basf-automotive innovation pipeline

BASF’s Automotive Innovation Pipeline

Bursa/ Turkey, 2011 October 13th

Dr. Christian SchmidtBASF R&D Verbund Automotive

Automotive Solutions Performance Passion Success

Bursa, October 13th 2011

125th anniversary of the automobile

cars love chemistry



Innovation ChainsFrom Megatrends to Products

Global Megatrends

Market Needs

PossibleSolutions

Projects ProductInnovation

Market Pull Innovation Chain

e.g. energy efficient mobility

e.g. light weightconstruction

e.g. CFRP for structuralparts

e.g. development of new polymer matrices

e.g. new resin formulation



Weight Reduction

Automotive Megatrends

Comfort &Quality

Environment &Sustainability

Energy Management

Propulsion & Catalysts

InnovativeMaterials

InnovativeMaterials



European Legislation for CO2 – EmissionOptions for Achievement

Average new car fleet emission[g CO2/km]

2010 2012 20162014 2018 2020

Weight Reduction

Catalysts &Fuel Additives

EnergyManagement

Energy DensityBattery

LightweightComposites

HeatManagement

150

130

120

140

110

100

90

Com

bust

ion

Engi

ne

Goal2012

Goal2020

Currentaverage/Germany

Elec

tric

Mob

ility

2025: possibly 70 g/km

152 g/km

120 g/km

95 g/km

Weight Reduction



Current Light Weight Concepts:Weight Percentage of Plastics in Cars

Weight Reduction

kgSteel 700Light metals 290Other metals 55Thermoplastics 190Elastomers 50Thermosets 35Thermoplastic elastomers 4Fluids & Chemicals 80Glass & Ceramics 40Textiles & Fabrics 35Paints & Adhesives 15Electronics 5Others 8

Weight distribution of materials in a mid-sized car (1500 kg)

ca. 20 % polymer materials,ca. 15 % plastics

Ratio of plastics will increase further to save additional weight



8

Porsche 3.2-liter 6-cyl. Boxer,

SOP 1972

BMW 2-liter L4 DI DieselSOP 1998

Status: commercial

Weight reduction: 40 - 50 % Ford Mustang GT 5.0-liter V8

SOP 2011

Ford 5.4-liter V8SOP 2004

Largest AIM in North America (weight-wise)

Weight Reduction

BASF Success Story AIM out of Ultramid®

From Simple to Multifunctional Modules



Short Fiber Reinforced Ultramid® ApplicationsWeight Savings max. 50 kg → 5 g CO2/ km

Ultramid®

oil pan

Ultramid® in car seatsWeight reduction: 20 %

Ultramid® structural insertsWeight reduction: 40%

Ultramid®

transmission cross beam

Ultramid® TOPWeight reduction: 40 %

Status: commercial

Interior

StructuralExterior

Powertrain

Ultramid®

engine mount

Weight reduction 50 %

Weight Reduction



10

How can we save even more weight by an optimized design of short fiber reinforced

thermoplastic parts?



MeasurementProcess

BASF Material model

PartBasic assumptions of modeling

Anisotropic Nonlinear Strain-rate sensitiveTensile-compression asymmetric Failure modelingTemperature dependent

Status: commercial

Integrative Simulation Ultrasim®

for Short Fiber Reinforced Thermoplastics

Weight Reduction



Optimized Design with Ultramid® CR and Ultrasim®

Status: commercial

Weight Reduction

Aluminum 100 % weight

Ultramid® CR 1st generation-35 % weight

Ultramid® CR2nd generation-50 % weight



Pedestrian Protection with Ultramid® CR and Ultrasim® - Lower Bumper Stiffener (LBS)

13

Process Material Part Joint development with OEM

Combination of BASF‘s product and engineering know-how

faster development and lower testing costs

40% savings in weight

highest rating in lowerleg impact test (5/5)

Status: commercial

Weight Reduction



14

How can we further substitute metals by more thermally and dimensionally stable

thermoplastics?



