LANXESS Factbook Lightweight Design

Fact Book – Innovative Lightweight Design

Agenda
1. LANXESS promotes “Green Mobility”
2. Why we need “Green Mobility”
3. Lightweight design helps enable “Green Mobility”
4. LANXESS makes lightweight design possible
5

6
LANXESS – a global specialty chemicals player with focus on
technology and innovation
Global success story
 Roughly 17,100 employees in 31 countries
 48 production sites worldwide
 2011 sales of EUR 8.8 billion
Specialty chemicals company
 Spun-off from Bayer in 2004, listed in the
DAX* since 2012
 Focus on: plastics, synthetic rubber,
specialty chemicals, intermediates
Strategy of targeted innovation
 Vital role in LANXESS’ growth
 Focus on process and product innovation
* German stock market index

LANXESS is Energizing Chemistry
 Premium specialty chemicals company
 More than 5,000 products for a diverse range of
applications
 High quality solutions enabling customers to
successfully meet current and future challenges
Premium quality Technical expertise
InnovationSustainability
 Commitment to sustainable development
 Creation of green solutions to meet the
challenges of global megatrends
 Development of environmentally-friendly
technologies, resource-efficient processes and
next-generation products
 State-of-the-art materials, services and solutions
that meet the most exacting standards
 Creating significant value for our customers, the
environment and our company
 Targeted innovation designed to meet customer
needs
 Pragmatic corporate culture drives product,
process and outside-the-box innovation
 Highly effective innovation network, combining
global reach with local expertise
LANXESS – global mission
7

Solutions for global megatrends
Urbanization
AgricultureMobility
Water
8

Special focus on “Green Mobility”
9

“Green Mobility” solutions for global challenges can have a
positive impact in four major areas
Infrastructure / urban planning
Means of transport
Information management systems
10
Energy

Six pillars of LANXESS’ contributions to “Green Mobility” –
all based on innovation and technology
11
Innovation & Technology
“Green Tires”
Sustainable
Leather
Management
Biofuels &
Renewable
Energy
Technical
Products
LANXESS
Contribution
Bio-Based
Raw Materials
Lightweight
Materials

Agenda
13

The future of mobility must be “green”
Conventional mobility reaches its limits
Source: International Energy Agency
* BRIC countries: Brazil, Russia, India, China
Key challenges
 Rising CO2 emissions threaten the global climate
and the environment
- Without appropriate countermeasures, global
CO2 emissions will double by 2050
 Increasing mobility demands are driven by
population growth and a growing middle class,
especially in BRIC* countries
 Finite resources such as fossil fuels will run out
inevitably
 Consumer needs concerning mobility are changing
14

Drivers for “Green Mobility”
Environmental
challenges
Growing
population and
middle class
Economic
challenges
Urbanization
Changing
consumer
demands
Politics
15

Growing population and middle class inevitably result in
even higher mobility
Sources: OECD Transport Outlook 2012; UN Population Division
* Income bracket of >US$ 6,000 and < US$ 30,000 per capita in BRIC countries ** Changes in passenger mobility compared to 2010
Growing world population
 In 2050, the world population is expected to reach 9.3 billion people
Growing middle class in BRIC
 In 2020, an additional 800 million people will achieve middle class
status in BRIC countries*
16
By 2050, all modes of mobility in emerging countries (including
BRIC) will have experienced considerable growth**
Cars / light-trucks: 5.7x increase
Two-wheelers: 3.8x increase
Rail: 3.0x increase
Main challenge: enabling continuous but sustainable growth
Aircraft: 2.5x increase
Bus: 1.3x increase

The situation today is critical
 CO2 emissions and other greenhouse gases lead to climate change
 Mobility accounts for up to 30% of global energy consumption
 About 18% of global CO2 emissions are related to mobility –
75% of which is generated by road traffic*
Alarming future development
 CO2 emissions in emerging countries (including BRIC) will more than
double (2002-2030)
 Emissions in OECD**-countries will still grow by about 25%
 Global mobility-related CO2 emissions are expected to grow by up to
2.4 times (2010-2050)***
Increasing mobility aggravates environmental problems
Urgent need for emission reduction
Sources: OECD Transport Outlook 2012; Institut du développement durable et des relations internationals
* Varying across countries ** Organisation for Economic Co-operation and Development: includes many of the world’s most advanced countries (see all 34
member countries on www.oecd.org) *** Total CO2 emissions from freight and passenger transport combined
17

Worldwide political initiatives to support a more sustainable
mobility – examplary initiatives to reduce CO2 emissions
USA aiming for a CO2
reduction of 17% during
the period 2005-2020*
Brazil aiming to reduce
greenhouse gas
emissions by at least
36% below projected
2020 levels
China aiming to reduce
CO2 emissions by
40-45% compared to
economic growth during
the period 2005-2020
Japan promising a 25% cut
in CO2 emissions by 2020
if all major economies
participate
India seeking to reduce
CO2 emissions by
20-25% compared to
economic growth during
the period 2005-2020
EU aiming for a 20% cut
in greenhouse gas
emissions during the
period 1990-2020**
South Korea planning to
reduce emissions by
30% below projected
2020 levels (4% below
2005 values)
Source: United Nations Framework Convention on Climate Change (UNFCCC)
* Provided that the awaited law on climate control comes into effect as scheduled
**As part of the EU Energy Efficiency Plan; for more information see http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=COM:2011:0109:FIN:EN:PDF
18

