FRANKFURT MOTOR SHOW - Plastic Omnium

F R A N K F U R T M O T O R S H O WPRESS K IT IAA 20 1 3// 1 2 -22 S E PT EMB ER 2 0 13

BODY PANELS AND MODULES

FUEL SYSTEMS

LIGHTWEIGHT AND EMISSION CONTROL SOLUTIONS

INNOVATING FOR A BETTER FUTURE


Plastic Omnium at a glance

WORLDWIDE INDUSTRIAL EXCELLENCE AND INNOVATION

The Plastic Omnium Group Innovation driving past and future growth

Plastic Omnium Automotive - a key partner to the worldwide automobile manufacturers Global performance through industrial excellence and talents

PLASTIC OMNIUM, A GLOBAL PLAYER

Plastic Omnium in Europe

Plastic Omnium in the Americas

Plastic Omnium in Asia

A POSITIVE COMMITMENT TO CLEAN MOBILITY AND TO LIVING ENVIRONMENT ENHANCEMENT

Bumpers, body panels and modules

New generation of rear closure systems

Structural composite parts for automotive mass production From semi-structural composite parts…

… towards high performance composite solutions

Front-end Modules (FEM) Active grille shutter

New CLA Mercedes-Benz front-end module

Fuel tank systems TSBM - a breakthrough technology for fuel system enhancement

Plastic fuel tank systems for hybrid vehicles

SCR systems

DINOx technology by INERGY

DINOx Compact

Controlled systems

- DINOx technology by INERGY

P.2

p.2

P.3

p.3

p.4

P.6

p.6

p.7

p.8

P.10

p.10

p.12

p.14

p.15

p.17

p.18

p.19

//

//

//

//

CONTENT

// PLASTIC OMNIUM AT A GLANCE

Independent, innovative and present in large key markets, Plastic Omnium is a key developer of technology designed to enhance sustainable mobility and the living environment, delivering solutions to environmental challenges faced by automobile manufacturers, local communities and their inhabitants.

Plastic Omnium continues to pursue its commitment to growth while strengthening its global leadership position in its two businesses:

• Automotive:bodypanelsandmodules,fuelsystems,lightweight and emission control solutions.

• Environment:productsandservicesforsustainablewaste management.

Operating in 29 countries with 107 manufacturingfacilities,ofwhich94arededicatedtotheproductionofautomotivecomponents,PlasticOmniumisabletoaddressthechallengesofafastchangingworld.In2012,thecompanygeneratedrevenueof4.8billionEuros.

By constantly pushing back boundaries andaccelerating the development of operations, PlasticOmnium has become a global player and trustedpartner over the last decade and plans to furtherincreaseitsfootprintandproductlinesoverthenext5years.Withits360°offeringaimedatcleanmobility,PlasticOmniumtakesitscustomersandpartnerstoanewdimension,whereinnovationisthegatewaytoabetterfuture.



PLASTIC OMNIUM: TWO ACTIVITIES

2012 Revenue: €4.8 Bn

AUTOMOTIVE


Bodypanelsand modules

Composite solutions

World leader

Fueltanksystems

SCRsystems

World leader

Wasteequipment and data

management systems

World leader

ENVIRONMENT


KEY FIGURES

countries29manufacturing facilities107

of revenue allocated to R&D5%employees22,000

AUTO EXTERIOR INERGY ENVIRONMENT

2

page 29 page 31 page 22

page 23

Other7%

Asian15%

American25%

French 22%

German

31%

A balanced portfolio:

2012 Automotive revenue

bycarmakernationality2012 Revenuebyregion

page 29

page 31

page 22

AMÉRIQUE DU SUD, AFRIQUE

5 %

ASIE

16 %

AMÉRIQUE DU NORD

27 %

FRANCE

15 %

EUROPE DE L’OUEST(hors France)

27 %

EUROPE DE L’EST

10 %

South America

and Africa 5%

Asia

16%

North America

27%

France15%

Western Europe

(excl. France)27%

Eastern Europe

10%

3


// FRANKFURT MOTOR SHOW // PRESS KIT IAA // 12 - 22 SEPTEMBER 2013

// THE PLASTIC OMNIUM GROUP

Plastic Omnium is a key enhancer of sustainable mobility and the living environment as a world leader in developing automotive and environmental technology.

PlasticOmniumAutomotiveDivisionspartnerwithcarmanufacturers todevelop innovative solutions thatrespondpro-activelytocustomers’expectationsofweightsaving,emissionsreduction,recyclabilityandpedestrianprotection.PlasticOmniumisconstantlybroadening itsproductportfolio andoffers awiderangeofplasticbodypanelsandmodules,compositestructural parts, fuel tank systems and emissioncontrolsystems.

Plastic Omnium Environment Division assists localauthoritiesincityplanningandwastemanagementby offering optimized cost solutions, from wastecontainerstomaintenanceservices.

Driven by the same entrepreneurial spirit since itscreationin1947,thePlasticOmniumGroupconductsitsaffairsresponsiblyandisfocusedonthefuture.Itcloselymonitorsnewopportunitiesand trendswiththegoalofdeliveringinnovativesolutionstailoredtomeettheneedsofcommunitiesandroadusers inafast-changingworld.

