AUTOMOTIVE LIGHT WEIGHT LAMINATION WARDS CONFERENCE 2017 HELMUT DOYEN, DIRECTOR OF SALES, SIKA AUTOMOTIVE
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1 AUTOMOTIVE LIGHT WEIGHT LAMINATION WARDS CONFERENCE 2017 HELMUT DOYEN, DIRECTOR OF SALES, SIKA AUTOMOTIVE
2 INTERIOR BONDING SOLUTIONS Application Lamination Door & Instrument Panels Headliners Load Floors Pillars Assembly Structural Bonding Decorative Parts Retainers Crash Pads Flocking Glove Boxes Consoles Technology SikaSense Water Based - Solvent Based SikaTherm - Water Based - Solvent Based SikaMelt - Hotmelt SikaMelt - Hotmelt SikaForce - 2C PUR SikaTherm - Water Based
3 OES - INTERIOR & EXTERIOR BONDING SOLUTIONS Component Bonding Interior Lamination Direct Glazing of Roof Systems Flocking Headlight Bonding Electronic Potting Interior Assembly
4 SIKA AUTOMOTIVE SOLUTIONS FOR OES WHEN INNOVATIONS LEAD TO BETTER VEHICLES > 5 MILLION DOOR PANELS FOR MULTIPLE OEMS ARE LAMINATED ANNUALLY WITH SIKA TECHNOLOGY. 25 MILLION DOORS ARE WATER PROVEN BY USING SikaMelt PRESSURE SENSITIVE ADHESIVE 3 MILLION Headliners LAMINATED WITH SikaTherm OUTFIT VEHICLE INTERIORS ANNUALLY 7 MILLION STEERING WHEELS MADE SOFT TO THE TOUCH ANNUALLY USING SIKA LAMINATION ADHESIVES 1 MILLION GLOVE BOXES FEEL VELVETY WHEN USING SikaTherm FOR FLOCKING 55 MILLION AIRBAG CONTROLS POTTED WITH SikaForce TECHNOLOGY SAVES PASSENGERS AND PEDESTRIANS LIVES. > 3 MILLION SPOILERS ARE BONDED EACH YEAR WITH SIKA TECHNOLOGY 2 MILLION ROOF MODULES ASSEMBLED ANNUALLY WITH SIKA TECHNOLOGY FOR MORE LIGHT INSIDE 25 MILLION HEADLAMPS BONDED WITH SIKA ADHESIVE TECHNOLOGIES LIGHT THE WAY FOR MORE THAN 12 MILLION VEHICLES ANNUALLY
5 ASSEMBLY OF WATER SHEDDERS Concept : Using foamed PSA hot melt vs Butyl Materials used PE films on painted steel Butyl density about 1.6 kg/l PSA hot melt about 1.0 kg/l foamed 40% kg/l final density 5 mm bead 3 m (118 ) 96 gr butyl vs 36 gr foamed PSA hot melt
6 LAMINATION TECHNOLOGIES SikaTherm Solvent Based SikaTherm Water Based SikaMelt PUR hot melt SikaMelt PO hot melt environmental benefits economic benefits
7 VW BEETLE LIGHTWEIGHTING
8 VW BEETLE, 1949
9 VW Beetle interior, 1949 Adhesive: SikaTherm - solvent based
10 VW Beetle interior, 1955 Adhesive: SikaTherm - solvent based
11 LAMINATION INSTRUMENT PANEL VW LUPO Concept: weight reduction using PP Spray Application SikaTherm - water based, pre-treated substrate Materials: GF PP with TPO skin
12 LAMINATION DOOR PANEL GOLF IV Concept : Door panel spray application SikaTherm water based adhesive Materials: ABS and TPO skin
13 LAMINATION PROCESS WITH SIKATHERM IR Vacuum Lamination Mixing Spray application Drying Press Lamination
14 MIXING
15 SPRAYING WATER BASED ADHESIVE
16 INNOVATIVE PRODUCTION Concept laminating more efficient, EHS oriented, simplified
17 GREENER - SIKAMELT -POLYOLEFIN HOT MELTS VACUUM LAMINATION OF TPO TO PP OR NF-PP SUBSTRATES WITH CURING & NON-CURING POLYOLEFIN HOT MELTS Pre-treatment step eliminated Pre-coating possible Easy application process Fast setting adhesive no crosslinking Operator & environmental friendly - No isocyanate no hazardous classification Excellent heat resistance unlimited open time
