Frankfurt's auto show-for plastics, it's all about integrationFrankfurt's auto show-for plastics, it's all about integration
November 1, 2005
Modules and systems continue to be the key words in the automotive suppliers'' lexicon, as revealed by some leading automotive parts processors at Frankfurt''s IAA car show in September.
For plastics processors serving the automotive industry-and, in fact, serving other industries including that of electronics/electrical parts-it is past time to learn how to integrate metal inserts, electrical wiring and so on into your plastics processing operation. As Laurent Burelle, chairman and CEO of Plastic Omnium (Levallois, France), pointedly noted, 90% of his firm''s budget has nothing do with the forming of plastics. Plastic Omnium claims to be the world''s second-largest supplier of automotive body parts and modules (number one in Europe for rear-end modules), and tops globally for fuel systems (as part of its Inergy joint venture with supplier Solvay).
But the company makes that 10% go a long way. Mark Szulewicz, president of Plastic Omnium Automotive Exterior, detailed Plastic Omnium''s work on a thermoset/thermoplastic hybrid tailgate that weighs 20-30% less than comparable steel-based tailgates and offers up to 20% lower system costs. The inner wall is a compression molded sheet molding compound (SMC) with the exterior skin of 30% filled polypropylene. The tailgate integrates the spoiler into the door at the top, and integrates rear crash protective parts at its bottom. Patents are pending on the bonding technology used to adhere thermoset to thermoplastic.
Door modules were highlighted by a number of Tier suppliers with new ones announced at Brose, Johnson Controls, and others. At Polytec Automotive (Lohne, Germany), managing director Norbert Schuling showed a concept door module. "We''re trying to have more integration in the mold," he explained; the firm has acquired a two-component molding machine and related robotics to do just that. Rather than being welded on in a second step, the fastening points on a door panel are injected onto the frame. Schuling did not identify materials used but says they are different.
Schuling says his firm''s acquisition last year of Findlay Europe brought in house the knowledge necessary to create entire door modules. "Our goal is to deliver both door module and trim," he said.
Johnson Controls, the world''s largest supplier of interior automotive parts, displayed its concept door module. Detlef Zimmermann, senior product business manager (doors), says that while about 30% of today''s cars have doors built on a "cassette" module, his firm expects that number to jump to 45% in the next few years. Johnson Controls'' concept allows components'' integration directly into the ready-to-install, and easily removable, door panel.
No gap between headlight and bumper
Plastic Omnium, in cooperation with partners Hella and Behr, also was involved in the development of a new front-end module as part of the three firms'' HBPO (Lippstadt, Germany) joint venture. Ralf Schmidt, VP R&D at HBPO, says the front-end module developed by the three takes full advantage of Hella''s lighting systems, and Behr''s engine cooling experience, as well as Plastic Omnium''s molding knowledge. The cooling module developed by Behr is about 80 mm shorter, about 30 mm thinner, and 1 kg lighter than comparable cooling modules.
The extra space created by reducing the size of the cooler allows HBPO to add other features, such as a molded PP part it calls the Several Function Stiffener (SFuse) to the bottom of the module. In case of collision with a pedestrian, the SFuse makes the pedestrian''s body turn so that it slides over the hood rather than being pushed under (and run over). It also absorbs about 30% of the impact energy. The upper edge of the cooling module also is set lower so that it is below the penetration depth used in the thigh impact test.
HBPO says its module already meets Phase 2 (takes effect in 2010) of Europe''s pedestrian lower leg protection directive 2004/102/EC. Schmidt says commercial programs should run by model year 2007/08 vehicles. He claims the HBPO module has "the first true zero-gap between lights and trim." Molded polycarbonate headlamp cover lenses have been extended so that these also now serve as bumper covers; the parts are transparent only in those spots where necessary for lighting with the rest painted inmold in the vehicle color. The extension means there is not the typical gap between headlamp and bumper; the two are connected from the non-visible side by flexible seals that HBPO has patented. The entire front-end module consists of just 19 parts, with assembly in only one direction-from the front-lowering assembly costs.
The December issue of MPW will include a market outlook for the automotive industry and include additional information from the IAA.
Matthew Defosse [email protected]
Japan''s influence growing
One of the very few plastics suppliers at the IAA said it plans to begin to focus intense marketing efforts on Japan''s carmakers. George Hamilton, president of Dow Automotive (Auburn Hills, MI), noted that Japanese carmakers control about 33% of total car production, including an increasing percentage of cars sold in North America and Europe. The firm also is pursuing ways to get its materials into use in other parts of a car. "We''re looking at cavity filling foams (to improve impact performance); foams for sound management; and working on particulate filter technology to help reduce nitrous oxide emissions [as required in Europe]," he said.
Among trends Hamilton identified is greater demand for molded-in color, already common for many car parts made in North America and Japan (Europe still has more painted parts for interior parts). That trend helped prompt the recent development of a low-gloss ABS from the supplier that he says now is being qualified and tested by potential customers for interior automotive parts. The new material brings improved scratch and mar resistance compared to the PP often used in these parts, explained Jerry Pritchett, VP plastics, fluids, films, and foams. "Plus, users are seeing reduced cycle times, and there may be opportunities for downgauging," added Pritchett.
Hamilton says the firm is the leading global supplier for ABS to the automotive market. Still in development is a low-gloss PC/ABS that he said will help overcome ABS'' limited heat performance; a PC/ABS grade could be used on dashboards and other parts "above the belt line," explained Hamilton. MD
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