Borealis and Borouge polypropylene (PP) materials facilitate the production of lightweight high performance automotive parts that meet the same rigorous demands as compact material and heavier parts, delivering cost-efficiency, weight reduction and improved environmental performance.
PP Pedal Carrier System
At the 2011 Société Française des Ingénieurs des Plastiques' (SFIP) Congress on June 8-9, Borealis and Borouge, one of the leading providers of innovative, value creating plastics solutions, will present their latest innovations for the automotive industry aimed at reducing vehicle weight. Designed to aid Tier One suppliers and original equipment manufacturers (OEMs) meet the market's current trends and challenges, Borealis and Borouge industry solutions can lower overall production costs through improved handling, reduced overall energy consumption and the elimination of manufacturing steps.
During the event, Emmanuel Boissard, Senior Application Development Engineer from Borealis, will present a paper entitled "Allégement dans l'Automobile: Nouveaux concepts matiére." The paper will highlight Borealis and Borouge's latest Innovative Solutions in Services (simulation), Products (PP specialties high flow) and Segments (under the bonnet, exterior, interior).
Borealis and Borouge's PP materials help to further advance cost-efficiency, weight reduction and environmental performance the current automotive industry's challenges. Key amongst them is the development of lightweight parts that can meet or even outperform parts made in metal and/or other engineered materials.
Global innovations in three key application areas
Key examples for under the bonnet:
Key examples for exterior:
- VW became the first automotive OEM to switch from glass reinforced polyamides to Borealis' high-performance PP for air intake manifolds (AIMs) thereby reducing weight up to 15% for VW models Golf, Polo, SEAT and Skoda cars with VW 1.4/63kW and VW 1.6/ 77kW MPI-based engines
- Borealis' innovative PP was selected for applications including pedal carrier systems for FIAT (several models) and OPEL (Corsa, Insignia) providing OEMs with a minimum of a 15% weight savings versus previous solutions as well as design freedom and very good processability
- Thanks to the latest generation of PP glass fiber from Borealis, front end modules (FEM) are also applications where Borealis PP specialties will be used in new platforms set to be commercialized in 2012. A weight savings of 15% will be achieved compared to the previous solution
Key example for interior:
- DAIMLER selected Borealis' innovative PP and PP high flow for body panels in their Smart Fortwo model (PC/PBT replacement) achieving a 15% weight savings
- Another success story in body panels is the IVECO Stralis where SMC has been replaced with Borealis' high performance PP, a 30% long glass fiber reinforced PP compound. Key benefits for IVECO include low gap tolerance, lower cycle time and lower scrap rate, low VOC and emissions and a 35% weight reduction
- In partnership with BMW and thanks to Borealis' innovative PP and process technology, the 7 and 5 Series Instrument Panel business case has been implemented to save 23% versus existing solutions, fulfilling the crash needs and dimensional requirements specified
- A customised all PP rear seat carrier was also developed for the new BMW 7 and 5 Series, delivering a significant weight reduction of 35% for the total system and improved recyclability by using an all PP solution.
Harald Hammer, Borealis' Vice President for Mobility, says, "Borealis and Borouge are innovating for and investing in the global automotive industry. We are committed to reducing vehicle weight with our lightweight innovations, expanding global supply capabilities for the automotive industry and strengthening our on ground support with strong local reinforcement."
Borealis is one of the leading providers 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
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.