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01/05/2007
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The new BMW X5 fender module is probably the most complex and highly integrated example we have seen to date, writes Roger Bishop.
The functions and parts included are pedestrian protection absorber, headlamp reinforcements, wheel housing, cleaning systems, airbag sensors and cooling devices.
Borealis formulated a thermoplastic polyolefin (TPO) compound, Daplen EF341AE, specifically tailored to BMW’s requirements, which included a Class A finish. The assembly is around half the weight of one with traditional steel components.
Pedestrian protection is in line with the EuroNCAP pedestrian safety regulations for 2010. It can deform up to 80mm on impact, significantly reducing the potential for major injury to a pedestrian in a low-speed collision.
The component manufacturer is Plastic Omnium whose engineers worked closely with BMW and Borealis on the fender’s design and development. Critical to the choice of 30% mineral-filled material were Plastic Omnium’s offline painting requirements and ease of processing. Daplen was also selected for its dimensional stability.
Klaus Maureder, application marketing manager for Borealis’ automotive business, says the “creation of the first 100% plastic one-module fender is a breakthrough for the automotive industry”.
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Author
Roger Bishop
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