Pioneering developments in high performance polypropylenes (PP) under the bonnet and on the vehicle exterior take centre stage on the Borealis and Borouge stand at the annual “Plastics in Automotive Engineering” conference organized by the VDI Association of German Engineers in Mannheim, Germany on April 6-7.
The innovations provide the latest proof of how award-winning materials made by Borealis, a leading provider of chemical and innovative plastics solutions, are increasingly used in automotive applications for their ability to provide both form and function while reducing costs.
Air intake manifold (AIM) - Borealis and Borouge will exhibit the glass-reinforced PP AIM now fitted to all 1.4 and 1.6 litre engines on Volkswagen (VW) Golf, Polo, Seat and Skoda models. The AIM is injection moulded in Xmod™ GB306SAF, a high performance 36% glass fibre reinforced compound that last year received the Frost & Sullivan 2010 Global New Product Innovation Award in the “Automotive under the Hood Plastics” category. The award recognises the ability of the compound to significantly lower system and production costs for automotive system suppliers and manufacturers.
Borealis Xmod GB306SAF represents a paradigm shift in this application area, traditionally dominated by glass reinforced polyamides, as it is specifically tailored for AIMs and other technical under the bonnet components that are exposed to high loads, peak temperatures of up to 140°C, continuous vibration, hot oil and chemicals. Borealis Xmod GB306SAF also contributes to improved production cost-efficiency, thanks to its lower processing temperatures and lower density. The usage of Borealis’ advanced PP solution significantly reduces part weight (as much as 15% less than polyamide). Considering that on average, 1 kg of PP used in a car can provide an estimated 8.3 kg CO₂ savings over its life cycle, Borealis’ material can make a significant contribution to energy savings and climate protection.
“Emissions and weight reduction are big challenges and substitution of heavy metal and engineering plastic components with lighter reinforced polyolefins enables weight and emissions targets to be achieved,” says Robert Outram, Global Programme Manager - Transportation Chemicals, Frost & Sullivan. “Borealis is a pioneer company in the field of advanced materials for automotive applications. Moreover, it has been successful getting its products to market where so many other plastics companies have failed.”
VW Touareg bumper fascias – VW also chose Borealis materials for their Touareg bumper fascias, as the display will show. The bumper fascias are made from Daplen™ VB4411, an elastomer modified PP (TPO) containing 10% mineral filler. Daplen was chosen because VW required a material with very low thermal expansion and a solution that would yield parts with “zero gap” dimensional tolerance.
Daplen compounds are widely recognised in the automotive community for meeting the ergonomic, aesthetic and high level performance and safety criteria required for today’s cutting-edge vehicles. VW is one of several major original equipment manufacturers (OEMs) to use these materials for body panels.
“Every year, the VDI conference brings in hundreds of automotive engineers from around the world, all along the automotive value chain,” says Harald Hammer, Borealis Vice President Mobility. “That is why we will be there again to illustrate our expertise and to show how we are a key partner for turning their ideas into reality. The close cooperation with our customers leads to the most cost-effective solutions to meet their needs for increased manufacturing efficiency, vehicle performance and safety, and environmental responsibility.”
Mobility Business Units
Borealis and Borouge’s Mobility Business Units specialise in supplying advanced polyolefin plastics to leading manufactures in the automotive industry. The portfolio of products includes materials for exterior, interior and under the bonnet applications, such as bumpers, body panels, trims, dashboard, door cladding, climate control units, air intake manifolds as well as battery cases. Through close collaboration with our customers, innovative technologies and our extensive product portfolio, Borealis and Borouge have established a leading position in the automotive market across Europe, South America and Asia.
Both companies find that customer-driven innovation is the only way to achieve and sustain progress. Through foresight and focus on customer needs, we continue to provide innovative solutions for the automotive industry that add real value throughout the value chain. We also know the high value that our customers in the automotive industry place on quality and product consistency. We pride ourselves on the performance of our products, and through ongoing investment in upgrades and new plant programmes, we continue to set new records for output efficiency and product reliability.
They believe that responsiveness is the foundation of fruitful customer partnerships. The Business Unit Mobility ensures this through their resources of strategically placed global hubs: Borealis Belgium, Borealis Central Europe, Monza (Italy), two compounding facilities in Brazil, Itatiba and Triunfo and two in China, Shanghai and Guangzhou (end 2012). In addition, they are supported by the innovation centres all over the world.
Borealis is a leading provider of chemical and innovative plastics solutions that create value for society. With sales of EUR 6.3 billion in 2010, customers in over 120 countries, and 5,100 employees worldwide, Borealis is owned 64% by the International Petroleum Investment Company (IPIC) of Abu Dhabi and 36% by OMV, the leading energy group in the European growth belt. Borealis is headquartered in Vienna, Austria, and has production locations, innovation centres and customer service centres across Europe and the Americas.
Through Borouge, a joint venture between Borealis and the Abu Dhabi National Oil Company (ADNOC), one of the world’s major oil and gas companies, the company’s footprint reaches out to the Middle East, Asia Pacific, the Indian sub-continent and Africa. Established in 1998, Borouge employs approximately 1,600 people, has customers in more than 50 countries and its headquarters are in Abu Dhabi in the UAE and Singapore.
Building on Borealis’ unique Borstar® technology and their experience in polyolefins of more than 50 years, Borealis and Borouge provide innovative, value creating plastics solutions for the infrastructure (pipe systems and power and communication cables), automotive and advanced packaging markets. In addition, Borealis offers a wide range of base chemicals from melamine and plant nutrients to phenol and acetone.
Today, Borealis and Borouge have a manufacturing capacity of over 5.4 million tonnes of polyolefins (polyethylene and polypropylene) per year of which 26% are the result of a recently completed capacity expansion in Abu Dhabi. An additional 2.5 million tonnes per year is scheduled for completion by mid-2014, creating the world’s largest integrated polyolefins plant. The companies continue to invest to ensure that their customers throughout the value chain, around the world, can always rely on superior products and security of supply.
Borouge (borouge.com) and Borealis (borealisgroup.com) are committed to the principles of Responsible Care® and proactively contribute to addressing the world’s water and sanitation challenges through their Water for the World™ (waterfortheworld.net) initiative.
Borstar, Xmod, Daplen and Water for the World are trademarks of the Borealis group.