HC Plastics News: Automotive lightweighting drives the demand for modified plastics for vehicles, and the automotive industry has become the fastest growing demand for modified plastics. The largest application areas of modified plastics downstream are home appliances and automobiles. The automobile industry has become the fastest growing demand for modified plastics due to the light weight of automobiles. It is expected that the annual average growth rate of domestic automotive modified plastics demand in the next few years is expected. Will be above 15%.
First, the introduction of modified plastics
1. Classification of modified plastics
Modified plastic refers to the modification of general plastics and engineering plastics by adding physical and chemical methods such as blending, filling, strengthening, copolymerization and cross-linking by adding suitable modifiers to improve their toughness, strength and stretchability. Resin/plastic obtained from properties such as impact resistance and flame retardancy.
Therefore, the upstream of the modified plastics industrial chain is a synthetic resin such as PE, PP, PVC, etc., which is modified by physical or chemical methods to obtain a modified plastic resin, and then subjected to extrusion, injection molding, calendering and the like to obtain a modified plastic product, Excellent performance, modified plastic products are widely used in home appliances, automobiles, construction and other industries.
Modified plastics industry chain
According to the modified function, the modified plastics include flame retardant resins, reinforced and toughened resins, plastic alloys, functional color masters, etc., each type can be subdivided according to different materials, and due to their respective Performance differences and application areas vary.
Classification of modified plastics
Modified plastics classification and use
2, modification technology
The modification technology includes physical methods such as blending, filling and reinforcement, and chemical methods such as copolymerization and cross-linking. The physical method is the most important modification method at present. Blending, filling, etc. need to select suitable modifiers and fillers to achieve specific Modification purpose.
(1) modifier
Modifiers, also known as auxiliaries, can be classified into processing aids and functional auxiliaries.
Processing aids are additives for improving the processing rheology and molding properties of plastics, including: lubricants - improving the flowability of substrates; heat stabilizers, antioxidants - improving the thermal stability of substrates; Agents - improve the dispersibility of the substrate; compatibilizers, coupling agents - improve substrate compatibility; bridging agents, tackifiers - improve the melting strength of the substrate.
Functional additives are mainly used to improve the physical and chemical properties of the substrate, including: fillers, crystal nucleating agents - improving the rigidity and strength of the substrate; impact modifiers - improving the impact of the substrate; ——Improve the flame retardancy of the substrate. The modified material can effectively prevent, delay or terminate the propagation of flame when attacked by fire source. Stabilizer—improves the weather resistance of the substrate; conductive coating filler, anti-resistance Electrostatic agent - improve the conductivity of the substrate, antistatic agent can reduce the static accumulation of plastic during processing and use, reduce the surface resistivity of the material; plasticizer - improve the hardness of the substrate; foaming agent - Change the density of the substrate; colorant - change the transparency and color of the substrate.
Use of some modifiers
(2) Modification method
The method for modifying the resin can be divided into physical methods and chemical methods, including filling, blending, strengthening, copolymerization, cross-linking, etc. Currently, the mainstream modification technology is a physics mainly filled, blended, and reinforced. Modification technology.
Filling is the blending of minerals, modifiers and other fillers with plastics to improve the shrinkage, hardness, strength and other properties of plastics; blending is the incorporation of one or more other resins, modifiers or minerals. To improve the original performance; reinforcement is to blend glass fiber and the like with plastic to enhance the mechanical strength of the plastic.
Modification technology
Once the modified formulation for filling, blending, and reinforcement is determined, the specific operation requirements for the downstream production equipment are not high. This technical characteristic determines that the key process of modified plastics production lies in the design of the modified formula. From the current situation, the original formula of the general-purpose large variety of modified plastics is basically in the open state of the market, while the high-performance professional type is changed. The formulation of plastics is in the hands of leading companies in all segments.
3. Application fields
Modified plastics are superior to general-purpose plastics in terms of flame retardancy, strength, impact resistance, toughness, etc., and are widely used in downstream applications, mainly in the fields of home appliances, automobiles, construction, office equipment, machinery, etc. It is the two largest application areas. In 2015, the domestic consumption of modified plastics has reached nearly 10 million tons. With the advancement of science and technology and the upgrading of its industry, its downstream applications are still expanding.
