The Future Direction of the Automotive Industry – and the Role of Plastics within it

1. Automotive Polymers
30 April 2015
David Greenwood
Professor, Advanced Propulsion Systems
WMG, University of Warwick, UK
d.greenwood@warwick.ac.uk

2. There are many drivers for Energy Efficiency
Energy
Efficiency
Industrial Opportunity
Climate Change &
Air Quality
Consumer demand
Energy Security
$
Source:Cornell University from Edwards 2001
Source:Adweek

3. Regulations drive CO2 reduction in most markets
Regulations for CO2 reduction are
driving technology change
Consumers appear largely
ambivalent at point of purchase
“real world” fuel economy is of
most practical interest
EU regulations have put a
price on CO2 at €95/g/km
through fines
US CAFE does similarly
China prevents sale of non-
compliant vehicles
Currently pass-car focus, but
other sectors likely to follow.

4. Broad consensus on passenger car roadmap

5. To meet CO2 reduction targets vehicle weights must
reduce by 20-30 kg every year
Weight reduction required by different vehicle segments
Source: Automotive Council UK 2013
35 kg/year
17 kg/year

6. But CO2 reduction comes at a price
• €30/(g/km) proven acceptable in western mass market
• Uptake of hybrids at ~€95/(g/km) breaking into early majority market
• EV’s at €300/(g/km) currently confined to early adopters
Source: Ricardo 2014

7. Weight reduction is worth 2 to 5 Euros per kg
For manufacturers facing
fines:
• Average car emissions
140g/km CO2
• 100kg weight reduction
gives ~ 4% CO2 reduction
(5.6g/km)
• At €95/(g/km) this is €532
• i.e weight saving has a
value of €5.3/kg
• This is on top of any cost
saving through switch to
plastics
For those not facing fines,
but selling on fuel
economy:
• Market has already proven
willingness to pay
€30/(g/km) for powertrain
improvements
• i.e weight saving has a
value of €1.7/kg
• This is on top of any cost
saving through switch to
plastics

8. Plastics are already widely use in automotive industry
Sources: Plastics Europe, Determinants of U.S. Passenger
Car Weight. International Journal of Vehicle Design 65 (1),
73-93 , F2012-E09-006 Proceedings FISITA 2012 World
Automotive Congress
End of Life Directive
from 1 Jan 2015
• 85% recyclable or reusable or
• 95% recyclable or recoverable
Affects material selection and
design, e.g. mixed materials, joining
systems* Automotive Council UK, Lightweight Vehicle & Powertrain Structures, Low Carbon Vehicle Event 2013
• In addition to switches, handles, fasteners, grills, cup holders
and many other small components, plastics are used
extensively within the major vehicle systems:
• Powertrain
– Covers, air induction, oil pan, coolant system, lubrication
system, hoses
– Typically require high temperature polymers with chemical
resistance
• Lighting
– optical clarity, complex geometry, aesthetics
• Vehicle
– Plastic bumpers facilitate compliance with pedestrian impact
requirements
– Reinforced plastics in door module can reduce weight and
improve NVH
– Closures provide opportunities for lightweighting: non-
structural, consolidation of multiple parts
• Interior
– For large mouldings, e.g. instrument panel, foam injection
moulding can reduce weight
– Seat systems targeted for weight reduction*
• Electrical
– Cables, insulation, cases, connectors
– Increased electrification and use of in-vehicle electronics

9. Greater use of current polymer technology can deliver
further weight savings
• The Multi Material Lightweight
Vehicle (MMLV) was
developed by Magna and Ford
as a US DOE project
• Weight saving of 364 kg using
commercially available
materials and production
processes
Component Material Weight saving
structural oil pan CFRP 30%
engine cover & mount CFRP 30%
cam carrier CFRP + Al 20%
wheels CFRP 30%
coil springs GFRP 35-55%
seats CFRP 40%
instrument panel beam & duct CFRP 35%
interior trim plastic foam 40%
rear window polycarbonate 35%
Sources: MMLV: Life Cycle Assessment," SAE Technical Paper 2015-01-1616, 2015 , Vehicle Lightweighting, Society Automotive Analysts, Oct 2014

10. Plastics in hybrid and electric powertrains
New components and systems offer new applications for
automotive polymers
• Batteries
– Electrically insulating fixtures, cases
– High voltage connectors
– Electrical sub-assemblies
• Downsizing engines and increased boost pressures raise
under-bonnet temperatures
– Chemically resistant plastics in EGR circuit
– Complex moulded manifolds for optimised air flow
• Lightweight chassis components to reduce energy
consumption in electric vehicles - €6-8/(g/km)
Pure Power XSP Lithium Pouch Battery
Supporting structure
GM Volt Battery Pack. Repeating frames and
manifolds made from injection moulded GFRP
BMW i3 uses plastics throughout the
vehicle for reduced weight and ability
to form complex geomtetries:
- CFRP body
- Seat shell
- Roof frame & pillar reinforcement
- Insulating foam
- Spring aids
- Instrument panel

11. Future Developments ?
• Polymer gears
– Currently used for low load applications but WMG research is finding
routes to powertrain use
• 3D Printing
– Complex geometry, Removes bulk of supply chain, Reduces
material waste, Maintains digital thread
– Used now for rapid prototyping
– ? Line-side component printing ?
– ? Mass personalisation ?
• Smart materials
– Variable transparency, air flow control, increasing conductivity
with temperature, self-healing composites
• Improved materials – Nano composites
– Self-lubricating
– Lower density resins
Strati: 3D printed, concept electric car

12. Thank You
David Greenwood
Professor, Advanced Propulsion Systems
WMG, University of Warwick, UK
d.greenwood@warwick.ac.uk