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Engineering Plastics

The document discusses the increasing use of engineering plastics in automobile applications. Over the last 30 years, plastics have increasingly replaced traditional materials due to advantages like lower cost, lighter weight, and resistance to corrosion. Polypropylene and other engineering plastics are commonly used in interior and exterior automotive parts. A typical car now contains around 162 kg of various plastics, used in systems throughout the vehicle.

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Akash Singh
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149 views27 pages

Engineering Plastics

The document discusses the increasing use of engineering plastics in automobile applications. Over the last 30 years, plastics have increasingly replaced traditional materials due to advantages like lower cost, lighter weight, and resistance to corrosion. Polypropylene and other engineering plastics are commonly used in interior and exterior automotive parts. A typical car now contains around 162 kg of various plastics, used in systems throughout the vehicle.

Uploaded by

Akash Singh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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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
 WEIGHT REDUCTION
 STYING – ASTHETICS
 FUNCTIONAL DESIGN
 PROPERTIES
 REDUCED MAINTENANCE
 CORROSION AND CHEMICAL RESISTANCE
ENGINEERING PLASTICS
APPLICATIONS
Demand of Thermoplastics
Market 2002 Mil. MT
High Performance Plastics <0, 1%
LCP, PEEK, PEI, PES, PSU < 0.1

ABS, ASA, SAN 5.8


PA 2
Engineering Plastics PC 2
POM 0.7
11.5 Mil. PBT/PET 0.7
PPO 0.3
MT
9%
PE 55.5
PP 30.6
Standard Products PVC 27.6
124 Mil. MT PS 10.7

91%
ENGINEERING PLASTICS
APPLICATIONS
PLASTICS CONSUMPTION IN A CAR - ABOUT 162 Kg
11.6% of Total Weight of the car

TYPE OF PLASTICS Kg TYPE OF PLASTICS Kg

Polypropylene (PP) 29 Polycarbonate (PC) 10


ABS + PC 10
Polyurathane (PUR) 34
Polyformaldehyde (POM, acetal) 2
Polyvinyl Chloride (PVC) 5
Polymethyl methacrylate 2
Acrylonitrile – butadiene- 6
(PMMA)
styrene (ABS)
Thermoplastics Polyesters (PET 2
PP+ EPDM 18
and PBT)
Polyamides (PA, Nylon) 22
Others 10
Polyethelene 12 TOTAL 162
ENGINEERING PLASTICS
APPLICATIONS
Factors for Material Choice
FR System
Mechanical Toxicology/
Properties Safety in Use

Electrical Engineering
Price
Properties Plastics

Thermal Various
Properties e.g. Pigmentability
Processing
ENGINEERING PLASTICS
APPLICATIONS
PLASTICS IN AUTOMOBILES

INTERIOR SYSTEMS

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

EXTERIOR SYSTEMS

 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


 Fuel Systems – Fuel Delivery, Fuel Tanks
 Air/ Water induction System – engine cooling and climate control
systems

OTHER SYSTEMS
 Safety related parts – impact zones
 Electrical & Electronics
 Lighting Systems
 Power train & chasis systems – steering, pedal & braking system
 Soft Trim Systems – Headliners, acoustics & carpets
ENGINEERING PLASTICS
APPLICATIONS
ADVANTAGES

 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 Door Trim
PP Talc Filled PP Talc Filled
ENGINEERING PLASTICS
APPLICATIONS

Reflector Housing
Hyundai Car Bumper
PP Talc Filled
PP Talc Filled
ENGINEERING PLASTICS
APPLICATIONS
Seat Components
PP Unfilled
ENGINEERING PLASTICS
APPLICATIONS
Wheel Chair Base Mixie Body
PP Unfilled PP Unfilled
ENGINEERING PLASTICS
APPLICATIONS

Switch Frame Instrument Holder Ford


ABS 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 Fuel Sub Tank
Nylon 6 GF 30 Nylon 66 GF 30
ENGINEERING PLASTICS
APPLICATIONS
Timing Chain Cover & Engine Oil Filter
Nylon 66 GF 30
ENGINEERING PLASTICS
APPLICATIONS

Glove Rail Seat Belt Anchor


Nylon 66 GF 45 Nylon 6
ENGINEERING PLASTICS
APPLICATIONS
Lever Combination Switch Relay Box
Nylon 6 GF 30 Nylon 6 Alloy
ENGINEERING PLASTICS
APPLICATIONS
ECU Case
Wire Harness Connector PBT GF 30
PBT
ENGINEERING PLASTICS
APPLICATIONS

Switch Base Actuator Case


PBT GF 40% PBT GF 30%
ENGINEERING PLASTICS
APPLICATIONS
Air Conditioner Fin Mirror Housing
PBT GF 45% PBT GF 30 Alloy
ENGINEERING PLASTICS
APPLICATIONS
Alternator Parts Power Module
PPS GF/ MD 30 PPS GF/ MD 50

Neutral Start Switch


PPS GF 40 Alloy
ENGINEERING PLASTICS
APPLICATIONS
Engine Mounting parts
Lamp Socket
PPS GF 40
PPS 40

Lamp Reflector PPS


GF/ MD 60
ENGINEERING PLASTICS
APPLICATIONS

THANK YOU

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