A THE PLASTIC OMNIUM GROUP

INNOVATION DRIVING PAST AND FUTURE GROWTH

Innovation ispartof thePlasticOmniumcorporateDNA and relies on a network of 1,400 engineersand technicians worldwide. The R&D network iscomposed of 14 global research and certificationcenters and regional development centers. At theendofyear2012,PlasticOmniumwasmanagingaportfolioof2,585patents.

Technological study, applied research, productinnovationanddevelopment-theR&DandMarketingteams assess changes taking place around theworld to find solutions to improve environmentalperformance and reduce costs with a focus oncleaner, lighter and safer products. The success ofthePlasticOmniumGroupcannotonlybeattributedtoproductdevelopment,butalsototheCompany’sworld-class knowledge of key industrial processessuch as injection and blow molding, painting,assembling,sequencingandlogistics.

engineers and technicians worldwide

R&D centers

1,400

14

patents2,585

South America

and Africa

6%

North America

16%

France

25%

Asia

21%

Western Europe

(excl. France)

19%

Eastern Europe

13%

2012 Employeesbyregion

// PLASTIC OMNIUM AUTOMOTIVE: A KEY PARTNER TO THE WORLDWIDE AUTOMOBILE MANUFACTURERS

A global player and leader, Plastic Omnium ispursuing its growth in theworld’s largestmarkets.Backed by a sustained investment policy, which isoneofthefoundationsofitsstrategy,theCompanygenerated85%ofitsrevenueoutsideFrancein2012.

GLOBAL PERFORMANCE THROUGH INDUSTRIAL

EXCELLENCE AND TALENT

WithitsglobalindustrialfootprintandR&Dnetwork,PlasticOmniumcollaborateswithcar-makersacrossthe globe on the development of new programs.Each project is thoroughly monitored accordingto standardised processes designed to guarantee quality,performanceandreliability.ThehighqualityofPlasticOmniumproductsandindustrialprocessesdemonstrates the level of expertise andexcellencerequired throughout the entire project’s life - fromdevelopment (design, simulationandvalidation) toindustrialisation(massproduction).

PlasticOmniumisabletomanageseveralcomplexprograms, on global platforms, with an increasingdemandinmodeldiversity.Fueltanks,forexample,aredesignedtoadapttovarioustypesoffuels–gasoline,diesel, biofuel – and different emission categories.

With aworldwideworkforce of 22,000 employees(75%ofwhomarebasedoutsideFrance),thegrowthanddevelopmentofPlasticOmniumisdrivenbythetalentofitsstaff.

Since itscreation,PlasticOmnium’sstrategy issup-portedbyacommitmenttoitsfiveI’s-Independence,Investment,Innovation,InternationalizationandInte-gration.

By promoting talent and excellence, empoweringteams, charting their career paths, focusing ondialogueandcommunicatingthe‘‘POWay’’,PlasticOmniumenablesemployeestosupport itsprojectsandserveitscustomersaroundtheworld.

Employee training is a key driver of excellence,enabling Plastic Omnium to adapt to changes in specific job skills and transmit expertise to localmanagersandoperatorsasnewfacilitiesopen.

A global company that operates locally, PlasticOmniumpromotes jobmobility between countriesas a means to create multicultural teams within a decentralizedorganization.

94 plants dedicated to the production

ofautomotivecomponents

Western Europe

Eastern Europe

North America

South America

5 2

16

12

35

Asia

24

Africa

BY

2016

BRICs

13OFWHICH

+16PLANTS

4

Plastic Omnium is the world leader in automotive

components and body modules, automotive fuel tank systems, and

waste container solutions. The Group employs more than 22,000 people in

29 countries around the world. As a company we are focused on independence, investment, innovation, international expansion and integration of new talents to pursue our growth.

Live a unique experience with us, driven by technology.

plasticomnium.com

SPIRIT OFINDEPENDENCE

DRIVEN BY TECHNOLOGY

© C

ompa

gnie

Pla

stic

Om

nium

07/

2013

– N

on-c

ontr

actu

al p

hoto

s –

All

mod

els

, tra

dena

mes

and

trad

emar

ks h

ave

been

regi

ster

ed b

y Co

mpa

gnie

Pla

stic

Om

nium

– R

epro

duct

ion

proh

ibite

d. C

redi

ts p

hoto

s: JP

Mes

guen

PLASTIC OMNIUM, A GLOBAL PLAYER

Plastic Omnium is constantly reinforcing its worldwide leadership. While consolidating its presence in mature markets through

innovative product design, Plastic Omnium works to establish operations in fast-growing markets and expand

in high potential regions.

IN TODAY’S FAST-CHANGING WORLD,

WE HAVE COMPETITIVE STRENGTHS

THAT WILL ENABLE US TO MEET NEW

CHALLENGES AND MANAGE NEW

PROJECTS IN OUR MARKETS

Laurent Burelle, ChairmanandChiefExecutiveOfficer

ofPlasticOmnium

EUROPE

PLASTIC OMNIUM IN EUROPE

•49 plants inBelgium,CzechRepublic,France,Germany,Hungary,Netherlands,Poland,Romania,Russia,Spain,Slovakia

and United Kingdom

•9 R&D facilities

•€2.1 Bn sales generated in 2012

•Delivering to Audi, AvtoVaz,BMW,Daimler,Ford,JaguarLandRover,Nissan,Opel,

Porsche,PSAPeugeotCitroën,Renault,Seat,Skoda,Suzuki,Toyota,Volkswagen

France being the historical ‘‘birthplace’’ of Plastic Omnium, it continues to host not only the Group’s headquarters, but the heart of the R&D network as well.