mobility – further examples (1/2)
Low emission zones in EU-countries and Japan
 11 EU countries (e.g. Germany, United Kingdom, Italy, Sweden,
Netherlands) and Japan (Tokyo)
EU-wide CO2 regulations
 Airline carbon tax: Since January 2012, all flights arriving at or leaving
EU airports pay a fee*
 CO2-limit values for new vehicles: Carmakers have to substantially
reduce the average CO2 emissions of all vehicles by 2020**
Development plan for electric mobility in Germany
 Goal: Strong e-mobility industry and over one million e-cars in 2020
Congestion charge in UK
 For vehicles within a specified zone between 7:00 am and 6:00 pm
* Exact amount to be paid depends on various factors; in general, fees are expected to rise in order to promote use of low-CO2 emission-airplanes
** Regulation (EC) No. 443/2009 of the European Parliament and of the Council of 23 April 2009 setting emission performance standards for new passenger cars:
http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=OJ:L:2009:140:0001:0015:EN:PDF
Low
emission
ZONE
19

mobility – further examples (2/2)
= $$$
20
* Since 2011, the ”Corporate Average Fuel Economy” (CAFE) measures the target values on the basis of the vehicle‘s „footprint“ (product of wheelbase and track
dimensions); the consumption of cars is supposed to go down by 5% (3.5% for light trucks)
Carbon emissions-based vehicle plan in Singapore
 Starting in January 2013, buyers of low-carbon-emission cars (i.e., less
than or equal to 160g CO2/km) qualify for rebates
Development plan for energy saving and new energy vehicles in
China
 Government incentives aim for five million electric and hybrid vehicles
by 2020
Fuel economy regulations in the USA
 New fuel economy standard of 4.3 l/100km for cars and light trucks by
2025*
Bike sharing in cities
 In 300 cities worldwide (e.g. Barcelona, Hangzhou, New York, Rio)
 Promoting bicycling is one of the easiest ways to curb carbon
emissions and reduce traffic congestion

Exceeding the target values can be expensiveObjectives of regulation
 Carmakers have to substantially reduce the
average CO2 emissions of all vehicles by 2020
 Manufacturers incur annual fines of up to EUR 95
per year for every gram above the target value (see
diagram on the right)
What this means for OEMs
 The values are calculated based on the weight of
the vehicle: this can result in different threshold
values depending on the OEM’s portfolio*
 OEMs need to find viable combinations of different
solutions to reduce CO2 in order to comply with the
guidelines as efficiently as possible
21
Sources: McKinsey; Regulation (EC) No. 443/2009 of the European Parliament and of the Council of 23 April 2009 setting emission performance standards
for new passenger cars: http://eur-lex.europa.eu/LexUriServ/LexUriServ.do?uri=OJ:L:2009:140:0001:0015:DE:PDF
* The threshold values for premium manufacturers are higher as luxury vehicles are heavier on average
EU – road traffic is a key component in initiatives to reduce
CO2: the obligation is on carmakers
140 g
95 g
75 g
0
4,035
12,350
European fleet
average 2010
Target
2020
Possible target
2025
CO2 output
Average CO2 output per
kilometer of all cars sold across
Europe by year
Potential fines**
EUR per vehicle in fleet
-46%
** As compared to the current average CO2 output in Europe of 140 g per kilometer
per car.
Ruling from 2015: EUR 5 for the 1st gram, EUR 15 for the 2nd gram, EUR 25 for the
3rd gram, and EUR 95 for the 4th gram and each additional gram
Ruling from 2030: EUR 190 per gram
Innovative approaches are essential in view
of the new requirements
130 g 710
Target
2015

Agenda
23

Environmentally friendly means of transport make an important
contribution to “Green Mobility”
24
 The future belongs to
modern forms of transport
offering improved energy
efficiency and minimal CO2
emissions, e.g. due to
- “Green Tires“
- Innovative drivetrains
- Aerodynamic
improvements
- Electronic assistance
systems
- Lightweight design
Infrastructure / urban planning Information management systems
Energy
Means of transport

Especially cars have the potential to be significantly improved
25
Source: “Green Mobility – Maßnahmen zur Verringerung von CO2-Emmissionen im Vergleich” (Green mobility – a comparison of measures for reducing CO2
emissions) by Prof. Dr. Horst Wildemann, Munich Technical University * Figures assume that long-distance buses and trains run at 44% average capacity;
airplanes at 73% capacity, and cars carry 1.5 persons; operating costs for a car carrying 3 persons equal EUR 11.30 ** Long-distance buses
 Cars have the highest operating costs of all
means of transport
 Negative environmental impact of cars due to
- High CO2 emissions per person transported
- Relatively short distance driven per 1 ton
CO2 emission
Operating cost per 100 km*
Industry must find ways to make
cars “greener”
Average CO2 emissions per person
EUR 26.00
EUR 11.30
EUR 9.90
EUR 8.60
380 g/km
150 g/km
40 g/km
20 g/km
**
**

The car is changing as requirements expand There are 900 million cars across the world –
a number that is set to more than double by
2050
 The result is that cars need to become both
more economical and more ecological
 Additionally, customer requirements are on
the rise:
- Higher safety standards (e.g. ABS, Airbags,
reinforced car body structure)
- Greater comfort and quality (e.g. air-
conditioning, audoio, satnav, and parking
systems)
- High-quality design
The requirements for modern cars are expanding – and with
them, vehicle weight
26
Sources: Valeo; Klimacampus; Automotive Now (1/2011) - KPMG International; VW; BMW
1886
2012
2016
2036
Reliability
Affordability
Safety
Fuel consumption
Sustainability
Connectivity
???
???
The consequence is a trend towards
greater weight
Over the last 40 years cars have continuously
got heavier
30%
Legislation InteriorSafety
25% 15% 22% 8%
Comfort Quality
Factors behind
the increase in
weight
Example: Mini Cooper