Modified plastics in the automotive sector
The automotive industry has become the fastest growing area for demand for modified plastics. According to market consultancy MarketsandMarkets, the market value of global automotive plastics is expected to increase from US$21.16 billion in 2012 to US$46.12 billion in 2012. Consumption is expected to increase from 7.1 million tons in 2012 to 11.3 million tons in 2018, 2013-2018. During the year, the compound annual growth rate of demand will reach 13.4% (China Knowledge Network: "The market value of global automotive plastics will exceed 46 billion US dollars in 2018" and "Global demand for automotive plastics will reach 11.3 million tons in 2018"). This is mainly due to: First, the global car production growth rate is stable; Second, the car lightweighting makes the amount of bicycle modified plastics increase.
The growth rate of domestic automotive modified plastics is much higher than the global average. The growth rate of domestic automobile production has been much higher than the growth rate of global automobile production in the past years. The domestic bicycle plastic consumption is far lower than that of developed countries such as Europe and the United States. The development space is huge, especially China is already the world's largest new energy automobile market. New energy vehicles need more support from lightweight technology. Therefore, the demand growth rate of domestic automotive modified plastics will be higher than the global average, and it will become the fastest growing area of ​​modified plastics downstream. According to Asian Chemical Consulting, it is expected to be domestic in the next 5 years. The automotive compound plastics industry will grow at a compound annual growth rate of more than 26%.
Second, automotive lightweight and automotive modified plastics demand
Automotive lightweighting is the future direction of the automotive industry, especially for new energy vehicles, the weight reduction directly means the increase in cruising range. Studies have shown that fuel vehicles can reduce vehicle weight by 10%, fuel efficiency by 6~8%, weight reduction by 100kg, fuel consumption per 100km can be reduced by 0.3~0.6L, and CO2 emissions per 100km can be reduced by about 5g ("Automotive For the pure electric vehicle, the weight of the whole vehicle is reduced by 10kg, and the driving range can be increased by 2.5km ("Application Status and Main Path Analysis of Automotive Lightweight Technology").
1. Automotive lightweight technology
As a systematic project, car lightweighting is not simply a separate weight reduction for a part. The change of local weight will affect other parts of the car to a large extent. Therefore, the weight of the car refers to the process of automobile manufacturing. Systematic engineering that combines design, manufacturing, and materials technology.
When designing a car for lightweight design, it is necessary to consider three factors: body structure safety, stiffness analysis, and weight reduction factor. ("Application Status and Main Path Analysis of Automotive Lightweight Technology")
(1) Body structure safety
The premise of lightweight car body and interior and exterior trim is that the car safety, body stiffness, fatigue durability, handling stability and vibration comfort meet the requirements. The purpose of the structural safety of the vehicle body is to protect the safety of the occupants in the vehicle. It belongs to the passive safety category of the vehicle. The safety performance of the vehicle body structure will directly affect whether the vehicle can meet the passive safety of frontal collision, side collision, rear collision, tumbling and low-speed collision. Claim.
At present, the passive safety regulations for automobiles in various countries include the European Regulation System (ECE/EEC) and the US Federal Motor Vehicle Regulation System (FMVSS). China's mandatory automotive passive safety standard (GB) is mainly based on the European regulatory system.
(2) Stiffness analysis
The overall stiffness of the vehicle body refers to the relationship between the load applied by the vehicle body and the amount of deformation generated by the body after the load is applied. The rigidity of the vehicle body reflects how to control the deformation of various parts of the body structure under the premise of meeting the requirements of assembly and use of the vehicle body. Therefore, if the rigidity design of the vehicle body is unreasonable, the vibration frequency of the vehicle body will be reduced, resulting in the ride comfort of the whole vehicle. Service life and collision safety, NVH performance, etc. do not meet the design requirements. The design of the modern body is to maximize the rigidity of the car body under the premise of reducing the mass of the car as much as possible.
