automotive interior solutions optimised performance and surface aesthetics
TRANSCRIPT
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Automotive
Interior SolutionsOptimised performance and surfaceaesthetics
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2 . Borealis / Borouge
Production
Customer Service Centre/
Sales Office
Head Office
Innovation Centre
Building on Borealis unique Borstar technology and
their experience in polyolefins of more than 50 years,
Borealis and Borouge provide innovative, value creating
plastics solutions for the infrastructure - pipe systems
and power and communication cables - automotive and
advanced packaging industries. In addition, Borealis
offers a wide range of base chemicals from melamine
and plant nutrients to phenol and acetone.
Borealis and Borouge are leading providers of chemical and
innovative plastics solutions that create value for society.
With sales of EUR 7.5 billion in 2012, customers in over
120 countries, and 5,300 employees worldwide, Borealis is
owned 64% by the International Investment Company (IPIC)
of Abu Dhabi and 36% by OMV, the leading energy group
in the European growth belt. Borealis is headquartered in
Vienna, Austria, and has production locations, innovationcentres and customer service centres across Europe and
Borealis and Borouge partners for long-term success
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Borealis / Borouge . 3
the Americas. Through Borouge, a joint venture between
Borealis and the Abu Dhabi National Oil Company (ADNOC),
one of the worlds major oil and gas companies, the
companys footprint reaches out of the Middle East to
Asia Pacific, the Indian sub-continent and Africa, where it
is also Borealis exclusive distributor. Established in 1998,
Borouge employs approximately 1,600 people, has
customers in more than 50 countries and headquarters inAbu Dhabi, UAE and Singapore.
Currently Borealis and Borouge have a manufacturing
capacity of more than 5.4 million tonnes of polyolefins
(polyethylene and polypropylene) per year. An additional
2.5 million tonnes is scheduled to come on-stream by
the end of 2013, creating the worlds largest integrated
polyolefins plant. Both companies continue to invest to
ensure that their customers throughout the value chain,
around the world, can always rely on superior products andsecurity of supply.
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4 . Borealis / Borouge
6 Dedicated to automotive solutions
7 Satisfying aesthetic and performance demands
8 Lightweight structural components
9 Delivering premium surfaces
10 Processing for optimal property balancing
11 Natural fibre reinforcement
12 Solutions for interior applications
14 Creative innovation
15 Contact
Contents
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Borealis / Borouge . 5
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6 . Borealis / Borouge
Engineering Applications a specialist Borealis and Borouge
business segment particularly focused on the development
of creative innovation polypropylene (PP) and thermoplastic
polyolefin (TPO) solutions for automotive applications.
Whether you are producing dashboards, door panels,
centre consoles, trims or structural components, Borealis
is the right partner for you. Our comprehensive ranges of
PP and TPO polymers and compounds have properties
that are balanced and tailored to precisely match your
application needs. As such they add value through helping
manufacturers to lower system costs, while providing reliable
performance to the highest global industry standards, as
well as enabling faster development-to-production cycles.
And, no less importantly, they reduce both material and
energy inputs for enhanced sustainability.
Staying ahead of trends
Our close working partnerships with OEMs and Tier
1 suppliers over many years have given us a unique
understanding of automotive value chain needs. Of special
importance is that our ongoing dialogue with partners
helps in the early identification of evolving market trends.
This allows us to focus the resources and scientific
skill-sets of our Innovation Centres on ensuring you have
the optimal, differentiated and integrated solutions that
meet tomorrows needs, before they become tomorrows
challenges.
Dedicated to automotive solutions
Door Cladding
Trim
Window Frame
Seat Carrier
Centre Console
Pedal Carrier
Dashboard Carrier
Dashboard
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Borealis / Borouge . 7
Visual appearance is the first and dominant influence on
the buyers perception of vehicle quality. Our PP and TPO
resins and compounds are developed to make a positive
contribution to that perception through, for example, the
generation of appeal through low gloss, scratch resistant
interior trims and cladding that emphasise style, as well
as providing for the design freedom that complements
aesthetic objectives.
Sense of touch has a special relationship to the way
we connect with our surroundings and through it our
appreciation of comfort. The haptic characteristics of our
PP and TPO materials for passenger contact applications,
such as smoothness, grained effect, soft-touch or stiffness,
whichever is appropriate, are given special consideration
in materials development. No less attention is paid to the
materials low emission and odour, non-fogging and sound
dampening characteristics, which complete our perception
of quality and the comfort of our driving experience.
