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Vehicle Lightweighting Improving the Performance of TPO Using Poes

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Vehicle Lightweighting Improving the Performance of TPO Using Poes Can we continue to lightweight vehicles using PP compounds? Workshop Dr. Olaf Henschke | Technical Service and Development Transportation, Dow Europe GmbH, Horgen, Switzerland Mrs. Marie Buy | Marketing Manager Transportation, Dow Europe GmbH, Horgen, Switzerland Dr. Jeff Munro | Research and Development Transportation Elastomers, Dow USA, Lake Jackson, Texas Dow Packaging & Specialty Plastics Outline • Introduction of Dow Polyolefin Elastomers in Automotive • Light Vehicle Industry Trends and Impact • Design of Thermoplastic Olefin (TPO) Compounds • Dow Solutions Addressing Industry Trends – ENGAGE™ Polyolefin Elastomers • Manufacturing Efficiency • Enhanced Lightweighting • Interactive APP – Modeling and Idea Generation General Business Automotive applications Polypropylene modifier providing impact resistance and stiffness & flow property balance • in Talc-filled/rigid and soft TPO formulations • for interior and exterior body-molded parts General Business Dow Evolves to Keep Pace with Automotive Needs 1970s 2.4MM 14.4MM 9.9MM 12.1MM 0.7MM 1.6MM Average Vehicle Production Source: Wikipedia General Business Dow Evolves to Keep Pace with Automotive Needs 1990s 1.0MM Launch of INSITE™ 16.6MM catalyst- based technology 8.4MM Launch of ENGAGE™ POE 8000 series 12.8MM 1.4MM Average Vehicle 1.6MM Production Manufacturing Technology Source: Wikipedia General Business Dow Evolves to Keep Pace with Automotive Needs 2000 to 2010s 3.7 to 1.9 MM Launch of ENGAGE™ POE 7000 series 12 to 7.1MM 20.1 to 15.6 MM Launch of high melt strength ENGAGE™ POE 24.2 to 35.1 MM Launch of ENGAGE™ 5.0MM XLT POE Average Vehicle 3.1 to 2.9MM Production Manufacturing Technology Source: Wikipedia General Business Dow Evolves to Keep Pace with Automotive Needs 2019 and Beyond Next generation… Average Vehicle Production Manufacturing 2020 Projected Global Production = 100 MM Cars Technology Source: OAIC General Business Light Vehicle Industry Trends and Impact Sustainability Safety Consumer Behaviors Manufacturing • Reduce GHG Emissions • Passenger Safety • Ride Sharing Efficiencies by lightweighting • Autonomous Vehicles • Electric Vehicles (EV) • SUVs IMPACT ON LIGHT VEHICLE • Thin walling • Airbags • Vehicle interior redesign • Ease of handling • Body panel replacement • Diverse and tougher skins • Fewer manufacturing steps • Tailgate • Part integration IMPACT ON TPO • Higher flow with improved • Fast crystallization for improved • Excellent scratch and chemical • Less rubber for same impact, or performance, capable of maintaining surface aesthetics during resistance same rubber for higher impact stiffness / toughness balance demoulding process • Low gloss and excellent grain retention • Fast cooling, quick demoulding, • Low coefficient linear thermal • Optimal low temperature impact as well as good soft touch feel shorter cycle time expansion (CLTE) to achieve tighter performance • Development of TPO systems for • High temperature resistance, gaps in-between exterior body panels tailgates passes hot water jet test enabling stringent