(3) Lightweight coefficient
The Lightweight Index (L) is a lightweight indicator for a vehicle that is currently highly accepted by the automotive industry. The smaller the light weight coefficient L value, the better the weight reduction of the vehicle body. The calculation formula of the body weight coefficient is shown in Figure 11, where L is the light weight coefficient, CT is the static torsional stiffness of the body with the windshield, m is the body mass of the body without the four doors and two covers, and A is the body. Projection area between four wheels.
It can be known from the calculation formula of the lightweight coefficient L that the weight reduction factor of the vehicle body can be reduced by increasing the rigidity or reducing the mass of the body. At present, automotive lightweight technology is mainly divided into three aspects: structural optimization design, lightweight material application and adoption of advanced manufacturing processes. Among them, the use of lightweight alternative materials is widely recognized in the industry and the most promising lightweight technology. The lightweight materials currently used are mainly high-strength steel, aluminum-magnesium alloy, modified plastic and composite materials.
Low-strength steel refers to steel with a strength of less than 201 MPa, while high-strength steel mainly refers to steel with a strength between 201 MPa and 550 MPa, and super-strength steel refers to steel with a strength greater than 550 MPa. In the automobile manufacturing work, steel materials are used more materials and are also the main components of the automobile structure. Under the same strength, the use of high-strength steel can effectively reduce the thickness of steel plates used in automobile manufacturing, and can be fundamentally mitigated. The weight of the car itself can effectively reduce the weight reduction factor L.
Compared with steel, the specific gravity of aluminum alloy is only 2.68 g/cm3 which is 30%. When the bending stiffness is equal, the weight loss potential is 49%; when the bending strength is equal, the weight loss potential is 38%. At present, the main application forms are as follows: aluminum alloy forgings for structural components such as automobile suspension brackets and wheels; mold castings for body shells and engine cylinder heads; aluminum alloy base tensile members for body structure; , rolled sheets such as covers, covers, etc.; shells, small castings with high strength.
The specific gravity of magnesium is smaller than that of aluminum alloy, which is only 1.74g/cm3 of steel, which has great potential for lightweight application. At present, the use of magnesium alloys in automobile parts manufacturing has been extensive, and more than 60 kinds of parts such as instrument panel skeleton and seat frame are made of magnesium alloy.
Modified plastics and composite materials have lower density and higher specific strength than metal materials. Currently, modified plastics and composite materials mainly include modified PP, modified PVC, modified PE, fiber composite materials, and metal. Base composite materials, thermoplastic resin composite materials, and the like. Modified plastics were mainly used in the interior and exterior decoration of automobiles. With the application of fiber reinforced plastics, they have been applied to structural parts of automobiles, especially the development of carbon fiber composite technology, making cars based on modified plastics and composite materials light. It is possible to quantify the overall solution.
2. New requirements for lightweighting of new energy vehicles
In recent years, new energy vehicles have developed rapidly. According to TGII, the global sales of new energy passenger vehicles reached 766,000 in 2016, and many countries including the Netherlands, Germany, France and the United Kingdom gave The timetable for the ban on the sale of fuel vehicles has made the development of new energy vehicles unstoppable. From the current technology, electric vehicles will be the main form of new energy vehicles in the next few years.
Prohibition of fuel vehicle timetable
The charging time of an electric car is long and the cruising range is not as good as that of a fuel car. The length of the charging time is determined by the charging and discharging principle of the lithium ion battery. The space for improvement is limited without changing the principle of charging and discharging of the battery. However, the cruising range is improved, but the simpler method is to carry more The battery to improve the cruising range, but more batteries not only means that the charging time is longer, it also means that the weight of the car will be heavier, the efficiency of the work will be lower, that is, the distance traveled by the car that consumes 1Kwh will be reduced. If you want to increase the cruising range under the premise of the same amount of power, you must achieve it by improving efficiency.
In order to make the electric vehicle consume a distance of 1Kwh, the most important method is to reduce the weight of the car. Studies have shown that the weight of the pure electric vehicle can be reduced by 10kg, and the driving range can be increased by 2.5km. The important weight reduction of 500kg, with the same amount of power, the cruising range will be increased by 125km, so the eagerness of electric vehicles for lightweight technology is very urgent.
