GE Plastics’ Automotive Business “Goes Big” With Seven-Segment Structure Geared To Meet Key Customer Needs

Body Panels & Glazing

For automotive manufacturers seeking to differentiate themselves to their customers with top technological advancements for automotive exteriors, GE Plastics’ Automotive division offers a variety of innovative weight-reducing and cost-out solutions for Signature Surfaces* in body panels, glazing, and no-paint solutions.

In the body panels segment, GE is helping drive cost out by eliminating the need for secondary paint operations with “no-paint” solutions. Advanced Lexan* SLX film provides automakers with a ‘paint-free’ option that can deliver a Class A surface finish with deep gloss consumer appeal. Furthermore, the film has the ability to withstand prolonged exposure to UV rays with minimal fading, and it offers greater scratch and chemical resistance when compared to similar films.

GE Plastics products also allow customized painting options through all three traditional paint methods. Off-line solutions include paintable – or molded-in-color – Xenoy* resin panels. On-line and in-line painted body panels can also be manufactured from Noryl GTX* resins.

In addition, two thermoplastic technology platforms in the works at GE Plastics introduce a new chapter in the company’s tradition of enabling automotive exterior body panels that offer a balance of lightweight performance, reliable properties against impact, and competitive cost. High Modulus Ductile (HMD) and High Performance ThermoPlastic Composites (HPPC) may signal two advanced materials solutions for automotive engineers who require weight reduction, design flexibility, improved moldability, and impact protection for large body panels. These technologies were developed to help respond to the growing demand from consumers to produce more stylish automobiles with greater interior space, higher speed, and optimized performance.

In the glazing area, wrap-around glazing takes design to a new level, helping to give drivers and passengers a better all-round view, while offering outstanding impact resistance. GE Plastics turned imagination into reality with Lexan resin glazing that can provide backlights, rear quarter windows, bidirectional and modulated panoramic roof systems with integrated features in complex shapes that glass materials cannot deliver.

Combining Lexan polycarbonate resin with Exatec® 900 coating, from Exatec LLC, an innovative plasma coating system that offers long-term weathering and abrasion resistance at higher levels of performance compared to traditional hardcoats. Additionally it offers customers leading solutions for customers seeking to provide consumers with a potential open-air view to the world.

In optimizing this technology Exatec LLC has recently introduced Exatec 900vt, a specially modified system for large-surface ‘vehicle tops’ that permits the simultaneous application of different coatings on the A and B sides of the roof glazing. This can save costs by eliminating the need for the weathering layer on the interior side. However, where regulatory specifications also require weathering protection on the inside, as in the case of side windows, Exatec 900 continues to be a preferred system.

Lexan resin glazing can offer weight savings of up to 50 percent vs. glass and metal systems, while helping to lower the center of gravity for greater stability. In support of these technologies, the company recently installed a new body panels and glazing machine in the Application Technology Center located in Bergen op Zoom, Netherlands and Shanghai, China.

Components

From bumper to bumper, GE Plastics offers a wide variety of high performance engineering thermoplastics and composites for exterior and interior component applications. Geloy* XTW resin, for example, is a game-changing material that may deliver three- to five-times better color and gloss retention than conventional acrylic-styrene-acrylonitriles (ASAs), and comes in a spectrum of colors. More than additives, this revolutionary resin uses new polymer building blocks to dramatically improve weatherability in exterior applications. While molded-in color eliminates paint and hard coat, automakers can also achieve blacks that are deeper and darker, whites that are brighter and cleaner, along with an excellent depth of image that will be noticed and appreciated by auto consumers.

Reduction of total systems costs may also be achieved by replacing secondary paint operations with a “no paint” alternative to metal. This is also possible for exterior components with the help of Geloy XTW resins and Visualfx* resin solutions. Visualfx resin is GE’s premium resin formulated with a variety of effects (i.e. luminescent, diffusion, and many more) inherent in the pellet to create colorful and exceptionally rich looking parts. Visualfx resins help designers to explore new boundaries without costly secondary paint and coating operations.

The newest grade of Noryl* resin can help manufacturers produce blow-molded spoilers with lower system costs by means of maximized efficiency in manufacturing via reduced sanding time. Thinner wall capability with equal performance along with higher heat performance, tensile and impact strength, and coefficient of thermal expansion (CTE) vs. high heat acrylonitrile butadiene styrene (ABS) also help manufacturers with reducing their system costs. This new grade may also provide lower odor and improved chemical resistance to gasoline and diesel fuel that can potentially cause damage to spoiler surfaces.

Another new material is high-heat, conductive Noryl GTX resin, which enables on- and in-line painting, while eliminating the need for a conductive primer. It can also provide improved paint transfer efficiency (reduced volatile organic compounds (VOCs)/sludge), cycle time reduction, and improved quality over comparable materials.

Noryl GTX resin is an excellent choice for tank flaps, providing automotive manufacturers a cost-effective, on-line painting solution vs. off-line painting. It also offers low warpage, dimensional stability, reduced environmental impact, and higher overall quality compared to traditional materials.

A further GE introduction is a new chrome plating grade of Cycoloy* resin for exterior and interior door handles, running boards, wheel covers, grilles, roof racks and trim components, Poised to respond to new trends, the new Cycoloy resin provides a strong and durable solution to fashionable metallic looks that give shine and gloss, and enable vehicle consumers to differentiate themselves from their peers.

