Fiber Glass Production Increases As Automakers Find New Uses
4 November 1998
Fiber Glass Production Increases As Automakers Find New Uses
PITTSBURGH, Nov. 4 - North American automakers, driven by
ongoing demand for more efficient and higher performing vehicles, used 56
percent more fiber glass in 1997 than they did at the start of the decade. A
seven percent increase is expected for 1998.
In 1997, 352 million pounds of fiber glass reinforcements for plastic were
consumed for automotive applications, compared with only 226 million pounds in
1990, according to PPG Industries , the world's second largest
producer of fiber glass. The 1998 total is likely to be about 377 million
pounds.
"Fiber glass sales for the auto industry have increased as manufacturers
seek new materials to build cars that cost less, are visually appealing and
easy to own," said Cliff Watkins, PPG's global marketing director for
thermoplastic reinforcements. "Preliminary estimates show an additional
growth of 19 percent by 2000."
Relying heavily on fiber glass reinforced plastics, or composites,
automakers are challenging producers and parts manufacturers to develop more
advanced applications. Composites are used for exterior parts such as bumpers,
fenders and hoods. Car interiors, including seats and instrument panels, also
contain fiber glass. Usage is even more extensive under the hood where
cables, radiator end caps, intake manifolds, valve covers, connectors and
components of ignition systems are made with fiber glass.
Fiber Glass Benefits
The trend of parts consolidation is where fiber glass is most applicable,
according to Watkins. Plastic parts using fiber glass as reinforcement can be
molded into sub-assemblies. By combining various components in a single mold,
part production is less expensive and assembly is faster, he said.
Fiber glass composites can even contribute to automotive brand identity.
The purr of a luxury sedan or thunder of a muscular sports coupe are created,
in part, by the composite intake manifolds in which complex air pathways
customize sound and vibration levels appropriate to the model.
There are other benefits of fiber glass composites. Fender-benders
require fewer trips to the body shop as composite bumpers and fenders absorb
and shrug off lesser impact pressures, Watkins noted. Flexibility is an added
feature, as fiber glass enables engineers to design exterior parts with
greater complexity and visual interest. Its lighter weight also helps fuel
efficiency.
Products reinforced with fiber glass keep pace with the desire of car
builders to extend vehicle life and reduce maintenance. For example, long-
life coolants are being developed to extend the length of time between fluid
changes. However, the newer coolants can be extremely corrosive to plastics,
shortening the life of radiators, heaters and even some air intake manifolds
that incorporate coolant cross-over channels.
To meet the challenge, PPG developed ChopVantage 3660 and MaxiChop 3662
fiber glasses for reinforcing nylon, which contributes to tripling the life of
plastic parts.
"These products can withstand a corrosive environment because of the
special coatings we place on the fiber," Watkins said. "We've drawn upon
PPG's competency in coatings technology and adapted it for fiber glass in this
particular application. The development of this product will enable under-
the-hood components to withstand these coolants and extend the vehicle's
service interval to 100,000 miles."
The engine air intake manifold is one example of a product reinforced with
fiber glass for which applications have grown dramatically during the 1990s,
according to Watkins. In 1993, nylon intake manifolds were introduced on one
United States vehicle product line and consumed 40,000 pounds of fiber glass.
In just four years, 12 different models have incorporated the part, increasing
fiber glass consumption to 7.3 million pounds. Fiber glass use among European
automakers is three times greater than in the U.S., where composite manifolds
were invented.
Demand for performance can create even more complications when designing
and building cars. Modern engines create intense heat, and parts designed to
help them meet environmental regulations must operate at these high
temperatures.
Such thermal conditions can cause electronic wiring to lose its durability
and begin fraying. PPG fiber glass is being used with braided sleeving and
wire wrapping for protection from extreme temperatures. This solution helps
car performance meet requirements of automakers, environmental standards and,
ultimately, car owners, Watkins emphasized.
What's Next
While fiber glass is being used in more automotive applications than ever
before, there is untapped potential for new products and increased use. "In
the case of the intake manifold, only 23 percent of U.S.-produced vehicles
utilize fiber glass reinforced composite," Watkins said. "Projections of
increased fiber glass consumption in the next century indicate that those
numbers will keep climbing."
As the automotive industry continues to demand higher- performing
products, how will producers of raw materials and plastic composites meet new
challenges? "Technology and innovation," according to Watkins. "At PPG,
we're using our experience and diversification to develop solutions that will
benefit the manufacturer and end user."
PPG is a major supplier of a variety of products for the global automotive
industry, with production facilities around the world. About 20 percent of
worldwide demand for fiber glass plastic reinforcements is met each year by
PPG plants. With annual sales of about $7.5 billion, the company is a leading
producer of coatings, flat glass and chemicals, in addition to fiber glass.