StyLight New material solution for lightweight design ACCE September 6-8, 2017 John Fialka, Business Development Manager
Contents AUTOMOTIVE FOCUS ON LIGHTWEIGHTING PROCESSING OF STYLIGHT CHARACTERISTIC PROPERTIES OF STYLIGHT DOOR PANEL DEMONSTRATOR KEY APPLICATIONS FOR STYLIGHT
DRIVERS FOR LIGHTWEIGHTING IN AUTOMOTIVE Slide 3
Fuel Efficiency US CAFÉ standards trend 60 250 260 55 54.5 240 Miles per gallon equivalent 50 45 40 35 35.5 222 40 46.8 190 163 220 200 180 160 Grams CO 2 emissions per mile 30 2016 2019 2022 2025 Model Year miles per gallon grams CO2 emissions per mile 140 Slide 4
Same message around the world Growing global concern to reduce greenhouse gas emissions Slide 5
Automotive OEM s Focus on Lightweight Material Solutions to meet CAFÉ & Emission Targets 10% reduction in vehicle weight can result in 8% fuel economy improvement Target 4.5 MPG reduction requires 25% weight reduction (900lbs) Light weight solutions also provide safety benefits American Chemistry Council issued roadmap to accelerate use of Plastics
JEC Composite Show 2017 Highlights Growth in TPC Automotive Applications Wiper tub Seat Frame Oil Pans Growth in Carbon Fiber Applications Growing commercial applications in Automotive i.e. Ford Super GT, GM Corvette hood & BMW I3 Electric car & 7 Series Aesthetic applications for high end vehicles
STYLIGHT - INNOVATION WITH THERMOPLASTIC COMPOSITES Slide 8
Endless fiber reinforced materials Semi-finished product (plate/sheets) Thermoplastic matrix = Thermoformable = no chemical reaction = short cycle time Reinforced with fabrics or non-crimp fabrics Glass Carbon No trapped air = no voids Fully impregnated Integration in the injection molding process possible (back molding with all styrenics possible)
The sheet manufacturing process
StyLight Processing
CHARACTERISTIC PROPERTIES OF STYLIGHT
Test Method and Materials Test speed: 5 mm/min Pre-load: 15 MPa F 35mm Name Stylight G290-1 PA6 [dry] TPC PC TPC Matrix mod. SAN PA6 [dry] PC Fiber E-Glass E-Glass E-Glass Reinforcement 8 x balanced glass fabric [2/2] 290 g/m² 4 x balanced glass fabric [2/2] 600 g/m² 8 x balanced glass fabric [2/2] 290 g/m² Thickness 2,0mm 2,0mm 2,0mm Fiber content 45% 47% 45%
Mechanical Properties F MPa FlexuralTest DIN EN ISO 14125 800 700 600 500 StyLight G290-1 PC TPC PA6 TPC [dry] 400 300 200 100 0 0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 % deflection Values are measured with balanced woven fabric 50/50, thickness 2mm, 8 layers at RT and dry, fiber volume content 45% to 47% Increases the stiffness by 15% and the strength up to 40% versus conventional Thermoplastic Composites available commercially
Temperature dependence modulus (SAN vs. PA6) Tensile modulus [MPa] 18200.00 18000.00 17800.00 17600.00 Theoretical Modulus Composite 17400.00 17200.00 17000.00 SAN (358N) PA6 dry (B3S) PA6 cond. (B3S) 16800.00 16600.00 16400.00-50 -30-10 10 30 50 70 90 Temperature [ C] Assumptions: Tensile Modulus Glass Fiber: 73000 MPa; FVR: 45%; Ideal adhesion fiber/matrix; Micromechanics approach: E II ( ) = E ϕ + E 1 ϕ Faser II Matrix
Mechanical Properties 250 HDT A 1,8 MPa DIN EN ISO 75 [ C] 200 150 100 50 0 PA6 TPC PC TPC StyLight
Impact Properties (Puncture impact Energy absorbtion) [J] 20 Impact resistance Ep DIN EN ISO 6603-2 18 16 14 12 10 8 6 4 2 0 PA6 TPC PC TPC Stylight *Values are measured with 300 g/m 2 fabric and 4 layers (Thickness 1 mm) at room temperature and ambient humidity. Despite a relative brittle matrix StyLight laminate provide a high impact resistance
