SABIC HIGHLIGHTS LIGHTWEIGHT MATERIAL TECHNOLOGIES FOR AUTOMOTIVE INDUSTRY AT CHINAPLAS 2017

Guangzhou, China, May 17, 2017 – With environmental protection and energy efficiency as prominent issues for China’s automotive sector, global petrochemicals maker SABIC is taking advantage of Chinaplas 2017 to advance discussions with automakers and their suppliers on a range of lightweighting possibilities from its broad portfolio of materials and collaborative part development capabilities.

Among those solutions is STAMAX™ resin, a long glass fiber-filled polypropylene (LGFPP) material. Leading global automakers have used the lightweight-enabling material since the early 2000s, primarily to manufacture large molded parts and semi-structural components. As much as 50 percent in weight savings can be possible with the use of this resin in tailgate components, front-end modules, door modules, seat structures and instrument panels.

“The trend to replace metal in those parts and many others has led the industry to move towards thermoplastics, and especially towards low-density polyolefin materials,” said Scott Fallon, global leader of SABIC’s Automotive business. “Alongside this shift has come the need for capable, intelligent suppliers who can support the design and development of components and optimize their performance in terms of taking out the most weight and producing the best quality. We are filling this role today in China and across the world because of the expertise we have built in polyolefin technology over the past couple of decades.”

Inner Tailgate Component with STAMAX Resin
As a demonstration, SABIC is showing during Chinaplas the inner tailgate structure from a recently launched vehicle in China, the eQ1 electric vehicle from Chery. Use of STAMAX resin allows the automaker to shave 40 percent in weight from the part compared to steel, while delivering the required stiffness. Additional advantages of using STAMAX resin include ease of assembly and integration with other parts, a modular-like design that can further improve vehicle assembly and dimensional stability. This solution comes with minimal warpage, excellent mechanical performance and corrosion avoidance.

SABIC not only provided material for the part, but delivered development support with computer-aided engineering analysis, allowing for prediction and optimization of the part’s performance.

SABIC produces STAMAX resin in the Asia Pacific region from its plant site in Shanghai, China, which began production in 2016. SABIC has two additional plants dedicated to the production of STAMAX resin, one in Europe (Genk, Belgium) and the other in North America (Bay St. Louis, Mississippi). These production facilities help SABIC deliver the materials consistency to meet specifications across world regions.

Progress in Polycarbonate Glazing
SABIC is also highlighting significant progress in advancing plastic glazing applications, which hits close to home for automakers operating in China.

SABIC is showing the world’s largest rear quarter window in LEXAN™ resin (GLX143 grade), a polycarbonate (PC) material. This window is from the new-generation Buick GL8 and GL8 Avenir luxury multi-purpose vehicles, which SAIC General Motors (SGM) launched in late 2016.

A two-shot injection compression molding process combining LEXAN resin with CYCOLOY™ resin (PC/ABS; XCM830 grade) results in a final part that is up to 40 percent lighter vs. conventional glass. This glazing solution allows for design features not possible in glass, as well.

Notably, this window is the first from a new production facility located in Yuyao City, China, the first mass production PC glazing line in the country. The facility belongs to Ningbo Shentong Auto Decorations, a long-time manufacturer of automotive plastic applications. SABIC worked very closely with Shentong to support development of the window system and enable production readiness.

“We see no let-up in the trend towards tougher vehicle emission and fuel economy standards in China,” said Fallon. “If anything, the country is accelerating its efforts – and this is putting more pressure on the industry to remove weight. We think lightweight technologies like LEXAN glazing present a significant opportunity for automakers to respond, especially with the new supplier capability in China now available to them.”

