FOCUS ON PLASTICS – AUTOMOTIVE (PART 1)

Introduction

This focus on the use of plastics in the automotive sector is not just about this industry.  The automotive industry is at the forefront of polymer development.  Firstly because there is a need to reduce vehicle weight to improve fuel consumption and reduce emissions.  Secondly, because of its highly competitive nature requiring constant efforts to reduce costs and introduce innovative design.

The high volume of vehicles manufactured makes the automotive industry attractive to the polymer manufacturers.  As a result, they are prepared to invest in the necessary research to develop new polymer grades to meet the exacting demands.

The purpose of this article is to illustrate some of the areas where plastic materials are used – often in demanding or innovative applications.  From this it will be possible to appreciate the potential for polymers in other industries and applications.  This is only an overview to demonstrate the capabilities of polymers, more detailed information on specific applications and the properties of these materials can be found on the various polymer manufacturers websites, e.g. DuPont and Ticona.

Let us take a look at each area of a vehicle in turn.

Exterior

Body Panels - Many body panels themselves are now injection moulded.  Front and rear end panels in PC/ABS or PET, for example.  This can be colour matched to the paintwork or, more commonly, painted along with the main body shell.  These materials are chosen not only for their inherent strength but also because they can withstand the baking cycle without deforming.

Sunroof Frames are moulded in thermoplastic polyester for their excellent mechanical and dimensional stability properties – after all you do not want a leaking sunroof.  The sunroof glass these days is less likely to be glass and more likely to be polycarbonate. 

Roof Panels -The trend for larger, ‘panoramic view’, clear roof panels or double-curved glazing has been made possible by the wider use of polycarbonates.  This material offers excellent impact strength, an important consideration, and is suited to outdoor applications with the addition of a UV Stabiliser.  This not only reduces weight but also makes possible three-dimensional design.

Wheel Covers - For cars that do not have alloy wheels, wheel covers are plastic mouldings.  As a rule slightly cheaper thermoplastics may be used, such as ABS.

From large body panels to smaller mouldings, such as door handles and wiper arms, plastics are increasingly replacing metal.

The application examples provided in the above features will not be confined to products manufactured by Rutland Plastics.

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