During2012,PlasticOmniumreinforceditsR&DnetworkinEurope.Whilsttwonewmanufacturingplantshavebeen established in the UK and Spain in order to support the new tailgate business, R&D investmentshaveincreasedandengineeringteamsextendedalso.

InadditiontoitsinternationalR&DcenterclosetoLyon- Σ-Sigmatech -dedicated toexteriorequipmentandcompositematerials,PlasticOmniumisbuildinganewR&Dcenter- α - Alphatech - in Compiègne to the north ofParis.Aimedatreinforcingthefuelsystemactivity,itwillbeoperationalinSeptember2014.Together,thesetwositeswillaccommodatemorethan1,000engineersand technicians.

InresponsetothequickeningpaceofdevelopmentofautomobileproductioninEasternEurope,PlasticOmnium is extending its footprint. Following theacquisitionofPlastalin2010,PlasticOmniumAutoExteriorisnowoperating3factoriesinPolandwhichmanufacturecomponentsforAudi,BMW,Fiat,Ford,GeneralMotors/Opel,SeatandSkoda.InApril2012,PlasticOmnium InergyandDetalstroykonstruktsiya(DSK), Russia’s leading producer of fuel systemsbecame partners. With two plants already inoperation, in Stavrovo andTogliatti, both ofwhichwork mainly for Renault Dacia and AvtoVAZ, thecompanyannounced itwouldbuild a newplant inSt. Petersburg that will be brought on stream in early2014.ThenewplantwillenablePlasticOmniumInergytomeetdemandinafast-growingmarketanddeliver1.5millionfuelsystemsinRussiaby2015.

6

THE AMERICASWith more than 19.5 million vehicles produced in 2012, of which 15.5 in North America, and an expected production increase of 2.5% in North America and 5.6% in South America by 2018, the Americas are dynamic markets with major car-makers.

PlasticOmniumsetupanewfacilityinHuron,Michigan.Thissecond-largestPlasticOmniumInergyplantworldwidewithasurfaceareaof30,000sq.m,wasbroughtonstreaminAugust2012.BuilttoproducefuelsystemsforFord,itcanhouseuptoeightblowmoldinglines.Withthenewplant,theCompanyhasstrengtheneditspresenceinNorthAmericaandhasbecomeakeyglobal partner to Ford.

PLASTIC OMNIUM IN THE AMERICAS

•21 plants in Argentina,Brazil,Canada,Mexico,UnitedStates

•2 R&D facilities


•Delivering to BMW,Chrysler,Daimler,Ford,GeneralMotors,Hyundai,Nissan,PSAPeugeotCitroën,Renault,Toyota,Volkswagen

In order to accompany Volkswagen, Plastic OmniumAutoExteriorinstalledanewpaintlineatitsplantinPuebla,wherebumpers for thenewGolf7aremanufactured. Inaddition,PlasticOmniumInergyhasbuiltitssecondplantinMexico,inPuebla,whichbegandeliveringfuelsystemsfortheJettainNovember2012.

Already benefiting from a plant in Curitiba, Brazil, PlasticOmnium Inergy has inaugurated a new plant in Sorocaba.Thisfacility,whichwillserveToyotaandHyundai,willfurtherreinforceitsindustrialfootprintinBrazil.

> THE COMPANY HAS BECOME

A KEY GLOBAL PARTNER

TO CAR MANUFACTURERS

WORLDWIDE

7 // FRANKFURT MOTOR SHOW // PRESS KIT IAA // 12 - 22 SEPTEMBER 2013

InChina,withanaverageannualproductiongrowthrateof9%andoutputexpectedtoreach24.8millionvehiclesby2016,PlasticOmniumfirstestablished itspresence in2006 through the creation of the joint venture “XieNO”- today, a 100% subsidiary known as Plastic OmniumComposites China - for the manufacture of compositetruckparts. Thiswas followedbya secondJV in2007between Plastic Omnium Auto Exterior and YanfengVisteon-YFPO-forexteriorautomotivecomponents.Atthattime,PlasticOmniumInergyopeneditsfirstfactoryinWuhan. Since then, the Group has been investing toincrease its production and development capacity forexterior components and fuel tank systems.By the endof 2013, the Group will run 20 factories and YFPO willopenanewdevelopmentcenterinAnting.In2012,ofthe98 automotive programs launched worldwide, 30 werelaunchedinChina.TheCompanyisaimingfor25%ofthecountry’sbumpermarketand12%ofitsfueltanksystemmarket by 2016 through supplies to both its traditionalglobalcustomersandnew,localcustomerssuchasBAIC,FAW,GAC,Geely,SAIC,JAC.

ASIA

With more than 40 million vehicles produced in 2012 and an expected production increase of 33% by 2018, Asia

remains the world’s largest automotive market. The Asian automotive industry is transforming rapidly as it attempts

to diversify its base by introducing fuel efficient and ecologically friendly cars. To cater to growing local and regional demand, a number of car-makers are working on expanding their production capacities.

