ENGINEERING PLASTICS APPLICATIONS INTRODUCTION Advancements made in engineering materials technology have resulted in a situation where metallic materials are no longer the only choice available for various applications. Over the last 30 years, plastics have been rapidly developed to the point where they have already started replacing many traditional materials in Automobile industry. Engineering Plastics and PP becomes a choice by virtue of its superior versatility and cost economics. Polymer scientists/ Chemists are building giant molecules in a dazzling array of plastics as substitutes for metals. Though only a few years ago selection of so called “ Engineering Plastics” was a simple and crude choice, today there is an almost inexhaustible list of different thermoplastics available and Polypropylene is leading the way by virtue of its versatility in different applications.

ENGINEERING PLASTICS APPLICATIONS WHY PLASTICS ? Plastics are not simply replacement materials, whereas it is based on technical merits, cost and other benefits makes plastics suitable due to the following: ECONOMY ECONOMY WEIGHT REDUCTION WEIGHT REDUCTION STYING – ASTHETICS STYING – ASTHETICS FUNCTIONAL DESIGN FUNCTIONAL DESIGN PROPERTIES PROPERTIES REDUCED MAINTENANCE REDUCED MAINTENANCE CORROSION AND CHEMICAL RESISTANCE CORROSION AND CHEMICAL RESISTANCE

ENGINEERING PLASTICS APPLICATIONS 11.5 Mil. MT 9% 124 Mil. MT 91% Demand of Thermoplastics High Performance Plastics <0, 1% Engineering Plastics Standard Products Market 2002 Mil. MT LCP, PEEK, PEI, PES, PSU < 0.1 ABS, ASA, SAN 5.8 PA 2 PC 2 POM 0.7 PBT/PET 0.7 PPO 0.3 PE 55.5 PP 30.6 PVC 27.6 PS 10.7

ENGINEERING PLASTICS APPLICATIONS PLASTICS CONSUMPTION IN A CAR - ABOUT 162 Kg 11.6% of Total Weight of the car TYPE OF PLASTICS Kg Polypropylene (PP) 29 Polyurathane (PUR) 34 Polyvinyl Chloride (PVC) 5 Acrylonitrile – butadiene- styrene (ABS) 6 PP+ EPDM 18 Polyamides (PA, Nylon) 22 Polyethelene12 TYPE OF PLASTICS Kg Polycarbonate (PC) 10 ABS + PC 10 Polyformaldehyde (POM, acetal) 2 Polymethyl methacrylate (PMMA) 2 Thermoplastics Polyesters (PET and PBT) 2 Others10 TOTAL162

ENGINEERING PLASTICS APPLICATIONS Engineering Plastics FR System Thermal Properties Processing Various e.g. Pigmentability Price Toxicology/ Safety in Use Electrical Properties Mechanical Properties Factors for Material Choice

PLASTICS IN AUTOMOBILES INTERIOR SYSTEMS Cockpit Systems Cockpit Systems Door Systems Door Systems Interiors Hard Trims Interiors Hard Trims Overhead Systems Overhead Systems ENGINEERING PLASTICS APPLICATIONS

PLASTICS IN AUTOMOBILES EXTERIOR SYSTEMS Bumper Systems (Lately integrated into Front-end systems) Bumper Systems (Lately integrated into Front-end systems) Body side claddings and cowl grills Body side claddings and cowl grills Spoilers, capping and exterior trims Spoilers, capping and exterior trims Body panels (Moving from sheet metal to plastics) Body panels (Moving from sheet metal to plastics) ENGINEERING PLASTICS APPLICATIONS

PLASTICS IN AUTOMOBILES UNDER THE BONNET SYSTEMS Fuel Systems – Fuel Delivery, Fuel Tanks Fuel Systems – Fuel Delivery, Fuel Tanks Air/ Water induction System – engine cooling and climate control systems Air/ Water induction System – engine cooling and climate control systems OTHER SYSTEMS Safety related parts – impact zones Safety related parts – impact zones Electrical & Electronics Electrical & Electronics Lighting Systems Lighting Systems Power train & chasis systems – steering, pedal & braking system Power train & chasis systems – steering, pedal & braking system Soft Trim Systems – Headliners, acoustics & carpets Soft Trim Systems – Headliners, acoustics & carpets ENGINEERING PLASTICS APPLICATIONS

ADVANTAGES More complex assemblies can be easily produced as one unit More complex assemblies can be easily produced as one unit Improved performance by reduction of vibration and noise Improved performance by reduction of vibration and noise Improved Impact Resistance Improved Impact Resistance Improved power to weight ratio Improved power to weight ratio Improved aesthetics Improved aesthetics Reduced Maintenance Reduced Maintenance No corrosion No corrosion ENGINEERING PLASTICS APPLICATIONS

Speedo meter Housing PP Talc Filled Door Trim PP Talc Filled

Reflector Housing PP Talc Filled ENGINEERING PLASTICS APPLICATIONS Hyundai Car Bumper PP Talc Filled

ENGINEERING PLASTICS APPLICATIONS Seat Components PP Unfilled

ENGINEERING PLASTICS APPLICATIONS Wheel Chair Base PP Unfilled Mixie Body PP Unfilled

ENGINEERING PLASTICS APPLICATIONS Switch Frame ABS Instrument Holder Ford ABS

ENGINEERING PLASTICS APPLICATIONS Engine Manifold – Nylon 6 GF 30

ENGINEERING PLASTICS APPLICATIONS Toyota Tray – Nylon 6 GF 25

ENGINEERING PLASTICS APPLICATIONS Honda Tray – Nylon 6 GF 45

ENGINEERING PLASTICS APPLICATIONS Radiator Fan Nylon 6 GF 30 Fuel Sub Tank Nylon 66 GF 30

ENGINEERING PLASTICS APPLICATIONS Timing Chain Cover & Engine Oil Filter Nylon 66 GF 30

ENGINEERING PLASTICS APPLICATIONS Glove Rail Nylon 66 GF 45 Seat Belt Anchor Nylon 6

ENGINEERING PLASTICS APPLICATIONS Lever Combination Switch Nylon 6 GF 30 Relay Box Nylon 6 Alloy

ENGINEERING PLASTICS APPLICATIONS Wire Harness Connector PBT ECU Case PBT GF 30

ENGINEERING PLASTICS APPLICATIONS Switch Base PBT GF 40% Actuator Case PBT GF 30%

ENGINEERING PLASTICS APPLICATIONS Air Conditioner Fin PBT GF 45% Mirror Housing PBT GF 30 Alloy

ENGINEERING PLASTICS APPLICATIONS Alternator Parts PPS GF/ MD 30 Power Module PPS GF/ MD 50 Neutral Start Switch PPS GF 40 Alloy

ENGINEERING PLASTICS APPLICATIONS Engine Mounting parts PPS GF 40 Lamp Reflector PPS GF/ MD 60 Lamp Socket PPS 40

ENGINEERING PLASTICS APPLICATIONS THANK YOU