RFP 5/17/2012

Innovative Interior Materials (Panel Session #6)

Alexander Jockisch: Director Business Development & Marketing, Benecke-Kaliko

Joel Myers: Senior Engineer - Plastics & Quality, Hyundai-Kia Tech Ctr

Nathan Mullinix: Vice President Global Research & Development, Eagle Ottawa

Ron Price: Panel Moderator, President: Global Polymer Solutions

RFP 5/17/2012

1959 6200 Series Cadillac

What’s New? : GLOBAL

Color - More stable/greener

Leather - Leather, TPO, PU, fabrics

Chrome - Plated plastics / Film

Steel - Composites / HS steel

Heavy - Lighter (MPG)

Safety? - You bet!

Exciting? - Yep! But not the same.

Cadillac XTS Interior

RFP 5/17/2012

Innovative Interior Materials: (Panel Session #6)

Materials: Polymer technology innovations: reactor/post reactor compounding

Compounding, compounds: Nepol™, Stamax®

Composites

Bio-plastics, low VOC, reduced CO2

Metals: HS steel, aluminum, magnesium

Films/Foils: In-mold decorations, TPO/foam skins, metallic, transparent,

“SMART” materials: ViviTouch® Actuator by Artificial Muscle Inc, .

Reinforcements:

Glass: fibers, continuous, short, balloons, woven

“Green”/Sustainable: bio, wood, plant fibers, Kenaf, coconut - - -

Nano’s: major innovative technology – future rapid growth

Carbon fibers, nano tubes, spheres – just now breaking out

Processes:

In-Plant/In-Line compounding, D-LGF

Injection/compression

Core back process (Visteon VIEPP)

Two shot, back molding, over molding

Mucell®,

A few Examples of the many Innovations in Materials and Processes

RFP 5/17/2012

PVC Thermoformed skin PU foam: foam-in-place

Inj. molded:

ABS or

PC/ABS or

PPO/PS

TPO skin PP Foam

PP + glass

TPO skin & Air bag door +

scratch resistance

PP

Foam

PP + foam+

glass

Three

separate

operations

Material

changes

Still 2 or 3

operations

One tool, two shots

Innovative polymers

Huge cost and wt save.

SABAIC’s STAMAX® LGFPP resin:

Instrument Panel by Faurecia

Instrument Panel Innovations

Bio based foam

RFP 5/17/2012

0 200 400 600 800 1000 1200

PP

PU

Nylon

PVC

ABS

PC

PE

Othr-Eng

PolyButy

Other

2000 2010

Automotive Plastics

Vehicle Production N.A.: 2000 =17.7MM 2010 = 12.2MM

0.0 10.0 20.0 30.0 40.0 50.0

Regular Steel

High St Steel

Plastics/Ompmosites

Aluminum

Iron Castigs

Rubber

Glass

Other

2000 2010

Automotive Material Content: N.A. Lt. Veh.

Lt Wt Drivers

MM lbs

Percent % Wt.

PVB

Plastics/Composites

Iron Castings

RFP 5/17/2012

Metal replacement:

reinforced air bag door

Metal replacement: door module

Paint elimination: Low gloss–soft feel resin

Encapsulated thermoplastic fibers

RFP 5/17/2012

Metal replacement: Seat

Control module bracket

Bio-Load floor: PP/coconut felt

Eliminating Compounding step:

Reactor TPO/talc reinforced

High Gloss Finish Without Paint • 8 complicated & contoured geometry

• 3 different zones, including head Impact

• Gloss > 92 required

• Deep jet black color

Ford Escape

RFP 5/17/2012

“Smart & Active Materials:

Magneto-Rheological Fluids (MRFs)

Shape Memory Alloys (SMAs)

Shape Memory Polymers (SMPS)

Electro-Active Polymers (EAPs)

What is an Active Material?

Responds with change in property

(dimensions, modulus, shear,

transparency via: thermal,

electrical, magnetic, conductive - -)

What they do

Change in structure or

morphology resulting in:

Change shape

Dimensions

Generate force

Material properties: elastic,

transparency, dielectric, magnetic

properties, conductive

Examples:

• Button: touch and feel movement,

makes contact

• Small current: becomes transparent

• Opens/closes vent

• Becomes conductive/completes

circuit (capacitive touch

switch/conductive ink printed on back)

RFP 5/17/2012

The automotive industries’ innovative materials:

Dynamic

Global incubation, creativity

Social and commercial drivers

Faster implementation

New rules