5

Resonator1

2

3

4

Modern Engine Concepts Need New Materials: Ultramid® Endure

Status: market launch

Heat aging at 220 °C

Charge-airlinesIntercoolercaps

Throttle valve

Intakemanifold

12 3

5

4

Tensile strength [MPa]

0

50

100

150

200

250

0 500 1000 1500 2000 2500 3000 3500time [h]

Ultramid® Endure

PPAPA 66/6

PA 66

PPS

Weight Reduction



Ultramid® EndureInnovative Stabilization Technology

PA 66 Ultramid® Endure

220°C / 1000 h 220°C / 3000 h2 mm 2 mm

500 µm 30 µm

Weight Reduction



17

How can we further substitute metals

by new light weight constructions?



Fiber-length0,1 1 10 100 [mm]

Advanced compositesStandardizedproperty [ - ]

Stiffness

Strength

Toughness

Statistic long Oriented endless fibersShort

Pressing, resin transfer moldingInjection molding

Relationship between Properties and Fibre Length in Reinforced Plastics

Weight Reduction



heating cooling

polymer meltfeeding (twin screw extruder) pelletizer

puller

Notched impact strength

Energy absorption

Warpage stability

Inverse Creep elongation

*Reference = Short glass fiber (SGF) Polyamide0 20 40 60 80 100 120

Ultramid® Structure LF

Reference*

Incineration

SGFLong glass fiber (LGF): More Performance through 3D network

Lightweight Composites - Long Glass Fiber Reinforced Ultramid® Structure


pultrusion die

Index Ultramid® Structure = 100 %

Crash absorber

LGF

Weight Reduction



20

The First Injection Molded Plastic Wheel Rim with Ultramid® Structure

Design-vorgabe

>> smart forvision in cooperation with BASF

IAA 2011, Frankfurt

Weight savings:

3 kg/ wheel rim 12 kg/car

18 kg equivalent to sprung weight

Weight Reduction


Bursa, October 13th 2011 Status: commercial

cutting

wetting&

mixing

PU-compo-nents

transport

oscillating nozzle

mold

glass roving

cutting

wetting&

mixing

PU-compo-nents

transport

oscillating nozzle

mold

glass roving

Long fiber injection with Elastoflex® Eglass fiber content 20-50 weight%foamed duroplastic polyurethanehigh temperature stability, superior impactstrength, high flexural modulusadhesion to thermoplastic sheetsthermal expansion coefficient between steel and aluminum

Polyurethanes for Long Fiber InjectionLFI-PUR

Weight Reduction



SolutionChallenge: Light weight substitution of metal chassis & frame

• Long / endless fibrereinforcement

• High fibre content ≥ 50%carbon or glass fibres

• Improved reactive systems• Multi-material solutions

Possible process technologies• RTM / RIM• Sandwich• Pultrusion

100%Weight /property

Ste

el

Alu Mg

CFK

(qua

si)

CFK

(uni

dir.)

-40%

-15% -20%-40%

Future light weight compositematerial concepts require

Weight reduction of 100 – 150 kg possible (10-15 g CO2/km)

~20 % of total weight

Concepts for the Future: Enter the Metal Core Domain for Further Weight Reduction

Weight Reduction



50 150100

Polyamide-RIM

Epoxy-RTM(Baxxodur®)

PU-RTM

500

1000

1500

Viscosity[mPas]

preform

press

mixing

componentA

pumps

B

Endless fiberreinforcement

Resin Transfer Molding (RTM)and Reaction Injection Molding (RIM)

Status: pilot

[sec]* Source: Fraunhofer ICT

component

BMW i3life module

Weight Reduction



Light Weight CompositesSandwich Structures

Weight

Stiffness

106%

3600 %

820%Strength

100%

100%

100%

600%

250%

102%

+ core 2t + core 6tSolidConstantthicknessof the faces, t

Faces withthickness tcore

Weight Reduction



25

Status: commercial

Paper based core materialLow density structure with good NVH propertiesWeight reduction 50-75%Sun shade, spare wheel cover, etc.