According to its sustainable growth strategy within the Asia region, Plastic Omnium started to pro-actively support regional car-makers throughstrategicallianceswithleadinglocalmanufacturersin2006.Today,PlasticOmniumcontinuestoinvestin thismarketwith the aim of supplying local and

global customers.

PLASTIC OMNIUM IN ASIA

•24 plants inChina,India,Japan,SouthKorea,ThailandandTurkey

•3 R&D facilities

•New Asian headquarters in Shanghai


•Delivering to BAIC,BMW,Ford, GeneralMotors,Hyundai,Isuzu,Mazda, Nissan,PSAPeugeotCitroën,Renault,

Skoda,SsangYong,Suzuki, Toyota,Volkswagen

> IN 2012, 30 PROGRAMS WERE

LAUNCHED IN CHINA

8

FROM INNOVATION TO JUST-IN-TIME

DELIVERY, A CONSTANT HIGH QUALITY

PERFORMANCE IS ASSURED


A POSITIVE COMMITMENT TO CLEAN MOBILITY AND TO LIVING ENVIRONMENT ENHANCEMENT

With 5% of its revenue allocated for Research and Development in 2012, innovation, ingrained in Plastic Omnium’s genetic code, is a day-to-day concern all over the world. As part of its commitment to environmentally responsible growth, Plastic Omnium designs green solutions for car-makers, from initial concept to the final product, while reducing costs and shortening development cycles.

This commitment is reflected in a wide range ofinnovative products that are designed to makevehicles lighter and cleaner, and solutions thatsupportgovernments’andlocalauthorities’initiativesto optimize and upgrade waste containerization,collectionandmanagementsystems.

Global warming and natural resource conservationareamongthekeychallengesfacingtheautomotiveindustry and governments. Plastic Omniumcontributesbyengagingtheseissueswithits‘360°offering’,respondingtocar-makers’needsforvehicleweight reduction,emissions reduction, recyclabilityandsafety.

Plastic Omnium technology will help to createtomorrow’smoreecologically-friendlyvehicleswithplastic components that are lighter and better suited to function integration than steel. Plastic Omniumalsotakesintoaccountallaspectsofenvironmentalprotectionandtheconservationofnaturalresourcesfrom design to end of the product’s life, alsoaddressingend-of-lifeplasticcomponentsrecycling.

//BUMPERS, BODY PANELS AND MODULES

PlasticOmniumAutoExteriorproducesover70,000outer panels (bumper covers, fenders, tailgatepanels,spoilers, rockerpanelsandcladdings)daily.Thesethermoplastic-injectedpanelsare35%lightercompared tosteelpanels. In somevehicles,plasticpanelsaccountfor50%ofthepaintedoutersurface.Progress in painting technologies allows lower costs andbetterenvironmentalperformance.

PlasticOmnium is recognized for its expertise andcapacitytoproduceworldwidebest-in-classpaintedbumpersandplasticpanels.Increasingly,globalcar-makersarereleasingvehiclesacross3or4continentsat the same time.With an excellent footprint andindustrial standards deployed in its 56 productionplants and 30 sequencing centers Plastic Omnium can accompany car-makers all around the globe.Forinstance,PlasticOmniumissupplyingtheBMWgroupinChinawiththenextX1bumpers(picture1)producedinShenyangplant,andVWgroupwiththeGolfA7bumpersinMexico(Pueblaplant).

Euro 5 EURO6.1 EURO6.2

2009 2014 2017

0

40

80

120

160

200

180 mg/km

80 mg/km

80 mg/km

Measured on theNewEuropean

DrivingCycle

Measured according to

theWorldLightVehicleTestProcedure

Mesured onanormalized

circuit

Reduction targetforNOxemissionsandmaximumemissions threshold

95 g ofCO

2/km

Reduction targets forCO

2 emissions

20202015

130 g ofCO

2/km

10

Thus, whatever the region, Plastic Omnium canachieve car-makers’ most stringent requirementsintermsofdimensionalaccuracy,paintandaspectquality. Furthermore, a network of 12 engineeringcenters worldwide applies best-in-class design and manufacturing standards adapted to car-makers’requestsmakingworldwideprojectindustrialisationadailytask,whichfurtherenhancesPlasticOmnium’sexpertise.

Beyondtoday’sproducts,PlasticOmniumcontinuesto innovate and find ways to improve its productofferings tomeet the demands of the automotiveindustryinthefuture.LightAirisaconceptbumper(picture 2) showing how tomorrow’s technologiescanfurtherimproveperformanceofPlasticOmniumautomotiveexteriorproducts.

This new aerodynamic bumper together with theuse of air-shutters can reduce the CO

2 emissions

of amid-sizeSUVby3g/km.Finally, themodularcomposite architecture of the LightAir concept-bumperenablesthefittingofthin-wallplasticbodypanelsofferingnewpossibilitiesintermsofpartcut-lines,shapesandaspects.

Besides this, the use of carbon compositethermoplastictechnologyprovidesthepossibilitytocuttheweightofthefrontcrashbeamandabsorbersby45%(3.5kg)andallowsgreaterstylingfreedomofthebumpers.