In the long run alternative energy sources will
replace fossil fuels for car engines
New drive concepts also adversely affect a car’s weight
27
Optimized
combustion
engine
Partial hybrid
Full hybrid
Plug-in hybrid
Range
extender
Electric vehicle
Start-stop systems,
regenerative brakes
Electric jump start, electric
driving at a low speed
Full hybrid with a large battery
and plug-in capability
Electric vehicle with an
internal combustion
engine to charge the
battery
???
Alternative drive systems need to be
compensated for – cars must be made lighter
Sources: “Lightweight, heavy impact” by McKinsey, “Elektromobilität – Anforderungen an Reifen, Fahrwerk, Antrieb und Marktpotenziale” (Electric vehicles –
demands on tyres, chassis, drive, and market potential) by Prof. Dr. Horst Wildemann, Munich Technical University
* Because, among other things, batteries and brake/insulation systems need to be larger
Emission-reduction measures based on
innovative drive systems increase weight
The result:
increased system costs*, impaired handling,
and reduced range

Lightweight design – a key technology for sustainable
mobility
28
Lightweight design compensates for the negative
consequences of new drive concepts (e.g. battery in
electric cars) – without lightweight design modern
mobility is unthinkable
Lighter cars increase fuel efficiency, reduce CO2
emissions in road traffic, thereby contributing to
“Greener Mobility”
Increasing demands for comfort and safety cause the
weight to spiral upwards – lightweight design
ensures that cars remain economical




Mass is a key factor in determining the resistances that act on a
vehicle – lightweight design is the logical solution
Even a savings of 100 kg enables enormous emission
reductions
29
 Driving resistance considerably influences vehicles’
fuel consumption and CO2 emissions
- The higher the resistance, the more energy is
required to move the vehicle
 Rolling, gradient, and acceleration resistances are
highly dependent on the vehicle weight and are thus
directly influenced by lightweight design
 Lightweight design is therefore suitable as an
effective means of reducing CO2 emissions and fuel
consumption
Acceleration resistance
mass x acceleration of the vehicle
Air resistance
(air density/2) x cw* x vehicle surface x
speed2
Source: “Green Mobility – Maßnahmen zur Verringerung von CO2-Emmissionen im Vergleich” (Green mobility – a comparison of measures for reducing CO2
emissions) by Prof. Dr. Horst Wildemann, Munich Technical University ** Based on a car weighing 1,400 kg and an average consumption of 8 l of
conventional fuel per 100 km, which corresponds to an output of 2.33 kg of CO2 per liter (basis of comparison: car with a life cycle of 120,000 km in six years)
Rule of thumb:
100 kg less weight means savings of 0.5 l fuel per
100 km and 11.65 g less CO2 per kilometer
travelled**
Rolling resistance
(mass x gravity) x rolling friction
Gradient resistance
(mass x gravity) x (gradient
height/gradient length)
* cw value: air-resistance coefficient

Battery range required by consumers in Germany in 2009
(in km)
Lightweight design is an effective way to optimize
e-mobility concepts
30
Lightweight design increases the range of electric
cars
 The drivetrain of a battery-driven electric car is
considerably heavier than the drivetrain of a car
with an internal combustion engine
 Weight is the key factor for e-cars’ range
 To increase the range you can either use bigger,
more expensive batteries or reduce the vehicle
weight
 The use of lightweight design compensates for
battery weight and thereby increases the range
 Even at costs of up to EUR 14.50 per kg*
lightweight solutions are still more cost-effective
than larger batteries
The average range is currently
just 135 kmLightweight design plays a central role in the
widespread use of e-mobility
Source: “Elektromobilität – Anforderungen an Reifen, Fahrwerk, Antrieb und Marktpotenziale” (Electric vehicles – demands on tires, chassis, drive, and market
potential) by Prof. Dr. Horst Wildemann, Munich Technical University
* Based on the battery price in 2011

Areas where lightweight design can be applied: Lightweight construction methods and
lightweight materials can significantly reduce
vehicle weight – and thus the driving resistance*
Vehicle weight can be reduced in various ways
31
* Weight savings can also be made by omitting components or downsizing. However, such measures are often not in line with customer expectations and may
result in marketing challenges
Drivetrain
Chassis
Car body
Electronics
Interior
Lightweight design
Lightweight
construction
methods
Lightweight
materials
(Share of weight of the vehicle components in %)

Less weight through a combination of lightweight
components and innovative concepts
 For example, various technologies have been
developed in the area of the car body:
- Multi-material construction: the optimal material is
used for each part
- Hybrid construction: usually a combination of steel
and aluminum
- Spaceframe construction: use of extruded metal
sections that enclose the passenger compartment
 However, it is only possible to reduce weight
substantially if lightweight construction methods are
used throughout the car
Lightweight construction methods – comprehensive
lightweight construction of all vehicle parts
32
Source: “Green Mobility - Maßnahmen zur Verringerung von CO2-Emmissionen im Vergleich” (Green mobility – a comparison of measures for reducing CO2
emissions) by Prof. Dr. Horst Wildemann, Munich Technical University
Successful lightweight construction uses
new technologies through the whole car

Saving weight through smart material combinations,
such as plastic/metal hybrid technology
Plastic/metal hybrid technology* permits more functions to be
integrated into car parts
 Combining the properties of both materials creates a higher
performance than either can achieve separately
- Metals such as steel and aluminum provide high strength and
stiffness
- High-tech plastics such as glass-fiber-reinforced polyamide improve
the components’ properties and allow a reduction in wall thicknesses
Significant benefits (in comparison with 100% steel components)
 Weight reduction of up to 50%
 High functional integration in the injection molding process reduces the
number of process steps, enabling costs to be cut by up to 40%
 Greater precision, quality, and strength
 Already successfully applied in practice numerous times
33
Hybrid technology is used in
many car components
Front end
Pedal system Roof frame
Structural
inserts
* Hybrid technology developed by LANXESS