Electric vehicle lightweight technology
The biggest difference between an electric car and a fuel car is that a large part of the weight of the electric car comes from the battery, and the weight of the battery is difficult to lower unless it finds a material with higher energy density or changes the current lithium-ion battery system. The weight of the interior, the chassis, etc. is a relatively feasible solution for its lightweight.
The weight of each part of a pure electric vehicle (kg)
The weight reduction of the interior can be achieved by using more modified plastics. The weight reduction of the body and the chassis, in addition to the above-mentioned use of high-strength steel, aluminum-magnesium alloy, researchers have even proposed the concept of a plastic body, proposed The concept of integrated ultra-light new energy vehicles, ultra-light new energy vehicles are mainly composed of driving battery unit, driving system, steering system, aluminum body frame, composite body, plasticized floor, etc., the body quality can be reduced to 850kg ( Including the battery), its all-plastic body design is an important part of the lightweight design of new energy vehicles. Compared with the traditional car body design, the design of the all-plastic body is an integrated, modular and integrated design. Achieve high levels of integration of functions and components, reducing the number of parts and reducing production costs.
3, modified plastics for vehicles
The role and status of modified plastics in the automotive industry is becoming more and more obvious. Currently, polypropylene (PP), acrylonitrile-butadiene-styrene copolymer (ABS), polyamide (PA), polycarbonate (PC), Plastics such as polyoxymethylene (POM), polybutylene terephthalate (PBT), reinforced polyurethane (PRT) and polyvinyl chloride (PVC) are widely used in automobiles. Among all automotive plastics, polypropylene accounts for up to 37%, followed by polyurethane, accounting for 17.3%, ABS resin for 12.3%, composites for 11.5%, and high-density polyethylene for 10.8%. It accounts for 6.8% and polymethyl methacrylate accounts for 4.4%.
Main varieties of modified plastics for vehicles
The application of modified plastics in automotive parts covers interior and exterior trims, functions and structural parts. With the development of fiber reinforcement technology, especially the development of carbon fiber composite materials, even the body and chassis can be completely modified plastics and composite materials. manufacture.
(1) Application of modified plastics on interior and exterior parts of automobiles
Dashboard
At present, the instrument panel mainly has two forms: a hard instrument panel and a soft instrument panel. The soft instrument panel is generally adopted by a relatively high-grade automobile, while the large passenger car, the truck and the like basically adopt a hard instrument panel. The instrument panel is generally made of modified PP material. The modified PP is mainly made of rubber toughening agent and inorganic filling material; the instrument panel skin material is mainly PVC/ABS, and PVC is resistant to impact and heat. Relatively weak, ABS mechanical properties and molding processing ability is better, and can be combined with PVC, the two can be combined to form a complementary.
Door panel
At present, the commonly used modified plastics for manufacturing the inner panel are ABS and PP, which are made into a skeleton, and have a buffer layer on the surface, and the buffer layer is made of PP foam, TPU, knitted polyester or the like. In some models of GM and Chevrolet, the frame and the panel are made of glass fiber reinforced unsaturated polyester sheet molding compound (SMC) material, and in some cars, natural fiber and PP hot pressing are also used. The method can effectively reduce the weight of the door, reduce the cost, and the sound insulation performance is obviously improved.
Body cover and chassis
The modified plastic makes the body cover. Compared with the metal cover, the body is smoother, the size is more precise, and the quality, noise, vibration and other conditions can be optimized. Therefore, the modified plastic is in the roof cover, engine cover and luggage compartment. Covers and other aspects are widely used. Ford uses SMC to make front guards, top covers, and hoods; in the new smart models of DaimlerChrysler, XenoyPC/PBT is used to make body panels.
In the chassis of a car, there is a big problem in plasticization due to the large load that needs to be withstood. At present, the application of modified plastics, such as modified PBT, modified POM, etc., is mainly used in the drive suspension system and the wear-resistant moving parts of the steering brake system.