BMW X1 bumper - worldwide best-in-class manufacturing

LightAir concept bumper – 3g/km CO2 emissions saving; weight saving

PICTURE 1

PICTURE 2


Alreadyagloballeaderintheplasticbumpermarket,Plastic Omnium introduced a plastic fender intomass-production in 1997. Today, fenders can eitherbeassembledon-linebeforepainting,orpaintedoff-lineandaddedontheassemblylineatalaterstage.Aplasticfendercanbeupto40%lightercomparedtoasteelonewhilebringingbetterimpactperformanceandadditionalfunctionintegration,especiallywhenassembledoff-line.

BMWaskedPlasticOmniumtodesignandproduceoff-linepainted fenders for thenewBMWX5SUV(picture 3). The part is injection molded with aspecific TPO compound to guarantee dimensionalaccuracy, low expansion under heat, surfacequalityandimpactresistance.Thefendersarethenpaintedwith awaterborne paint system. For eachset of fenders produced, the color ismeasured at6 different points thanks to a spectrocolorimeterinstalledonarobotarmattheendofthepaint-lineinordertoensureaperfectcolor-matchwiththeX5mainbody.Thisnewfenderalsoincorporatesanair-guidancefeaturewhichimprovestheair-flowinthewheel-arch area.

Thermoplastictechnologyalsoallowsgreaterstyling-freedomandmoreaerodynamically-designedpartsinordertoreducefuelconsumption.Fasciaair-inletscanbeoptimizedandequippedwithshutterswhenengine cooling is not necessary (the equivalent ofa 1 g CO

2/km reduction). Front and rear spoilers

reduceturbulencearoundthecarandimproveroad-handlingstability.

For example, roof spoilers are integrated into therear end of the car. Not only do these parts playan important role in thevehicleaerodynamics,buttheyalsoaddtothedesignofthevehiclegivingnewpersonalitytothecaraswellasintegratingfunctionssuch as stop lights,wipers and variouswiring andantennae. The roof spoiler of the newNissan Leafelectricvehicle(picture4)ismanufacturedbyPlasticOmnium in its Measham plant in the UK. It is a twin-shelldesignwiththetopcoverinthermoplasticalloygivinghighdimensionalstabilityandaspectqualityafter body-color painting. The part incorporates asolarpaneltopowerauxiliaryequipmentinordertopreservethebatterychargeandtoenhancefurtherthedrivingrangeofthisvehicle.

// NEW GENERATION OF REAR CLOSURE SYSTEMS

Plastic Omnium Auto Exterior will produce over1million tailgates in 2013, andmore than 5millionvehicles have been equippedwith PlasticOmniumtailgatessofar.PlasticOmniumhasdevelopedandproducedcompositerearclosuresystemssince1996.In 2010, Plastic Omnium launched the first hybridcompositeandthermoplastictailgate,calledHigate,for thePeugeot508SWfollowedbyRangeRoverEvoquein2011,JaguarXFandnewRangeRoverin2012(picture5).ThefirstcompositetailgateinChinaisnowinproductionfortheRoeweE50electricvehicle.

PICTURE 3

PICTURE 5

PICTURE 4

BMW X5 fender – thermoplastic injection molded

12

Nissan Leaf roof spoiler – large and complex painted body panel part

Range Rover Higate – hybrid thermoplastic/thermoset tailgate

In 2013, Plastic Omnium will launch 5 additionalcomposite tailgates amongwhich, the new RangeRover Sport and the new Citroën C4 Picasso (picture 6). These 2 tailgates also exploit theadvantages of the Higate technology wherethe inner panel – made of thermoset SMC andcontributing a high level of geometrical accuracy– comes together in a clam-shell design with aPP thermoplastic outer panel providing a Class-Asurface finish and styling freedom. In the case oftheC4 Picasso such a designwould be extremelydifficulttorealise insteeloraluminiumtechnology.Alsoin2013,PlasticOmniumwillintroduceafurthernewtechnologyintothemarketintheformofhybridthermoplastic. This technology utilises glass-filledthermoplastic olefin for the tailgate structure (PPLGF).ItisappliedonthenewPeugeot308tailgate (picture7)weighing less than 12kgwhichequatesto a 25% weight reduction compared to its steelequivalent.

Thesetwotechnologiesallowforalargenumberofvehicle applications, from larger tailgates to high-volume mid-size and smaller tailgates providingweightreductionsof5to10kgpervehicle.Besidesthestyling freedomandweight saving the tailgateprovides,awidevarietyoffunctionintegrationmakescomposite materials a popular choice for closuresystems. Low speed crash compliance, integrationof rear lighting, antennae andmotorization can allbe carried out at an optimised cost.

Tomeet theexistingdemandforhybrid thermosetand thermoplastic tailgates, as well as assist newcustomers in developing composite solutions,Plastic Omnium is strengthening its industrial capacity through investment dedicated to thesetechnologiesinSpainandtheUK.Usingitsalreadyextensiveexpertiseandknowledge,PlasticOmniumisnowconcerningitselfwiththenextgenerationofcompositetailgates(picture8).

