enabling economical vehicle light weighting through new glass reinforcement solutions
DESCRIPTION
Presentation by Hans Van der Steen, Owens Corning,Global Business Development Leader, Structural Composites, at CAMX on October 16, 2014. Sheet molded compounds (SMC) allow the automotive industry to make large and complex parts at affordable cost, while meeting the specific requirements for structural applications in automobiles. This presentation reviews the performance of glass fiber multi-end rovings in epoxy resin systems and highlights the specific benefits this solution brings to the automotive industry.TRANSCRIPT
Enabling Economical Vehicle Light Weighting Through New Glass
Reinforcement SolutionsHANS VAN DER STEEN, OWENS CORNING,
Global Business Development Leader, Structural Composites
October 13-16, 2014 Orange County Convention Center
Orlando, FL
Copyright © 2014 Owens Corning. All Rights Reserved. Image copyright: © Misha - Fotolia.com, © istock.com
Source: Owens Corning Marketing Intelligence
The Drivers for Composites in Transportation
Need for light, less pollutant vehicles50% of automotive sales from BRICIncreased comfort demands
Improve fuel efficienciesNew OEM & market concentrationIncreased vehicle functionality
Advanced composites solutionsAdvanced polymersHigh strength metalsNew battery materials & chemicals
Lower CO2 emissionsUrbanizationGlobalization
Mega Trends
AutomotiveIndustry Trends
TransportationTrends
Impact forMaterials
and Chemicals
2000 2005 2010 2015 2020 202520
25
30
35
40
45
50
55
60
65
9
11
13
15
17
19
21
23
25
27
Canada 2025: 56.2
Brazil 2017[3]: 40.9S. Korea 2015: 39.3
China 2020[1]: 50.1
Japan 2020: 55.1
EU 2021: 60.6
Mexico 2016 : 35.1
US 2025[2]: 56.2
US
Canada
Mexico
EU
Japan
China
S. Korea
India
Brazil
US km/lMiles p
er
gasoline g
allon n
orm
alize
d t
o
CA
FE t
est
cycl
e
km/l
Regulations, the key driver for Light Weighting
Source : International Council of Clean Transportation ( ICCT), May 2014http://www.theicct.org/info-tools/global-passenger-vehicle-standards.
Solid lines : historical performanceDashed lines : enacted targetsDotted lines : proposed targets
In Europe, the legal target of 130g/km set for 2015, is met two years in advance. 2013 CO2 emissions for new cars sold, fell 4% to an average 127grams/km.Source: European Environment Agency April 2014
The 95 gr/km cap on CO2 emissions in the EU will be fully implemented by 2021, and no longer 2020 as initially foreseen.Source: European Commission report Feb 2014
The Chinese government revealed a new mandate requiring at least 30 percent of all automobiles purchased by the government to be electric or “new energy” vehicles by 2016Source: China’s Ministry of Industry and Information Technology July 14
Region
Enforcement scheme
Fiscal: Penalty for excess emissions
Non-fiscal:Revoke type-approval
certificate
Non-fiscal: publish name of
manufacturer
US x x EU x Japan x xCanada x x China x xS-Korea x
The Trigger for Light Weighting, Regional Regulations
Source: International Council of Clean Transportation ( ICCT), May 2014
Dependent on weight
36%
Independent of weight
64%
Fuel consumption breakdown
Efficient Diesel Engines
Smart Gasoline Engines
Alternative Power Train Designs
Alternative Transmission Systems
Use Of Bio Fuels And Bio Diesel
Light Weighting With The Use Of Composite
Ways to reach emissions & Fuel efficiency targets
-100Kg -0.35 l/100km -9.0 g/km
Pie data source: Owens Corning estimate, September 2014
Structural Composites,the applications
Cross member
Pillars
Seat structures
Back seat floor
Central floor system
Roof structure
Door structure(crash beam)
Battery housing
Suspension
Bumper beams(crash cans)
Steel vs. Aluminum vs.Steel Composites vs. Steel
Weight Reduction ↓ ↓↓
Process Complexity ↑ ↑Raw Mat. Cost ↑ ↑↑
Design Freedom = ↑Function Integration = ↑
Source: Owens Corning estimate, September 2014
Structural Composites,Competitive Solutions
Approximately200kg of weight
reduction per vehicle will be required
to address OEMsCO2 gap
Short term Aluminum will displace
steel for one onone replacement,
With pure focus on weight out.
Medium-long term Composites allow for
enhanced function integration,
But requiresre-engineering ofthe car modules.
Vehicle production expected to
exceed 100MM units* by 2020
Potential ofweight out due to
composites is estimated at ~100 kg
by 2022 (20-25kg of
reinforcementsper car)
Source: Owens Corning estimate, September 2014The graph excludes the amount of non structural composites used in vehicles today
2015 2016 2017 2018 2019 2020 2021 20220.00
5.00
10.00
15.00
20.00
25.00
30.00
Kg
Co
mp
os
ite
s/ V
eh
icu
le
HighlyStructural
(300Kt)
Structural(200Kt)
Semi-Structural
(300Kt)
The Oportunity for Reinforcements in Structural Composites,
Source: Owens Corning estimate, September 2014
Why SMC forstructural composites
Steel vs. SMC versus Steel SMC versus Aluminum
Weight Reduction ↓↓ =
Function Integration ↑ ↑↑
Investments ↓↓ ↓↓
Raw Mat. Cost ↑↑ ↑
Design Freedom ↑ ↑↑
Process Complexity ↓ ↓
Cycle times ↑ ↑
Carbon Footprint ↓ ↓↓
FAST IMPREGNATION
CO2 EMISSION REGULATIONS
ME 1510 ROVING
VEHICLE LIGHT WEIGHTING
EXCELLENT PROCESSABILITY
LOW VOC EMISSIONS
DESIGNED FOR NEW EPOXY SMC
TECHNOLOGY
ME1510 MULTI-END ROVING
Designed for use with Epoxy SMC
Fast impregnation
Excellent process-ability
Good surface appearance
Designed for SMC low VOC3 emissions
Up to 25%2 part weight reduction
vs. steel
(1) Owens Corning lab, Besana, It, Nov.2012, Epoxy material system (2) Owens Corning SMC Technical Cost Modelling analysis, 2013(3) Volatile Organic Compound
Improved mechanical properties vs. standard
SMC materials
ME1510 MULTI-END ROVINGProduct Benefits
Up to 63%1
glass loading achievable
UP TO 25% PART WEIGHT
REDUCTION VS. STEEL
Improved mechanical
properties vs standard SMC
SUPERIOR STRENGTH AND FLEXURAL MODULUS+ 20% compared to Owens Corning ref. product+ 23% compared to competitor
SMC molded laminates, Owens Corning Besana pilot line, Summer 2013 Pictures courtesy BASF, Germany
Flexu
ral St
rength
[Mpa]
Flexu
ral M
odulus [Gpa *
10]
Tensile
Stre
ngth [M
pa]
Impact
Charpy [
KJ/m²]
050
100150200250300350400450500
OC_ME1510OC_P204Competition
Good bonding
Weak bonding
Up to 63%1
glass loading achievable
ME1510 MULTI-END ROVINGProduct Benefits
Automotive Light Weighting will be one of the drivers for composites growth in the next decade.
SMC is an attractive Process Technology for Structural Composites
Epoxy SMC = no VOC emissions & good fatigue
Owens Corning ME1510 allows for high glass loading which results in better mechanical properties.
Summary