European Cars Get More Plastic

Automotive Industries, May, 2001 by Lora J. Bingham

Twenty years ago, plastic was simply an interior and trim material on European cars. But things have drastically changed since then. Plastics' increased use is being driven by weight reduction mandates and stricter emission standards, according to "Plastics in European Cars 2000-2008," a report published by Rapra Technology Ltd. (www.rapra.net)

Although plastic is not the only material being used to reduce weight (making vehicles more efficient), its use is expected to grow by 13 percent between 1999 and 2003. It leaps to a projected 15 percent between 2003 and 2008.

New uses for plastics account for much of that growth, among them bumpers, deck lids and doors. A few applications, such as plastic roofs, are in the experimental stage. Renault has used EP resins for suspension leaf springs. New safety systems such as additional airbags and redesigned knee bolsters rely on plastic, too. And more uses are entering the engine compartment, particularly engine and camshaft covers.

"Plastics are a mature product in many areas like the fuel system and interior trim," says I.G. Helps, the report's author. "Body panels, however, seem to offer a lot of scope for the use of plastics, and under-the-hood applications are an area where incremental applications are continually reported."

As European automakers search for ways to make vehicles more efficient, more applications for high-tech plastics are being found. Thus, steady growth in the use of most of these lightweight materials is expected through the decade.

Estimated Use of Plastics in Cars by Weight
(thousands of tons)
RESIN                      1999   2003    2008
THERMOPLASTIC
PE                        173.6  195.4    223.2
PP (inc. PP part of TPO)  684.9  832.5  1,047.0
PVC                       139.8  134.3    126.4
ABS   styrenics           159.1  175.6    195.8
PA                        154.3  180.6    215.5
PBT   PET                  86.9  101.6    121.3
PMMA                       27.0   30.9     36.5
PC                         50.2   58.6     70.0
POM                        21.2   24.2     28.8
PPE                        42.4   48.7     57.3
Other                       9.7   10.9     12.5
THERMOSETS
UP resin                   63.7   63.7     63.7
PUR                       298.9  343.0    401.6
Other                      17.3   17.3     17.3
TOTAL                     1,929  2,218    2,617
Total Plstics use by Type and weight in an Average Car
Use (lbs. per car)
TYPE OF PLASTIC
Bumpers                 (22.0)  PP, ABS PC
Lighting                (11.0)  PP, PC, ABS PMMA, UP
Other reservoirs         (2.2)  PP, PE, PA
Under-hood components   (19.8)  PA, PP, PBT
Electrical Components   (15.4)  PP, PE, PBT, PA, PVC
Dashboards               (3.3)  PP, ABS, PA, PC, PE
Upholstery              (17.6)  PVC, PUR, PP, PE
Interior Trim           (44.0)  PP, ABS, PET, POM, PVC
Seats                   (28.6)  PUR, PP, PVC, ABS, PA
Body, inc. body panels  (13.2)  PP, PPE, UP
Fuel Systems            (15.4)  PE, POM, PA, PP
Exterior Trim            (8.8)  ABS, PA, PBT, ASA, PP
Polyethlene (PE); Polypropylene (PP); Polyvinyl Chloride (PVC);
Acrylonitrile Butadine Styrene Copolymer (ABS); Acrylonitrile
(ABS); Acrylonitrile Styrene Acrylic Ester Copolymer (ASA);
Polyamide (PA); Palybutylene Terephthalate (PET); Polymethyl
Methacrylate (PMMA); Polycarbonate (PC); Polycetals (POM);
Polyphenylene Ether (PPE); Unsaturated Polyester Resins (UP);
Polyurthane (PUR)
Source: RAPRA Technology LTD.