DSM PRESENTS RECENT INNOVATIONS IN AUTOMOTIVE E&E APPLICATIONS

DSM Engineering Plastics

DSM Engineering Plastics is one of the world's leading suppliers of quality engineering thermoplastics providing customer value through sustainable solutions that reflect the DSM People, Planet and Profit strategy. DSM Engineering Plastics delivers innovative opportunities for customers who design or produce electrical applications, electronic equipment, cars, barrier packaging films as well as many mechanical and extrusion applications. These markets are served with a broad portfolio of high performance materials including Akulon® 6 and 66 polyamides, Arnitel® TPC, Arnite® PBT and PET polyesters, Yparex® extrudable adhesive resins, and Stanyl® high heat 46 polyamides. Most recently, DSM Engineering Plastics introduced the first new polymer of the 21st century: Stanyl® ForTii™. DSM Engineering Plastics had sales in 2008 of EUR 761 with 1500 employees employed worldwide. More on: www.dsmep.com.

DSM – the Life Sciences and Materials Sciences Company

Royal DSM N.V. creates innovative products and services in Life Sciences and Materials Sciences that contribute to the quality of life. DSM’s products and services are used globally in a wide range of markets and applications, supporting a healthier, more sustainable and more enjoyable way of life. End markets include human and animal nutrition and health, personal care, pharmaceuticals, automotive, coatings and paint, electrical and electronics, life protection and housing. DSM has annual net sales of EUR 9.3 billion and employs some 23,500 people worldwide. The company is headquartered in the Netherlands, with locations on five continents. DSM is listed on Euronext Amsterdam. More information: www.dsm.com.

Akulon®, Arnite®, Arnitel®, Stanyl®, Stanyl® ForTii™, and Yparex® are registered trademarks of Royal DSM N.V.

Appendix A: Key electrical systems used in a (future) car:

Convenience

• Seat Adjustment

• Seat heating

• Electric Windows

• Electric Power Steering

• Tip-tronic gearbox

• Telematics/Infotainment

Thermal Control

• Climate Control

• Catalytic Converter Heating

• Electrical water pump

• Windscreen Defrosting

E-power Management System

• Micro, Mild, Full Hybrid

• Energy Storage/Battery

• Electrical motor Drive

Safety

• Air Bags

• Active Suspension, Anti Blocking Systeem (ABS), Electric Stability Program (ESP)

• Anti collision systems

• Auto Windscreen wiper system

• Daytime Running Light Lighting (LED),

• Brake force Dep. backlight

Fuel Economy

• Engine Management

• Electromagnetic valves

• Ignition

• Fuel Injection

• Integrated Starter Generator

• Electrical Oil pump

• Injection

Appendix B: Current DSM product range that meets the needs of the industry

Arnite® PBT/PET

Because of its dimensional stability and excellent chemical resistance, this material is widely used for fuse boxes, Electric Control Unit (ECU) Covers, actuator housings and sensors. In addition to standard glass-reinforced grades, DSM also produces a special Arnite TV8 260 Grade with high thoughness, improved hydrolysis resistance and enhanced fatigue performance. This grade is used, for example, for rear wiper gear housings.

To minimise tool correction costs, a special 30% glass fibre filled PBT/PET grade is available which significantly improves the warpage behaviour compared to standard PBTs, without sacrificing the mechanical or flow performance of other low warpage materials. Moreover, this new Arnite TV4 461 grade has low outgassing/fogging characteristics, ideal for optical applications like rain sensors and headlamp adjustment parts.

An intrinsic property of PBT is its extreme high dielectric strength, a key value for high voltage applications like ignition systems. In ignition ramps, Arnite TV6 241T – a 20 percent glass-reinforced and toughened grade – provides enhanced resistance to thermal shock compared to standard PBT. This grade is also suitable for insert mouldings. For components with increased thermal and dynamic demands, where PBTs no longer fulfil the requirements, e.g. LED headlamp cooling fans. Arnite PET offers new areas of cost-down possibilities to replace well known HHR alternatives like PPAs.