(2) Application of modified plastics on functional parts and structural parts
bumper
Automobile bumpers are one of the main components of modified materials. Most of the bumpers on the market are made of plastic products. The panels of bumpers are PP, PC/ABS, PC/PBT, etc. The skeleton is Wood or metal and other materials, the middle part is PP foam material. Such materials are not conducive to recycling from the perspective of environmental protection. After continuous innovation, TPO can be used in the production of bumper panels, glass materials can be reinforced with glass fibers, foamed PP can be used in the middle part, and bumpers can be made from materials with the same properties. It can be cleaned and dried before being recycled.
Fuel tank
In the production of fuel tanks, modified plastics also play an important role, can be mixed according to a certain proportion of resin, adhesive, PA and other materials, and then blow molding. In addition, fuel tanks can be made from materials such as ultra high molecular weight high density polyethylene, copolymerized PA, and EVOH resin.
Engine intake manifold
There are some difficulties in the production of intake manifolds in automobiles, mainly because the shape of the intake manifold is more complicated. At present, most of the modified plastics are manufactured using the AIM process in the manufacture of engine intake manifolds, in Chrysler, In some Cadillac models, the fiberglass reinforced PA is used in the intake manifold.
The temperature of the engine will increase continuously during the operation of the engine, so the components around the engine must be subjected to a high temperature of 220 degrees Celsius while maintaining high strength. If it is colder, it must also withstand low temperature performance. Therefore, PA66 materials are generally used to ensure the performance of plastic parts.
Clutch execution system
Because the clutch is often operated in a high temperature environment and is also affected by the pressure lubricant, the metal material is used in the traditional manufacturing process, but in the continuous test, the advantages of the modified plastic clutch manufacturing system are more obvious when manufacturing the clutch execution system. The use of 50% long fiber reinforced black nylon LFRT raw materials provides higher stability and cost savings.
(3) Application of fiber reinforced plastics in automobiles
Fiber reinforced plastic is a composite material of resin and reinforcing fiber. The automotive industry mainly uses glass fiber reinforced thermoplastics, which have low density, easy molding, flexible design, corrosion resistance, impact resistance, vibration resistance, heat insulation and electrical insulation. Easy to apply, high strength and low cost.
At present, the front fenders, hoods and tailgates made of glass fiber reinforced unsaturated polyester sheet molding compound (SMC) have been widely used in automobile bodies; glass fiber mats reinforced with glass fiber (felt) as reinforcing material Thermoplastic composites (GMT) have been initially applied to components such as seat frames, bumpers, battery brackets, instrument panels, floors, guards, hoods, pedals, and back doors.
(4) Application of carbon fiber composite materials in automobiles
Carbon Fiber is a fibrous carbon material with a diameter of usually several micrometers and a carbon content of usually more than 90%. Carbon fiber has quite good physical properties. The key mechanical indexes are tensile strength and tensile modulus. Tensile strength refers to the maximum stress that the material can withstand before tensile fracture. The tensile modulus refers to the material being subjected to tensile stress. The ratio of stress to deformation, the higher the modulus value, the better the stiffness of carbon fiber. Theoretically, the tensile strength of carbon fiber can reach 180 GPa, and the tensile modulus is about 1000 GPa.
In addition to excellent physical properties, carbon fiber also has excellent chemical properties, such as corrosion resistance, high temperature resistance, good electrical and thermal conductivity, so carbon fiber composites made of carbon fiber and various matrix materials after composite process are the first. The aerospace and military fields are widely used.
Carbon fiber composites are not only superior in mechanical properties to metal materials, but also have much lower density, which is beneficial to reduce the weight of products, which is very important in areas such as aerospace and other areas where weight is extremely sensitive. In recent years, with the development of carbon fiber composite molding technology and the reduction of cost, more and more applications in automobile lightweighting have been applied, and it can even be used to make automobile bodies. Its appearance has led to the development of vehicles based on modified plastics and composite materials. The realization of lightweight solutions is possible.
Physical properties comparison between carbon fiber composites and other materials
(5) Automotive lightweight solutions
In summary, with the development of fiber reinforced plastics technology, especially the development of carbon fiber composite technology, the overall lightweight solution of automotive based on modified plastics and composite materials has become possible. The main obstacle now is that the price of carbon fiber is too high. The price of large tow carbon fiber used in the automotive industry is currently above US$15/kg. Only when the price drops to US$10/kg or below, the intermediate price is around RMB300,000. The car can be used on a large scale.
