AUTOMOTIVE | INTERIORS AND EXTERIORS


Right: BMW car has a physically foamed rear lower trim


University of Technology who examined studies on the influence of the coating on physical thermoplastic foam injection moulding (TFI). Over the investigation period of 100,000 cycles, tactile and optical analysis methods showed that the ceramic coating has a positive effect on the flow behaviour within the mould cavity. “Ceramic tool coatings repre- sent an alternative for optically streak-free TFI components without an increase in cycle time,” the partners say.


Major independent compounder RTP says the


trends toward increased fuel economy in internal combustion engine vehicles, more efficient electric vehicles, and sourcing sustainable materials continue to push the limits of engineering thermo- plastics in various ways. “Long glass fibre polypro- pylene (LGF PP), due to its lightweight, good mechanical properties, and reduced costs, has seen incredible success and growth in replacing metal and heavier engineering polymer-based materials like short glass fibre reinforced polyam- ides over the years,” says Zach Halverson, Business Development Manager – Structural Products, adding that RTP is “pushing the boundaries of LGF PP capabilities, opening new opportunities for part conversions that were never before possible.” One example he cites is for under-the-hood


applications requiring resistance to elevated temperatures. RTP now offers a range of LGF PPs that can exceed 1,000 hours at 150°C heat ageing requirements. For example, one grade, RTP 0199 X 151095, shows a 17% loss in tensile strength after 1,000 h (to 83MPa), a 29% gain in tensile modulus (to 8.3GPa), and a 30% fall in tensile elongation (to 1.6%). RTP also offers LGF PPs for such high-visibility applications as instrument panels, integrated door


modules, and liftgates. And it has released a new generation of carbon fibre reinforced PPs with densities up to 30% lower and possibly even more than short glass reinforced PAs. Another compounder of polypropylene, including LGF PP, is Inno-Comp in Hungary. It too points to OEM strategies of reducing weight. “Material processors are focusing on thinner-wall applications, which creates the opportunity to reduce the material volume and cause price reduction. In this case the material requirement is high flowability,” it says. “With the circular economy recycling solutions are more and more important too. These materials are widely used for the exterior applications fields, and nowadays the interior is also targeted where the emission and odour properties are big challenges.” Inno-Comp has been offering long-glass-fibre compounds since early 2018. The portfolio originally comprised standard types like 30-60% PPs, “but now we have successfully developed special LFT solutions to achieve the application fields where the engineering compounds are dominant”, says Balázs Kugler, Sales Engineer. “Our Innopol grades offer halogen-free flame


retardancy [one example is CS 2-L830 HFR N], electrically conductive solutions [CS 2-L830 EC B], and tribologically optimised compounds [CS 2-L830 LF N], as well as types containing recycled materials. These grades are also available in


Table 1: Typical properties of Inno-Comp Innopol long fibre reinforced PP grades, based on 50% Innopol CS 1-L860 N and containing different masterbatches


Innopol CS 2-L830 HFR N Innopol CS 2-L830 EC B Innopol CS 2-L830 LF N HFFR


Density, g/cm³ Tensile modulus, MPa


Tensile stress at yield, MPa Tensile strain at yield, %


Notched Charpy impact strength @ 23°C, KJ/m² Flammability UL94 @ 1.6mm Surface resistance, Ohm Source: Inno-Comp


18 INJECTION WORLD | November/December 2020 1.33


8,950 116 2,00 16


V-0 -


Electrically conductive 1.29


9,000 113 1.75 11 -


1,000


Wear resistant 1.20


6,950 118 2.50 27 - -


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IMAGE: REHAU/BMW


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