LyondellBasell PP Compounds for Automotive – Weight Saving Made Easy

\LyondellBasell PP Compounds for Automotive – Weight Saving Made Easy
There is still untapped potential to save 10 kg or more of weight per vehicle in automotive applications with polypropylene (PP) compounds. With all car manufacturers striving to make parts lighter without compromising on strength and safety standards or improve on the design and surface features of visible parts, LyondellBasell offers a range of advanced copolymers to address this challenge.

Low density compounds in exterior parts
One new development to be highlighted includes advanced PP materials for exterior parts. The use of Hifax resins in the bumpers for the new Audi A4 and the BMW i8 realize a significant weight saving compared with the materials used before. BMW now uses Hifax grade TKC 461X, a low density PP compound with 12 % talc content and reported weight savings of 7%. Hifax grade TKC 435X is now used by Audi and this 9% talc-filled grade replacing a 20% predecessor grade offers an even bigger weight saving. Both materials display a low thermal coefficient of expansion throughout the required temperature range and a good balance between toughness and stiffness.
An example for cost saving in automotive applications is the use of Hifax grade TRC 134P in the rocker panel of the BMW i3. Using metallic pigments to color this part in “Electric Blue”, which is the signature color of all BMW hybrid vehicles, not only eliminated a subsequent paint process with lower system costs but also saved weight compared to the painted PP compound material used before.

In order to demonstrate the innovative strength from other geographic regions, an extractor grille from North America is displayed. In the Hood Extractor Grille for the Dodge Viper ACR Extreme, Hifax grade TYC 1235X is used. This material has been designed as low density PP compound to replace engineering resins (PC/ABS) and sheet metal applications.

Aesthetics in automotive interiors
LyondellBasell has also recently introduced Softell Textile to its comprehensive portfolio of products for interior automotive applications. Injection molded components made out of new PP compound display a textile-like surface finish requested by modern automotive material engineers and designers.

Softell Textile is a scratch resistant, low gloss PP compound with a pleasant soft touch. Due to its excellent low temperature impact strength it is well suited for interior components with integrated airbag system. Therefore, it can potentially be used as trim for the A, B or C pillar. Customers also

reported that the components could now be produced more cost effectively with lower reject rates compared to the use of real textile fabrics.

Today, automotive designers also place a strong emphasis on engine covers as a design element in the engine compartment. VW has recently replaced a polyamide engine cover with Hostacom resin from LyondellBasell and reported weight savings of 25% – with a significant improvement in sound dampening. The glass-fiber reinforced compound was used as a “drop-in” solution providing better processability. Due to its good thermal stability, it passed all the required test procedures.

LyondellBasell (NYSE: LYB) is one of the largest plastics, chemicals and refining companies in the world. Driven by its 13,000 employees around the globe, LyondellBasell produces materials and products that are key to advancing solutions to modern challenges like enhancing food safety through lightweight and flexible packaging, protecting the purity of water supplies through stronger and more versatile pipes, and improving the safety, comfort and fuel efficiency of many of the cars and trucks on the road. LyondellBasell sells products into approximately 100 countries and is the world’s largest licensor of polyolefin technologies. In 2018, LyondellBasell was named to Fortune magazine’s list of the “World’s Most Admired Companies.”
SOURCE: LyondellBasell