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ENGINEERING PLASTICS APPLICATIONS. INTRODUCTION - PowerPoint PPT Presentation
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ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
INTRODUCTIONINTRODUCTION
Advancements made in engineering materials Advancements made in engineering materials technology have resulted in a situation where technology have resulted in a situation where metallic materials are no longer the only choice metallic materials are no longer the only choice available for various applications. Over the last available for various applications. Over the last 30 years, plastics have been rapidly developed 30 years, plastics have been rapidly developed to the point where they have already started to the point where they have already started replacing many traditional materials in replacing many traditional materials in Automobile industry. Engineering Plastics and Automobile industry. Engineering Plastics and PP becomes a choice by virtue of its superior PP becomes a choice by virtue of its superior versatility and cost economics. Polymer versatility and cost economics. Polymer scientists/ Chemists are building giant scientists/ Chemists are building giant molecules in a dazzling array of plastics as molecules in a dazzling array of plastics as substitutes for metals. Though only a few years substitutes for metals. Though only a few years ago selection of so called “ Engineering ago selection of so called “ Engineering Plastics” was a simple and crude choice, today Plastics” was a simple and crude choice, today there is an almost inexhaustible list of there is an almost inexhaustible list of different thermoplastics available and different thermoplastics available and Polypropylene is leading the way by virtue of its Polypropylene is leading the way by virtue of its versatility in different applications.versatility in different applications.
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
WHY PLASTICS ?WHY PLASTICS ?
Plastics are not simply replacement materials, Plastics are not simply replacement materials, whereas it is based on technical merits, cost whereas it is based on technical merits, cost and other benefits makes plastics suitable due and other benefits makes plastics suitable due to the following: to the following: ECONOMYECONOMY WEIGHT REDUCTIONWEIGHT REDUCTION STYING – ASTHETICSSTYING – ASTHETICS FUNCTIONAL DESIGNFUNCTIONAL DESIGN PROPERTIESPROPERTIES REDUCED MAINTENANCEREDUCED MAINTENANCE CORROSION AND CHEMICAL RESISTANCECORROSION AND CHEMICAL RESISTANCE
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
11.5 Mil.
MT9%
124 Mil. MT91%
Demand of ThermoplasticsDemand of ThermoplasticsHigh Performance Plastics High Performance Plastics
<0, 1%<0, 1%
Engineering PlasticsEngineering Plastics
Standard ProductsStandard Products
Market 2002 Market 2002 Mil. MTMil. MT
LCP, PEEK, PEI, PES, PSU LCP, PEEK, PEI, PES, PSU < 0.1 < 0.1
ABS, ASA, SAN ABS, ASA, SAN 5.8 5.8PA PA 2 2PC PC 2 2POM POM 0.7 0.7PBT/PET PBT/PET 0.7 0.7PPO PPO 0.3 0.3
PE PE 55.555.5PP PP 30.630.6PVC PVC 27.627.6PS PS 10.710.7
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
PLASTICS CONSUMPTION IN A CAR - ABOUT 162 Kg PLASTICS CONSUMPTION IN A CAR - ABOUT 162 Kg 11.6% of Total Weight of the car11.6% of Total Weight of the car
TYPE OF PLASTICS TYPE OF PLASTICS KgKgPolypropylene (PP)Polypropylene (PP) 2929Polyurathane (PUR)Polyurathane (PUR) 3434Polyvinyl Chloride Polyvinyl Chloride (PVC)(PVC)
55
Acrylonitrile – Acrylonitrile – butadiene- styrene butadiene- styrene (ABS)(ABS)
66
PP+ EPDMPP+ EPDM 1818Polyamides (PA, Nylon)Polyamides (PA, Nylon) 2222PolyethelenePolyethelene 1212
TYPE OF PLASTICS TYPE OF PLASTICS KgKgPolycarbonate (PC)Polycarbonate (PC) 1010ABS + PC ABS + PC 1010Polyformaldehyde (POM, Polyformaldehyde (POM, acetal)acetal)
22
Polymethyl methacrylate Polymethyl methacrylate (PMMA)(PMMA)
22
Thermoplastics Thermoplastics Polyesters (PET and Polyesters (PET and PBT)PBT)
22
OthersOthers 1010TOTALTOTAL 162162
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Engineering Plastics
FR SystemFR System
Thermal Thermal PropertiesProperties
ProcessingProcessing
Various Various e.g. e.g.