Design with lightweight materials – lighter materials that
satisfy all requirements
34
The right material needs to be used for the
right application
 Choosing lighter materials aims to reduce the
weight of the car
 Depending on where it is used, the
requirements for a vehicle component – and
thus the material it is made of – vary greatly
- For example, materials in the engine
compartment must be particularly heat-
stable
 In the interior, aesthetic considerations are
relevant as well as weight

Overview of important lightweight materials
– metals (1/2)
Sources: McKinsey; EMPA Thun; F. Schröter: “Höherfeste Stähle für dem Stahlbau – Auswahl und Anwendung” (Higher-strength steels for steel construction –
selection and application) (Bauingenieur 9/2003); ATZonline; AutomobilIndustrie
NB: All information on the various lightweight materials (pages 35-38) is based on data from the beginning of 2012
High-profile examplesMaterial
Aluminum
Description
 Steel varieties that are stronger than
regular steel
 The same requirements can be met
with less material
Magnesium
High-strength steel
(HSS)
 Used extensively in aerospace
 The material is also becoming more
relevant in vehicle manufacturing
 Despite having a lower density than
steel, aluminum exhibits good stiffness
 The lightest metal that can be used on
a large scale offers great potential for
weight saving
 Gaining significance through alloys with
improved material properties and as a
matrix material in composites
 Even in the 1930s, the VW Beetle had
a magnesium gearbox and engine block
 Today the material is experiencing a
revival in gearbox housings at Audi and
Mercedes-Benz
 Parts in the interior, e.g. cross -
car beams, steering wheel rims
and seat frames
 Die-cast casings
 Components that require
strength and plasticity, e.g. side
impact bars
 Structural and functional
components, e.g. sub-frame or
axle carrier
 Die-cast casings, e.g. engine
blocks or gearbox housings
 The Golf VII from VW is lighter than its
predecessors; the bodywork in
particular is almost 9% lighter due to
HSS
 Large parts of the bodywork of the Audi
Q5 are made of (ultra-)high-strength
steels
 The bodywork of the Mercedes SL and
other chassis parts largely consist of
aluminum
 In the BMW i3 the bodywork base is an
aluminum spaceframe which houses
the battery and the drive unit in the rear
35
Fields of application

 Production costs are currently still very
high due to the high labor input involved
(including increased safety
requirements due to the risk of fire)
 Magnesium is also increasingly being
used in medium-sized cars
Current use by vehicle
class
Part weight*
(compared to steel)
Part costs*
(compared to steel)**
Overview of important lightweight materials
– metals (2/2)
 Mainly for small/medium-
sized cars with
conventional or hybrid
drivetrains
 Mainly for luxury
medium-sized cars, the
premium class, and
electric cars
 Mainly for luxury
medium-sized cars, the
premium class, and
electric cars
Source: McKinsey; emobility tec * The comparison of piece weight and costs for the materials depends on the application and thus difficult to forecast; the
data is based on expert assessments ** Assuming 60,000 parts produced per year
80%
Summary
 The costs are higher than for steel due
to the more energy- and technology-
intensive production process
 The use of aluminum in medium-sized
cars, however, will increase
 The benefits of high strength and
stiffness are counterbalanced by
constraints on design freedom
 Due to the good performance, HSS will
become an important factor in serial
production
36
Material
Aluminum
Magnesium
High-strength steel
(HSS)
Meaning of the symbols from left to right: small car, medium-sized car, premium class, electric car, luxury car, racing car

Plastic
Glass-fiber-reinforced
plastic (GRP)
 Plastics are subdivided into
thermoplastics and thermosets, which
have different properties
 Plastics can be reinforced, for example
with short glass fibers
Carbon-fiber-reinforced
plastic (CRP)
Overview of important lightweight materials – innovative
plastics and composite materials (1/2)
 Fiber-plastic composite material in
which continuous glass fibers are
embedded in a plastic matrix
 The selection of the matrix material
(thermoplastic or thermoset)
considerably influences material
properties*
 The gearbox oil pan of the Audi R8 is
made of a short glass-fiber-reinforced
thermoplastic
 The Audi A8 has a plastic spare wheel
well that is glued into the aluminum
bodywork
 Widespread use is made of GRP in
premium cars, e.g. the trunk lid on the
Mercedes CL
 Instead of aluminum, Audi uses GRP in
the lower beam of the front end of its A8
Sources: McKinsey; EMPA Thun, AVK – Industrievereinigung Verstärkte Kunststoffe e.V.; ATZonline; Toho-Tenax
* GRPs with thermosets cannot be reshaped after the matrix has solidified, but they can withstand high temperatures; GRPs with thermoplastics soften at high
temperatures, but can be more easily formed and shaped; in contrast to thermosets they can be more easily recycled
 BMW is planning to use CRP in the
serial production of its i3 and i8 electric
car models
 The monocoque bodywork of the
Lamborghini Aventador is largely made
of CRP
 Components that require a high
level of strength and stiffness,
e.g. vehicle frames, engine
covers, or tail gates
 External and internal parts as
well as engine compartment
components that require a
medium level of strength, e.g.
housing parts, covers, brackets,
pedals
 Components that require a high
level of strength, e.g. hoods and
flaps, front ends, seat structures,
airbag housings
 Fiber-plastic composite material in
which continuous carbon fibers are
embedded in a plastic matrix
 The carbon fibers are baked at 1,300 °C
– after which they have a 40 times
higher tensile strength than steel
37
High-profile examplesMaterial Description Fields of application

