Automotive plastics on display

Edited by the Engineeringtalk editorial team Mar 13, 2002

The Automotive Business of Owens Corning will be showing a selection of novel structural and acoustic composite solutions this week at the 26th VDI Conference on Plastics in Automotive Engineering.

The Automotive Business of Owens Corning will be showing a selection of innovative structural and acoustic composite solutions this week at the 26th VDI Conference on Plastics in Automotive Engineering in Mannheim, Germany.

"As a leader in the global composites market, OC Automotive understands the demands of automotive customers - weight reduction, cost reduction, improved structural and acoustic performance, application and design customisation and quicker speed to market", says Andy Hopkins, acting general manager of OC Automotive.

OC Automotive provides solutions in the form of value-added material systems, parts and design and engineering services, all of which are tailored to fit the needs of each individual customer.

For its stand at the VDI conference, OC Automotive has assembled a concise and easy-to-view exhibit featuring examples of the latest in innovative composites technology for the automotive industry.

The company's business managers and technical staff are available to answer questions.

Some of Owens Corning's most recent automotive applications on display at the booth will be a preformable system for large applications, Silentex noise control system, StaMax thermoplastic composites, and a rear quarter section and a European sports car hood, moulded in Sprint CBS.

The corner module piece of a General Motors 1500 Series Silverado pickup truck box demonstrates the first high-volume commercial application of a new preform technology pioneered by Owens Corning - the OC Preformable System.

This technology combines a proprietary glass fibre with unique binder technology to enable efficient manufacturing of reinforcement preforms.

For the Chevrolet Silverado, the moulded parts reduce the total weight of the vehicle by more than 22.7kg.

The tailgate itself is 6.8kg lighter than a current steel tailgate, which makes it easier to open and close.

A significant breakthrough in the use of composite materials in the North American automotive market is beginning to take place as OEMs incorporate composite materials to enhance the performance of pickup trucks.

Long awaited by the composites industry, new composite fenders, tailgates and cargo boxes are showing consumers the tough side of advanced composite materials.

Automakers say the composite parts resist dents, scratches and rust - problems that have traditionally plagued pickup truck owners.

The cargo box represents the largest structural composite part used in light truck production.

A full-scale General Motors 1500 Series Silverado pickup truck is also located close to the main entrance area of the conference centre.

The list of major automotive manufacturers and exhaust suppliers specifying Owens Corning's Silentex noise control system continues to grow.

Car makers now using the system include DaimlerChrysler, Ford, Toyota, Volvo and Volkswagen.

The system is now specified as standard equipment on 5.5 million vehicles worldwide.

All Owens Corning operations that manufacture Silentex are ISO9001 certified.

The Silentex noise control system is a totally integrated system using high-temperature glass fibre roving, tailor-made muffler filling machinery and a cost-effective filling process.

Owens Corning's Advantex roving exhibits significantly higher heat and corrosion resistance than traditional absorbent materials.

The increased durability of the continuous Advantex glass fibre allows silencers to be designed with consistent sound quality for the life of the vehicle.

Owens Corning is also showcasing StaMax P long fibre thermoplastic composites, a new material system designed for innovative semistructural solutions in the automotive market.

StaMax P is lighter, stronger and more cost-efficient than competitive materials.

The 2002 BMW Mini front-end carrier made with StaMax P thermoplastic composite demonstrates how the material can integrate component functions and reduce weight and overall system costs compared to steel.

StaMax is a joint venture formed in 1999 between Owens Corning and DSM Automotive of The Netherlands.

A rear quarter section on display, moulded in one step using Sprint CBS, a unique carbon fibre and epoxy composite, demonstrates how the material can produce body panels equivalent to 0.8mm steel with 81% weight savings.

In addition, a European sports car hood will also be on display.

This application weights only 4.2kg compared with 14.0kg for the original part.

Panel properties for this application are equivalent to 1/32in steel.

The unique material moulding process saves on capital investment and labour costs.