PigmentabilityPigmentability
PricPricee
Toxicology/ Toxicology/ Safety in Safety in
UseUse
ElectricaElectrical l
PropertiPropertieses
Mechanical Mechanical PropertiesProperties
Factors for Material ChoiceFactors for Material Choice
PLASTICS IN AUTOMOBILESPLASTICS IN AUTOMOBILES
INTERIOR SYSTEMSINTERIOR SYSTEMS
Cockpit SystemsCockpit Systems Door SystemsDoor Systems Interiors Hard TrimsInteriors Hard Trims Overhead SystemsOverhead Systems
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
PLASTICS IN AUTOMOBILESPLASTICS IN AUTOMOBILES
EXTERIOR SYSTEMSEXTERIOR SYSTEMS
Bumper Systems (Lately integrated Bumper Systems (Lately integrated into Front-end systems)into Front-end systems)
Body side claddings and cowl grillsBody side claddings and cowl grills Spoilers, capping and exterior trimsSpoilers, capping and exterior trims Body panels (Moving from sheet metal Body panels (Moving from sheet metal
to plastics)to plastics)
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
PLASTICS IN AUTOMOBILESPLASTICS IN AUTOMOBILES
UNDER THE BONNET SYSTEMSUNDER THE BONNET SYSTEMS Fuel Systems – Fuel Delivery, Fuel TanksFuel Systems – Fuel Delivery, Fuel Tanks Air/ Water induction System – engine cooling and Air/ Water induction System – engine cooling and
climate control systemsclimate control systems
OTHER SYSTEMSOTHER SYSTEMS Safety related parts – impact zonesSafety related parts – impact zones Electrical & ElectronicsElectrical & Electronics Lighting SystemsLighting Systems Power train & chasis systems – steering, pedal & Power train & chasis systems – steering, pedal &
braking systembraking system Soft Trim Systems – Headliners, acoustics & carpetsSoft Trim Systems – Headliners, acoustics & carpets
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
ADVANTAGESADVANTAGES
More complex assemblies can be easily More complex assemblies can be easily produced as one unitproduced as one unit
Improved performance by reduction of Improved performance by reduction of vibration and noisevibration and noise
Improved Impact ResistanceImproved Impact Resistance Improved power to weight ratioImproved power to weight ratio Improved aesthetics Improved aesthetics Reduced MaintenanceReduced Maintenance No corrosionNo corrosion
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Speedo meter Speedo meter HousingHousing
PP Talc Filled PP Talc FilledDoor TrimDoor Trim
PP Talc Filled PP Talc Filled
Reflector HousingReflector HousingPP Talc FilledPP Talc Filled
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Hyundai Car Bumper Hyundai Car Bumper PP Talc FilledPP Talc Filled
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Seat ComponentsSeat ComponentsPP UnfilledPP Unfilled
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Wheel Chair BaseWheel Chair BasePP UnfilledPP Unfilled
Mixie BodyMixie BodyPP UnfilledPP Unfilled
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Switch FrameSwitch FrameABS ABS
Instrument Holder Ford Instrument Holder Ford ABS ABS
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Engine Manifold – Nylon 6 GF 30Engine Manifold – Nylon 6 GF 30
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Toyota Tray – Nylon 6 GF 25Toyota Tray – Nylon 6 GF 25
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Honda Tray – Nylon 6 GF 45Honda Tray – Nylon 6 GF 45
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Radiator Fan Radiator Fan Nylon 6 GF 30Nylon 6 GF 30
Fuel Sub Tank Fuel Sub Tank Nylon 66 GF 30Nylon 66 GF 30
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Timing Chain Cover & Engine Oil Filter Timing Chain Cover & Engine Oil Filter Nylon 66 GF 30Nylon 66 GF 30
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Glove RailGlove RailNylon 66 GF 45Nylon 66 GF 45
Seat Belt Anchor Seat Belt Anchor Nylon 6Nylon 6
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Lever Combination SwitchLever Combination SwitchNylon 6 GF 30Nylon 6 GF 30
Relay BoxRelay BoxNylon 6 AlloyNylon 6 Alloy
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Wire Harness ConnectorWire Harness ConnectorPBTPBT
ECU CaseECU CasePBT GF 30PBT GF 30
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Switch BaseSwitch BasePBT GF 40%PBT GF 40%
Actuator CaseActuator CasePBT GF 30%PBT GF 30%
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Air Conditioner FinAir Conditioner FinPBT GF 45%PBT GF 45%
Mirror HousingMirror HousingPBT GF 30 AlloyPBT GF 30 Alloy
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Alternator PartsAlternator PartsPPS GF/ MD 30PPS GF/ MD 30
Power ModulePower ModulePPS GF/ MD 50PPS GF/ MD 50
Neutral Start SwitchNeutral Start SwitchPPS GF 40 AlloyPPS GF 40 Alloy
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
Engine Mounting Engine Mounting partsparts
PPS GF 40PPS GF 40
Lamp Reflector Lamp Reflector PPS GF/ MD 60PPS GF/ MD 60
Lamp SocketLamp SocketPPS 40PPS 40
ENGINEERING PLASTICS ENGINEERING PLASTICS APPLICATIONSAPPLICATIONS
THANK YOUTHANK YOU