Why Plastic Materials Will Become The Mainstream Of Automotive Smart Surfaces

Why Plastic Materials Will Become The Mainstream Of Automotive Smart Surfaces

With the increasing popularity of smart cars, the user's perception of the value of the car is gradually changing from a simple travel tool to a personalized “third living space”, in which the smart cockpit, as the core carrier of this change, is experiencing significant evolution.

By integrating advanced electronics and information technology with intelligent design and interaction systems, smart cockpits are designed to provide drivers and passengers with a more convenient, comfortable and safe travelling experience, thus significantly enhancing the intelligence of the in-vehicle environment.

Against this backdrop, Smart Surface has emerged as an important innovative technology in the field of smart cockpit. It is a key medium for multimodal interaction and plays a pivotal role in the construction of smart cockpits by cleverly integrating automotive interiors with electronic functions, which are not only decorative but also powerful and functional. As the market continues to expand, smart surfaces have also become the object of competition among OEMs, TIER1, new forces, and technology giants.

Smart Surfaces Market Overview

Smart Surfaces is an innovative interior process that enables “functional”applications by integrating electronic sensors with a wide range of interior materials including, but not limited to, leather, fabric, wood, glass, plastic, natural fibers, metal, etc. These materials are not only used for decorative purposes, but also to execute commands. These materials are not only used for decorative purposes, but can also carry out commands that, when activated, can produce light, heat, or emit commands, sounds, and so on.

According to Zoss Auto Research report, the application of automotive smart surfaces in 2024 shows rapid growth, and the market penetration rate continues to rise. Specifically:

From January to September 2023, sales of models equipped with smart surfaces were 256,000 units.

In January-September 2024, sales of models equipped with smart surfaces climbed to 525,000 units, with a penetration rate of 3.4%. Compared to the same period last year, sales of this model type increased by 105.1% year-on-year.

In terms of cockpit carrying parts, smart surfaces are mainly concentrated in the steering wheel, centre console, doors, dashboard function area and other parts of the car, providing a variety of functions such as sensing, temperature control and lighting.

From January to September 2024, among different smart surface models, the number of models with smart surfaces applied to the centre console was the highest, with sales reaching 234,000 units.

Applications on doors, roofs, and steering wheels also showed rapid growth, with sales reaching 111,000, 21,000, and 75,000 units in January-September 2024, respectively.

Breakdown to specific components:

Centre Console: Adopts intelligent surface interior, integrating various functions such as information display and air conditioning control, and transforming the originally cumbersome physical buttons into a simple touch-type operation interface. This not only enhances the convenience of operation, but also makes the centre console more simple, atmospheric and modern in appearance.

Door interior panels: The intelligent surface design enables integrated operation of door lock control, window control and other functions by touch, and supports the hiding of related functions in the inactive state. This not only enhances the ornamental appearance of the door trim, but also improves the convenience of operation.

Steering Wheel: Intelligent Surface, on the other hand, enables multi-functional controls such as volume adjustment and driving mode switching, allowing drivers to operate more conveniently during driving.

Why is plastic leading the pack

In addition to electronic components, smart surface trim materials mainly include plastics, metals, wood veneers, translucent leather, fabrics, etc. The most frequently used materials in 2024 are plastics. According to Plastics Insight, the material with the highest application frequency in 2024 is plastic, and the related smart surface models are more likely to combine “plastic material”with “touch control programme”, which is expected to remain the mainstream in 2024-2025.

So why plastics in the smart surface materials, become the mainstream of automotive smart surface applications, Plastic Vision listed four major reasons, in the analysis, I believe that will allow readers to understand the logic behind the meaning:

1. Plastic surface, intelligent cost-effective choice

Talking about the choice of materials, the first choice can not be separated from the cost considerations. Plastic, with its low-cost advantage, occupies an important position in large-scale automotive production, effectively controlling the cost of the car.

Taking the centre console bezel as an example, ABS/PC plastic, as a mainstream material, shows excellent plasticity, and can easily meet the challenges of complex design and meet the needs of diversified models. At the same time, its excellent weather resistance, including corrosion and abrasion resistance, enables the plastic to resist minor scratches and chemical erosion in daily use and maintain long-lasting beauty. In terms of heat resistance, plastics usually have a certain degree of resistance to high temperatures, but may deform when exposed to high temperatures for a long period of time. Leather is relatively weak in this regard, and high temperatures may cause it to dry out and crack.

What's more surprising is that plastic, with its recyclable and renewable properties, fully meets the current environmental protection concept and adds a touch of unique glamour to smart surfaces. For example, in models such as Geely Boyue Cool and Link 08, recyclable PC/ABS materials are used in large quantities in the centre console, realising an environmentally friendly upgrade of smart surfaces.

2. Intelligent interaction, car display primary plastics

In fact, we will focus on the definition of intelligent surfaces in the steering wheel, centre console, doors, dashboard functional areas and other subdivided parts, we will find that the so-called general-purpose plastics or engineering plastics can be used for most of its brackets, shells, protective frames, and the same applies to the in-vehicle display.

