Engineering lightweight solutions for the global automotive industry

Several new and upgraded material solutions engineered to enable the automotive industry to achieve greater cost efficiency, higher performance and improved sustainability in vehicle components have been developed by Borealis and Borouge. The new lightweight grades FibremodTM WE380HP and DaplenTM EE058AI are representative of Borealis and Borouge’s commitment to offering new and multi-faceted solutions to automotive OEMS around the globe and will be showcased in October at the IZB 2014 in Wolfsburg, Germany, along with a Brazilian premiere grade. In so-called hybrid grades, reinforcing polypropylene (PP) with a combination of glass fibre and mineral filler yields a special performance grade. As one such grade, Fibremod WE380HP is a new hybrid PP compound comprised of 20% glass fibre reinforcement and 10% mineral filler. It is intended for use in both structural and visible automotive parts, such as under-the-bonnet (engine covers, gear housings) and high-end interior applications (window frames, arm rests). As a replacement for other materials, Fibremod WE380HP is a lightweight solution that contributes to lower fuel consumption and reduced CO2 emissions without compromising on visual aesthetics or performance. The grade can bear a high mechanical load, offers excellent processability, outstanding dimensional stability, low warpage, good heat resistance and allows for self-colouring. In addition to this multi-talented new material, other lightweight grades being highlighted at the IZB include the pioneering PP natural fibre grades NJ200AI and NJ201AI, both of which allow for 9% weight savings when compared to a PP-T20. The recently-launched thermoplastic olefin (TPO) compound Daplen EE058AI is not only lightweight, but also offers tiger stripe-free technology, as does the upgraded DaplenTM EE189HP. Automotive OEMs continue to seek out materials that help reduce overall vehicle weight in order to improve fuel consumption and fulfil stringent CO2 emissions standards, while still meeting requirements in terms of efficient processing and surface aesthetics. The phenomenon of tiger stripes - the visually recognisable periodic change of surface gloss – is caused by converting processes and is a general problem of all thermoplastic materials, including polyolefins. The newly-developed, tiger stripe-free TPO compound Daplen EE058AI boasts an excellent property profile and is a fitting replacement for conventional T15 and T20 interior materials. DaplenTM EE158AIB is a 13% mineral-filled thermoplastic olefin (TPO) compound. This grade had already been adopted by Volkswagen as the ideal material solution for the European production of door panels in its new Up! model, and has now been chosen for Up! production in Brazil as well. This is the first time Volkswagen has selected a PE/PP TD13 material for its South American production operations. The grade helps the manufacturer achieve its lightweighting targets whilst providing excellent mechanical performance, high UV and scratch resistance, low emission and fogging, and superior aesthetics. Borealis and Borouge material solutions are also being implemented in the Up! model’s dashboard, centre console, pillar and sill panels.