High performance TPE in Automotive?

2 Trends in Automotive Technology Yesteryears “You can have any colour as long as it is black”

3 Today Trends in Automotive Technology

4 Use of Polymer in Cars 11.2% (142Kg) of total weight, (excluding tires). Source: BMW 31.90%51.10% 5.80% 10.80% 10.40% BodyInteriorDriveChassisE&E

5 Facts and Figures Over 2 millions tonnes of Plastics in Europe alone. The most widely specified material. More than 1000 plastics parts. On average, 100kg of plastics replaces Kg of conventional materials. E.g. 4.2Kg lighter in Engine cover and 5Kg in Fuel tanks. Cuts oil consumption by 12 million tonnes and reduce CO 2 emissions by 30 millions tonnes/p.a. just in Western Europe.

6 The future Trends in Automotive Technology

7 Reduce exhaust emissions. Better fuel economy. Improved safety. Increase comfort and convenience. Reduce weight Vs functionality. Reduce COST!!!! Trends in Automotive Technology

8 European Union Directive 2000/53/EC “End of Life Vehicle” 8 to 9 million tonnes of waste every year. Trends in Automotive Technology  Design and Manufacture for Re-use, Re-cycle and Re-covery.  Reduction and Control of Hazardous substances.

9 Noticeable shift from: Thermosets to Thermoplastics. Amorphous to Crystalline polymers. Moderate to High temperature materials. Approx. 25% increase in volume of Plastics. Trends in Automotive Technology

10 What is a TPE or TPR? Stiffness Vs. Temperature E-modulus Thermoset Thermoplastic Thermoset Elastomer Thermoplastic Elastomer Room temperature

11 RubbersPlastics Rockwell R Rockwell R Rockwell R Shore D Flexural Modulus (MPa) 1000 Shore A Polypropylene Elastic Band Scales

12 Sarlink* from DSM PP + Crossed linked EPDM rubber. Shore 40A to 50D. Low density. Fluid resistance comparable to GP polychloroprene rubber. Excellent fogging properties with low VOCs emission. Easy to colour. Two-shots with Polyolefins. Hydraulic engine mount heat shield Bellows & Dust covers

13 Alcryn* from APA Melt process-able rubber. Shore 55 to 80A. Outstanding UV and Ozone resistance. Oil, Grease and Fuel resistance. Elastic properties of nature rubber. Two-shots with PVC, ABS, PC. Tail light housing Corner mouldings

14 Elastollan* from Elastogran Thermoplastic Polyurethane. Shore 55A to 74D. Polyester & Polyether types. UL94-VO:Halogen free. Transparent grades. Two-shots with ABS, PA, PBT, PC. New Aliphatic TPU with improved hydrolysis and UV resistance. Cable connection Gear lever noise & vibration damping

15 Hytrel* from Du Pont Thermoplastic Polyester Copolymer Ether Ester. Shore 30 to 82D. Excellent flex fatigue. Noise & vibration damping. High tensile & tear strengths. Heat resistance. Two-shot with PBT, ETPV*. Combustion Air Swirl Generator Trucks Auxiliary Springs

16 Two-shots Bond strength? Tensile Adhesive Strength (MPA) Alcryn* 2160Elastollan* 1180AETPV* 90A01 Nylon PBT % GR PETNo data 6.6 TPC-ETNo data87.1 PC4.127No data PC/ABS4.724No data ABS5.487No data

17 Finally introducing……. DuPont ™ ETPV engineering thermoplastic vulcanizates Description: a high performance cross-linked elastomer dispersed in: a high performance thermoplastic elastomer Recycling code (ISO 11469): > AEM + TPC - ET < AEM = ethylene acrylic elastomer TPC - ET = thermoplastic ether ester elastomer

18 DuPont™ ETPV is a thermoplastic elastomer in the shore A range that resists >150 o C in air for hours (retains >50% of elongation at break & tensile strength) in combination with good oil resistance. The thermoplastic elastomer brings: Excellent oil and grease resistance Excellent flexural resistance Allows usage on standard thermoplastic processing equipment Significant cost savings versus cross-linked rubber Excellent oil and heat resistance Recyclability The combination of these materials brings : Heat resistance Low hardness Creep- and compression set resistance The cross-linked elastomer brings: ETPV*

19 Tensile strength after ageing in air at 150ºC DuPont™ ETPV 60A01L NC010 DuPont™ ETPV 60A01HSL BK001 DuPont™ ETPV 90A01 NC010 DuPont™ ETPV 90A01HS BK001 Tensile strength (MPa) 0h 1000h 2000h 3000h ETPV*

20 Epichlorohydrine (ECO) 300°C 275°C 250°C 225° C 200°C 150°C 175°C 125°C 100°C 75°C 50°C J H G F E D C B A Type No req.140%120%100%80%50%30% 20%10% Class ABCDEFG HI DuPont™ ETPV Vamac ® Kalrez ® Viton ® Fluorosilicone Polyacrylate (ACM) HNBR Hytrel ® Alcryn Nitrile (NBR) Silicone Silicone (HS) EVA (high VA) Ethylene-propylene Sarlink Butyl Geolast SBR & NR EPDM Hypalon Olefinic TPE Neoprene Oil Resistance (% swell in ASTM #3 Oil) Heat Resistance ASTM D2000 / SAE J200 Specifications. N.b. The purpose of this chart is to give a general overview. Formulation may affect compound performance. ETPV*

21 Automotive body plugs with excellent resistance to heat and chemicals Zytel® 70G30 DuPont™ ETPV 90A01 NC010 Oil reservoir cover with integrated seal Formed to fit, this fuel vent tube is scheduled for production in a 2005 model North American car. Ignition Coil boot Better Fuel Vent Tubes Applications

22 Automotive air ducts with excellent flexibility, oil and Chemical resistance, and performance at 150ºC New design ~0.5 kg ~1kg Part weight Hard segments may be made in Hytrel® BM6574 BK316 Opportunity for DuPont™ ETPV Rubber Conventional design PA 15% GR Rubber What about?

23 What about?

24 Benefits Vs Rubber Fast Thermoplastic processing. Standard thermoplastics equipments. No post mould curing of parts. Supplied in form ready to use. No plasticizers. Lower density. Often lower material price Vs. high performance rubbers. Recyclable.  Lower production costs.  Thermoplastic processors to enter new markets.  Higher productivity.  Higher quality consistency.  Performance not change by migration & no contamination.  Lighter components.  Lower production costs.  Use of regrinds.  Meets environmental requirements.

25 The future Trends in Automotive Technology

A Polymer for Every Application