1. High Value Metal Replacement in Automotive Powertrain Applications
New Opportunities with Thermosets Under the Hood
Jim Cederstrom
Automotive Business Development Manager
Bulk Molding Compounds, Inc
Sept 16, 2009
SPE – Automotive Composites Conference & Exhibition

2. Past Drivers for Plastics (Vehicle Weight Gain)
Market Share (%)
Lbs
*Source: U.S. Environmental Protection Agency, Light-Duty Automotive Technology and Fuel Economy Trends: 1975 Through 2008

3. Past Drivers for Plastics (Vehicle Weight Gain)
Consumer Preference
High displacement engines (Fun to Drive)
4 wheel drives
Advanced climate control systems
NVH improvements
Infotainment systems
Advanced Safety Systems
Anti-lock brakes, Stability/Traction Control, Airbags
Emissions Systems
Fed Tier II and CARB LEV requirements
Negative impact on cost/weight/CAFE

4. Plastics Growth in Vehicles (Weight reduction)
250 lbs of Plastics/Composites
331 lbs of Plastics/Composites
More than 30% increase
Average 150 lbs vehicle weight reduction
UTH last to grow
*Source: American Chemistry Council

5. Typical Application Requirements
Temperature Resistance: -40C to 130C
Chemical Resistance:
Coolant, Brake Fluid, Fuels, Solvents, NaCl, Humidity, Hot Engine Oil
Vibration/Impact Resistant
Structural Rigidity
Creep Resistance
Long Term Dimensional Stability

6. Progression of Plastics Under the Hood
PP, PA66, PBT
BMC, SMC, PA66,
PA6, PA66
PPA, PPS, PA4,6, BMC,
Phenolic
18 lbs
9 lbs
Lbs of Plastic
1985
1995
2005

7. What’s Next for Composites Under the Hood? (Market Drivers)
RESULT
Dramatically increased emissions and fuel economy regulations
US CAFE - 35 mpg
US Emissions Fed Tier 2 and CARB LEVII (CO2, NOx)
EURO 5 and EURO 6 Emissions
Rising fuel prices
Extended warranties
Consumer sentiment towards greener vehicles
Drive toward energy independence
Vehicle Downsizing
Engine Downsizing
More Efficient Powertrains
Complex Powertrain Controls
Alternative Fuels/Energy
More extreme requirements
Renewed and aggressive focus on lightweight materials and cost reductions

8. New and more demanding applications
TECHNOLGY TRENDS
RESULT
GDI and diesel engines
Turbo/super charging
Highly active intake systems
Electronically controlled valve actuation/timing
Drive by wire systems
Cylinder deactivation
EGR
Alternative/bio fuels
Engine start/stop systems
Hybrid Electric Powertrains
More complex systems
Tighter packaging space
Higher heat
Higher pressures
More corrosive fluids
Added Cost
“Higher Performance Polymers”
Existing composite apps
New hydraulic/mechatronic systems

9. Future Growth in Plastics Under the Hood (New Requirements for PT Composites)
Higher Temperature Resistance: -40C to 150C (>200C)
Mechanical Strength and Impact Resistance Across a Wider Range of Temperatures
Chemical Resistance (New more aggressive fluids):
Long Life Engine Coolants: OAT, HOAT
Alternative fuels: Flex fuels, Diesel Fuel, BioDiesel Fuels
EGR gases
Long Term Dimensional Stability
Tighter tolerance requirements
Across wider temperature range
Creep Resistance (high temp)
Longer Warranty Periods

10. Bulk Molding Compound (BMC) Composite Materials
Long history of BMC composites in demanding automotive applications
More than 90% of all automotive headlamp reflectors are produced in BMC
Very high temperature resistance, high precision parts, low system cost.

11. BMC Composite Material Composition
(Wide Range of Materials/Properties)
20%
50%
25%

12. Composite Cost Comparison
On a cost / unit volume basis thermosets offer significantly higher value compared to many High Performance Thermoplastics.

13. Thermosets offer a much higher Performance vs. Price ratio
BMC vs. High Performance Thermoplastics
LCP, PEEK
PEI
Phenolic
PPS
VE-BMC
PE-BMC
PERFORMANCE
PPA, PA4,6
PA66, 6,
PBT, PET PP
Thermosets offer a much higher Performance vs. Price ratio
PRICE

14. BMC vs. High Performance Materials

15. Moisture Absorption (%)
BMC Precision Net Shape Molding
BMC composites provide the tightest tolerance and dimensional stability over any other high performance composite material
Material
Mold Shrinkage (%)
CLTE (μm/m°C) RT to 150°C
Moisture Absorption (%)
Aluminum
0.70 20
BMC Dimension X
0.00 18
0.15
PPS (50% GF)
0.33 58
0.03
PEI (30% GF)
0.30 48
0.25
PA6,6 (30% GF) 61
>1.0

16. Key Factors Driving Dimensional Improvements in BMC
Normally lower shrinkage BMC’s result in higher CTLE, and less compressive creep resistance
Optimization of the low profile additives, resin cross-linking density, filler system, and fiber have resulted in a new BMC composite systems that provide the maximum creep resistance, lowest possible CTLE and smallest possible molded part tolerances
These breakthroughs can now being translated in to various high precision powertrain applications.
Intake Systems
Pump Housings
Transmission
Systems