So far, a large number of functions have alreadybeen incorporated from steel design solutions.Designing tailgates using composite materialsolutionswillallowfurtherfunction integrationandstylingfreedomaswellasadditionalweightsaving.The prototype tailgate presented features a largeinnerpanel inCarbonSMCmaterial [leftvisibleontheprototype]inordertoobtainamaximumweightreduction. Lighting functions are integrated eitherinexteriorpanelsorinthecompositestructure,andaerodynamic spoilers and side deflectors reducethe drag coefficient. Combined, the use of newcomposite materials and the associated design and

integration opportunity can deliver a 10% weightreductioncomparedtoprogressalreadymadewithall-aluminium design.

PICTURE 6

PICTURE 7

PICTURE 8


Peugeot 308 - full thermoplastic tailgate

Citroën C4 Picasso Higate – hybrid tailgate molded in color

Carbon reinforced tailgate – a 10% weight reduction compared to progress already made with all-aluminium design

// STRUCTURAL COMPOSITE PARTS FOR AUTOMOTIVE MASS PRODUCTION

FROM SEMI-STRUCTURAL COMPOSITE PARTS...

With 25,000 tons of composites compoundedannually,PlasticOmniumisthemajormanufacturerin Europe, accounting for 30% of the compositeapplications produced for the automotive market.PlasticOmnium’s range includesproducts thatcanbe assembled either:

• Directly on the vehicle assembly line (on-line),before painting,withminimumdisruption to theproduction process (fender carrier, front-endcarrier,trunkfloor,innerhood)

• Orafterpainting(off-line),withmodulesthatcanbe pre-assembled such as tailgates.

Plastic Omnium can offer the best of boththermoplasticandthermosetcompositesandoffersefficient hybrid solutions of composites with steelor aluminium. Over-molding of steel or aluminiuminsertscanmakealltheseproductscompatiblewiththe vehicle’s metal structures. A first applicationof a composite trunk floor spot-welded to the carbodygoes intoproduction in2013onthenewPSAPeugeotCitroënEMP2platform(picture9).Itbringsa 40% weight saving compared to the traditionalsteel solution while keeping the assembly processunchangedforthecar-maker.

PlasticOmniumhasacquiredauniqueexpertiseforpedestriansafety,developingabumpersystemandfender carrier that protect pedestrians’ legs andhead.Hoodswithintegratedprotectionstructurearecurrentlybeingdevelopedforfutureapplication,withmetal skins assembled by hemming to compositeinner panels designed for outstanding head impactcriteriavalues(picture10).

...TOWARDS HIGH PERFORMANCE

COMPOSITE SOLUTIONS

Asagloballeaderinprovidingcompositesolutions,PlasticOmniumAutoExteriorbroadensitsrangeofinnovativeproductofferingswithhighperformancecomposites that provide significant reductionsin vehicle weight. The new generation of highperformancecompositesthatareindevelopmentwillusenewtypesoffabrics,resinsandfibers,includingcarbon.Withthesenewformulations,themechanicalproperties of new composites will be significantlyimproved.Thesecompositescanbeapplieddirectlyto the structure of the vehicle as they are able towithstand significantly higher levels of stress.Highperformancecompositestructuralpartswillbegintodevelop on themarket by 2017. A potential above100kgweightsavinghasbeenidentifiedonthecarbodythankstothedevelopmentoftheseplasticandhighperformancecompositesolutions.

In order to propose the best material and process foragivenapplication,PlasticOmniumisdevelopingboth thermoplastic and thermoset composite solutions. Production-tooled parts have beendesigned and produced in thermoplastic composite insert molding (HTPC), advanced SMC and highpressureRTM.ResultsobtainedsofarallowsPlasticOmnium to develop the optimum material andtechnology choice for each application to achievespecifications. Extensive research into materials’characteristics has been conducted and composite applicationscannowbedesignedbyfiniteelementanalysis(FEA)forstatic,crash,vibrationandfatiguespecifications.

PICTURE 9PICTURE 10

Hybrid aluminium /composite hood specifically designed for head impact management

14

Peugeot 308, Citroën C4 Picasso - on-line steel over-molded composite trunk floor

Structural parts targeted to apply these highperformance composite materials are main floors,pillars, cross members as well as reinforcementsto improve closures’ stiffness-to-weight ratio.PlasticOmniumhasstarted thevalidationof theseapplicationsinmass-productionfortheautomotiveindustry thanks to a unique dedicated pilot lineinstalled in its Σ-SigmatechinternationalR&DcenterinFrance.Scale1partsarebeingdesigned,processedandvalidatedformarketreadinessin2017.

AfirstexampleofamainfloorusingHighPerformanceComposites is displayed (picture 11). This part hasbeendesignedtoachievea50%weightsavingusingchoppedandcontinuousfibers (glassandcarbon)in an advanced SMCprocess. It comprises a twin-shelldesign,bondedandrivetedtogether.Theflooris compliantwith crash requirements (side, lateral,pole) andcan replace a complex,multi-piece steeldesign with over 20 separate stamped parts. Itfeatures a flat under-body shape for aerodynamicperformance and is compatible with an on-lineassemblyprocesswithsteelpartsusingbondingandrivetingtechniques.