Let's take the car display cover as an example, its material is divided into two kinds of glass and plastic plate. And the breakdown can be divided into glass/explosion-proof film + glass, PC, PMMA plate, PC/PMMA composite plate and other materials. Among them, PC, PC / PMMA composite plate has excellent optical properties, good toughness, is currently one of the popular materials for car display cover.

Meanwhile, the optical film materials for smart large screen, used to improve the display effect (such as brightness enhancement film, diffusion film, etc.) are very important, and these film materials are usually made of polyethylene, polyester and other polymers. Encapsulation materials usually include polymer materials such as epoxy resin and silicone resin.

For example, in August 2024, Yanfeng launched the Optical Texture Trim Series, which is the industry's first automotive-grade optical film three-dimensional, multiple gradient, technological bionic, and crystal texture can be achieved through the micro-nano optical technology to create a more extreme experience of the luxury atmosphere of the cockpit, which can be applied to a wide range of surfaces of the automotive interior.

3. Transparent parts in the car, plastic continues to penetrate

Automotive lamps and lanterns as an important part of one of the plastic applications, which consists of reflectors, lenses, shells / light sources, electronic circuits, and mounting accessories. According to Plastic Vision, China's automotive lamps and surrounding commonly used plastics are mainly PC, PP, PS, ABS, PBT/PET, PMMA and other modified plastics.

In the interior field, high-performance, high-transmittance plastic materials such as PC, PMMA, etc., with their excellent light transmittance, weather resistance and processing performance, provide an ideal solution for ambient light (light guide strip) on smart surfaces.

These materials not only meet users' high demands for safe, smart, personalised and versatile ambient lighting, but also drive the continuous innovation and development of interior ambient lighting technology. As the market for interior ambient lighting continues to expand, high-performance plastic materials will usher in even broader development space and application opportunities.

For example, in April 2024, Changshu Auto Trim launched door ambient lighting, which consists of wood grain LED, light-transmitting PU and light-transmitting fabric in order from top to bottom, and all three of them can be used to achieve DIY lighting at a later stage, in which the wood grain LED, through the embedded inductive vibration mechanism, can realise occupant-defined virtual touch control functions.

4. Plastic wood composite materials to create texture

In recent years, with the enhancement of low-carbon environmental awareness, wood plastic composite (WPC) has been initially involved in the field of automotive manufacturing, its formula in the content of wood materials is gradually increasing. Plastics Insight has learnt that current research into WPC in automotive manufacturing has achieved significant results. A number of studies have shown that WPC can be used as an effective substitute for traditional plastics such as PP, ABS and PU.

According to the special plastic vision in May this year, Shaanxi University of Science and Technology, Associate Professor You Xiangyu hand in hand with the Canadian Biomass Products Research and Development Centre and Japan's Hokkaido University's scientific research team, these new composite materials using advanced in-situ modification of the capacitance enhancement technology and polymer network enhancement technology, even if the lignin content of up to 60% of the case, but still be able to maintain excellent mechanical properties, fully in line with the automotive manufacturing of the instrument panel, It fully meets the strict requirements of automobile manufacturing for parts such as instrument panel, inner door panel and so on.

Plastic-wood composites combine the texture of wood with the excellent weather resistance of plastics, a breakthrough that has already been achieved in the laboratory stage, laying the foundation for the creation of smart surfaces with excellent performance in the future.

Automotive flame retardant materials and the application of flame retardants

In the field of automotive manufacturing, the use of flame retardant materials plays a crucial role in ensuring the safety of vehicles, especially when plastic materials are widely used. Common automotive plastics such as ABS (Acrylonitrile Butadiene Styrene Copolymer) and PP (Polypropylene) can greatly improve their flame retardant properties after being modified by adding flame retardant to better adapt to the complex interior of the car and the use of the environment that requires a high degree of safety.

ABS plastic is widely used in automotive interiors and some exterior parts due to its good overall performance, such as high strength, good toughness and easy processing and moulding. However, the flammability of ABS without flame retardant is relatively high, and it is easy to burn and release a large amount of harmful fumes when encountering an open flame or a high-temperature heat source. To solve this problem, different types of flame retardants such as bromine flame retardants and phosphorus flame retardants are added to ABS. Bromine flame retardants release bromine radicals with fire-extinguishing effect during the combustion process, which interferes with the chain reaction of combustion, thus achieving the effect of inhibiting the spread of fire; phosphorus flame retardants mainly generate phosphoric acid and other substances when they are decomposed by heat, which are able to form a layer of protective film on the surface of the plastics, blocking oxygen and preventing the transfer of heat, thus slowing down the speed of combustion.

