Polymers in Automobiles: Candace Demarti Henry Antonovich Kevin Reinhart

Polymers in Automobiles
Candace “Mustang” DeMarti

Henry “Firebird” Antonovich
Kevin “Camaro” Reinhart
Overview
• Plastics vs. Metals

• Polymer Applications in Automobiles
- Instrument Panels
- Engine
- Windows
- Tires
- Body Panels
Why use plastics?
• Oil Embargo (1970’s) and Japanese

Competition
• Compete with other materials based on:
– Weight savings
– Design flexibility
– Parts consolidation
– Ease of fabrication
Show & Tell
Car Part Polymer

Trim Panels (3) Polypropylene (PP)
Impact Absorber Thermoplastic Olefin (TPO)
Radio Housing ABS/Polycarbonate(PC)
Door Outer Panel ABS/Polycarbonate(PC)
Handle Polypropylene (PP)
Fog Light Cover Thermoplastic Elastomeric
Olefin (TEO)
Tire Elastomers
Application Material Processing Method
Load-Bearing Glass-fiber reinforced Pressing of resin
- bumper beams polyester resins compounds
Moldings/covers Polyurathane Injection Molding
- front apron Polypropylene
- spoiler Polyethlene
- wheel-well liners
- radiator grill Acrylonitrile-butadiene-
- hood styrene (ABS)
- fenders Polycarbonate
- trunk
Protective Polyvinyl chloride Injection Molding/
Moldings Ethylene-Propylene Extrusion
Terpolymers
Energy Polyurethane Liquid Reaction
Absorbing Foam Foaming
Instrument Panels (IP)
• Polycarbonate/ABS resins
• Introduction of airbags in IP design
• Injection Molding vs. Blow Molding
Instrument Panels (IP)
Engine
• ULTEM polyetherimide (PEI) resin to replace

aluminum under the hood for 1st time
• High-performance
amorphous resin from
GE
• Complete air management

modules can be made of
thermoplastic
Throttle Body
Body Panels
• Plastic Body Panels -

Chevy Corvette since
1953
Sheet Steel - still most commonly used for vehicle
body structure
Aluminum - weighs less but costs more
Plastics - increasingly used for metals parts
replacement
Choosing a material:
1. Cost
2. Flexural Modulus
3. Coefficient of Thermal Expansion
4. Chemical Resistance
5. Impact Resistance
6. Heat Deflection Temperature (HDT)
“On-line” vs. “Off-line” painting
• Better color match • Larger choice in

• Incorporate in existing materials
facilities • Additional steps take
• Assembly line time
temperatures exceed • More plastics will
200oC enter the market as
Alloys: assembly lines are
Polyphenylene ether/polyamide redesigned
ABS/Polyesters
ABS/Polycarbonates
Sheet Molding Compound
(SMC)
• Highly cross-linked and highly filled
• Polymer component is polyester
• Suitable of compression molding
• Molded product combined high modulus
with high strength
• Body panels (hoods and deck lids)
• More expensive than metal, but lower tooling
cost
Applications of SMC
• Bottom line benefits

– Tooling for SMC hood was 23% of steel
– Weight savings of 18%
• Growth of applications
- Body panels on GM’s Lumina, TransPort, and
Silhouette
- Structural components - valve covers, grille-
opening reinforcements, fascia supports, etc.
• 250 million lbs. of SMC was used in 1997

Applications of SMC
• Composite front fenders and hood design

for 1995 Lincoln Continental
• Result of need for lighter-weight and more
cost efficiency integrated system
• SMC fenders and hood
• Bottom line benefits:
– SMC fender tooling was 40% of projected tooling
for steel fenders
– Comparative weight saving was 33%
Solitary Bumper Beam
• For 1997 Saturn coupe

• Injection molded from GE Plastics’
Xenoy 1102
• Single part that replaces functions of
17 parts on previous system
• To absorb impact, specially designed
molded-in towers crush upon impact
Windshields
• Toughened Safety Glass (TSG)

- tempered glass
• Laminated Safety Glass (LSG)

- two panes of glass bonded together
using polyvinylbutyral
Tire Components
• Tread
• Sidewall
• Bead-high tensile brass-plated steel coated
with rubber
• Radial Ply-belts of rubber coated cord
• Innerliner
• Reinforcing Fillers-carbon black
• Chemicals-antidegradants, curitives
Desirable Properties of Tire
Components
Maximum Minimum
Tread Traction Wear, Cut Growth,
Roll Resistance
Sidewall Adhesion, Weather Cracking,

Oxidative Stability, Flex Cracking, Heat
Cleanability Buildup, Scuffing
Wire Coat Wire Adhesion Heat Buildup
Ply Coat Cord Adhesion Heat Buildup
Innerliner Ply Adhesion, Air Permeability,

Oxidative Stability Flex Cracking,
Heat Buildup
Elastomers in Tires
• Natural Rubber (NR)

• Polyisoprene Rubber (IR)
• Styrene Butadiene Rubber (SBR)
- 1.89 billion lbs/yr (1993)
• Polybutadiene Rubber (BR)
- 1.03 billion lbs/yr (1993)
Natural Rubber (NR)
• 99.99% cis Polyisoprene

• Good low temperature flexibility.
• Low Tg (-65 C). Low heat buildup.
• 200,000 to 400,000 MW. Easy Processing.
• Has high tensile and tear properties. Stress
crystallizes.
• Excellent dynamic fatigue
• Poor resistance to oxygen, ozone, hydrocarbon
solvents and heat.
Polyisoprene Rubber (IR)
• Same cis structure as NR, but also contains

low levels of 3,4 and trans 1,4 polyisoprene.
• Above structures prevent stress
crystallization and thus has lower tensile and
tear properties.
• 300,000 to 500,000 MW.
• Other properties similar to NR .
Polybutadiene Rubber (BR)
• Good low temperature flexibility.

• High abrasion resistance.
• Low heat buildup.
• Low tensile strength. Generally
blended with SBR or NR.
• Improves aging resistance of NR.
Styrene Butadiene Rubber
(SBR)
• Dynamic properties determined by styrene,

1,4 and 1,2 butadiene levels.
• Improved strength, abrasion resistance, and
blend compatibility over BR alone.
• Addition of styrene results in lower cost and
contributes to the good wearing and bonding
characteristics.
Elastomers Used in Tire
Components
Tread Sidewall Wire Coat Ply Coat Innerliner
NR NR NR NR NR
BR BR BR BR SBR
SBR SBR IR SBR
IR

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Polymers in Automobiles

Candace “Mustang” DeMarti

• Plastics vs. Metals

• Oil Embargo (1970’s) and Japanese

Car Part Polymer

• ULTEM polyetherimide (PEI) resin to replace

• Complete air management

• Plastic Body Panels -

Sheet Steel - still most commonly used for vehicle

• Better color match • Larger choice in

• Bottom line benefits

• 250 million lbs. of SMC was used in 1997

• Composite front fenders and hood design

• For 1997 Saturn coupe

• Toughened Safety Glass (TSG)

• Laminated Safety Glass (LSG)

Sidewall Adhesion, Weather Cracking,

Wire Coat Wire Adhesion Heat Buildup

Ply Coat Cord Adhesion Heat Buildup

Innerliner Ply Adhesion, Air Permeability,

• Natural Rubber (NR)

• 99.99% cis Polyisoprene

• Same cis structure as NR, but also contains

• Good low temperature flexibility.

• Dynamic properties determined by styrene,

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