclusive Marketing by A. Schulman Production by LEIS Polytechnik

24 NYLAFORCE Properties Mechanical Properties comparable to aromatic Polyamide Above 80 C, higher strength and flexural modulus than Aromatic Polyamide Lower water absorption than Aromatic PA Melting point comparable to PA6 or PA66 respectively Very attractive price

25 NYLAFORCE Properties

26 Nylaforce A 60 Accelerator pedal support

27 Reasons for Polymer blends Created to combine the best properties of each componenent Widens the field of application High quality surfaces! Schulablend (PA/PP)! Schulablend (ABS/PA)

28 SCHULABLEND (PA/PP) Properties of Schulablend (PA/PP) High dimensional stability at higher temperature Good impact strength Excellent surface appearance without painting Excellent Scratch resistance Good adhesion to TPE Reduced water absorption Low density, good volume price

29 SCHULABLEND (PA/PP) SCHULABLEND B12 G8 SHI SCHULABLEND SHI for highest impact strength combined with excellent scratch resistance Part of a door handle system

30 SCHULABLEND (ABS/PA) M/MK Extremly high impact strength Good dimensional stability at high temperatures Good glossy and matt surface aspect with good scratch resistance Good adhesion to TPE Easy to process Good resistance to automotive fluids Low density High accoustical insulation properties Good Price performance

31 SCHULABLEND (ABS/PA) M/MK 100 dry conditionned Very high impact strength ensure safe and easy assembly ABS/PA PA 6 ABS PC/ABS Nissan ventilation grid

32 Overview of the Advantages of SCHULABLEND (ABS/PA) M/MK A. Schulman Compared to ABS Compared to PA 6 Chemical resitance Impact strength Surface (matter surface) Higher Heat resistance (see Vicat) Good acoustical dampening Better processability Lower surface resistivity Higher dimensional stability (smaller anisotropy) Lower water absorbtion Higher impact strength (especially dry)

33 Applications for SCHULABLEND (ABS/PA) Automotive industry Parts for safety in head impact area Frame for ventilation system Switches Handles Covers Electrical Industry/Household Goods Housings, Switches, Covers

34 Applications and potentials for special techniques Possibility to integrate more functions Better Properties Better Aesthetics Better Cost/Performance ratio 2K moulding Laser marking and welding Gas and Water Injection Metal substitution

35 2K: Invision + PP gear stick Gear Stick VW

36 2 K SCHULAMID 6 switches from Stoneridge-Pollak

37 Gas Injection Gas Injected lever made with Schulamid 6 GF 15 GID Perfect Surface No switch-over mark due to a slower cristallinisation Significantly Bigger Processing window Good balance between Impact and Stiffness VW/Audi by Stoneridge-Pollack

38 Water Injection with SCHULAMID 6 GF30WIT Door Handle for the Astra

39 EVO-Bus Rack support

40 FIM calculation for material choice

41 SCHULAMID 66 LGF50 Extremly high Stiffness Highr Impact strength lower warpage 30 % weigth reduction 75 % Cost reduction compare to metal For 1420N, only 10mm elongation EVO Dachträger (ehemaliges Entwicklungsprojekt)