With high-performance plastics such as Durethan®, Pocan®, and Tepex®, LANXESS is already paving the way today for the cars of tomorrow
As lightweight as possible and environmentally compatible – the demands placed on the cars of the future are increasing worldwide. There are a number of reasons for this, such as a growing scarcity of resources, coupled with a rapid rise in mobilization, especially in emerging markets. Subsequently, the need to reduce environmentally harmful carbon-dioxide emissions (CO2) per vehicle is also increasing. On top of this, the higher demands of consumers must also be considered. Today’s consumers want more efficient models that are also safe, provide a high level of comfort, and go easy on the environment.
Sustainable mobility solution: lightweight design
Meeting all these needs creates challenges for car manufacturers and suppliers. One key technology here is lightweight design, because as efficient as a combustion engine these days may be, in the long run, automakers will most likely be able to cut the fuel consumption of gasoline- and diesel-powered vehicles further by reducing overall vehicle weight. In this matter, LANXESS offers innovative solutions with its high-performance plastics Durethan®, Pocan® and Tepex®. They can replace many metal applications in cars and, in doing so, help lower fuel consumption while ensuring maximum safety. Such plastics are already used today in the body and the interior of a vehicle, such as in engine mountings and seat components, as well as for fuel doors and door handles.
Automakers under pressure
Given stricter CO2 limits set by the European Commission, there seems to be no way around this shift in the automotive industry. Beginning in 2020, a limit of 95 grams of CO2 per kilometer will apply to all newly registered passenger cars. It was still 130 grams in 2015. “In order to meet this target, vehicle manufacturers are quite simply putting their cars on a diet,” says Tim Arping, Head of Marketing at LANXESS in the High Performance Materials business unit. “It is already possible to save up to 0.5 liters of fuel for every 100 kilometers with a weight reduction of 100 kilograms. Depending on the engine and type of fuel, that means between 8.8 and 12.5 fewer grams of carbon dioxide per kilometer.”
Plastics already make up approximately 15 percent of a modern medium-sized vehicle nowadays. However, Tim Arping believes that this percentage will continue to increase – including with a view to electromobility. “Electric cars have a greater range if the vehicles are lighter,” he explains. “The motor has to move less mass, which means the battery doesn’t have to work as hard.” The options that are available to satisfy consumers’ desire for the greatest possible range are therefore limited: “Either I install a larger battery – which comes with high costs – or I reduce the vehicle’s weight by using plastic components that are extremely stable, but still light.”
Plastics in the bodywork
The high-tech plastics Durethan®, Pocan®, and Tepex® from LANXESS provide numerous benefits in this regard. For one, not only are they lighter than steel or aluminum, but they can also withstand aggressive biofuels. On top of this, they can be combined with other materials, such as metal. Thanks to this hybrid technology developed by LANXESS, it is also possible today to manufacture load-bearing, highly durable components that are on a par with their strictly steel competitors when it comes to safety and stability. At the same time, numerous functions can be integrated into the hybrid modules using LANXESS plastics, thereby saving system costs. One example of this is front-end systems. “As a hybrid made from plastics and metal, they are up to 40 percent lighter than strictly metal designs,” Tim Arping says. “And in combination with our Tepex® technology, which can be used to include glass or carbon fibers in the plastic material, it is possible to cut down on weight even further.”