painting tests General Business Design of Thermoplastic Olefin (TPO) Compounds Polypropylene Polypropylene Matrix Material Homopolymer or Impact Copolymer Mineral Filler Good Processing and Temperature Resistance Increase Stiffness, Control Shrinkage, Nucleate Elastomer Increase Toughness, Talc Performance at Low Filler Temperature Polyolefin Elastomer Typically formulation DOEs are used to determine the performance window General Business Dow Solutions Addressing Industry Trends 16 14 ENGAGE 8137 12 10 Manufacturing Enhanced Efficiency Lightweighting 8 Shorter cycle-time Thinner walls and improved rubber 6 efficiency min) (g/10 index Melt ENGAGE 8200/7 ENGAGE 7447 4 Higher Flow 2 ENGAGE 8100/7 ENGAGE 7467 ENGAGE 8842 Stiffness/ Toughness Balance ENGAGE XLT 8677 ENGAGE 8150/7 0 0.872 0.87 0.868 0.866 0.864 0.862 0.86 0.858 0.856 Density (g/cm3) General Business General Business Dow Solutions Addressing Industry Trends 16 ENGAGE™ 11567 ENGAGE 11527 Melt Index at 190°C/2.16 kg 1 14 (g/10 min) ENGAGE 8137 Density 0.866 12 (g/cm3) 10 ENGAGE™ 11547 8 Melt Index at 190°C/2.16 kg 5 (g/10 min) 6 Density 0.866 min) (g/10 index Melt (g/cm3) ENGAGE 8200/7 ENGAGE 11547 ENGAGE 7447 4 ENGAGE™ 11527 2 ENGAGE 11567 Melt Index at 190°C/2.16 kg ENGAGE 8100/7 15 ENGAGE 7467 ENGAGE 8842 (g/10 min) ENGAGE XLT 8677 ENGAGE 8150/7 0 Density 0.866 0.872 0.87 0.868 0.866 0.864 0.862 0.86 0.858 0.856 (g/cm3) Density (g/cm3) General Business Offer Broad Range of Benefits Property Features Value Improvement Low Glass Transition Less rubber for same impact, or Cost/ Performance 10% less rubber for same Temperature same rubber for higher impact Optimization: Improved impact impact performance or higher rubber efficiency Fast Crystallization Fast cooling, Quick demoulding, Cost Optimization: Shorter cycle >15% cooling time reduction Shorter cycle time times and improved aesthetics Manufacturing Efficiency High Melting Point High temperature resistance, Cost/ Performance Enables 2 coat paint systems Passes hot water jet test Optimization: Improved (vs current 3 coat) enabling stringent painting tests paintability High Flow while Thinner walls yet, meet Performance Optimization: 10% improvement on MFR Retaining Impact mechanical property targets in Lightweighting/ fuel economy and 10% thinner = 16% faster addition to improved CLTE and shorter cycle time cooling (Thinwalling for complex parts) Enhanced Lightweighting Data based on tests and research conducted by Dow. Users should confirm results by their own tests. General Business Interactive Modeling Session Output TPO Properties Input Variables Flow MFR 230°C, 2.16 kg Level of Polyolefin Stiffness Elastomer Flexural Modulus Toughness Notched Charpy Impact Resistance at 23°C Level of Talc Filler Notched Charpy Impact Resistance at - 30°C Instrumented Dart Impact Resistance at - 40°C Melt Index (Flow) Thermal Expansion of Polyolefin Coefficient of Linear Elastomer Thermal Expansion General Business Enable Cost / Performance Optimization Low glass transition temperature High rubber efficiency Flexural Modulus (MPa) MFR 230 °C, 2.16 kg Charpy Impact - 30 °C (kJ/m²) 1500 24 MFR, MFR, at Charpy Notched 22 1250 20 18 1000 16 14 750 12 Flexural Modulus 10 – 30 500 8 ° C 6 250 4 2 0 0 ENGAGE™ 8100 ENGAGE ™ 11567 ENGAGE™ 8200 