Flexural Stiffness vs Strength Stiffness [GPa] 80 70 60 50 40 AlSi1.2Mg0.4 Glass fibersweave50/50 * Carbon fiber weave 50/50* Stylight C200-1 PA6/CF 30 20 10 PA6 GF30 SMC PC/ GF Epoxy / GF (RTM) Stylight G290-1 PA6/GF 0 ABS GF16 0 100 200 300 400 500 600 700 800 Strength [MPa] *Values are measured according to ISO 14125, balanced woven fabric 50/50, at room temp and dry, fiber volume content 45% to 47%
Mechanical Properties GF-PA6 GF-SAN Sharp broken fibers (cutting edge) = good fiber matrix adhesion Fiber pull out = poor fiber matrix adhesion
Test Method: Laser Scanning Microscope Representative measuring point Measurement picture With applied filter Measured lines
Surface appearance 20 Waviness LSM (laser scanning microscope) [µm] 18 16 14 12 10 8 6 4 2 0 PP TPC PA6 TPC PC TPC SAN Stylight TPC SAN based sheets provide reduced surface waviness compared to semi-crystalline matrices and even in relation to high flow PC SAN most suitable matrix for aesthetic applications
Different Surface Appearances Black GF StyLight painted / clear coat Black GF StyLight + foil GF StyLight with clear coat Black GF StyLight decorated with a foil Black GF StyLight decorated with a foil Carbon StyLight with clear coat
Comparison chart PC TPU StyLight PA PP Properties Aesthetic applications Structural applications Mechanical performance ++ + +++ ++ + Impact strength +++ +++ ++ ++ +++ Processability* - +++ +++ + +++ Secondary operation** ++ +++ +++ + - Heat resistance above 100 C + + +/- ++ + Chemical resistance - +++ ++ +++ +++ Dimensional stability ++ ++ +++ - - Surface waviness ++ ++ +++ - - Low water uptake + + +++ - +++ * Includes formability, processing temp., drapability ** includes painting, gluing, foil decoration,
Product Portfolio
DEMONSTRATOR
Optimization of Lay-up Total Thickness 1,2 mm (+/-0,1 mm) extra polymer surface layer random glass 50 g/m² 4 layers glass woven fabric twill 2/2, 290 g/m²
The StyLight Demonstrator Molded Surface Organosheet with high gloss surface Design Foil Organosheet with grained surface
KEY APPLICATIONS FOR STYLIGHT
Key Applications for StyLight Automotive Seat structures Front end module Door carrier Firewall Center console Body panels Interior trims Parts with carbon fiber look
STYLIGHT - VIDEO Slide 30
STYLIGHT CONCEPT DEVELOPMENTS Slide 31
Center Console StyLight Concept Weight savings through part reduction Combining basic structure with outer panel (integral design) High stiffness Big cross section Good mechanical properties of StyLight organo sheets Increased installation space due to integrated basic structure Reduced wall thickness Smaller design possible Simple geometries Low tooling costs State-of-the art production technology at high volume Thermoforming + Injection moulding (1 tool per part) Benefits: weight reduction, improved packaging, function integration
Conclusion StyLight sheets provide Very high strength/stiffness compared to PA6 or PC based sheets. Impact resistance similar to PA6 composite or PC composite. Reduction of surface waviness compared to semi-crystalline matrices and even compared to high flow PC Dimensional stability and chemical resistance Surface suitable for aesthetic applications (painted or decorated) Easy processabilitywith compression / injection molding Possible weight reduction of up to 50% StyLight - A new and promising solution for LightWeight design
John Fialka, Business Development Manager Mobil: 248-320-7230 E-Mail: john.fialka@styrolution.com For more information visit www.ineos-styrolution.com