 CRP is still very expensive to
manufacture due to scalability
challenges and high energy
requirements in production
 In the near future, the use of CRP will
be limited to special models and e-
vehicles in limited numbers
Overview of important lightweight materials – innovative
plastics and composite materials (2/2)
 Plastics are used in all
vehicle classes
 Used in the premium
class, the luxury
segment, electric
vehicles, and motor
racing
 Used in the luxury
segment, electric
vehicles, and motor
racing
Source: McKinsey; emobility tec; Toho-Tenax */** See explanations on page 35
*** The estimate refers to GRP with thermoplastic as the matrix material; higher costs are anticipated for thermosets
 The strength of plastics can be
increased by a combination with other
materials or by adding short fibers
 Due to their suitability for a wide range
of applications and their good
performance, the use of plastics in
automotive production will continue to
increase
 With thermoplastics as the matrix
material, GRPs are already suitable for
mass production and also easier to
recycle than thermosets
 GRPs will play an important part in
serial production in the long run
*
38
Current use by vehicle
class
SummaryMaterial
Glass-fiber-reinforced
plastic (GRP)
Carbon-fiber-reinforced
plastic (CRP)
Plastic
Meaning of the symbols from left to right: small car, medium-sized car, premium class, electric car, luxury car, racing car
Part weight*
(compared to steel)
Part costs*
(compared to steel)**

Manufacturers are using various materials to make lighter,
eco-friendlier cars
Existing technologies and materials offer ideal preconditions
for the promotion of lightweight materials
39
 Thermosetting fiber-reinforced materials have
high weight-saving potential; however, CRP
components in particular are still expensive
 There are new opportunities in the area of
continuous-fiber-reinforced thermoplastic
materials
- Manufacturing costs and processes are
already suitable for mass production today
 OEMs, suppliers and material manufacturers
need to work closely together to enable rapid
utilization of this class of materials
All industry players must work together to
develop lightweight design further
130 g
(target 2012)
Need for action: EU target values are
not yet being met
(OEMs’ CO2 emissions in g per km in 2011)
95 g
(target 2020)
Source: Boston Consulting Group; McKinsey
Material Weight savings in %
High-strength steel
Serial production
capability
Aluminum
Magnesium
Plastic
GRP
CRP
20%
30%
40%
20%
35%
50%





( )

Important for lightweight design in serial production:
everyone involved needs to move in closer step
40
Source: KPMG’s Global Automotive Executive Survey 2012
* Suppliers that manufacture complex modules or in some cases complete vehicles
Financial service providers
Traditionalplayers
New
players
Manufacture of
 Tier 1: vehicle modules/systems
 Tier 2: vehicle parts
 Tier 3: vehicle parts and
raw materials
Suppliers
 Design, manufacture,
assembly
 Brand management
 Financing
OEMs
Shift in value creation structures: suppliers will play an
increasingly important role in the future
+ Cooperation
+ Networkability
 New component suppliers
(e.g. components for lightweight design)
 Manufacturers of information systems
 Tier 0.5 suppliers* and new OEMs
Aftermarket
Car rental and
fleets
Dealers
 Mobility service providers
€

The lightweight design trend increases the production
volume of lightweight materials in the car industry
The market for lightweight materials is growing
dynamically – outlook
41
The use of lightweight materials is growing fastest in the
car industry
Source: McKinsey; Financial Times Deutschland: “Kunststoff im Autobau” (Plastic in car manufacturing)
* A similar trend is forecast for GRP (no data is available for this) ** High-strength steels, aluminum, magnesium, plastic (above and beyond current use),
CRP, GRP *** Forecast is dependent on the development of raw material prices
The significance of lightweight materials is
growing – for all market players
(annual production volumes in millions of tons and annual growth rate in %)
The market for lightweight components will grow from
roughly EUR 70 billion to more than EUR 300 billion
in 2030***
+13%
+1% +17%
Change in lightweight
share**
(percentage share of the
overall material mix)
Volume
(in millions of tons)
2010
2030
+38 PP
67
29
Auto
109.5
139.7
34.1
0.2
2010 2030
Wind
Aviation
8.0
0.1
101.4
174.0
Market
volume
(in EUR billion)
70 300
8%
(CAGR)
CAGR for car
industry
+2%

Use of lightweight design in other transport sectors –
further potential (sidebar)
42
Sources: McKinsey; Dr. Bittmann: “Leichtbau Zug um Zug” (Lightweight construction step by step), in “Kunststoffe” 10/2004; Hacotech; Focus magazine
* EU tractor unit (40 t)
Aviation
 In aviation, lightweight materials already account for
more than 80% of all materials used
- Increased usage is anticipated in particular for
CRP and high-strength steel
Trains
 GRP and CRP are well established as materials for
the interior and exterior body panel on trains as they
enable the manufacture of elegant designs
Ships
 Using GRP can considerably reduce fuel
consumption in comparison with aluminum ships
Trucks
 Traditional trucks* have an empty weight of around
13 tons – 5.5-6 tons can be saved with CRP

Agenda
43

LANXESS materials and technologies for
innovative lightweight design
 Make vehicles lighter and offer a high level of
design freedom
 Increase fuel efficiency and reduce CO2
emissions
Our products, technologies and innovations
enable us and our customers to create
solutions for contemporary and sustainable
mobility
Innovative lightweight design – energized by LANXESS
44

 Our experts in the High Performance Materials (HPM)
BU support our customers by providing state-of-the-art
solutions that contribute substantially to the customer‘s
success
 Between 2012 and 2014, EUR 125 million has been
earmarked for investments in expanding the global
production network for high-tech plastics
 E.g. new world-scale plant for polyamide plastics in
Antwerp
 Focus on product innovations in the area of high-tech
plastics and composites that enable our customers to
develop lightweight solutions to meet the challenges of
growing mobility
45
Research and
development
Production sites
Technical support
LANXESS is committed to products for lightweight
applications – especially high-tech plastics and composites

