Abstract
Research & Engineering questions / objectives – Issues
The European regulations for automotive pollution levels are getting progressively more restrictive. By mid 2014, the objective is to reach 130g of CO2 /km, and by 2020 the polluting emissions should not exceed 95g CO2/km. Therefore, the automotive industry must innovate to find technical solutions that meet these requirements. One of the technical solutions proposed is to limit polluting emissions by downsizing the weight of plastic parts in the current systems.
Without reducing our technical requirements, this paper presents the evaluation of a technical solution for lightweight with our current plastic materials through the addition of chemical foaming agents.
Methodology
Global vision of technical lightweight solutions with our plastic raw materials and therefore on our automotive parts: climate control parts and under the hood parts.
Explanation of the choice between the plastic material, the part and the process with the technical lightweight solutions evaluated.
Results
Synthesis of all tests performed for process and part validation, for fan system support. Analysis of mechanical property evolutions linked to weight reduction on specimens cut in the parts, at initial state and after ageing, according to the application.
Limitations of this study
The interactions between part & process such as the flow length/thickness ratio and the limitations between product & mechanical and temperature performance linked with specification requirements, define an application scope.
Why is it new in the field?
Some of these technical lightweight solutions are already implemented in other technical fields (such as domestic appliances) as well as in the automotive industry but for other parts such as door panels.
Innovation lies in the association between these technical lightweight solutions with our high performance applications (mechanical properties, stiffness in temperature, ageing under mechanical constraint)
Conclusion
Valeo expects to get positive results thanks to these technical lightweight solutions. Our aim is to integrate our new solutions in new projects and in serial production with thermal applications in the very near future.
KEYWORDS – Lightweight, plastic, under hood parts, climate control parts, foaming