First-to-market: Innovative next generation lightweight technologies ready for mass production

Transcription

1 First-to-market: Innovative next generation lightweight technologies ready for mass production Thomas Babl Head of Technical Marketing & Engineering Services, Asia-Pacific High Performance Materials Business Unit GTAI Forum Chemical Industry Tokyo, April 24, 2014

2 LANXESS a global specialty chemicals player with focus on technology and innovation Specialty chemicals company Spun-off from Bayer in 2004, listed in the DAX 30* since 2012 Focus on: plastics, synthetic rubber, specialty chemicals, intermediates Global success story Roughly 17,300 employees in 31 countries 52 production sites worldwide 2013 sales of EUR 8.3 billion Strategy of targeted innovation Vital role in LANXESS growth Focus on process and product innovation * German stock market index 2

3 LANXESS is Energizing Chemistry Premium quality Premium specialty chemicals company More than 5,000 products for a diverse range of applications High quality solutions enabling customers to successfully meet current and future challenges Technical expertise State-of-the-art materials, services and solutions that meet the most exacting standards Creating significant value for our customers, the environment and our company LANXESS global mission Commitment to sustainable development Creation of green solutions to meet the challenges of global megatrends Development of environmentally-friendly technologies, resource-efficient processes and next-generation products Sustainability Targeted innovation designed to meet customer needs Pragmatic corporate culture drives product, process and outside-the-box innovation Highly effective innovation network, combining global reach with local expertise Innovation 3

4 Increasing mobility aggravates environmental problems The situation today is critical CO2 emissions and other greenhouse gases lead to climate change Mobility accounts for up to 30% of global energy consumption About 18% of global CO2 emissions are related to mobility 75% of which is generated by road traffic* Alarming future development CO2 emissions in emerging countries (including BRIC) will more than double ( ) Emissions in OECD**-countries will still grow by about 25% Global mobility-related CO2 emissions are expected to grow by up to 2.4 times ( )*** Urgent need for emission reduction Sources: OECD Transport Outlook 2012; Institut du développement durable et des relations internationals * Varying across countries, ** Organisation for Economic Co-operation and Development: includes many of the world s most advanced countries (see all 34 member countries on *** Total CO 2 emissions from freight and passenger transport combined 4

5 Even savings of 100kg will enable enormous emission reductions Driving resistance considerably influences vehicles fuel consumption and CO 2 emissions The higher the resistance, the more energy is required to move the vehicle Rolling, gradient, and acceleration resistances are highly dependent on the vehicle weight and are thus directly influenced by lightweight design Lightweight design is therefore suitable as an effective means of reducing CO 2 emissions and fuel consumption Mass is a key factor in determining the resistances that act on a vehicle lightweight design is the logical solution Acceleration resistance mass x acceleration of the vehicle Rolling resistance (massx gravity) x rolling friction * c w value: air-resistance coefficient Air resistance (air density/2) x c w *x vehicle surface x speed 2 Gradient resistance (massx gravity) x (gradient height/gradient length) Rule of thumb: 100 kg less weight means savings of 0.5 l fuel per 100 km and g less CO 2 per kilometer travelled** Source: Green Mobility Maßnahmen zur Verringerung von CO 2 -Emmissionen im Vergleich (Green mobility a comparison of measures for reducing CO 2 emissions) by Prof. Dr. Horst Wildemann, Munich Technical University, ** Based on a car weighing 1,400 kg and an average consumption of 8 l of conventional fuel per 100 km, which corresponds to an output of 2.33 kg of CO 2 per liter (basis of comparison: car with a life cycle of 120,000 km in six years) 5

6 Vehicle weight can be reduced in various ways Areas where lightweight design can be applied: (Share of weight of the vehicle components in %) Lightweight construction methods and lightweight materials can significantly reduce vehicle weight and thus the driving resistance* Electronics Interior Lightweight design Car body Drivetrain Chassis Lightweight construction methods Lightweight materials *Weight savings can also be made by omitting components or downsizing. However, such measures are often not in line with customer expectations and may result in marketing challenges 6

7 High-tech plastics for lightweight applications Car area Components with LANXESS contribution Car body Roof frame Frontend Spare wheel well Structural insert Cross car beam Drivetrain Engine oil pan Cylinder head cover Gas tank liner Gearbox oil pan Interior Airbag housing Bracket Seat pan Pedal / pedal bracket Chassis Steering rod 7

8 Plastic/Metal Hybrid Technology (PMH) enables lightweight structures Denting or buckling of lightweight structures due to the thin wall F 1 Strengthening the structure with small forces carried by plastic ribs F 1 Metal + Sheet metal F 2 F 2 Polymer Support >> F 1 F 2 Mechanical fixing High-tech plastics keep metal in shape 8