No drippingExcellent edge wettingLower processing temperatureunder development

VW Tiguan

MB M-class

Jaguar XK8

Audi A4

Elastoflex® E3532

Light Weight CompositesPU Based Honeycomb Structures

Weight Reduction



Weight Reduction


Comfort &Quality


Energy Management


InnovativeMaterials

InnovativeMaterials



Optimized Catalysts for Improved Propulsion Efficiency


Alternative fuels Modern propulsion conceptsDiesel

Compressed natural gas (CNG)

Biofuels (biodiesel B30, bioethanol E85)

Gasoline direct injectionLean burn enginesDownsized engines

Hybrid cars

10 %

20 %

25-75 %

10-20 %

20-30 %©Fiat

Find the perfect fit: Optimization of the catalyst system by BASF Catalysts

potential for efficiency improvement & CO2 reduction



Selective Catalytic Reduction

CatalysedSootFilter

NOx [g/km]

HC+NOx[g/km]

CO [g/km]

Soot [g/km]

1.0

1.0

2.0

0.1

EURO1EURO2 DOCEURO3EURO4EURO5

CSF Soot Filter

0.3

0.3

1.0

0.05

EURO5EURO6DieselOxidationCatalyst

LNT Lean NOxTrap Catalyst

or

Status: commercial

Catalyst Systems for Diesel Passenger Cars to Meet EU Emission Legislation




KEROPUR®

Gasoline Performance Packages

Potential of 2 % fuel savings (3 g CO2/km) Status: commercial

Effective deposit control ensuresa clean intake system

Friction modifiers reduce frictionbetween cylinder walls (blue)and piston rings (red) of the engine

Corrosion protection of metal surfaces

WithKeropur®

KEROPUR® ensures clean Intake Valve

Deposits onIntake Valve

WithoutKeropur®




Status and Future Innovations of Li-Ion Batteries by BASF


LNCMO

LFP, LVP

1

10

100

1000

10000

100000

0 25 50 150 175 200 250 300

Ni-Cd Ni-MH

Li-Ion

Li-S

Li-Ion high voltage

BASF R&D activities:improved materials,

new battery concepts

BASF commercialactivities:

cathode materials,electrolytes…

pow

er d

ensi

ty /

W/k

g

standardised range in km

Pb/acid

75 100 125Pilot,

production 20122500 t/a, USA



5

107

162

90

132

110

EV - electricity based on renewable sources only

EV - electricity based on current German energy mix

Potential for improved ICE

EV - electricity based on fossil fuels only

20

Current German new car fleet average 15220

Average CO2 emissions (g/km)…

Electricity based on CO2 neutral sources is crucial for sustainable mobility

Direct emissions from car

Indirect emissions from production and electricity generation

Overall CO2 Emission Balance of Mobility



Bursa, October 13th 2011Chemistry enables sustainable energy sources for tomorrow’s mobility

Renewable Resources – Wind PowerComplex Structure of a Rotor Blade

Light weight structureExtrusion foams: Styrodur® C

Hull materialsBaxxodur®

epoxy adhesivesand infusion & lamination systems

Protective coatingWindCoat Contour & Finish,OLDODUR BladeProtect &BladeCoat

BALSA

PVC foam

PET foam

Complex “hybrid”structures




Weight Reduction


Comfort &Quality


Energy Management


InnovativeMaterials

InnovativeMaterials



Three “Pillars” of Electromobility

Higher energy efficiencyfor heating & coolingless energy used for heating & cooling reduced seasonal

variation of range, increased range

in summer & winter

Heat Management

Higher storage capacity

of batteriesHigher driving

range of vehicle

Battery(Materials)

Light Weight Construction

Lower weightlower energy

consumptionfor driving

overall increased range




Improve the energy efficiency of a car’s climatisation system (heating & cooling) to

• increase thermal comfort of passengers • reduce seasonal variation of driving range,

esp. in electric cars

Automotive Heat Management:Definition

*: In a wider sense also heat management for battery system (to maintain optimal operation temperature of 20-25 °C)

Energy Management



40

50

60

70

80

90

100

-20 -10 0 10 20 30 40

ambient T / °C

max

imal

rang

e (%

)

