Ford Battery Pack and Citroën Rear Quarter Window with SABIC Materials

Thermoplastics from SABIC Enabling Automotive Innovation

Touted as America’s most fuel-efficient five-passenger vehicle, the all-electric Ford Focus relies on its high-voltage EV battery pack to achieve an extended driving range of 76 miles, fuel economy of 105 miles per gallon equivalent (MPGe) and a fast charge time. Ford selected SABIC’s NORYL GFN resin for the battery housing because the material enables thin-wall molding to free up space for more battery cells.

The combination of thin-wall design and low specific gravity of the NORYL GFN resin reduces weight by 15 percent. This modified-polyphenylene ether (MPPE) resin also delivers excellent dimensional stability and property retention in demanding environments.

The elegant design of the Citroën DS5 is enhanced by its softly curved rear quarter windows that smoothly integrate an aerodynamic spoiler and roof pillar. LEXAN GLX resin enables a 3D design that cannot be executed with glass, and also cuts overall glazing weight by one-fifth. These are the largest rear quarter windows in production, and also the first to use injection-compression molding to reduce residual stresses. The components benefit from the high cleanliness, weatherability and coating compatibility of this new SABIC material.

Four Additional SPE Automotive Innovation Award Nominations Highlight Industry Progress, Versatility of SABIC Materials

In addition to the two finalist applications, SABIC materials were featured in four additional award nominations:

· The front fender of the 2013 Mitsubishi Outlander Sport compact sport-utility vehicle (SUV) was nominated for groundbreaking two-cavity injection molding using
SABIC’s NORYL GTX resin. Molding the right and left components simultaneously cuts cycle time in half. The design integrates brackets for the pedestrian energy absorber.
· The 2013 Chevrolet Volt portable EV charger, made by Delphi Corp., relies on multiple SABIC VALOX™ resin grades, which provide high performance and regulatory compliance.
· The 2012 Fiat Panda’s rear bumper beam is the first hybrid plastic/steel bumper system capable of e-coating (electro-deposition coating) by the OEM. It is made from
NORYL GTX resin. This approach reduces weight and cost and provides superior energy absorption vs. metal alone.
· The 2013 Lincoln MKZ luxury sedan's console cupholder inner doors are the first to use nano talc-filled CYCOLOY™ resin for an interior, molded-in color application. The SABIC material provides improved heat resistance compared to unfilled acrylonitrile butadiene styrene (ABS) and PC/ABS, allowing the OEM to meet high temperature load-deflection requirements.

Automotive plastic innovations with SABIC materials and backing have, since 2009, produced 7 SPE Automotive Innovation Award category winners, including last year’s coveted Hall of Fame award (the first all-plastic integrated door-hardware module, the SuperPlug) and the overall Grand Award winner (Ford Escape SUV and Kuga CUV instrument panel). An additional 11 applications with SABIC materials were named finalists over this same time period.