engineering plastics applications

ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS

INTRODUCTIONINTRODUCTION

Advancements made in engineering materials Advancements made in engineering materials technology have resulted in a situation where technology have resulted in a situation where metallic materials are no longer the only choice metallic materials are no longer the only choice available for various applications. Over the last available for various applications. Over the last 30 years, plastics have been rapidly developed 30 years, plastics have been rapidly developed to the point where they have already started to the point where they have already started replacing many traditional materials in replacing many traditional materials in Automobile industry. Engineering Plastics and Automobile industry. Engineering Plastics and PP becomes a choice by virtue of its superior PP becomes a choice by virtue of its superior versatility and cost economics. Polymer versatility and cost economics. Polymer scientists/ Chemists are building giant scientists/ Chemists are building giant molecules in a dazzling array of plastics as molecules in a dazzling array of plastics as substitutes for metals. Though only a few years substitutes for metals. Though only a few years ago selection of so called “ Engineering ago selection of so called “ Engineering Plastics” was a simple and crude choice, today Plastics” was a simple and crude choice, today there is an almost inexhaustible list of there is an almost inexhaustible list of different thermoplastics available and different thermoplastics available and Polypropylene is leading the way by virtue of its Polypropylene is leading the way by virtue of its versatility in different applications.versatility in different applications.


WHY PLASTICS ?WHY PLASTICS ?

Plastics are not simply replacement materials, Plastics are not simply replacement materials, whereas it is based on technical merits, cost whereas it is based on technical merits, cost and other benefits makes plastics suitable due and other benefits makes plastics suitable due to the following: to the following: ECONOMYECONOMY WEIGHT REDUCTIONWEIGHT REDUCTION STYING – ASTHETICSSTYING – ASTHETICS FUNCTIONAL DESIGNFUNCTIONAL DESIGN PROPERTIESPROPERTIES REDUCED MAINTENANCEREDUCED MAINTENANCE CORROSION AND CHEMICAL RESISTANCECORROSION AND CHEMICAL RESISTANCE


11.5 Mil.

MT9%

124 Mil. MT91%

Demand of ThermoplasticsDemand of ThermoplasticsHigh Performance Plastics High Performance Plastics

<0, 1%<0, 1%

Engineering PlasticsEngineering Plastics

Standard ProductsStandard Products

Market 2002 Market 2002 Mil. MTMil. MT

LCP, PEEK, PEI, PES, PSU LCP, PEEK, PEI, PES, PSU < 0.1 < 0.1

ABS, ASA, SAN ABS, ASA, SAN 5.8 5.8PA PA 2 2PC PC 2 2POM POM 0.7 0.7PBT/PET PBT/PET 0.7 0.7PPO PPO 0.3 0.3

PE PE 55.555.5PP PP 30.630.6PVC PVC 27.627.6PS PS 10.710.7


PLASTICS CONSUMPTION IN A CAR - ABOUT 162 Kg PLASTICS CONSUMPTION IN A CAR - ABOUT 162 Kg 11.6% of Total Weight of the car11.6% of Total Weight of the car

TYPE OF PLASTICS TYPE OF PLASTICS KgKgPolypropylene (PP)Polypropylene (PP) 2929Polyurathane (PUR)Polyurathane (PUR) 3434Polyvinyl Chloride Polyvinyl Chloride (PVC)(PVC)

55

Acrylonitrile – Acrylonitrile – butadiene- styrene butadiene- styrene (ABS)(ABS)

66

PP+ EPDMPP+ EPDM 1818Polyamides (PA, Nylon)Polyamides (PA, Nylon) 2222PolyethelenePolyethelene 1212

TYPE OF PLASTICS TYPE OF PLASTICS KgKgPolycarbonate (PC)Polycarbonate (PC) 1010ABS + PC ABS + PC 1010Polyformaldehyde (POM, Polyformaldehyde (POM, acetal)acetal)

22

Polymethyl methacrylate Polymethyl methacrylate (PMMA)(PMMA)

22

Thermoplastics Thermoplastics Polyesters (PET and Polyesters (PET and PBT)PBT)

22

OthersOthers 1010TOTALTOTAL 162162


Engineering Plastics

FR SystemFR System

Thermal Thermal PropertiesProperties

ProcessingProcessing

Various Various e.g. e.g.

