Low-E Poly

Initially developed by our sheet and roll stock group to support the manufacture of fuel cells for the VW Passat, Spartech's Low-E Poly sheet is also engineered to meet the most demanding performance criteria for OEM's looking for a solution to the California Air Resources Board (CARB) emissions requirements. Target market segments for Low-E Poly include automotive, lawn & garden, and power sports.



Spartech Multi-Layer Barrier Sheet – Low-E Poly

Recent EPA and California Air Resource Board legislation will require manufacturers of <225 cc engines to develop fuel systems that will emit less than 1 gram hydrocarbon and >225 cc engines less than 2 grams of hydrocarbons in a 24 hour period. The current plastic fuel tanks do not meet these regulations and there is no drop in solution to meet the new standards. Twin sheet thermoforming, based on providing a barrier technology have surfaced as the most viable solution. Spartech's Multi-layer technologies are exempt from CARB testing and future emission litigation.

Multi-layer Sheet for Twin Sheet Thermoforming is a Proven Technology

• Twin sheet fuel cells based on Spartech's multi-layer barrier sheet has been embraced by automotive suppliers such as Visteon and Spartech's Low-E Poly alloy is currently in production for the VW Passat.
• Twin sheet fuel tanks manufactured with Spartech's Low-E Poly barrier sheet are CARB approved and exempt from EVAP testing.
• The twin sheet process uses existing, in place technology with an established tooling and equipment supply base.
• Twin sheet process will allow for same mold transitioning from mono-layer to multi-layer material.

Typical Sheet Constructions

"A" virgin skin layers – 2 "B" layers capture the generated trim – 2 "C" adhesive layers tie the construction together – 2 "D" layer is the vapor layer – 1
"A" virgin skin layer (often with color) – 1 "B" layers capture the generated trim – 1 "C" adhesive layers tie the construction together – 2 "D" layer is the vapor layer – 1 "E" layer is the inner structural layer (often virgin material) – 1

Lower Cost

• Twin sheet forming process enables us to add ancillary devices, such as fuel pumps, in cycle, no "ship in the bottle" secondary options.
• Twin sheet thermoforming brings into play increased design flexibility when compared the traditional "Square" blow molded tank.
• The twin sheet process utilizes multiple cavity tools versus single tool blow molding in same cycle (>100,000 EAU).

Higher Quality Fuel Cells

• Twin Sheet thermoforming produces tighter tolerance parts when compared to blow molding.
• Spartech's advanced manufacturing experience allows us to provide specific material ratios of the dissimilar materials to provide a composition that performs the required task and provides to required structure. This expertise allows for optimized material usage, lighter parts and overall efficiency.

Ecological Impact Volumes

The sheet volume for Low E Poly Alloy is 9 million pounds for 2005 which adds approximately 360,000 emission compliant fuel cells in use. Spartech is forecasting 2006 sheet volumes of 22 million pounds for Automotive and Power Sport tanks which will add more than 600,000 new engines storing their gas in low emission emitting fuel cells contributing to an overall cleaner air value.

The composite structure is designed to be "self consuming", ultimately there will be a time of steady state consumption where offal and edge trim are completely entrained within the primary design, and other "filler" plastics will be required to provide the desired wall thickness. This is possible with the use of engineered compatibilzers or other modifiers to regrind matrix that can improve the impact strength or other physical properties of the structure.

		Low-E Poly is an advanced material and part of our Green Initiative program. Its unique multi-layer design virtually eliminates the evaporative emissions of gasoline in fuel cells and helps keep our air clean. In recent tests, it not only met the current and future requirements of the CARB and EPA, but exceeded them. Read more about our Green Initiative.