// FRONT END MODULES

ACTIVE GRILLE SHUTTER

Globalmarketleaderinfront-endmodules,HBPOhasnowmovedsuccessfullyintotheactivegrilleshuttersector. At the 2011 IAA, HBPO unveiled a speciallydesignedactivegrilleshutter,towidespreadacclaim.This new technology is gaining in popularity, andcustomerstrustinHBPO’shard-wonexpertise.Seriesproduction of the latest HBPO product is slatedto begin shortly. Through ongoing development inthis area, newgenerations of the technology havealreadybeencreated,allowingHBPOtosupplementthecomponentsofitsfront-endmoduleswithactivegrilleshuttersandthusexpanditsproductportfolio.ThistechnologyhasallowedHBPOGmbHtosecurea solid foothold in the market in just two years

(picture12).

PICTURE 11


On-line high performance composite main floor

PICTURE 12

Active grille shutter

NEW CLASS CLA MERCEDES-BENZ

FRONT END MODULE

HBPOissettingnewstandardswiththeMercedes-BenzMFAplatform.FollowingthesuccessfullaunchoftheB-Class,theA-Classhasbeenrolledoutwitha completely new appearance. The latest memberoftheA-Classfamily isthenewCLA.All front-endmodulesforthisplatformaresuppliedbyHBPOtothe Rastatt (Germany) and Kecskemét (Hungary)assemblyplantsonajust-in-sequencebasis(picture13).

Thesenewmodelsposedspecialchallenges.HBPOmetthemall,succeedinginreducingtheweightofthefront-endmodulebymorethan20%comparedwith the precedingmodel. Thisweight saving alsocontributes to greater fuel efficiency, and thus toa reduction in CO

2 emissions. Due to the special

designoftheassemblycarrierasastructuralfront-endmember,ahighdegreeofrigidityisachieved.

This isonlypossiblebymeansofaspecialprocessappliedtothecenter-pieceofthefront-endmodulewhere the polymer interior high-pressure formingtechnology provides the desired result. Thanks tothe process know-how and experience of HBPO’sengineers,furthersuitabletechnologiescanbeusedforthefront-endmodule,reducingthetimerequiredfor assembly by some 30%. The assembly of thefront-endmoduletothevehiclepresentsaparticularchallenge.Fordesignreasons,withtheMFAmodelsitisnotpossibletoinstallthefront-endmodulefromthefront.

Instead, an installation and attachment techniquedeveloped by HBPO is used, in which themoduleis installed from the side via the wheel housing.The difficult task of aligning and adjusting theheadlamps is solved by orienting the units usingspecific reference surfaces. The precision achievedinthismannerdoesnotaffectonlythetimerequiredfor assembly; the greater impact is the reducedinvestment in expensive alignment andadjustmenttechnology.

Thismodule is a showcase for the know-how andexpertiseofHBPO,thefront-endmodulespecialist.Themoduleisregardedasanintegralwhole.Onlyinthiswaycanthefullsynergyeffectsandadvantagesberecognizedandimplemented.

PICTURE 13

16

// FUEL TANK SYSTEMS

With 17million plastic fuel tank systems producedin 2012, Plastic Omnium Inergy equips 1 out of 5vehiclesproducedintheworld.

A blow molded high-density polyethylene fuelsystembringsanaverageweightsavingof20%to30%incomparisonwithanequivalentsteelsystem,helping to significantly reduce CO

2 emissions.

This positive weight differential is the reason whyalmost70%ofvehiclesproducedworldwidein2012are equipped with plastic fuel tank systems. TheincreaseinuseofplastichasbeengreatestinAsia,where strong growth in automobile production has beenaccompaniedbythereplacementofsteelfueltanksystems(whichstillrepresent47%oftheAsianmarket).

In addition to the significant weight reductionadvantage, a plastic fuel system offers the bestcompromise between technical requirements and cost. Through various manufacturing processes,a plastic fuel system is able to meet the higheststandards for evaporative emissions. Its shapeflexibilityoptimizestheavailablespaceinthevehicle,allowingforcomplexarchitectureandahighdegreeofintegrationoffunctionsandcomponents.Aplasticsolution therefore optimizes fuel load and offers acorrosion-proof systemsuited to carrying typesofliquidfuelincludingbioethanolandbiodiesel.

Inparticular,fuelfillerpipesbenefitaswellfromtheweightsavingbroughtbytheuseofplastic.INERGYproposesattractiveblowmoldedfillerpipesolutionswhich match the performance of steel ones andarecompatiblewiththemoststringentevaporativeemission regulations. Finally, they can be weldeddirectlytothetank,whichprovidesasignificantcostsavingopportunityforthisfunction(picture14).

The elasticity and strength provided by plasticsguarantee unequalled performance during crash.Because all vehicles with internal combustionengines can be equipped, the plastic fuel systemremainsakey-component for thecarof tomorrow.As an undisputedworld leader in this field, PlasticOmnium Inergycontinues toprovide technologicalsolutions for vehicle manufacturers to create themobilitysolutionsoftomorrow.

TSBM - A BREAKTHROUGH TECHNOLOGY FOR FUEL

SYSTEM ENHANCEMENT

TSBM - Twin Sheet BlowMolding – is a patentedprocess from INERGY which combines thecomponent integration possibilities of half-shellprocesses with the advantages of the standard blowmoldingprocess.Withthisinnovativeprocess,INERGY is able to reach new performance levelswith regards to:

•Weightsaving-TSBMallowsfurtheroptimizationofwallthicknesscontrolandinternalcomponents’shapes.