Pittsburgh, US
Gastonia, US
Krefeld-Uerdingen, DE
Antwerp, BE
Dormagen, DE
Hamm-Uentrop, DE
Wuxi, CN
Hong Kong, CN
Jhagadia, IN
Porto Feliz, BR
Brilon, DE
Filago, ITOrange, US
Leverkusen, DE
R&D center
46
LANXESS develops and manufactures its products for
lightweight solutions via a global network
Global compounding network
X-Lite® technology for lightweight leather
High-tech plastics
Other lightweight materials
São Paulo, BR
Mumbai, IN
Site for upstream-integration
Therban® high-performance rubber

47
We combine high security of supply with technical expertise
Upstream-integration** is the key to quality
Raw materials
 Glass fibers
Engineering
know-how
 Cyclohexane
 Sulfur
 Ammonia
 Caprolactam*
 Cyclohexanone
 KA oil
 Oleum
 Sulfur dioxide
 Hydroxylamine
* Caprolactam is the starting material for the polymerization of polyamide 6
** Upstream-integration: mergers or partnerships with companies from upstream stages in the economic process to achieve efficiency gains
Our customers benefit from an efficient value chain
HPM intermediates
High-tech
plastics/composites
Polymerization
Compounding
Polyamide (PA)-based
high-tech plastics
Polybutyleneterephthalate
(PBT)-based high-tech
plastics
Continuous-fiber-reinforced
thermoplastic
high-performance composites
Excellent
product and
application
development
TEPEX®

LANXESS high-tech plastics are the ideal substitute for metal
 Compared to steel or aluminum, the polymers Durethan® and Pocan®
offer lower density and thus lighter design
 Further benefits
- New options in terms of design
- Combination options with other materials for tailor-made solutions
(e.g. hybrid technology)
- Resistance to chemicals, aggressive bio-fuels, corrosion, etc.
- Cost reduction due to efficient processing techniques
 The proportion of plastics in modern cars is already around 15%, and
this trend is on the rise, thanks to innovative material combinations
48
With its expertise in high-tech plastics, LANXESS is
leading the market
Whether alone or in combination with metal – plastics from
LANXESS are the ideal material for lightweight solutions

LANXESS is revolutionizing hybrid technology with Tepex®
composite sheets for structural components*
 Tepex® composite sheets are continuous-fiber-reinforced materials
with a thermoplastic polymer matrix
 The plastic/plastic hybrid technology combines Tepex® with
Durethan® injection molding
 Various tailor-made LANXESS plastics, fiber materials and injection
molding compounds can be used depending on the component
requirements
 The hybrid components are an excellent alternative to steel or
aluminum components
- Lower density enables weight savings of up to 50%
- High strength and stiffness ensure greater safety
- Economical to manufacture and already in serial production
49
* Used in the lower beam of the Audi A8 and the bumpers of the BMW M3
Bottom image: Audi A8 front end
LANXESS offers innovative technologies –
Tepex® hybrid technology for even lighter cars
TEPEX®

LANXESS has comprehensive specialist knowledge for all phases
of modern component development
 The development of high-end applications requires specialized
knowledge and the dedication of all players
 The outstanding engineering expertise of LANXESS enables
innovative lightweight solutions that are characterized by both low
weight and high performance
 Expert services along the entire customer value chain
- Material Development
- Computer Aided Engineering
- Concept Development
- Part Testing
- Processing
50
LANXESS: excellence in engineering
Our bundled engineering knowledge enables tailored
lightweight solutions

Many car components can be made lighter thanks to
products from LANXESS
51
Steering rod
Cylinder head cover Transmission belt
Gearbox oil panEngine oil pan
Car structure Components featuring LANXESS contribution
Car body
Drivetrain
Chassis
Gas tank liner
Bracket
Seat structures
Lightweight
leather
Pedal system
Interior
Airbag housing
Front end
Cross car beam
Spare wheel well Structural insertRoof frame

Roof frames using plastic/metal hybrid technology
 Compared to a steel solution, the component is 30% lighter and costs
the same
Front ends using hybrid technology
 Plastic/metal hybrid technology front ends are around 10-40% lighter
than full metal front ends; the weight of hybrid aluminum front ends
can be further reduced with Tepex® inserts
 Hybrid front ends made from plastic and metal are already widely
used; as plastic bonds well with Tepex®, the weight can be reduced
even further*
How solutions from LANXESS help reduce weight – car
body examples (1/2)
52
* The lower beam of the current Audi A8 front end that is already in serial production contains a Tepex® U-profile
Roof frame
Front end
Car body Drivetrain Interior Chassis

How solutions from LANXESS help reduce weight –
car body examples (2/2)
53
Spare wheel well:
front view
Structural inserts
 Injection-molded inserts made from glass-fiber-reinforced PA6 enable
substantial weight reduction and increased passenger protection
Spare wheel wells made from 60% glass-fiber-reinforced plastic
 The component is glued directly to the bare bodywork and not only
carries the spare wheel and on-board tools, but also stiffens the rear
part of the vehicle
Cross-car beams
 Cross-car beams with plastic/metal hybrid construction provide
substantial benefits, enabling cable and air ducts or brackets for the
steering column to be easily integrated, for example
Rear view
Structural insert
Cross-car beam
ChassisCar body InteriorDrivetrain

Car gas tank with a liner made from PA6
 High-pressure containers can be produced much more easily and
cost-effectively using plastic
 With a coating made from continuous-fiber-reinforced plastic, they are
up to 75% lighter than all-steel tanks – with the same loading
capability
High-performance rubber for transmission belts
 In comparison to conventional chain drives, rubber belts are not only
lighter, but they increase engine life and fuel efficiency*
Cylinder head covers made from glass-fiber-reinforced plastic
 LANXESS Durethan® is a popular choice for this application thanks to
its high temperature resistance and favorable surface qualities
drivetrain examples (1/2)
54
* Up to 1 liter of fuel is saved per 100 km
Cylinder head covers
Transmission belt
Gas tank liner
Car body ChassisDrivetrain Interior