Driving Range Dependence of ElectricCars as Function of Ambient Temperature

schematic representation- urban drive situation (< 50 km/h average speed; start and stop)- for T > +30 °C: 1000 W/m² solar irradiation assumed

e.g. 150 km

Psychological threshold: range of 100 km

> 100 km

seasonal reduction of range

Energy Management



40

50

60

70

80

90

100

-20 -10 0 10 20 30 40

ambient T / °C

max

imal

rang

e (%

)

Improvement potential whenrange reduction is lowered by20, 30 or 50 %

Driving Range Dependence of ElectricCars as Function of Ambient Temperature

schematic representation- urban drive situation (< 50 km/h average speed; start and stop)- for T > +30 °C: 1000 W/m² solar irradiation assumed

Energy Management



IR reflective film for glazing

Status: pilot

Insulation foams andHigh performance foams

Status: commercial/ pilot

Status: commercial

IR reflective pigmentsfor coatings and interior

NIRVis

cool

outside inside

reflective film glazing

Polymer foams for thermal insulation

IR reflective pigments for coatingsIR reflective pigments for interior surfacesIR reflective films for glazing

Other technologies (electrochromic systems,self-switching IR absorbers, latent heat storages)

Simulation and system analysis

Overview on BASF’s AutomotiveHeat Management Technologies

Solar heat management

Energy Management



Saving potential ~ 45 % by combination of all measures in summer case

Electric car: Summer conditions Effect of heat management measures

Total cooling requirement: 3.0 kW Average energy requirement for driving:

~ 3kW @ 20 km/h, ~10 kW @ 60 km/h, ~16 kW @ 100 km/h

Outside: +30°C & sunny at noonInside: +20°C

0

20

40

60

80

100

Statusquo

ThermalInsulation

IR reflectivecoating

IR reflectivewindows

Chassis~ 30%

Windows~ 70%

Simulation and System AnalysisSummer Case for Mid-Sized Electric Car

energy consumption / rel. %

combinedpotential

-45 %

InsulatedWindows

Energy Management



40

How can we improve energy management for

combustion engine cars?



Energy ManagementPUR Thermal Engine Encapsulation

Status: pilot

BenefitsEngine reaches operating temperaturefaster, i.e. less cold starts

Reduced CO2-emission 6-9 g/km

Additional sound insulation

No application in conventional cars yet

Thermal Engine

Encapsulation

Future potentialsStart stop mode

Hybrid on/off engine mode

Down sizing

Energy Management



Energy ManagementThermoelectric Effect

Status: lab phase

Technology: Conversion ofa temperature differenceinto electric energy

Key application: Recoveryof waste heat from exhaustgas stream

Thermoelectric materialand module integrationdetermine performance

Challenge:Transfer material improvementinto module performance

Material potential>10% efficiency

Potential savings:up to 3 g CO2/km0 100 200 300 400 500 600 700 800 900 1000 1100

0,0

0,2

0,4

0,6

0,8

1,0

1,2

p-SiGe

n-SiGen-PbTe

n-Bi2Te3

p-Bi2Te3p-PbTe

T [°C]

cold

hot +

_Efficiency

[Z T]

Energy Management



43

First Transparent Solar Roofand Transparent OLED

Transparent organic LEDEfficient area lighting

Adjustable colours

OPV

Transparent organic photovoltaics cellsAlso work withdiffuse light

OLED

Status: lab/ pilot phase

Energy Management



Weight Reduction


Comfort &Quality


Energy Management


InnovativeMaterials

InnovativeMaterials



45

How can weimprove scratch resistance

of car coatings?



Improved Scratch Resistance by iGlossHybrid Material with Nano Hard Phase


20 nm

TEM Elastic polymerprevents plastic scratch

Hard phase preventsabrasive scratch

Hybrid material coating:• Elastic polymer + in situ formed nano hard phase

High toughness + excellent scratch resistance

Comfort & Quality



47

Multiple crockmeter testing 10, 50 & 100 times

Hard phase in bulk, not only in top layer

Outstanding andenduring dry scratch

resistance

Comfort & Quality

Improved Scratch Resistance by iGlossHybrid Material with Nano Hard Phase




48

How can we create surfaces that combine

individual design and high performance?



