Targeted technics:
Plastic components in vehicle construction
This dual trend in modern vehicle technology – with the weight of vehicles in successive generations increasing despite the more systematic use of lightweight construction methods – stands in opposition to clear ecological parameters and limitations. Without jeopardising or reversing the progress made in the areas of safety and comfort, real reductions in vehicle weight can only be achieved as a result of new approaches to materials and new manufacturing technologies. Solving these problems represents a major challenge for the automotive industry and its suppliers.
REASONS FOR USING PLASTIC COMPONENTS
ECONOMIC AND ECOLOGICAL COSIDERATIONS
Potential for lightweight
construction - weight savings,
reduced consumption, conservation of resources
Low energy requirement for manu facturing, processing and recycling
HIGH ENERGY ABSORPTION/ELASTIC PROPERTIES
Reduction of minor damage, hence better safety rating
Improved active and passive safety
Increased pedestrian safety (lowering of permitted HIC values from
2005/2010 (ACEA/EC))
CORROSION-PROOF
Stable in terms of weathering and ageing, resistant to chemicals
WIDER RANGE OF MODELS
Low-cost manufacturing processes for small volumes of parts
(niche model (SUV))
Different versions can be produced without any problem
NEW CONSTRUCTION METHODS
Multi-functional construction
methods
Integration of components/modular technology/complex aerodynamics
Practically no design limitations
TRANSPARENT TO ELECTROMAGNETIC RADIATION
Integral aerial capability
Navigation/communications/ maintenance/diagnostics
SAFETY HAS INCREASED DUE TO
airbags, sensor systems, control systems (ABS, ESP etc.)
front, rear and side impact protection
COMFORT HAS INCREASED DUE TO servomotors, sensors
navigation and communication systems
increasingly high standards in interior acoustics and interior comfort
better performance of motorised components
ENVIRONMENTAL FRIENDLINESS HAS INCREASED DUE TO
reduced consumption lower emissions – catalytic converters systematic
lightweight construction and use of
lightweight materials
accompanying reduction in overall costs
Exterior fittings - applications and requirements
| FITTINGS (small) |
FITTINGS (large) |
VERTICAL SURFACES |
HORIZONTAL SURFACES | |
| APPLICATION |
Mirrors Air intake Wheel trim Rubbing strips/trim Door handles |
Bumpers Body panels Sills |
Wings Doors Rear side sections Hatchbacks |
Bonnets Boot lids Roof |
| REQUIREMENTS POSSIBLE |
High-gloss Contrasting colours Ease of processing Ductile properties |
Paint/metallic High gloss Ease of processing Ductile properties Elasticity |
Paint/metallic High-gloss Ease of processing Ductile properties Elasticity |
Paint/metallic Lower CLTE High-gloss Ease of processing Ductile properties High rigidity |
| MATERIALS |
PP PC/ABS PC/ASA |
PP-EPDM PC/PBT PUR PC/ABS PC/ASA |
PP-EPDM SMC PA/PPO PUR-GF PC/ABS; PC/PBT PC/ASA |
SMC PPO/PA PC/ASA PUR-GF PC/ABS PC/ASA |
Exterior fittings – different paint finishes and surface treatment
| PROCESS |
ADVANTAGES |
DISADVANTAGES |
MATERIALS Thermoplastics |
MATERIALS Duroplastics |
| ONLINE PAINTING |
Colour matching Low painting costs Lower logistical and assembly costs |
Restricted choice of materials Reduced impact resistance |
PPO/PA PA/ABS |
SMC BMC PUR-GF |
INLINE PAINTING |
Colour matching Process temperature 160 ºC |
Paint contaminated by dirt Higher assembly and cleaning costs Reduced impact resistance |
PC/ABS PC/ASA PO/PA PC/ASA |
SMC BMC PUR-GF |
| OFFLINE PAINTING |
Wide choice of materials Modular approach |
Colour matching Painting costs Logistical and assembly costs |
PP-EPDM PC/PBT PC/ABS PCASA |
PUR-GF |
| DIRECT PAINTING |
No painting costs |
Colour matching Class A Scratch resistance Resistance to UV light (additional clear coat) Cost of repairs |
PC/PBT PC/ASA ASA |
|
| IN-MOULD DECORATION |
No painting costs | Costs of process Costs of in-mould materials Colour matching Repairs |
Various | PUR-GF |
The AUTOMOTIVE INDUSTRY is one of the most significant driving forces in the development and use of
innovative technology.