Plastic applications for E-Mobility

Transcription

1 Plastic applications for E-Mobility Jürgen Selig Application Development, LANXESS Business Unit Semi-Crystalline Products Automotive Days Poland October 27-28, 2011

2 E-Vehicles: a stunning rise Bringing electric vehicles onto the roads gets a lot of support from governments 1 mn electric cars on German roads in 2020 Nationale Plattform E-Mobilität 7,500 USD incentive for buying an electric vehicle 25 bn USD research budget Department of Energy Estimated 1.5 bn USD for development of electric cars Chinese government Why has the EV become a skyrocketing topic? 2

3 Driving forces for E-cars can be ecological and economical aspects (1/2) Regulations Oil / gas prices New Brands / new image EU Commission 2007: Limit of CO 2 per car 130 g/km in 2012 All-time high in 2007: >140 USD / barrel Tesla Motors: Roadster in 2008, 1 st all electric sports car 3

4 Driving forces for E-cars can be ecological and economical aspects (2/2) Increasing oil prices Targeted CO 2 emissions in EU for 2012: 130 g/km Targeted CO 2 emissions in EU for 2020: 95 g/km Ban of dirty cars in city centers, e.g. London or Stockholm - 10 GBP per day (7h - 18h) congestion charge - Exceptions: EVs + PlugIn-Hybrids Better linked public, more car sharing - High up-front battery costs less important - E.g. Autolib in Paris, following Vélib - 3,000 electric cars and 700 stations - Reserved parking lots Wheel-To-Wheel CO 2 emissions combustion vs. electro engine (g/km) Reduction compared to combustion engine 2008 Ø combustion engine 2008 Germany Ø combustion engine 2020 Germany EV (lignite)* EV (hard coal)* EV (natural gas)* EV (Ø kw portfolio 2020, Germany) EV (nuclear / renewable energies) Source: RWE; *Assumption: best available technology 4

5 All major OEMs have firm plans to bring electric vehicles to mass production We ll sell nothing but hybrids by % of the global car market could be EV by 2020 E-cars will be accepted much, much faster than we have accepted Massive investments of OEMs and Tier1 suppliers in electric / hybrid technology and battery development International cooperations: - Daimler-Tesla - Toyota-Tesla - Daimler-Evonik (Li-Tec) - Renault-Nissan-NEC - VW-Sanyo - Bosch-Samsung (SBLimotive) - Volvo-Magna Steyr - Daimler-BYD A hype? The automobile s future? - GM-LG Chem - BMW-Brilliance

6 Announced and in-series electric vehicles (selection) Source: Daimler / Roland Berger / RWE 6

7 In the next years hybrid vehicles will be more important, but this could change after 10 years In the next 10 years hybrids will be more important than all-electric vehicles; hybrids still have combustion engines Tbd. The questions of lightweight and power management are of highest importance Source: JD Power 7

8 There are still a lot of challenges to overcome Technical challenges, e.g. high voltage electric shock for rescue workers / repair workers battery performance / chemicals fire, emission of hazardous substances complex electronics malfunction, car stranding how to get the car warm in winter? Logistical challenges, e.g. replacement battery management recharging stations and time Ecological aspects, e.g. sourcing of rare earth metals recycling of batteries Costs Car cost calculation: Peugeot ion vs. Peugeot Filou Comparison of costs (4 years holding period; 10,000 km per year) 700 EUR per month Peugeot ion As of February 2011 Fixed costs Operating costs Loss in value (incl. costs for repairs and tires) Peugeot Filou Peugeot ion 49 kw (67 horsepower), monthly leasing charge: 584 EUR (advance payment not necessary, incl. loss in value and costs for repairs and tires) Peugeot Filou 50 kw (68 horsepower), basic price: 10,990 EUR Source: ADAC 8

9 However, there are already many solutions Smart fortwo electric drive 2 nd generation 3 rd generation Production volume >2,000 cars Five digit number Power Climate control 20 kw constant 30 kw peak 35 kw constant 55 kw peak Maximum speed 100 km/h >120 km/h Acceleration (0-60 km/h) (0-100 km/h) Battery 6.5 s Lithium-Ion (Tesla) 5.0 s < 13 s Lithium-Ion (Deutsche ACCUmotive) Yes Source: finanznachrichten.de 9

