Plastics Technology

JUN 2017

Plastics Technology - Dedicated to improving Plastics Processing.

Issue link: http://pty.epubxp.com/i/827817

Contents of this Issue

Navigation

Page 48 of 83

for cost-efficiency. They reportedly offer a superior finish for unpainted parts such as door panels. Trinseo has also developed lower-density Pulse PC/ABS products that not only enable lower weight and cost in parts, but also offer low gloss, easy flow, faster cycles, high impact strength at low temperatures, heat resistance optimized for the majority of interior auto components, and low odor and VOCs. For example, Pulse GX50 is approved by BMW for UV and hydrolytic stability and is used on the BMW 1 series, i3 and i8. Mark Minnichelli, director of technical development at BASF's performance mate- rials division, points to Ford's new Lincoln Continental, which features an innovative seating architecture. With its 35% glass-filled, impact-resistant Ultramid nylon 6, BASF contributed a 20% weight reduction for the front-row seat pan vs. the metal predecessor, and 15% cost savings. Minnichelli also heralds the use of a 20% carbon-fiber rein- forced Ultramid nylon 66 to produce the grille-opening reinforce- ment (GOR) on the 2016 Ford Shelby GT359 Mustang. