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01/10/2004
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Dow Automotive has developed a bonded plastic-metal instrument panel cross-car beam structure, integrating the air delivery system, column support structure and a range of other functions. The design has been validated by a European vehicle OEM.
The enabling technology is cited as the company’s Betamate adhesives. These allow a steel cross-car metal stamping to be bonded to a plastics structure. Together, they form very strong closed box sections for attaching the steering column but also forming the air ducts. The component has satisfied all crash and NVH requirements.
European Automotive Design readers may recall our April 2002 report on Dow Automotive’s experimental work in this field. At that time we reported on the original development of Betamate low energy substrate adhesive, its application to a prototype front-end module and its potential use for cross-beam members, door module carriers, tailgates and bumper systems, roof modules and floors.
The adhesive is a two-part acrylic that cures at room temperature, with the help of airborne moisture, and does not require peroxide initiators or the use of flame or plasma surface pre-treatments.
It can structurally bond any plastic, including the extremely low surface energy molecule found in Teflon (polytetrafluorethylene). As such it is an ideal adhesive for use with polypropylene (PP) and polyethylene (PE).
The degree of integration in the hybrid IP cross-car beam is impressive. It not only supports the steering column and integrates the fresh air and (possibly) defrost/demist delivery system, but also includes the centre console structure and the passenger side airbag mounting. Dow Automotive says packing space is freed up, overall system cost is reduced and weight is reduced (over steel cross-car beam solutions).
Materials that can be joined to each other or to metal substrates include: LGF-PP, LGF-ABS, PC/ABS or GF PC/ABS).
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Author
Roger Bishop
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