DSM Engineering Plastics has introduced a range of both new materials and specific grades of existing materials, designed to deliver the required performance, whilst meeting the overall industry trends for lighter, more effective and greener solutions.

According to Richard Frissen, Business Development Manager Automotive at DSM Engineering Plastics, E&E is one of the major drivers for innovation in the automotive industry: “For years, the value of electric and electronics content in automotive has been growing between 5-10% per annum. New electrical systems and components are added to improve car comfort, safety or fuel economy. Engineering plastics play an important role in this segment, mostly as casing to contain and protect electrical and electronic content from its environment and/or to secure electrical insulation. Typical applications include electrical components such as junction boxes, ECU housings, E-motors, gear housings, bobbins, connectors, switches and wire harness insulation.

“Another main driver is the hybridisation & advanced battery technology as the most predominant ‘Green’ trend of the industry, with its main goal to realise fuel economy and reduced CO2 emissions. These new hybrid systems are facilitating and growing the need for new on-demand systems such as electrical power steering, electrical water and electrical oil pumps, as they can easily supply the electric power needed. For instance, by replacing a mechanically driven water pump by an electric one, with the additional benefits that it can be regulated and operated independently from the engine, approximately 0,2l/100km of fuel can be saved.”

Mr. Frissen adds: “However, as the automotive industry continues to look for system cost reduction, improved reliability and weight reduction for fuel economy, it is important that any innovation should not lead to a significant increase in car weight and/or reliability issues originating from complexity of the electrical wire harness architecture.”

In these types of applications, the majority of engineering plastics being used are PAs and PBTs because they offer either easy processing and assembly (PA6) or dimensional stability and high dielectric strength (PBT). For use at higher temperatures, there is a need to move to materials that offer a higher heat resistance. As major supplier of many of these polymers, DSM Engineering Plastics has a long track record in this industry segment, and is able to match highest quality and reliability demands.

On part component level, DSM contributes to the industry drivers by offering innovative solutions for parts integration (e.g. Laser Direct Structuring Technology), reduced wall thicknesses (e.g Stanyl® High Flow PA46), cycle time reductions (e.g. Akulon® Ultraflow® PA6) and base polymer cost-down alternatives like PPA replacement by Arnite® PET.

Richard Frissen concludes: “DSM Engineering Plastics is committed to continuing to meet the needs of the automotive E&E industry with a broad innovative product portfolio, market know-how and long track record.”

For additional information see below:

Appendix A: Key electrical systems used in a (future) car
Appendix B: Current DSM product range that meets the needs of the industry

Appendix A: Key electrical systems used in a (future) car:

Convenience

• Seat Adjustment
• Seat heating
• Electric Windows
• Electric Power Steering
• Tip-tronic gearbox
• Telematics/Infotainment

Thermal Control

• Climate Control
• Catalytic Converter Heating
• Electrical water pump
• Windscreen Defrosting

E-power Management System

• Micro, Mild, Full Hybrid
• Energy Storage/Battery
• Electrical motor Drive

Safety

• Air Bags
• Active Suspension, Anti Blocking Systeem (ABS), Electric Stability Program (ESP)
• Anti collision systems
• Auto Windscreen wiper system
• Daytime Running Light Lighting (LED),
• Brake force Dep. backlight

Fuel Economy

• Engine Management
• Electromagnetic valves
• Ignition
• Fuel Injection
• Integrated Starter Generator
• Electrical Oil pump
• Injection

Appendix B: Current DSM product range that meets the needs of the industry

Arnite® PBT/PET
Because of its dimensional stability and excellent chemical resistance, this material is widely used for fuse boxes, Electric Control Unit (ECU) Covers, actuator housings and sensors. In addition to standard glass-reinforced grades, DSM also produces a special Arnite TV8 260 Grade with high thoughness, improved hydrolysis resistance and enhanced fatigue performance. This grade is used, for example, for rear wiper gear housings.

To minimise tool correction costs, a special 30% glass fibre filled PBT/PET grade is available which significantly improves the warpage behaviour compared to standard PBTs, without sacrificing the mechanical or flow performance of other low warpage materials. Moreover, this new Arnite TV4 461 grade has low outgassing/fogging characteristics, ideal for optical applications like rain sensors and headlamp adjustment parts.