Car engine oil pans made from polyamide 66 for turbocharged
engines
 The engine oil pan made from polyamide 66 weighs about a kilogram
less than a steel component solution; it is about 50% lighter than an
aluminum version
Gearbox oil pans made from highly glass-fiber-reinforced
polyamide 6
 The high-tech material’s stiffness enables a very shallow design for
the oil pan, making it even lighter
drivetrain examples (2/2)
55
Engine oil pan
Gearbox oil pan
ChassisCar body InteriorDrivetrain

Tepex® housings for passenger airbags
 The thickness of the side walls can be reduced from 3-4 mm to
0.5-1 mm by using Tepex®
hybrid technology – without
compromising on stiffness or strength
 This results in a casing that is 30% lighter than designs made from
injection-molded thermoplastics
Car brake pedals using Tepex® hybrid technology*
 The world’s first polyamide brake pedal reinforced with continuous
glass fibers and designed for mass production
 It is roughly 50% lighter than comparable traditional steel brake
pedals, but just as mechanically strong
interior examples (1/2)
56
Airbag housing:
rear view
ChassisInterior
355 g:
Tepex®
hybrid technology
526 g:
Plastic/metal
hybrid technology
794 g:
Steel
The evolution
of the brake pedal
* Plastic/plastic hybrid technology.
Car body Drivetrain

Lighter leather
 LANXESS products accompany all stages of leather manufacturing.
The innovative X-Lite® process enables high-quality leather to be
produced that is up to 20% lighter
Plastic seat structures
 In comparison to seat structures made from plastic alone,
Tepex® inlays can reduce the weight of car seat components
by up to 50%
interior examples (2/2)
57
Leather for car seats
Plastic seat shells
ChassisInteriorCar body Drivetrain

Steering rods
 In contrast to metal, the use of high-tech plastics for structural
components of the chassis, such as the steering rod, offers many
benefits
- Weight savings
- Cost-effectiveness through efficient manufacturing and assembly
processes
- Reliable when subject to high dynamic mechanical stresses
58
Steering rod
Car body ChassisInterior
chassis examples
Drivetrain

LANXESS major products for innovative lightweight solutions
59
* Although primarily offering other „green“ benefits, the use of X-Lite® and Therban® also enables weight savings
“Green Tires”
Sustainable
Leather
Management
Biofuels &
Renewable
Energy
Technical
Products
LANXESS
Contribution
Bio-Based
Raw Materials
Lightweight
Materials
TEPEX®

 Automotive (e.g. front ends, connectors, intake manifolds, door handles)
 Trains and airplanes
60
Durethan® – polyamide (PA)-based high-tech plastics
 Weight reduction directly leads to increased fuel efficiency and reduction
of CO2 emissions
 Does not require finishing, generates little waste, involves short cycle
times and can also be used without coating
 High-tech plastics such as Durethan® make cars lighter by replacing
metal parts contributing directly to lower fuel consumption and thus lower
CO2 emissions. They are corrosion resistant and new design freedom can
be realized in combination with a higher degree of functionality.
 Reduces vehicle weight and improves performance
 Hybrid technology: Durethan® reduces weight of certain structural
components by up to 50% (compared to metal)
 Design freedom
Note: Durethan® is a product of the BU HPM
Application
Character-
istics
Green aspect
Short
description
“Green Tires”
Sustainable
Leather
Management
Bio-based
Raw
Materials
Biofuels &
Renewable
Energy
Technical
Products
LANXESS
Contribution
Lightweight
Materials

 Automotive (e.g. connectors, housings, electro motor housings)
61
Pocan® – polybutylene terephthalate (PBT)-based
high-tech plastics
of CO2 emissions
 Does not require finishing, generates little waste, involves short cycle
times and can also be used without coating
 High-tech plastics like Pocan® make cars lighter by replacing metal parts
contributing directly to lower fuel consumption and thus lower CO2
emissions. They are corrosion resistant and new design options can be
realized in combination with a higher degree of functionality.
 Lightweight alternative to metal parts in the automotive industry
 Economic production process for car body applications
 Design freedom
Note: Pocan® is a product of the BU HPM
Application
Character-
istics
Green aspect
Short
description
“Green Tires”
Sustainable
Leather
Management
Bio-based
Raw
Materials
Biofuels &
Renewable
Energy
Technical
Products
LANXESS
Contribution
Lightweight
Materials

 Automotive (e.g. front ends, seat structures, pedals)
62
Tepex® – continuous-fiber-reinforced thermoplastic composite
sheets
 Weight reduction leads to increased fuel efficiency and reduction of CO2
emissions
 Resource efficient and recyclable
 Thermoplastic composite sheets (Tepex®) have excellent mechanical
properties due to their reinforcement with glas-, carbon or aramid fibers
and in combination with their low density they offer great potential for
lightweight design. Additionally, composite sheets are suitable for volume
production, guarantee resource efficient processing and are easy to
recycle.
 Tailored thermoplastic composite sheets (Tepex®) for lightweight
applications
 Tepex® reduces weight by up to 50% (compared to metal)
Note: Tepex® is a product of the BU HPM
Application
Character-
istics
Green aspect
Short
description
TEPEX®
“Green Tires”
Sustainable
Leather
Management
Bio-based
Raw
Materials
Biofuels &
Renewable
Energy
Technical
Products
LANXESS
Contribution
Lightweight
Materials

