JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009 - 26

FEATURE “Automotive” g…/… Automotive thermoplastic composites: Global recession, technology responses Fig. 4: Average fleet fuel economy by global region Global macroeconomic and fuel price effects on automotive TPCs The emergence of a new middle class in developing countries (1, 2, 7), the population increase (3), the inevitable increase in fuel prices (4) and the progress in ED vehicles and advanced battery technology (5, 6) will: - boost the value of weight saving (10% weight reduction yields 7% fuel economy improvement); - restructure the automotive supply chain (Figure 5); - encourage part consolidation. Automotive TPCs will benefit from these shifts in the automotive and macroeconomic paradigm. Fig. 6: Paths to the LFG - TP Auto Market economics of the direct processes (D-LF-TPCs) are favourable for high-volume, large parts. Several suppliers offer D-LF-TPC processes (Dieffenbacher, Krauss-Maffei, PlastiComp – see illustrations in Ref. 7). Automotive applications for TPCs Some examples of applications for LGF-type TPCs are shown in Table 1 below. Table 1: Example of auto applications for LGF-type thermoplastic composites Application Status Front end module/carrier Established in Europe; starting in the U.S. - Started in Europe (Faurecia and Johnson Controls) - Gaining share in the U.S. - D-LF-PP injection and compression compete LW-RT (PP) competes with D-LF-PP See Figure 9 - Talc PP outer, LGF-PP inner - Vehicle growth sector - Starting point for E-LFT - See Figures 7 and 8 Replaces early GMT usage Replaces SMC and metal SGF and LGF compete Starting in natural fibre composites Stimulated by advanced battery growth and ED vehiclesture Stimulated by shifts in vehicle overhead design Instrument panel substrate and structural ducts Underbody shield Door hardware module Hatchback door Load floor Fig. 5: Global macroeconomic effects on auto TP composites Spare tyre well/ storage module Seating structure Paths to market and supply chain for automotive TPCs Mineral-filled TPCs reach the automotive market via the compounder and are usually fabricated by injection moulding. LGF-TPCs reach the market via several competing compounding and fabrication paths (Figure 6). Non-integrated compounders compete but the economics (especially for LGF-PP) strongly favour back-integrated PP resin suppliers. In contrast to purchased LGF compounded pellets, the Engine covers Battery cases, carriers, support Overhead console/ headliner structure Note: Further illustrations and photos in Ref. 7 As reinforced TPCs evolve from short fibre to long fibre, the relatively easy next step involves localized reinforcement with endless fibres (e.g. tapes) to place the stiffness and impact jec composites magazine / No53 November - December 2009

JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #53 - November/December 2009