ENGINEERING PLASTICS APPLICATIONS INTRODUCTION Advancements made in engineering

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: n ECONOMY n WEIGHT REDUCTION n STYING – ASTHETICS n FUNCTIONAL DESIGN n PROPERTIES n REDUCED MAINTENANCE n CORROSION AND CHEMICAL RESISTANCE

ENGINEERING PLASTICS APPLICATIONS Demand of Thermoplastics Market 2002 High Performance Plastics <0, 1% LCP, PEEK, PEI, PES, PSU Engineering Plastics 11. 5 Mil. MT 9% Standard Products 124 Mil. MT 91% ABS, ASA, SAN PA PC POM PBT/PET PPO PE PP PVC PS Mil. MT < 0. 1 5. 8 2 2 0. 7 0. 3 55. 5 30. 6 27. 6 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 Polycarbonate (PC) 10 ABS + PC 10 Polyformaldehyde (POM, acetal) 2 6 Polymethyl methacrylate (PMMA) 2 PP+ EPDM 18 Thermoplastics Polyesters (PET and PBT) 2 Polyamides (PA, Nylon) 22 Others 10 Polyethelene 12 TOTAL 162 Polypropylene (PP) 29 Polyurathane (PUR) 34 Polyvinyl Chloride (PVC) 5 Acrylonitrile – butadienestyrene (ABS)

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

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

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

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

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

ENGINEERING PLASTICS APPLICATIONS Speedo meter Housing PP Talc Filled Door Trim PP Talc Filled

ENGINEERING PLASTICS APPLICATIONS Reflector Housing PP Talc Filled 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 Power Module PPS GF/ MD 50 Alternator Parts PPS GF/ MD 30 Neutral Start Switch PPS GF 40 Alloy

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

ENGINEERING PLASTICS APPLICATIONS THANK YOU