 Automotive (service brand standing for the high-end engineering know-
how for all stages of advanced component development)
63
HiAnt® – excellent product and application development
 Efficient application of high performance materials for optimal lightweight
structures
 Result: increased fuel efficiency and reduction of CO2 emissions;
contribution to e-mobility
 The development of high-end applications requires specialized expertise
and special efforts from all development partners. HiAnt® stands for
outstanding engineering know-how for all stages of advanced component
development resulting e.g. in innovative composite systems that are, at
the same time, lightweight and strong.
 Engineering know-how at the highest service level: Material
Development, Computer Aided Engineering, Concept Development, Part
Testing, Processing
 Smart solutions energized by LANXESS due to optimum use of material
potentials (e.g. with hybrid technology)
Note: HiAnt® is a product of the BU HPM
Application
Character-
istics
Green aspect
Short
description
“Green Tires”
Sustainable
Leather
Management
Bio-based
Raw
Materials
Biofuels &
Renewable
Energy
Technical
Products
LANXESS
Contribution
Lightweight
Materials

64
Further products for innovative lightweight design
 Pre-product for surfaces of transport vehicles like trains or airplanes
 Maleic anhydride enables lightweight design and decreased surface
resistance, resulting in positive environmental effects with regard to fuel
consumption and CO2 emissions
Maleic Anhydride
Maleic
Anhydride
(MSA)
(BU Advanced Industrial
Intermediates)
TP LXS 51066
TP LXS 51099
Mesamoll®
(BU Functional Chemicals)
TP LXS 51066
TP LXS 51099
(BU Functional Chemicals)
 Plasticizer for polyurethanes, PVC and rubber, that are used for the
automotive industry
 The phthalate-free plasticizer Mesamoll® provides plastics with high
elasticity and flexibility. In addition, it optimizes the processing properties
of polymer materials which leads to improved product quality
 Bonding agents for tarpaulins of trucks
 The phthalate and solvent free bonding agents TP LXS 51066 / 51099
enable the bonding of flexible PVC coatings on polyester and polyamide
fabrics
“Green Tires”
Sustainable
Leather
Management
Bio-based
Raw
Materials
Biofuels &
Renewable
Energy
Technical
Products
LANXESS
Contribution
Lightweight
Materials

65
X-Lite® – technology for the manufacturing of lightweight
leather
 X-Lite® enables the production of durable leather with a full and soft
handle, attractive appearance and an up to 20% lighter weight compared
to conventionally produced leather of equivalent thickness. This weight
reduction effect in automobiles or aircrafts leads to improved fuel
consumption.
Note: X-Lite® is a product of the BU Leather
Application
Character-
istics
Green aspect
Short
description
 Seats in cars, airplanes and trains
 Lightweight upholstery leather products
of CO2 emissions of cars, planes and trains
“Green Tires”
Sustainable
Leather
Management
Bio-based
Raw
Materials
Biofuels &
Renewable
Energy
Technical
Products
LANXESS
Contribution
Lightweight
Materials

66
Therban® – hydrated nitrile rubber
Note: Therban® is a product of the BU High Performance Elastomers
 Automotive (timing belts)
 Railway (railway cables)
 Aerospace
 High-performance elastomer with exceptional oil- and temperature
resistance
 Light alternative to chains (e.g. driving belts, timing belts)
 Weight reduction and better transmission efficiency directly lead to
increased fuel efficiency and reduction of CO2 emissions
 Increased durability  resource efficiency
 With its excellent properties (resistant against heat and oil, excellent
mechanical behavior), Therban® (HNBR) is for example used for timing
belts in automotive valve trains. Due to their low weight and their
efficiency, they are a sustainable alternative to metal chain drives.
Application
Character-
istics
Green aspect
Short
description
“Green Tires”
Sustainable
Leather
Management
Bio-based
Raw
Materials
Biofuels &
Renewable
Energy
Technical
Products
LANXESS
Contribution
Technical
Products
Lightweight
Materials

LANXESS enables lightweight solutions for sustainable
mobility
To ensure sustainable mobility, carmakers will need to
considerably reduce their cars’ energy consumption and
CO2 emissions in the future
With its innovative materials and its expertise in
lightweight design, LANXESS is helping the automotive
industry replace metal in cars with lighter components
– lightweight design energized by LANXESS

Lightweight design plays a key role in this process, as it
increases fuel efficiency, reduces CO2 emissions and
compensates for the increase in weight associated with
new drivetrain technologies


67

This presentation contains certain forward-looking statements, including assumptions, opinions and views of the
company or cited from third party sources. Various known and unknown risks, uncertainties and other factors
could cause the actual results, financial position, development or performance of the company to differ materially
from the estimations expressed or implied herein. The company does not guarantee that the assumptions
underlying such forward looking statements are free from errors nor do they accept any responsibility for the future
accuracy of the opinions expressed in this presentation or the actual occurrence of the forecasted developments.
No representation or warranty (express or implied) is made as to, and no reliance should be placed on, any
information, including projections, estimates, targets and opinions, contained herein, and no liability whatsoever is
accepted as to any errors, omissions or misstatements contained herein, and, accordingly, none of the company
or any of its parent or subsidiary undertakings or any of such person’s officers, directors or employees accepts
any liability whatsoever arising directly or indirectly from the use of this document.
Safe harbour statement

MASTHEAD
As of March 2013
LANXESS AG
51369 Leverkusen
Germany
Phone +49 214 30 33333
www.lanxess.com

LANXESS Factbook Lightweight Design

Recommandé

Recommandé

Contenu connexe

Tendances

Tendances (20)

En vedette

En vedette (20)

Similaire à LANXESS Factbook Lightweight Design

Similaire à LANXESS Factbook Lightweight Design (20)

Plus de LANXESS

Plus de LANXESS (13)

Dernier

Dernier (20)

LANXESS Factbook Lightweight Design