Satisfying aesthetic and performance demands
Wide processwindow
Flowability
Cycle time
Density
Impact
Stiffness
Odour
Heat resistance
Light resistance
Haptic
Scratch resistance
Gloss
Class-A surface
PhysicalProperties
Stabilisation
Processability
SurfaceQuality
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8 . Borealis / Borouge
Lightweight structural components
For applications, such as structural carriers, requiring optimal stiffness/toughness balance our reinforced PP compounds
provide the strength and durability to replace metals. In doing so, they enable significant vehicle weight savings and greater
fuel economy without any compromises in mechanical properties. Moreover, they give reliable, corrosion-free performance
throughout a vehicles lifespan.
GB215HP
BMW
BMW 7 series dashboard carrier in foamed
Fibremod GB215HP, a 20% long glass fibre
reinforced PP compound.
Benefits
- 20% weight saving replacement
of a previous 2-component construction
- Compatible with BMWs SGI injection
technology
- High stiffness and strength
- Excellent warpage behaviour
- Lower system costs
GD302HP
BMW
BMW rear seat carrier in Fibremod GD302HP, a
30% short glass fibre reinforced PP compound.
Benefits
- 35% weight saving replacement
of a hybrid steel-PUR concept
- Lower system costs
- Excellent impact behaviour
- Low warpage and high dimensional stability
GE277AI
VW
VW Golf A7 IP carrier in Fibremod GE277AI,
a 20% short glass fibre reinforced PP
compound.
Benefits
- Specifically designed to be processed with
Structural Foam Injection Moulding (SFIM)
- Combines high flowability with a high
stiffness/impact ratio
- High dimensional stability
- High weld strength
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Borealis / Borouge . 9
Vehicle interior surfaces have a major influence on buyers
perception of quality. Where a quality feel and finish was
once considered the preserve of expensive, high-end
brands, today it is a common OEM goal across
economy-level cars as well. Because of that, interior
aesthetics provide car makers with an important
opportunity for differentiating their offerings from those of
competitors.
Borealis and Borouge PP and TPO materials meet OEMobjectives with optimised solutions that deliver surfaces
exhibiting:
Non-stickiness
Low gloss
High scratch resistance
Absence of flow marks (Tiger stripe-free)
Cosmetic surfaces
A number of new grades have been launched with this flowmark-free PP matrix. But also the existing grade slots were
upgraded so this Borealis innovation could contribute to
the avoidance of flow marks on applications across a very
broad processing window.
An optimal fit
Moreover, the visual and haptic aesthetics of interior
surfaces are supported by the excellent dimensional
stability of PP grades and advanced reactor thermoplastic
polyolefins (rTPO) that offer a low Coefficient of Linear
Thermal Expansion (CLTE). This allows closer gap
tolerances for more visually attractive finishes, when
design calls for parts made from materials with dissimilar
mechanical properties to be fitted in close proximity to
each other.
Underwritten by safetyAlthough not an appearance aspect of our PP and TPO
solutions, their impact resistance and non-splintering
performance are no less important, as they underwrite
visual value. In the event of collision these properties in
panels and fascias contribute to driver and passenger
safety adding a further comfort factor.
Maximising ambient lighting
Enhanced ambient light to increase appeal to the
style conscious buyer, as well as driver and passengerconvenience, is becoming a popular trend in automotive
interior design. As an answer to this, a growing number of
automakers are turning to translucent PP.
Borealis advanced PP solutions maximise ambient light to
create brighter, differentiated interiors, without design or
cost penalties.
Delivering premium surfaces
TigerStripes
[MSE]
Parameter B
ParameterA
40
30
20
10
0
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10 . Borealis / Borouge
Borealis and Borouge PP and TPO solutions for interior
components are formulated to provide the characteristics
necessary for enhanced processing, including:
A broad processing window
High flow enabling ease of filling complex geometries
and long, thin wall constructions
Low shrinkage
Faster cycle times for increased machine utilisation andproductivity
However, Borealis offers processing guidelines that can
unlock the fuller potential of Borealis tailor-made solutions.
For example, creating PP that exhibits very low gloss can
lead to the unwanted effect of reducing the materials
scratch resistance. Within the auto industry this often
means that the performance level of one property is traded
for the raised performance of the other, whereas the
contribution of both is essential and of equal value to the
finished part.