Emerging Solutions from SABIC
SABIC has material solutions of relevance to help meet needs and requirements for components across the entire vehicle. Some additional technologies SABIC will highlight while engaging with industry at Chinaplas include:

• A new material to support vehicle electrification – ULTEM™ film UTF120, based on polyetherimide (PEI) resin technology. This is a high heat and high energy density dielectric film that meets the most stringent technical demands, for use in professional-grade dielectric capacitors. ULTEM™ UTF120 film exhibits stable properties through range of temperature (-40 °C to +150 °C) and frequency, including stable capacitance, good insulation resistance, high dielectric constant (Dk) and low dissipation factor (Df). The wide operating temperature capability of ULTEM™ UTF120 film based capacitors enables reliability and eliminates the need for active cooling for converter applications. “The successful commercialization of UTF120 film has enabled SABIC to enter the high temperature film capacitor market. Eliminating the need for active cooling will enable our customers to have a simpler and more flexible system design in electric vehicle application. This is also a stepping stone towards next-generation dielectric film products, and provides translation opportunities for ultra-thin film to other application areas,” said Dr. Alan Tsai, Director, High Performance Forms, Specialties, SABIC. ULTEM™ UTF120 enjoys high temperature dimensional and mechanical stability, and is capable of passing 260oC reflow soldering process. It is inherently flame resistance and is recyclable.
• For the automotive lighting aftermarket, two new grades are available for applications requiring clarity and toughness: SABIC® PC ALS01 and ALS02. Each of these grades deliver an improved balance of flow and impact performance versus some of the incumbent materials available for headlamp lenses today. Higher flow can mean shorter cycle times, increased productivity and lower overall system costs. Typically, however, high flow compromises impact strength. With these two new PC grades from SABIC, the trade-off is less significant. SABIC® PC ALS01 is a medium flow material, while the ALS02 grade delivers high flow. These clear PC ALS grades offer excellent optical properties, easy flowability and mechanical strength, and good coating adhesion.
• Additional engineering plastic materials like polyoxymethylene (POM) and polymethyl methacrylate (PMMA) are now part of SABIC’s portfolio for automotive. POM is a thermoplastic material that features high strength, exceptional dimensional stability, low friction coefficient, and excellent wear properties, making it a fit for applications that require precision and durability. In automotive, fuel pumps, fuel caps and seat belts may use POM materials. PMMA, also a thermoplastic material, exhibits high clarity and light transmittance, even higher than glass – as well as scratch resistance and low weight. In automotive, PMMA is a candidate material for applications like taillights and interior lighting.
• SABIC is presenting a new range of synthetic rubber materials, including polybutadiene (BR) and ethylene propylene diene (EPDM) rubbers. Tires produced from BR material from SABIC can be used to develop tires that are safer, fuel efficient and long lasting. The material may allow for greater wet grip, abrasion resistance and lower rolling resistance – key performance attributes of tires. EPDM rubber can be used for a wide range of automotive applications, such as weather seal profiles and wires and cables. The key attribute of this material is its weathering and ozone resistance. EPDM materials from SABIC offer high durability for products like glass run seals and can effectively serve as a barrier to water, dust and noise.

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SABIC invites visitors attending CHINAPLAS 2017 in Guangzhou to attend its technical seminars at Shangri-La Guangzhou Hotel to learn more about our materials and solutions:

• SABIC new FDA & lens grade polycarbonate, POM and PMMA products & applications, 18 May 2017 (Thu), 13:30-15:30
• SABIC EPDM / BR for Tyre and Construction, 18 May 2017 (Thu), 16:00-18:00

Samples of SABIC’s inner tailgate component with STAMAX resin, rear quarter window in LEXAN™ resin and more will be available for viewing at Shangri-La Guangzhou.

SABIC is also inviting CHINAPLAS participants to visit material-machine demonstrations SABIC is holding in partnership with leading manufacturers companies at their respective booths. Visitors will be able to see and experience for themselves how SABIC’s innovative materials are processed to become competitive end-products, helping customers achieve safety, convenience, sustainability and cost-effectiveness.

Follow the SABICChinaPlas WeChat account for more information and the latest news:

An engineered polyolefin material from plastics-maker SABIC has allowed Chinese automaker Chery to shave 40 percent in weight from the inner tailgate structure of its recently launched eQ1 electric vehicle. The SABIC material is STAMAX™ resin, a long glass fiber-filled polypropylene (LGFPP). Use of this low-density material lightens the inner tailgate structure compared to steel and can deliver the required stiffness. In addition to its material, SABIC provided development support with computer-aided engineering analysis, allowing for prediction and optimization of the part’s performance.