PigmentabilityPigmentability

PricPricee

Toxicology/ Toxicology/ Safety in Safety in

UseUse

ElectricaElectrical l

PropertiPropertieses

Mechanical Mechanical PropertiesProperties

Factors for Material ChoiceFactors for Material Choice

PLASTICS IN AUTOMOBILESPLASTICS IN AUTOMOBILES

INTERIOR SYSTEMSINTERIOR SYSTEMS

Cockpit SystemsCockpit Systems Door SystemsDoor Systems Interiors Hard TrimsInteriors Hard Trims Overhead SystemsOverhead Systems



EXTERIOR SYSTEMSEXTERIOR SYSTEMS

Bumper Systems (Lately integrated Bumper Systems (Lately integrated into Front-end systems)into Front-end systems)

Body side claddings and cowl grillsBody side claddings and cowl grills Spoilers, capping and exterior trimsSpoilers, capping and exterior trims Body panels (Moving from sheet metal Body panels (Moving from sheet metal

to plastics)to plastics)



UNDER THE BONNET SYSTEMSUNDER THE BONNET SYSTEMS Fuel Systems – Fuel Delivery, Fuel TanksFuel Systems – Fuel Delivery, Fuel Tanks Air/ Water induction System – engine cooling and Air/ Water induction System – engine cooling and

climate control systemsclimate control systems

OTHER SYSTEMSOTHER SYSTEMS Safety related parts – impact zonesSafety related parts – impact zones Electrical & ElectronicsElectrical & Electronics Lighting SystemsLighting Systems Power train & chasis systems – steering, pedal & Power train & chasis systems – steering, pedal &

braking systembraking system Soft Trim Systems – Headliners, acoustics & carpetsSoft Trim Systems – Headliners, acoustics & carpets


ADVANTAGESADVANTAGES

More complex assemblies can be easily More complex assemblies can be easily produced as one unitproduced as one unit

Improved performance by reduction of Improved performance by reduction of vibration and noisevibration and noise

Improved Impact ResistanceImproved Impact Resistance Improved power to weight ratioImproved power to weight ratio Improved aesthetics Improved aesthetics Reduced MaintenanceReduced Maintenance No corrosionNo corrosion



Speedo meter Speedo meter HousingHousing

PP Talc Filled PP Talc FilledDoor TrimDoor Trim

PP Talc Filled PP Talc Filled

Reflector HousingReflector HousingPP Talc FilledPP Talc Filled


Hyundai Car Bumper Hyundai Car Bumper PP Talc FilledPP Talc Filled


Seat ComponentsSeat ComponentsPP UnfilledPP Unfilled


Wheel Chair BaseWheel Chair BasePP UnfilledPP Unfilled

Mixie BodyMixie BodyPP UnfilledPP Unfilled


Switch FrameSwitch FrameABS ABS

Instrument Holder Ford Instrument Holder Ford ABS ABS


Engine Manifold – Nylon 6 GF 30Engine Manifold – Nylon 6 GF 30


Toyota Tray – Nylon 6 GF 25Toyota Tray – Nylon 6 GF 25


Honda Tray – Nylon 6 GF 45Honda Tray – Nylon 6 GF 45


Radiator Fan Radiator Fan Nylon 6 GF 30Nylon 6 GF 30

Fuel Sub Tank Fuel Sub Tank Nylon 66 GF 30Nylon 66 GF 30


Timing Chain Cover & Engine Oil Filter Timing Chain Cover & Engine Oil Filter Nylon 66 GF 30Nylon 66 GF 30


Glove RailGlove RailNylon 66 GF 45Nylon 66 GF 45

Seat Belt Anchor Seat Belt Anchor Nylon 6Nylon 6


Lever Combination SwitchLever Combination SwitchNylon 6 GF 30Nylon 6 GF 30

Relay BoxRelay BoxNylon 6 AlloyNylon 6 Alloy


Wire Harness ConnectorWire Harness ConnectorPBTPBT

ECU CaseECU CasePBT GF 30PBT GF 30


Switch BaseSwitch BasePBT GF 40%PBT GF 40%

Actuator CaseActuator CasePBT GF 30%PBT GF 30%


Air Conditioner FinAir Conditioner FinPBT GF 45%PBT GF 45%

Mirror HousingMirror HousingPBT GF 30 AlloyPBT GF 30 Alloy


Alternator PartsAlternator PartsPPS GF/ MD 30PPS GF/ MD 30

Power ModulePower ModulePPS GF/ MD 50PPS GF/ MD 50

Neutral Start SwitchNeutral Start SwitchPPS GF 40 AlloyPPS GF 40 Alloy


Engine Mounting Engine Mounting partsparts

PPS GF 40PPS GF 40

Lamp Reflector Lamp Reflector PPS GF/ MD 60PPS GF/ MD 60

Lamp SocketLamp SocketPPS 40PPS 40


THANK YOUTHANK YOU