• System efficiency - TSBM allows more designflexibility and freedom in the positioning ofinner components, thus reaching higher useablecapacityandoptimizingventingfunction.

• Permeation control - inserting componentsinside the fuel tank allows the reduction of thenumberofopeningsinthetankshellwhichhelpsTSBMfuelsystemsmeetthemostsevereemissionregulations.

• Acoustic performance – TSBM allows for theintegrationofanti-sloshnoisedevices(INBAFFLE)(picture15).

This patented process enabling the integration oflarge and complex shape components, offers aneasyway to integrate internal reinforcements inalllocations for sealed fuel tanksystems,becomingasolutionofchoiceforplug-inhybridvehicles.


PICTURE 14

PICTURE 15

BAIC C71 filler pipe

Cadillac CTS TSBM fuel tank

PLASTIC FUEL TANK SYSTEMS FOR

HYBRID VEHICLES

Theelectrificationofvehiclesbringsnewchallengesforfueltanksystems:sloshnoisereduction,smallercapacity, management of fuel vapors during longelectrical driving only. Plastic Omnium Inergy isdeveloping a complete range of solutions for anytype of hybridisation fromMild to PHEV and evenEREV.

Amongthosesolutions,INWINisINERGY’ssolutionfor PHEV (picture 16). Benefiting from TSBMtechnology, it consists of a reinforced light-weightplasticfueltanksystemthatcanwithstandpressuresfrom -160 mbar up to +350 mbar with minimaldeformation. Compatible with the most stringentemissions norms such as Lev3/PZEV or Euro6, itprovides aweight savingof 5 to 10 kg comparedtosimilarfueltanksystemsinsteel.PlasticOmniumInergyisinpre-developmentwithcarmanufacturersforsuchsealedfueltanksystems.

// SCR SYSTEMS

Asexhaustemissionregulationsbecomemoreandmorestringent,theautomotiveindustryistakingthechallengeandinvestinginordertoanswerthemostsevereones.This requires thedevelopmentofnewtechnologiesliketheon-boardconversionofnitrogenoxides (NOx). Plastic Omnium Inergy developsunique inventive and environmentally friendlysolutions that pre-empt upcoming regulations to providelong-standingsolutionstothechallengeofcleanermobility.

DINOx TECHNOLOGY BY INERGY

Selective Catalytic Reduction (SCR) is a veryeffective and widely used diesel emission controltechnology,whichisbasedonaverysimplesystem.A urea solution, called AdBlue® or DEF (DieselExhaust Fluid), is injected into the exhaust lineupstreamofanSCRcatalyst.Uponcontactwiththehot exhaust gases, it is transformed by hydrolysis intoammoniaandthenreactswithnitrogenoxides(NOx) to create non-polluting nitrogen and watervapor. Using its experience in managing on-boardfluids, INERGYhasdevelopedstorageanddeliverysolutions for passenger cars and light commercialvehicles; its latestproductoffer isDINOxPremium.Thissystemintegratesallrequiredfunctions(filling,storage,delivery,ventingandheating)intoaplasticurea tank for on-board Adblue® management and offers further options such as temperature andfluid level sensingaccording toOEMspecifications(picture17).

PICTURE 17

Dodge RAM 2500/3500 HD SCR tank system

18

PICTURE 16

Plastic fuel tank system for PHEV

DINOX COMPACT

AtthisIAA,INERGYintroducesDINOxCompact,itsnextgenerationSCRtanksystemtechnology.

Compatible with Euro 6 stage 2 applications, thisnext generation offers even more flexibility andintegration possibilities.

// CONTROLLED SYSTEMS

PlasticOmniumInergyhasacquiredkeycompeten-ciesinelectronicstobeabletoofferintelligenttanksystems combining hardware, proprietary softwareandOn-BoardDiagnostics(OBD)(picture18).

ThankstoitsparticipationtotheAutosarConsortium,Plastic Omnium INERGY softwares and strategiescanbeseamlessly intregrated into thevehicle.Thelevel of control and share of responsibility can beadjustedtomatcheachOEM’suniquepracticesandneeds.

INERGYcontinuestodevelopspecificstrategiesforbothcontrolsandOBDrequiredspecificallyonbothfuelorSCRtanksystems.

Come and discover these latest developments onourboothinourInnovationLab.


PICTURE 18

DINOx Control Unit

ThisdocumentalsoexistsinFrenchandGerman.

Design:Triil

Production: Cap & Cime PR

Photocredits:PatrickGalabert,Jean-PhilippeMesguen,JeremyNicholl/Interlinks

INNOVATING FOR A B ETT ER FUTURE

1,rueduParc-F-92593LevalloisCedex

Tel.:+33(0)140876400//Fax:+33(0)147397898

www.plasticomnium.com

Press Contact

TarickDali-DGMConseil

78,avenueRaymond-Poincaré

F75116Paris//+33(0)140701189

Date post:	18-Mar-2023
Category:	Documents
Upload:	khangminh22
View:	0 times
Download:	0 times

FRANKFURT MOTOR SHOW - Plastic Omnium

Documents