New Weathering Resistant Luran® S SPF30


Luran® S (ASA)

• Weathering resistant, impactmodified SAN based engineering plastic

• Especially suited for exterior applications

• New SPF stabilization technology for even higher weathering resistance

Gloss retention (ISO4892-2A)outdoor weathering simulation

0102030405060708090

100

0 200 400 600 800 1000 1200 1400 1600 1800 2000hours of testing

Glo

ss le

vel (

%)

ABSABS UVASAASA UVLuran® S SPF30

retention of gloss, colour and impact properties even after prolonged UV exposure

Comfort & Quality



50

Greyscale ISO 4892-2A

012345

500 1000 1500 2000 2500

Test time (hr)

Luran HH-120 Standard Stablization Luran HH-120 SPF Stablization

Luran® HH-120 SPF Piano Black

examples of high gloss Luran S (above) & Luran® HH (right)

automotive applications

Luran® HH-120 (AMSAN)

• Excellent high gloss for decorative parts

• Intense color deepness (Piano Black)

• Easy processing• Vicat B > 120 °C

Application of new SPF stabilization technology allows substitution of PMMA in exterior applications

Comfort & Quality




51

Elastoskin®

In Mold Coated PUR Spray Elastomer

High surface quality – soft touch

Multicolored surfaces in one step

Lowest emissions

Extreme freedom of design

Release agent

IMC

PU Skin

Status: commercial

Comfort & Quality



soft touch structureair permeable pores

Status: pilot phase/ market launch

Steron® Technology Process and Properties

structuring spraying adhesion strip off

texturedmold

Steron®

coatinglamination product

Comfort & Quality



Steron® Technology New Options for Individual Surface Design

Steron® Coating

carrier:textiles, leather,paper, foam, plastics, wood, metal...

dash board surfaceStatus: pilot phase/ market launch

Comfort & Quality



54

How can wecreate ceramic or metal surfaces

with the design freedom of thermoplastics?



“Green part” “Brown part” “Sintered part”Granulate

MIM

Original design

50% weight reduction

Catamold®

Molding Metals and Ceramics like Plastics Benefits of metal or ceramic injection molding (MIM/ CIM)Production of complex, small parts - ease of automation, low specific production costsHigh product quality

~200°C ~100°C ~1400°C

Status: commercial

Comfort & Quality



56

Catamold®

High Class Surfaces

BMW i-drive rotary knob

BMW gear shift leverDecorative interior parts -

made of black zirconia

Status: commercial

Comfort & Quality



Unique network of cross divisional material experts forexcellent haptics and design, crash management, weight reduction and comfort in automotive seating

Multi rigidity foams:PUR (Elastoflex®)

Structural parts inUltramid®

Smart textiles for flat heating

Humidity control with Luquafleece®

Excellent design with Steron®, Catamold®

BA

SF p

rodu

ct p

ortfo

lio fo

r sea

ts

e.g.>> smart forvision

Comfort & Quality

BASF Global Competence Team SeatingDesign – Safety – Light Weight – Comfort

Crash management with Neopolen® (EPP)

Cathodic e-coatCathoguard®



Weight Reduction


Comfort &Quality


Energy Management


InnovativeMaterials

InnovativeMaterials



Ultramid® S Balance PA 6.10 from Renewable Resources

Ricinus communis L.

Castor oil

Ricinoleic acid

• 63% biobased• Long-chain polyamide• Low water uptake• Lower density• High media resistance

Sebacic acid

PA 6.10

Environment & Sustainability

Status:commercial



Halogen Free Flame Retardants inUltradur® and Ultramid®

Status: market launch/ commercial

►Halogen free flame retardance

Ultradur®

halogen free FR

Recycling

Smoke density

Fire behavior

Density

Electrical Property

Mechanics

Costs

PBT halogenated

ideal for E&E applicationslight colour, high design freedom

Environment & Sustainability


Bursa, October 13th 2011 >> smart forvision

Hyundai i-flow

Cross-divisional Competencies Combined:Concept Cars in Cooperation with BASF


Bursa, October 13th 2011 62

We help our customers to be

more successful !

http://www.automotive.basf.com

basf-automotive innovation pipeline

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