17. BMC Composite (% dim change)
BMC Dimensional Change/Fluid Exposure
Part dimensions can also be affected by the absorption of various automotive fluids.
BMC demonstrate very low dimensional change to most automotive fluids.
Dimensional Change (%) After Exposure to Various Automotive Fluids (2000 hours)
Fluid
BMC Composite (% dim change)
Dexcool (93°C)
0.05
Used Engine Oil (150°C)
0.00
ATF (150°C)
0.01
Gasoline (24°C)
0.03
Power Steering Fluid (150°C)
Brake Fluid (150°C)
0.14

18. BMC Electronic Throttle Valves
BMC Dimension X Polyester Composite
Cost savings: %
Weight savings: 25-30% (≈ 0.5lb)
Zero mold shrinkage
Tight/repeatable tolerances
+0.03/-0.06mm, 90mm bore
+/ MM ,20mm bore
Reduced manifold dynamic loading
Improved icing / no heating
Possible electric motor down sizing
Improves safety during crash

19. BMC in Engine Oil Applications (Engine Sealing)
Excellent Track Record
>60 MM parts w/o failure
Strong/Rigid Parts at High Temps
Excellent Flatness/Tolerances
Excellent Creep Resistance
Engine front/timing covers
Pressurized Engine Lubrication Circuit

20. BMC Thermal Mechanical Performance
BMC composites offer very high glass transition temperatures and exceptional stiffness enabling metal replacement in dimensionally critical applications with constant mechanical loading under long term high temperature exposure
Material
Tg (°C)
Flexural Modulus 23°C (GPa)
Flexural Strength 23°C (Mpa)
Aluminum
68.9
BMC Composite
200
13.2
154
PPA (33% GF)
125 10
PPS (40% GF) 90
11.1
225
PA 6,6 (33% GF) 55
6.4
180

21. Rigidity at Elevated Temperature
(BMC vs. Engineering Thermoplastics)

22. BMC High Pressure Engine Oil Applications (Oil Pump and Filter Housings)
BMC TDV584, BMC 665, BMC 695
Piece price savings: %
Weight savings: 25-30% lb
Strong/rigid material at high temps (150°C)
Withstands high oil pressure/cycling
> 15bar
Low deflection
Self lubricating formulation for low wear
Tight/repeatable print tolerances
Very low creep/CTE

23. BMC Property Retention vs. Fluid Aging
150°C 2000hr Engine Oil Exposure
150°C 2000hr ATF Exposure
120°C 2000hr Long Life Coolant Exposure

24. BMC Pump Applications (Electric Pump Housings)
BMC TDV584, BMC 665, BMC 695
Electric engine oil pumps
Electric auxiliary CVT pumps
Electric/auxiliary coolant pumps
ICE thermal efficiency control
Charge-air cooling
Battery cooling for electric vehicles
Electronics cooling for electric vehicles
Vacuum pumps for braking
Electric fuel pump inlet/outlet

25. BMC High Temperature Exposure (Engine Covers/Heat Shields)
Higher engine compartment temps >150°C
BMC low cost/high temp solution for covers/heat shields
Continuous use temps > 220°C
Low S.G
Class A surface
Excellent flatness
Low thermal conductivity
0.5 W/mK
Easily painted, colored, coated
Inherently flame retardant
200°C 2000hr Air Exposure

26. BMC Alternative Powertrain Systems
(Hydrogen Fuel Cell)
Low cost/high performance material solution for proton exchange membrane (PEM) “Bi-Polar” plates
Excellent balance of conductivity, moldability and physical properties
Excellent resistance to aggressive fuel cell stack environment
Very flat and dimensionally stable plates
Very thin plates to 1mm (web thickness as low as 0.3mm)
Innovative conductive adhesive/sealant for anode- cathode bonding – 50% stack height reduction
Successful Automotive OEM Pilot Programs

27. BMC Alternative Powertrain Systems
(Electric Vehicles)
Long history high voltage applications
High Dielectric Strengths (>15 kv/mm)
High UL Relative Temp. Index (RTI) rating (160˚C)
High volume resistivity retention with humidity exposure (1E+14 Ωcm)
High Comparative Tracking Index to prevent carbon tracking (>600 Volts )
Inherently flame resistant (UL-94-HB/V0)
Low CTE – Excellent for overmolding and insulating metal components

28. BMC Alternative Powertrain Systems
(Hybrid Electric Vehicles)
Power distribution module boxes
Inverter/converter boxes/frames
Battery pack frames
Thermal management system components
Overmolded electrical lead frames/bus bars
High voltage connectors
Low cost/high temp solution for heat shielding/thermal barriers

29. Summary
Molding parts to the correct dimensions, with very tight tolerances, and a wide processing window, has never been easier than with BMC.
BMC composites maintain tighter print tolerances out of mold and at elevated temperatures as compared to higher cost high performance thermoplastics...and are highly suited for metal replacement in powertrain applications
BMC thermosets offer the most cost-effective performance at elevated temperatures under load, pressure, and chemical exposure in automotive applications compared to metal and engineered thermoplastics.
BMC materials are suited for metal replacement in hybrid vehicle powertrains, from highly conductive solutions to high dielectrics