Lighting

Automotive lighting systems made from GE Plastics’ resins have proven to be tough, stylish, and durable against the high heat of projector and fog lamps. Millions of vehicles worldwide already rely on standard Lexan resin grades to help provide high impact resistance and clarity in headlight lenses and bezels while simultaneously creating Signature Surfaces.

Ultem* XH6050 resin, also delivers extraordinarily high modulus, plus outstanding heat resistance to 225 C. It also offers exceptional dimensional stability, strength and durability, and it is 100 percent recyclable using standard equipment.

The lighting segment at GE continues to help light the way for the automotive industry of today and tomorrow with new developments that offer signature surfaces and new tools to differentiate manufacturers.

Structures & Interiors

The experience of GE Plastics’ Automotive business in safety and structures and interiors is broad, encompassing instrument panels, headliners, and energy absorption systems that include injection-molded Federal Motor Vehicle Safety Standard (FMVSS) and solutions to meet Pedestrian Impact Protection requirements across the globe. Confirming this, a pedestrian protection energy absorber for the 2005 Suzuki Swift ‘sub-compact’ automobile featuring GE’s Xenoy resin, was named the first-ever winner in the Safety System category of the 2005 SPE Automotive Innovation Awards program.

The Suzuki energy absorber is injection molded from GE’s Xenoy resin and meets the EU regulation and contributes to obtaining Euro NCAP3. Using Xenoy resin that has an ideal balance of stiffness and ductility for this application, the co-work between SUZUKI and GE to study the design of energy absorber lay behind this outstanding project. Integrated front-end modules (FEMs) also support the development of lightweight all-plastic FEMs.

In support of these efforts, the company has installed a new pedestrian impact test system at its Moka Technology Center in Moka City, Tochigi, Japan, to help automotive customers validate new material technologies for front-end safety systems. This expanded pedestrian impact capability enables head impact tests with child and adult head forms according to the Japan New Car Assessment Program (J-NCAP) regulations, and lower-leg impact tests according to EEVC WG 17 regulations in Europe.

With a new Instrument Panel program in the works, GE presents a stylish and safe solution with the seamless integrated airbag door instrument panel system made with Lexan EXL resin. Innovative design enables the seamless integration of the air bag door into the instrument panel, for outstanding aesthetics, while helping to contribute to safety by facilitating robust air bag deployment without fragmentation, even at –40 C.

Under the Hood

Under the hood high performance components also provide benefits that may reduce cost, weight, integrate parts, and maintain high dimensional stability vs. metal. Furthermore, some applications may provide glass replacement in addition to ecologically optimized benefits.

With the introduction of GE’s Flexible Noryl resin these benefits can also be extended to wiring systems. GE’s Flexible Noryl resin can help meet the need for high-performance cable that also addressed requirements for halogen-free parts.

Flame-retardant Flexible Noryl resin offers the auto industry a new wire coating solution that provides superior properties compared to polyvinyl chloride (PVC) and cross-linked polyethylene (XLPE) and is an excellent candidate for thin- and ultra-thin-wall coatings that significantly reduce weight and size, and meet halogen-, chlorine-, and lead-free part requirements.

GE’s Flexible Noryl resin provides the key properties that leading automotive customers are seeking, including excellent temperature and flammability performance compared to other materials. For example, GE’s Flexible Noryl resin is rated at 110 C while PVC is rated at 85 C and further developments should boost the GE resin’s rating to 125 C. Using the GE material to replace traditional cable insulation also contributes an average weight reduction of 25 percent.

Electronic throttle bodies molded from GE’s high-heat Ultem resins may lower system cost and reduce parts by up to 30 percent, while eliminating machining and lowering weight by up to 50 percent when compared to traditional metal materials.

With a wide applications base ranging from air intake systems to engine covers to new flexible wire, GE Plastics offers a broad portfolio of engineering resins and composites designed to withstand high-heat and harsh chemical environments.

New Markets

GE is continuously investigating new technologies such as fibers, composites, hybrids and fuel cells and the solutions potential they may offer the automotive industry. It also evaluates current trends with a view to identifying and predicting new concepts and systems that can support OEMs and tier suppliers in the future.

In embracing the future, GE offers some of the most advanced global expertise, resources and support available in today’s fiercely competitive automotive industry. GE is one of only a few global players in resin and silicone technologies that can offer OEMs and Tier 1 customers the wherewithal to address safety and environmental legislation, as well as consumer demands for additional features, sophisticated aesthetics and design styling.

Design Innovation and Technology Demonstration

In addition to advancing its own technology, GE is also committed to advancing design innovation for its automotive customers. Toward this end, the company provides outstanding design support, application development, technical support, and customer service to OEMs and top tier suppliers around the globe. The active role GE plays in customers’ product development cycles continues to fuel emerging automotive needs relating to vehicle aesthetics, efficiency and performance.

GE uses traditional engineering tools, as well as state-of-the-art structural and mold filling analyses, predictive modeling and prototyping, and thinking-outside-the-box creativity. In conjunction with its growing basket of advanced materials, GE aims to deliver system solutions that add customer and consumer value by making vehicles safer, more cost efficient and more effectively differentiated. GE supports OEMs and Tier suppliers in all areas of application development from trend analysis and teardown, and product conceptualization through to commercialization.

Reader enquiries

GE Plastics, Automotive

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4600 AC Bergen op Zoom

+31 164 29 31 48

anne.clement@​ge.com