4. Market analysis of modified plastics for vehicles
(1) Global automotive modified plastics market
At present, the highest use of modified plastics is German bicycles. The use rate of modified plastics has reached 22% for 300-360 kg, and the average level in Europe and the United States has reached 16% for 210-260 kg. The use of modified plastics for bicycles is only 8% at 100-130 kg.
In 2016, a total of 21.86 million passenger cars were produced in Europe and the United States, while China produced 24.24 million passenger cars. The calculated weighted average amount of modified plastics for global passenger cars was 152-191 kg, with a median of 171. kilogram. In 2016, the global passenger vehicle output was 72.1 million vehicles, and the required modified plastics were 12.33 million tons. According to the unit price of 18,000 yuan/ton, the global market for modified plastics for vehicles in 2016 was 221.9 billion yuan.
According to forecasts, by 2020, global passenger vehicle production will reach 81.48 million units, and considering the increase in the consumption of modified plastics for bicycles under the light weight trend of automobiles, it is assumed that by 2020, the global use of bicycle modified plastics will increase to 200 kg. The market space will be close to 300 billion yuan, and the average annual growth rate from 2017 to 2020 is about 7%. The major players in the global automotive modified plastics market are large chemical companies such as BASF, PolyOne, Dow DuPont, Covestro and others.
(2) China's automotive modified plastics market
At present, there are thousands of enterprises in China engaged in the production of modified plastics, but there are only more than 70 enterprises above designated size (capacity of more than 3,000 tons). From the perspective of production capacity, domestic enterprises account for about 73%, and foreign or joint ventures account for about 27%. %, but from the market share, domestic market share is only 30%, while foreign companies have a market share of 70%. At present, foreign large enterprises that have established modified plastic production bases in China include SABIC, DuPont, SOLVAY, Dow, BASF, LANXESS, BAYER, Celanese, Asahi Kasei, Polyplastics, and Samsung. Company, LG Company, Kumho Company, Netherlands DSM Company, etc.
Further specific to the field of modified plastics for vehicles, according to the domestic passenger vehicle output of 24.24 million in 2016 and the 115 kg of bicycle modified plastics, the domestic demand for modified plastics for vehicles is 2.78 million tons, and the market space is 400. More than 100 million yuan (calculated according to 15,000 yuan per ton). However, compared with 40% of the world's modified plastics used in the automotive industry, China is only about 10%. In addition, the growth rate of domestic passenger vehicles is much larger than the growth rate of global passenger vehicles. According to the prediction of the Geshi Automobile Research Institute, China will take 2020. The production capacity of vehicles will reach 28.85 million (in 2017, the growth rate is 6.95%, the growth rate in 2010 is 5.15%, the growth rate in 2019 is 3.01%, and the growth rate in 2020 is 4.75%). The development potential of domestic automotive modified plastics is huge.
On the other hand, the “Technology Roadmap for Energy Saving and New Energy Vehicles†issued by the China Automotive Engineering Society in October 2016 pointed out that by 2020, 2025, and 2030, the vehicle quality should be reduced by 10% and 20% respectively compared with 2015. %, 35%. In addition, China is also the world's largest new energy vehicle market. In 2016, new energy passenger vehicle sales accounted for 43.7% of the world's total. In the next few years, it will grow at a rate of about 40% per year. By 2020, production will reach 2 million units. Energy vehicles are more dependent on lightweight technology, so the amount of domestic bicycle modified plastics will increase significantly.
It is conservatively estimated that even if the domestic consumption of modified plastics for passenger cars will only reach 150kg by 2020, the market space will be close to 65 billion yuan, and the average annual growth rate will reach 11% in 2017-2020; if the bicycle usage reaches 2020 by 2020 Now the global average is 170kg, the market space will exceed 70 billion yuan, and the average annual growth rate will reach 15% in 2017-2020. If the bicycle consumption will catch up with the global average of 200kg by 2020, the market space will exceed 85 billion yuan. The average annual growth rate for 2017-2020 will be close to 20%. 
Editor in charge: Wang Ning 12
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