18 LAMINATION DOOR PANEL VW GOLF VI Concept bolster: pre-coating skin with SikaMelt - non reactive Olefin hot melt Materials: foam backed fabric with PP wood fiber Concept door upper: coating SikaMelt - PUR hot melt Materials: ABS with TPO skin
19 LAMINATION DOOR BOLSTER DODGE RAM Concept : pre-coating skin with SikaMelt - non reactive olefin hot melt Materials: PP with TPO skin
20 LAMINATION DOOR BOLSTER ACURA MDX Concept : pre-coating skin with SikaMelt - non reactive olefin hot melt Materials: PP with TPO skin
21 DOOR BOLSTER LAMINATION OPEL ASTRA Concept : pre-coating skin with SikaMelt - non reactive olefin hot melt Materials: PP with foam backed fabric
22 VACUUM-LAMINATION OF TOP ROLL HYUNDAI Concept : pre-coating skin with SikaMelt - non reactive olefin hot melt Materials: PP substrate with TPO skin
23 VACUUM-LAMINATION DOOR PANEL MERCEDES CLA Concept : pre-coating skin with SikaMelt - non reactive olefin hot melt Materials: PP substrate with TPO skin
24 LAMINATION OF LOAD FLOOR VW TOUAREG/PORSCHE CAYENNE Concept : pre-coating skin with SikaMelt - non reactive olefin hot melt Materials: PUR honeycomb with PP top coat and carpet
25 LAMINATION DOOR BOLSTER VW POLO Concept : pre-coating skin with SikaMelt - non reactive Olefin hot melt Materials: PP with foam backed fabric
26 LAMINATION DOOR PANEL VW ATLAS DOOR PANEL Concept : pre-coating skin with non reactive Olefin hot melt, Press lamination of bolster, vacuum lamination of door upper Materials: PP and TPO skin Concept armrest: coating with SikaMelt - PUR hot melt Materials: ABS and TPO skin
27 NATURAL FIBRE REINFORCED PLASTICS (NFRP) IN THE AUTOMOTIVE INDUSTRY
28 NFRP IN AUTOMOTIVE INDUSTRY BIO COMPOSITES Bio Composites Natural fibres (hemp, flax, jute, sisal, abaca, kenaf) Wood flour and fibres Natural fibre reinforced plastics (NFRP) Wood-Polymer Composites (WPC) (bio based) Polymers Source: Carus & Ederer et al. 2015
29 NFR-PP IN AUTOMOTIVE INDUSTRY PROCESSING TECHNOLOGIES & GRADES Compression molding Hot-compression molding of natural fiber based mat and polypropylene Injection molding PP-natural fiber granules 30-50% NF, 45-65% PP, 5% additives Resin-Transfer-Molding (RTM) Long fiber compression processes Fiber grades: wood, recycled cotton, flax, kenaf, hemp
30 3 MASS COMPARISON IP Mass per Part (Kg) 33% Mass Save mm TPO 2.2 mm 30% LGPP 1.8 mm 30% LGPP 2.2 mm 20% LGPP 1400 gsm Natural Fiber - GFPP / CHyM Mass (kg/instrument panel)
31 MASS COMPARISON DOOR
32 VACUUM-LAMINATION DOOR PANEL MERCEDES E-CLASS Concept : pre-coating skin with SikaMelt - non reactive olefin hot melt Materials: 75% NF-PP, TPO skin
33 VACUUM-LAMINATION DOOR PANEL BMW 7 SERIES Concept : pre-coating skin with SikaMelt - reactive olefin hot melt Materials: 60% NF-PP, TPO skin
34 NEXT GENERATION LAMINATION Tier 1 suppliers manufacture a variety of interior parts being laminated in one plant The variety of substrates ABS, PP, NF requests different adhesives In the past, polar substrates like ABS could only be laminated with polar adhesives In the future? Concept : pre coating skin with SikaMelt - Non reactive Olefin hot melt Materials ABS, PP, NF-PP with TPO skin or fabrics Advantages: Product related no isocyanate, easy application, ready to use parts Process related one application equipment with one adhesive
35 THANK YOU FOR YOUR ATTENTION
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