Plastics and the Automotive Industry

Today’s average automobile contains 240 pounds of plastics – up from 60 pounds in 1970. This increase has come primarily from the recognition that plastics offer increased functionality, weight reduction and performance. In addition, advanced capabilities related to the integration of systems and enhanced occupant protection can only be obtained through the use of advanced polymeric systems.

Plastics can be found in most areas of the automobile: exterior (trim, body panels, bumpers); interior (headliner, instrument panel, trim); underhood (engine, electrical, mechanical) and underbody (fuel tanks, tubing). Of these application areas, interiors account for the largest use of plastics (50%), with powertrain/exteriors accounting for nearly 20% of total plastics use.

Plastic materials can be subdivided into two major categories: thermoplastics and thermosets. Thermoplastics account for the vast majority of plastics used in automobiles at a ratio of nearly 4:1.
In 2000, approximately 4 billion pounds of thermoplastics of all types were used by the automotive industry. Materials range from advanced styrenics (e.g., DYLARK engineering resins) to polyolefins, polyesters, polycarbonates, elastomers, Nylon, terpolymers and various polymeric blends.

Although the use of plastics has advanced considerably from the 1970s, much work remains - from the replacement of structural components (primarily in metal today) to the replacement of traditional window materials, to the extended use of plastics in exterior panels and energy absorbent systems.

As automobile sales continue to advance globally - from 51 million light vehicles in 1998 to 56.5 million in 2003 - and as the recent recovery in the economy broadens to encompass most parts of the world, exciting opportunities will materialize for OEMs and systems suppliers to expand their creative use of plastics to meet the steadily increasing demands of consumers for function, performance and cost. Additionally, high-growth markets like China - growing in automobile sales from 600,000 units in 2000 to a projected level of nearly 4 million in 2007 - will continue to place high demands on plastic materials suppliers.

NOVA Chemicals continues to work closely with OEMs and systems suppliers to identify and develop valuable solutions for the automotive industry through the advancement of DYLARK engineering resins in key applications.

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