Long glass fiber polypropylene, a promising replacement for steel in cars

BEIJING, CHINA (Commodity Online):Long glass fiber polypropylene (LGFPP) may emerge as a preferred alternative to steel in front-end-module (FEM) in cars if the demonstration shown at the recently concluded Shanghai Auto Show is any indication.

The first Chinese-developed model vehicle with an all-plastic front-end module (FEM) was developed by Chang'an Automobile Co, one of China's largest automakers and the material LGFPP was developed by SABIC Innovative Plastics.

This major application uses STAMAX LGFPP resin to replace steel, cutting part weight by up to 40% and total vehicle weight by about four kilograms. In addition to weight reduction for improved fuel economy and lower emissions, the all-plastic FEM solution reduces overall system costs for Chang’an by enabling modular assembly for improved efficiency on its production line. This recent work with Chang’an illustrates SABIC Innovative Plastics’ ability to support automotive OEMs as they strive to develop lighter vehicles for improved fuel economy and lower emissions, while also lowering overall costs.

“We take a great deal of pride in having worked closely with Chang’an to advance both the design and production of the new CX30,” said Lisa Tang, general manager for China, Automotive, SABIC Innovative Plastics. “This project exemplifies the technical competency of our team in China and the ability to apply our expertise to help automotive OEMs innovate and take advantage of opportunities for reduction in both weight and cost by using our STAMAX LGFPP resins.”

 
In addition to the front-end module – which fully integrates the radiator, headlamps, lock bridges and bumper beams – Chang’an’s CX30 model uses SABIC Innovative Plastics’ Noryl GTX* resin for the fuel-filler door or tank flap. Molding the part from Noryl GTX resin enables it to be painted online along with the rest of the body in white. Typically, the part must be molded and painted by the component supplier, which can potentially cause color mismatches with the body.

The SABIC Innovative Plastics team delivered comprehensive technical support, training, advanced computer analyses and engineering design services on request to help Chang’an meet its goals.

 
“We are delighted with the support we received from SABIC Innovative Plastics,” said Wang Xiao, R&D director of interiors and exteriors for Chang’an Automobile. “Drawing on their materials and application leadership and technical know-how, we achieved significant improvements in quality and productivity. Integrating 22 metal components into one injection-molded part has greatly simplified the front-end structure of the CX30 model for lighter weight, easier assembling and overall cost reduction. This leap forward, combined with other advancements, helped us to produce high quality, world-class vehicles that will greatly please our customers.”

Ms. Xiao added: “As a leading Chinese auto brand, Chang’an Automobile continues to invest significant resources in the field of non-metallic materials and in advanced technologies to provide our customers with increasingly innovative and high quality vehicles.”

More and more automotive OEMs are using STAMAX LGFPP resins in structural applications because the material delivers high-quality performance that can replace steel, reduces weight and lowers system costs. In addition, SABIC Innovative Plastics is able to provide local support with its substantial global reach, according to a company press release.

STAMAX LGFPP resin grades support the design of semi-structural automotive applications that combine light weight with functional integration, such as front-end modules, door modules, instrument panel carriers, tailgates and seating systems.