Plastics has to innovate to succeed in cars

Edited by the Engineeringtalk editorial team Sep 11, 2001

Resin suppliers, together with OEMs and processors, must continue to introduce innovative products and technologies to further drive the development of new applications for engineering. plastics in th

Resin suppliers, together with OEMs and processors, must continue to introduce innovative products and technologies to further drive the development of new applications for engineering plastics in the automotive market, according to a new study from Frost and Sullivan.

Developing technologies that are credible alternatives to traditional materials such as metal and glass can be expected to open up new market opportunities.

David Platt, Senior Plastics Industry Analyst at Frost and Sullivan explains; "lower growth is predicted for engineering plastics in the automotive industry during the period 2001-2007 because of the downturn in European car production and also due to the growing market maturity for plastics in a number of important automotive applications.

Car producers will however continue to strive for lower costs, weight reduction and fuel economy, while at the same time introducing more comfort and safety features into their products.

These requirements, combined with technological innovation, will drive the development of new applications for engineering plastics in passenger cars." There are many examples of how new technologies are being developed to create opportunities for plastics in the automotive market.

Some of the most notable are: * GE Plastics Noryl products based on blends of polyphenylene oxide have the advantages of better heat resistance and conductivity, which has led to their replacement of other polymers in bumper systems.

Noryl's better heat resistance and lower odor emissions also gives it an advantage over PC/ABS for car instrument panels.

* Bayer's "hybrid technology", binding plastics and steel, which lowers weight and module costs and creates a high load-bearing capacity while allowing high energy absorption has led to its use in components for doors, seats, front ends and bumper brackets.

* Exatec's automotive glazing systems based on polycarbonate are thought to give a weight saving of around 40% compared with glass.

Product and systems development is focussed on the rear and side windows, which should be ready for market testing in 2002.

In 2000, the total tonnage of engineering plastic used in passenger cars was 1.4 million tonnes, the study forecasts that in 2007 this will have risen to 1.7million tonnes, representing a 2.6 % compound annual growth rate.

This is significantly lower than the previous 4 years when unit rate growth averaged nearly 6% per annum.

Use of plastics in electrical and lighting systems and under the bonnet applications will show the fastest growth rates, whilst the market shares for both interior and exterior plastics will decline.

Polypropylene is by far the most commonly used resin and is found mainly inside the car for instrument and door panels.

However, over the forecast period it is expected to lose market share to other polymers such as PC/ABS blends.

This new study is an in-depth analysis of trends in the use of all types of engineering plastics, throughout the range of automotive application areas.

It gives an insight into the competitive structure of the market and makes strategic recommendations for future success in this market.