10 Logistical challenges: building up a charging infrastructure History: The 3-way catalytic converter could not work before all gas stations were up-graded with lead free gas Daimler Smart car2go, car sharing concept 1 st test phase Ulm, Germany: 200 regular cars; 15,000 registered users 2 nd test phase Hamburg, Austin / Texas, Vancouver 3 rd test phase e.g. San Diego, USA: 300 E-drives; 1,000 charging stations Further charging infrastructure projects Renault and Vinci Autoroutes are planning to build 738 charging stations till 2013 at French motorways Peugeot and DB Energie cooperate in building up a charging infrastructure for Peugeot ion Many charging stations (RWE, E.ON,...) already in Germany (1 mn vehicles covered) Sources: Autoplenum, rp-online, RWE 10

11 A standardization for the charging devices is mandatory, but already in progress Kick-off meeting (pre-standardization for E-cars) in 2008 with OEM s (Daimler, Opel, Renault / Nissan, Toyota, VW, BMW, Volvo) and energy suppliers (RWE, E.ON, Vattenfall, EnBW, edf, endesa, Enel, edp) Now VDE / DKE is in the lead Sources: RWE; VDE 11

12 Technical challenge: the high-voltage technique does lead to different requirements for the powertrain Source: autozeitung.de 12

13 New requirements for battery components trigger new opportunities for polymers (weight reduction) (1/4) Battery housing carrier Weight carrying (Full-EV: up to 200 kg) / energy absorption Fixation to the car body Protection from surrounding media Electro-magnetic shielding? Sources: A123, electricvehiclesite.com 13

14 New requirements for battery components trigger new opportunities for polymers (weight reduction) (2/4) Battery housing carrier Solution: PA6-GF + metal insert-hybrid Simplified metal sheets stabilized by complex plastic structures Based on very successful application of PA + metal-hybrids in front ends of most cars Benefits over pure metal structures: - weight saving: less and thinner metal sheets, stabilized by plastic structure - cost saving: no welding, no corrosion protection, reduced tool costs - potential to integrate more functionality, e.g. cell holders, cable fixation, etc. Audi TT front end 14

15 New requirements for battery components trigger new opportunities for polymers (weight reduction) (3/4) Battery housing cover Protection from surrounding media Leak-proofness to carrier Electro-magnetic shielding? Solution: warpage optimized PA6 / PBT - High stiffness / creep stability PA6-GF60 Durethan BKV60EF - Improved surface PA6-(GF+GB)30 Durethan BG30X - Benefits over sheet metal / SMC: - Potential weight reduction by ~30% - Potential cost reduction, no welding - No post-work required, higher toughness 15

16 New requirements for battery components trigger new opportunities for polymers (weight reduction) (4/4) Battery cell holders Dimensional stability, little warpage Flame retardancy V-0 (very likely) Solution: warpage reduced PA / PBT - Highly reinforced PA6-(GF+MD)60 Durethan BM65 X FM30 - Warpage improved PBT-ASA-GF20 Pocan TP Cells Source: Freudenberg 16

17 High voltage power electronics require different materials than current automotive electrical systems Housing and inside carrier of - power electronics - charger - battery disconnect unit - engine control unit - start / stop control unit -... Connectors Charge connectors Strong demand for special flame-retardant Polyamides and Polyesters 17

18 LANXESS can help you develop applications for electric mobility Battery housings - Light weight structures for battery carriers, e.g. HiAnt technology - Optimized materials for large battery covers Electronic components - Flame retardant grades - Low warpage and high dimensional stability grades Charging stations - Suited materials for plugs / connectors (male / female) - Suited materials for protection of the charging station (lightning, overvoltage, ) - 18

19 Summary Electric mobility can gain market share even in the near future (especially car sharing) There are some challenges, but there also ideas / solutions This time all OEMs and system suppliers as well as governments make strong efforts LANXESS offers a wide product portfolio and technical support to work on E-Mobility 19

20 Thank you Further questions? 20

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22 Safe harbour statement This presentation contains certain forward-looking statements, including assumptions, opinions and views of the company or cited from third party sources. Various known and unknown risks, uncertainties and other factors could cause the actual results, financial position, development or performance of the company to differ materially from the estimations expressed or implied herein. The company does not guarantee that the assumptions underlying such forward looking statements are free from errors nor do they accept any responsibility for the future accuracy of the opinions expressed in this presentation or the actual occurrence of the forecasted developments. No representation or warranty (express or implied) is made as to, and no reliance should be placed on, any information, including projections, estimates, targets and opinions, contained herein, and no liability whatsoever is accepted as to any errors, omissions or misstatements contained herein, and, accordingly, none of the company or any of its parent or subsidiary undertakings or any of such person s officers, directors or employees accepts any liability whatsoever arising directly or indirectly from the use of this document. 22