9 Our high-tech plastic developments contribute to weight reduction in cars Frontend 1 st generation Frontend 2 nd generation Frontend 3 rd generation System carrier: 1997 In-mold assembly: 2005 High-modulus materials: since 2012 in serial production Steel sheet: 1.5 mm thickness Single steel sheet supported and functionalized by overmolded high-tech plastics Glass fiber content in plastics: 30%* Weight reduction vs. steel: ~ 30% Aluminum / steel sheet: 1.2 / 0.8 mm thickness Several smaller sheets are mounted with overmolded high-tech plastics Glass fiber content in plastics: 30%* Weight reduction vs. 1 st generation: ~ 15% Aluminum / steel sheet: 1.0 / 0.7 mm thickness Sheets are overmolded with less but extremely stiff high-tech plastics Glass fiber content in plastics: 60%* Weight reduction vs. 2 nd generation: ~ 15% *Weight percentage 9

10 Our solution for 4 th generation structural parts hybrid technology with composite sheets and plastic/plastic hybrid Plastic/Composite Hybrid Technology combines the advantages of two different materials 10

11 What are Bond-Laminates composite sheets? Continuous fibre reinforced thermoplastic composites (CFT) Title text block 1 Title text block 2 Title text block 3 Composite sheet State-of-the-art technology for aircrafts High-tech plastics matrix materials reinforced with woven fabrics Fabrics made of continuous fibers (fiber length = part length) Glass, carbon or aramid fibers (also hybrid) 2D-semi-finished products (sheets) completely impregnated with thermoplastic matrix Advantages of hybrid composite parts Low weight (density e.g., 1.8 kg/dm³) High stiffness, strength and energy absorption No corrosion, efficient recycling No investment for additional tools (e.g. for steel stamping) Suitable for thermoforming into 3D shape Full-plastic composite parts as alternative to plastic-metal structures 11

12 Production of semi-finished product Impregnation and Consolidation Alignment of textile and polymer Continuous production Constant thickness and quality Production width currently up to 1250 mm 12

13 Different textile design Unidirectional (UD) Fiber orientation in one direction unidirectional or multiaxial non-crimp Orthotropic Fibers in two directions normal to each other orthotropic or balanced design Multiaxial non-crimp 13

14 Integration of composite sheet into the hybrid composite part through in-mold forming IR heater Heating up above melting point Shaping during the closing of injection molding tool Subsequent injection molding of rib pattern Demolding Video clip: steering column bracket (40 s) 14

15 Innovation first brake pedal with composite sheet Development project: brake pedal Co-operation with ZF Friedrichshafen, a leading automobile supplier for drive technology and chassis New brake pedal with ~ 50% weight reduction compared to standard steel pedal Additional benefits include: Function integration Reduction of process steps No corrosion protection needed Easy recycling Steel: 794g Evolution of brake pedals Plastic metal hybrid: 526g Mounted pedal block Composite sheet: 355g 15

16 Joint development of a passenger airbag container based on composite sheet technology Series production airbag container Partnership with Takata AG, Aschaffenburg a leading producer of occupant-safety-systems Successful development of new passenger airbag housings with composite sheets Contains gas generator and airbag Weight: 550g Prototype container with composite sheets Conventional parts made of steel metal sheets or injection molding materials 35% weight reduction compared to series part Weight: 360g 16

17 Plastic Metal Hybrid and Tepex Hybrid Technology Bending and Torsion on HiAnt Beam weight related force / [N/g] Hybrid with steel insert Hybrid with Tepex insert weight specific torque / [Nm/g] 0,6 0,5 0,4 0,3 0,2 0,1 Hybrid with Tepex insert Hybrid with steel insert deflection / [mm] torsion angle / [ ] Hybrid with composite sheet insert (2.0 mm) + Durethan BKV30 Weight 346 g Hybrid with steel sheet insert (0.7 mm) + Durethan BKV30 Weight 400 g Based on Arping, Nickel, Haspel, Malek 17

18 TEPEX application example Nike soccer shoe in series production Application: Nike Soccer Clash Collection soles Soles made of TEPEX Saving of weight Outstanding flexibility and energy recovery Reduction of cleat pressure on the foot sole TEPEX dynalite108/208/408 EURO 2012: ~ 50% of goals scored with TEPEX -soles Material: TPU/Glass/Carbon/Hybrid Cleats backmolded 18

19 TEPEX application example Blackberry back housing in series production Application: Housing Blackberry Bold 9900 Slimmest Blackberry smartphone ever Thin and very stiff battery door Functional elements: clips, antenna Carbon look glass fabric TEPEX dynalite108 Thickness: 0.55 mm Material: TPU/Glass, Rips and functional elements backmolded (PA6GF60) 19

20 TEPEX application example Opel Astra seat-shell in series production Application: Seat Opel Astra OPC Your continuous fiber construction stands out due to high stiffness and outstanding strength. The crash behaviour is much better compared to steel or long fiber reinforced plastics. per seat we save ca. 800g of weight TEPEX dynalite102-r600(2)/47% Thickness: 1.0 mm Material: PA6/Glass; Rips and functional elements backmolded Thermoplastic C-FRPs play an important role in the future of lightweight design 20

21 TEPEX application example miscellaneous in series production Several TEPEX applications Swiss military helmet Campagnolo bicycle parts Casco ski helmet Giro cycle helmet 21

22 Innovative solutions for sustainable mobility from Germany Lighter cars increase fuel efficiency, reduce CO 2 emissions in road traffic, thereby contributing to Greener Mobility Tepex: First next generation lightweight technology ready for mass production Lightweight design energized by LANXESS 22 22

23 23