ENGAGE™ 11547 ENGAGE™ 8137 ENGAGE™ 11527 15 % 15 % 15 % 15 % 15 % 15 % Melt Index 1 Melt Index 5 Melt Index 15 These are typical properties, not to be construed as specifications. General Business Enable Cost / Performance Optimization Low glass transition temperature High rubber efficiency Flexural Modulus (MPa) MFR 230 °C, 2.16 kg Charpy Impact - 30 °C (kJ/m²) 1500 24 22 MFR, MFR, at Charpy Notched 1250 20 18 1000 16 14 750 12 10 Flexural Modulus 500 8 – 30 6 ° C 250 4 2 0 0 ENGAGE™ 8100 ENGAGE ™ 11567 ENGAGE™ 8200 ENGAGE™ 11547 ENGAGE™ 8137 ENGAGE™ 11527 15 % 13,5 % 15 % 13,5 % 15 % 13,5 % Melt Index 1 Melt Index 5 Melt Index 15 These are typical properties, not to be construed as specifications. General Business Enable Cost / Performance Optimization Hard TPO 15% ENGAGETM 8200 reduced to 13.5% ENGAGETM 11527 Soft TPO 39% ENGAGETM 8842 reduced to 36% ENGAGETM 11567 General Business Enable Cost / Performance Optimization Low glass transition temperature High rubber efficiency Flexural Modulus (MPa) MFR 230 °C, 2.16 kg Charpy Impact - 30 °C (kJ/m²) 1500 24 22 MFR, at Charpy Notched 1250 20 18 1000 16 14 750 12 Flexural Modulus 10 – 500 8 30 ° 6 C 250 4 2 0 0 ENGAGE™ 8150 ENGAGE ™ 11567 ENGAGE™ 8100 ENGAGE™ 11547 ENGAGE™ 8200 ENGAGE™ 11527 15 % 13,5 % 15 % 13,5 % 15 % 13,5 % Melt Index 0.5 to 1 Melt Index 1 to 5 Melt Index 5 to 15 These are typical properties, not to be construed as specifications. General Business Manufacturing Efficiency General Business Enable Processing Optimization Melt Index Density Maximum Flow at Product Name at 190°C/2.16 kg (g/cm3) 220°C (mm) (g/10 min) ENGAGE™ 11567 0.866 13.5 % 1 434 Reference ENGAGE™ 8200 0.870 15 % 5 454 ENGAGE™ 11547 0.866 13.5 % 5 457 ENGAGE™ 11527 0.866 13.5 % 15 480 General Business Enable Improved Temperature Resistance ENGAGE™ 11547 High Melting Point Low Glass Transition ENGAGE™ 8200 -80 -60 -40 40 60 80 100 120 140 160 °C Soft TPO formulation with 39 % POE General Business Enable Processing Optimization Fast Crystallization ENGAGE™ 8200 ENGAGE™ 11547 -80 -60 -40 0 20 40 60 80 100 120 140 160 °C Soft TPO formulation with 39% POE General Business Enable Processing Optimization ENGAGETM 11000 Series – Cycle Time Study Part Dimensions: 920 x 80 x 45 mm Wall thickness: 2 mm Part Weight: 730 g Maximum Flow Path: 580 mm Melt Temperature: 220 °C Initial Cycle Time: 47 seconds General Business Enable Cycle Time Reduction Cooling time Cooling time Cooling time Cooling time Cooling time Sample 15 seconds 13 seconds 11 seconds 9 seconds 7 seconds ENGAGE™ 11567 ENGAGE™ 8200 ENGAGE™ 11547 ENGAGE™ 11527 General Business Enable Cycle Time Reduction Cooling Time 15 13 11 11 9 7 Total Cycle Time 44 42 40 41 40 36 ENGAGETM 8200 15% ENGAGETM 11527 13.5% General Business Better Compatibility and Particle Size Distribution Hard TPO Morphology 15% ENGAGE™ 8100 reduced to 13.5% ENGAGE™ 11567 ENGAGE™ 8100 ENGAGE™ 11567 General Business Enable Improved Paint Adhesion TMA Indentation 500 Water jet temp. 0 High-melting ENGAGETM ENGAGE XLT 8677 Polyolefin Elastomers -500 TraditionalENGAGE 8842 Polyolefin Elastomers -1000 -1500 -2000 Dimensional Change, µm -2500 -3000 Paint-TPO Paint -3500 Interface 30 50 70 90 110 130 150 170 Is Intact Temperature, °C TPO Heat
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