Borealis has developed specific processing parameters
for its own PP materials that allow very low gloss to be
achieved with no negative influence on scratch resistance.
Processing for optimal property balancing
Tooling for sustained appearance and performance
To ensure that interior components, like dashboard
fascias, inner door panels and pillar trims, maintain a
high aesthetic appearance over the long-term, material
scratch resistance is especially important to protect
against abrasions and marring. However, interior mouldings
predominantly use grained surfaces, determined by the tool
used, and these can have a negative impact on scratchresistance properties. Therefore Borealis materials for
interior applications have been developed specifically to
deliver improved grain effect in combination with superior
resistance to scratching.
Ultimate performance, however, is highly dependent on
tooling design as different grains exert varying influences
on the finished components degree of scratch resistance.
Gloss60[-]
Tool contact temperature []
11090 130 150 170 190 210
4.03.83.63.43.23.02.82.62.42.2
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Borealis / Borouge . 11
A next step in lightweighting vehicles is the replacement of
traditional glass fibres and minerals in structural parts with
even lighter-weight, lower density fillers such as natural fibre
compounds (NFC), for example hemp and flax, and woodfibre compounds (WFC). Moreover, as renewable resources
they can make a positive contribution to sustainability within
the automotive industry.
Building on this potential, Borealis is engaged in the
development of a new generation of injection moulding PP
WFC grades for non-appearance and appearance interior
parts.
Customer values Sustainable, renewable sourced modifier
Light weight potential (8-10% weight saving)
High surface aesthetics (low gloss, excellent scratch
and good haptic characteristics)
New design effects
Energy efficient in processing
Product benefits versus conventional 20% mineral filled
PP copolymer
15C higher heat distortion temperature
Better scratch resistance and lower gloss
Equivalent shrinkage
Borealis PP WFC and NFC grades, bridging performance
needs between mineral filled and glass fibre reinforced PP,
are seen as having an ideal fit in applications ranging from
centre consoles and dashboards to door inner panels and
pillar covers.
Natural fibre reinforcement
Physical properties
PP Wood fibre 20%PP Talcum 20%
Charpy V-notched impact+23C [kJ/m2]
Tensile Modulus[MPa]
Gloss [%]
Density[g/cm3]
Scratchresistance
[dL*]
HDT A [C]
1.8
1,900
3
0.5
65-70
2,500
0.95
1.05
1.3
3
55
6
2,400
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12 . Borealis / Borouge
Solutions for interior applications
Grade
Fillercontent[wt%]
Density[kg/m]
MFR230C/2.16kg
[g/10]
Flexural
modulus
[MPa]
Tensilestress
at yield[MPa]
Impact,Charpynotched
23C[kJ/m]
Impact,Charpynotched-20C[kJ/m]
HDT B(0.45Mpa)
[C]
Shrinkageindication
[%]Typical applications
Copolymers
BE677AI - 905 14 1,450 26 8 4 100 1.5 Door cladding, interior cladding
EG066AI - 905 22 1,000 20 38 8 81 1.5 Door cladding, interior cladding
BG055AI 2.5 920 22 1,850 35 3.5 1.5 108 1.5 Climate control housings
Homopolymers mineral filled
MD231U 20 1,050 6 2,700 36 3 1.2 125 1.1 Climate control parts
ME212U 20 1,050 13 3,100 32 3 1.5 120 1.1Climate control parts, interiortrims
PS65T20 20 1,050 23 2,700 32 2.5 1.5 110 1.1 Door Inserts, cladding
MD441U 40 1,220 6 4,700 32 2.4 1.2 132 0.9 Structural parts
Copolymers mineral filled
MG160AI 10 985 22 1,950 25 7.5 3.5 110 1.2 Interior trims
ME266U 20 1,050 12 2,500 28 6 2.5 115 1.1 Structural interior parts
ME268AI 20 1,050 12 2,400 26 6 2.5 100 1.1 Interior trims
EF267AI 20 1,040 16 2,500 27 6.5 2.8 105 1.1 Interior trims
FSC65T30 30 1,150 5 3,000 23 7 2.5 125 0.9 Structural parts
TPO Compounds
EE058AI 9 950 12 1,700 17 25 5 95 1.0 Dashboard, door cladding
EE168AI 10 960 14 1,750 20 25 5 97 1.1 Dashboard, door cladding
EG163AI 10 960 25 1,400 19 45 6 92 1.1 Dashboard, door cladding
EE158AI 13 980 11 1,750 23 25 5 95 1.0 Dashboard, door cladding
EE189HP 15 1,000 13 1,750 21 26 3.5 94 1.0 Dashboard, door cladding
EE288HP 20 1,040 12 2,050 23 16 3 95 0.9 Dashboard, door cladding