The ABS masterbatch ABS-P-20M and antimony compound T3 launched by YINSU Flame Retardant have excellent performance in ABS flame retardant. 20% of ABS-P-20M can achieve UL94-V0 and high efficient halogen-free flame retardant effect. ABS-P-20M and Antimony Complex T3 are a new type of environmentally friendly flame retardant, which has good compatibility with ABS materials, further enhancing the fire safety of ABS materials in automotive applications, and meeting the stringent requirements of automotive manufacturing for flame retardant materials.

PP plastic is also one of the commonly used materials in automotive manufacturing. It is commonly used in automotive seats, dashboard frames and other parts due to its low density, low cost and better chemical resistance. However, the flammability of PP also makes it necessary to undergo flame retardant treatment. The choice of flame retardant for PP is also more diverse, such as magnesium hydroxide, aluminium hydroxide, such as inorganic flame retardant is one of the common choices. When they are heated, they will absorb a lot of heat to decompose and release water vapour, which on the one hand reduces the ambient temperature, and on the other hand, the water vapour can dilute the concentration of combustible gases in the combustion area, thus achieving the purpose of flame retardancy. In addition, some composite flame retardants are also being developed and applied to further enhance the flame retardant effect of PP through the synergistic effect of various flame retardant mechanisms.

PPV2-8H and PPAP-15 flame retardants of YINSU Flame Retardant have also attracted much attention. PPV2-8H is a kind of high-efficiency flame retardant specially developed for PP recycled materials, featuring good flame retardancy, self-extinguishing off the fire, low additive quantity, low cost, and can be injected into PP directly to reduce the cost. Moreover, it has less influence on the physical properties of PP after being added to PP materials, which guarantees the normal use and processing performance of automotive parts. As a halogen-free intumescent flame retardant, PPAP-15 has the advantages of environmental protection, good anti-separation performance, and very small mould corrosion, which provides a reliable flame retardant guarantee for auto seats, dashboard skeleton and other parts using PP materials.

The research and application of automotive flame retardant materials and flame retardants have been in continuous development, not only to take into account the enhancement of flame retardant performance, but also to take into account the addition of flame retardants to the original physical properties of plastics, chemical stability, and processing performance, etc., to ensure that automotive parts to meet the safety requirements of flame retardant at the same time, but also to maintain the good use of the performance and quality of the appearance of the car, all-round protection of the safety of the car in the process of driving. It ensures that the automotive parts meet the requirements of flame retardant safety while still maintaining good performance and appearance quality, and protects the safety of automobiles in all aspects during driving.

Conclusion

From interior and exterior trims to powertrains, plastics have permeated every component of automobiles like mercury falling to the ground, and have become an indispensable key material in the automotive manufacturing field due to their wide range of applications and depth of involvement. In the incremental market of intelligent surfaces with great potential for development, whether it is in the steering wheel to facilitate the realization of convenient operating functions, or in the centre console to integrate multiple functions to create a simple, atmospheric and modern appearance, or in the door, dashboard and other parts of the car to play their unique decorative and functional role, plastics have shown irreplaceable value, and all-around participation in the shaping of the automotive intelligent experience. Plastics have demonstrated their irreplaceable value, and have participated in the shaping of intelligent automotive experiences in all aspects, making them a mainstream solution that is well deserved.

As the application of plastics in the automotive industry becomes more and more extensive, the issue of automotive safety is receiving more and more attention. It is important to know that the internal structure of the car is complex, the electrical wiring is crisscrossed, in the operation of the vehicle, there is a potential risk of fire due to faulty wiring, high temperature environment and many other factors. Once the fire occurs, if the plastic material used in the car lacks good flame retardant properties, the fire will be very easy to spread rapidly, and then the lives of the people inside the car as well as the overall safety of the vehicle caused a devastating blow. Therefore, in order to ensure the safety of automobiles under all kinds of working conditions, the role of flame retardant plastics in the automobile manufacturing process becomes crucial and indispensable.

In the professional field of flame retardant plastics, YINSU Flame Retardant, with its professional R&D team, profound technical accumulation and deep insight into the high safety standards of the automotive industry, has been actively engaged in the research and development of products for the plastics industry. Focusing on solving the technical problems of flame retardant plastics, they have developed a series of flame retardant plastic products suitable for the automotive industry by applying advanced scientific concepts and innovative technological methods. These products not only have reliable flame retardant properties, which can effectively curb the spread of fire at critical moments, but also take into account the diversified requirements of automobile manufacturing in other aspects, such as maintaining good mechanical properties to adapt to the installation and use of different components, and possessing stable chemical properties to ensure that there is no deterioration of performance under long-term complex environments. This series of products developed by YINSU Flame Retardant Company undoubtedly provides a strong guarantee for the automotive industry to use plastic materials in a safer and more secure way, and also helps the automotive industry to move forward steadily and without any worries in the pursuit of intelligence and comfort, so that plastics will continue to blossom in the field of automobiles, and better serve automobile manufacturing as well as the travelling needs of the majority of consumers.