An intrinsic property of PBT is its extreme high dielectric strength, a key value for high voltage applications like ignition systems. In ignition ramps, Arnite TV6 241T – a 20 percent glass-reinforced and toughened grade – provides enhanced resistance to thermal shock compared to standard PBT. This grade is also suitable for insert mouldings. For components with increased thermal and dynamic demands, where PBTs no longer fulfil the requirements, e.g. LED headlamp cooling fans. Arnite PET offers new areas of cost-down possibilities to replace well known HHR alternatives like PPAs.

Akulon® PA6, PA66
Generally speaking, Polyamides are widely used and the preferred material for Auto E&E components, provided dimension stability requirements and part tolerances can be matched. Especially for complex E-Box housings, low warpage requirements are met by using so called hybrid 10% glass-fibre / 20% mineral and 10% glass-fibre / 20% glass-spheres grades.

Apart from standard grades, DSM has introduced two Akulon Ultraflow hybrid grades (K-FHGM24, K-FHGR24) for Auto E&E components. These Akulon Ultraflow grades can reduce production costs through 20-40% shorter cycle times as compared to standard PA6 grades, whilst offering improved surface appearance (for example: keyless-go housing modules and processing advantages for complex ECU housings (lower pressure). For connectors and switches, DSM has a range of Akulon Ultraflow alternatives.

Stanyl® PA46
Thanks to its processing advantage in flow, short cycle time, high toughness and unmatched creep performance, Stanyl PA46 is ideally suited for components that need to meet the highest requirements for thermal resistance, oil resistance, or wear performance (gears).

The material’s characteristics allow thinnest wall section design to reduce weight and cost, or even to improve part performance at same component size. Typical application areas are E-motor parts, ABS ECU-Housings, sensors, day time running light lamp sockets, connectors, automatic gear box actuator parts, solenoids & bobbins and starter/alternator hybrid system parts.

In addition to standard grades, DSM offers special Stanyl High Flow Grades for thin-wall electric insulation purposes of E-motors, tailor made for on demand systems like ABS, Heat Ventilation and Cooling (HVAC), Electrical water & Oil Pump. Stanyl (PA46 - GF30) easily outperforms PPAs for thin-walled over-molding of a stator of an electric water pump. In end laminates used for rotor electrical insulation, wall thickness as low as 0.3 mm can be achieved. Even though walls are extremely thin, Stanyl still meets all electrical and mechanical requirements due to its unique toughness and creep performance.

Recently introduced Stanyl OCD2100 grades offer improved heat aging stability for extreme thermal conditions in the newest hybrid applications, able to withstand temperatures of up to 210°C for 5.000 hours and more.

Arnitel® Thermoplastic copolyester
Thermoplastic copolyesters (TPCs) are well known by cable converters working for the Automotive Lighting industry. DSM has developed a special Arnitel grade for primary wire insulation. Arnitel UM551 shows extreme low outgassing and fogging behaviour at 150 °C and sufficient ductility at very low temperatures. These especially required for adaptive forward light/ Dynamic Bending Light (AFL/DBL) functionality.

A newly developed Arnitel C product family is an even higher heat, flame retarded (V-2) and at the same time hydrolysis stable copolyester for the temperature segment T4/T5.. Main applications for Arnitel C are wire and cables as well as convoluted tubes for under the bonnet applications, withstanding up to 175°C for 3.000 hours and more. Additionally, Arnitel C offers outstanding abrasion resistance and fatigue properties, has excellent media compatibility, can easily be surmoulded with thermoplastic connectors and is recyclable. Arnitel C grades are designed to meet today’s regulatory needs such as ISO6722 and LV112. Due to its halogen freedom, the absence of plasticizers and other hazardous substances, Arnitel C flame retardant grades are also the materials of choice for the environmental conscious automotive future.

Laser Direct Structuring (LDS) innovation
LDS is a simple and precise environmentally friendly technology for producing 3D molded interconnect devices, which enables significant component count, space, height and cost reduction, through part integration. After molding, the interconnect pattern is directly written on the part and the conductive paths are plated where the plastic has been activated by the laser. DSM Engineering Plastics has already introduced a new grade of Xantar LDS PC/ABS suitable for Laser Direct Structuring (LDS) applications like antennas in mobile telecom products. Auto E&E systems and components such as sensors, where integrated circuitry is used to replace traditional printed circuit boards, can also benefit from this technology to save costs and space.