Akulon® PA6, PA66

Generally speaking, Polyamides are widely used and the preferred material for Auto E&E components, provided dimension stability requirements and part tolerances can be matched. Especially for complex E-Box housings, low warpage requirements are met by using so called hybrid 10% glass-fibre / 20% mineral and 10% glass-fibre / 20% glass-spheres grades.

Apart from standard grades, DSM has introduced two Akulon Ultraflow hybrid grades (K-FHGM24, K-FHGR24) for Auto E&E components. These Akulon Ultraflow grades can reduce production costs through 20-40% shorter cycle times as compared to standard PA6 grades, whilst offering improved surface appearance (for example: keyless-go housing modules and processing advantages for complex ECU housings (lower pressure). For connectors and switches, DSM has a range of Akulon Ultraflow alternatives.

Stanyl® PA46

Thanks to its processing advantage in flow, short cycle time, high toughness and unmatched creep performance, Stanyl PA46 is ideally suited for components that need to meet the highest requirements for thermal resistance, oil resistance, or wear performance (gears).

The material’s characteristics allow thinnest wall section design to reduce weight and cost, or even to improve part performance at same component size. Typical application areas are E-motor parts, ABS ECU-Housings, sensors, day time running light lamp sockets, connectors, automatic gear box actuator parts, solenoids & bobbins and starter/alternator hybrid system parts.

In addition to standard grades, DSM offers special Stanyl High Flow Grades for thin-wall electric insulation purposes of E-motors, tailor made for on demand systems like ABS, Heat Ventilation and Cooling (HVAC), Electrical water & Oil Pump. Stanyl (PA46 - GF30) easily outperforms PPAs for thin-walled over-molding of a stator of an electric water pump. In end laminates used for rotor electrical insulation, wall thickness as low as 0.3 mm can be achieved. Even though walls are extremely thin, Stanyl still meets all electrical and mechanical requirements due to its unique toughness and creep performance.

Recently introduced Stanyl OCD2100 grades offer improved heat aging stability for extreme thermal conditions in the newest hybrid applications, able to withstand temperatures of up to 210°C for 5.000 hours and more.

Arnitel® Thermoplastic copolyester

Thermoplastic copolyesters (TPCs) are well known by cable converters working for the Automotive Lighting industry. DSM has developed a special Arnitel grade for primary wire insulation. Arnitel UM551 shows extreme low outgassing and fogging behaviour at 150 °C and sufficient ductility at very low temperatures. These especially required for adaptive forward light/ Dynamic Bending Light (AFL/DBL) functionality.

A newly developed Arnitel C product family is an even higher heat, flame retarded (V-2) and at the same time hydrolysis stable copolyester for the temperature segment T4/T5.. Main applications for Arnitel C are wire and cables as well as convoluted tubes for under the bonnet applications, withstanding up to 175°C for 3.000 hours and more. Additionally, Arnitel C offers outstanding abrasion resistance and fatigue properties, has excellent media compatibility, can easily be surmoulded with thermoplastic connectors and is recyclable. Arnitel C grades are designed to meet today’s regulatory needs such as ISO6722 and LV112. Due to its halogen freedom, the absence of plasticizers and other hazardous substances, Arnitel C flame retardant grades are also the materials of choice for the environmental conscious automotive future.

Laser Direct Structuring (LDS) innovation

LDS is a simple and precise environmentally friendly technology for producing 3D molded interconnect devices, which enables significant component count, space, height and cost reduction, through part integration. After molding, the interconnect pattern is directly written on the part and the conductive paths are plated where the plastic has been activated by the laser. DSM Engineering Plastics has already introduced a new grade of Xantar LDS PC/ABS suitable for Laser Direct Structuring (LDS) applications like antennas in mobile telecom products. Auto E&E systems and components such as sensors, where integrated circuitry is used to replace traditional printed circuit boards, can also benefit from this technology to save costs and space.