EE250AI 20 1,040 13 2,000 22 30 3.5 94 0.8 Dashboard, door cladding
EF261AI 20 1,040 14 1,800 18 45 4.6 94 0.7 Dashboard, door cladding
EG273HP 17 1,020 20 2,000 22 20 4 110 1.1 Dashboard, door cladding
EG265HP 20 1,040 21 1,800 18 55 6 97 0.7 Dashboard, door cladding
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Borealis / Borouge . 13
n.r. = not relevant
Grade
Fillercontent[wt%]
Density[kg/m]
MFR230C/2.16kg
[g/10]
Flexural
modulus
[MPa]
Tensilestress
at yield[MPa]
Impact,Charpynotched
23C[kJ/m]
Impact,Charpynotched-20C[kJ/m]
HDT B(0.45Mpa)
[C]
Shrinkageindication
[%]Typical applications
Natural fibre reinforced
NJ200AI 20 975 18 2,500 33 4 1.5 136 1.1 Non-appearance interior parts
NJ201AI 20 975 23 2,150 30 4 1.5 126 1.1 Appearance inter ior parts
Glass fibre reinforced
GE277AI 20 1,040 12 4,200 85 11 9.5 155 0.8 Instrument panel carriers
GD302HP 30 1,160 3.5 5,600 65 24 13 155 0.5 Seat carriers
GB477HP 40 1,210 2.5 9,200 134 12 11 155 0.4 Seat carriers
Long glass fibre reinforced
GB601HP 60 1,470 n.r. 14,100 135 25 20 167 n.r. PP-LGF concentrate
BJ400HP - 905 90 1,350 25 4.5 2.2 88 1.6
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14 . Borealis / Borouge
At Borealis and Borouge we are dedicated to developing
materials solutions which meet both the existing and the
projected needs of the industries we serve.
This process is guided by creative innovation:
Working with partners to identify needs before they
become challenges and developing solutions that add
value along the supply and production chain through to
and including the end user
Reducing the use of non-renewable resources through
creative design and where possible their replacement
with renewable raw materials
Lowering energy consumption in both production and
end-use, as well as emissions of damaging by-products
such as CO2
Minimising process dependence on fresh water reserves
Limiting and eliminating waste through continuous
efficiency improvements
To support these goals Borealis operates three world class
Innovation Centres. These are engaged in the development
of new materials and the improvement of existing materials,
as well as customer technical services ranging from
part design and prototype simulation to the production
and testing of batch samples and assistance with the
initiation of series production. They are also tasked with the
ongoing improvement of Borealis own methodologies and
processes.
Creative innovation
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Borealis / Borouge . 15
Shestakoff-Fotolia.com
www.borealisgroup.com
www.borouge.com
Contact
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Disclaimer The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borealis extends no warrantiesand makes no representations as to the accuracy or completeness of the information contained herein, and assumes no responsibility regarding theconsequences of its use or for any printing errors. It is the customers responsibility to inspect and test our products in order to satisfy himself as to thesuitability of the products for the customers particular purpose. The customer is also responsible for the appropriate, safe and legal use, processingand handling of our products. Nothing herein shall constitute any warranty (express or implied, of merchantability, fitness for a particular purpose,compliance with performance indicators, conformity to samples or models, non-infringement or otherwise), nor is protection from any law or patent to beinferred. Insofar as products supplied by Borealis or its subsidiary companies are used in conjunction with third party materials, it is the responsibility ofthe customer to obtain all necessary information relating to the third party materials and ensure that Borealis products when used together with thesematerials are suitable for the customers particular purpose. No liability can be accepted in respect of the use of Borealis products in conjunction withother materials. The information contained herein relates exclusively to our products when not used in conjunction with any third party materials.
Contact:www.borealisgroup.comwww.borouge.comengineering.applications@borealisgroup.com
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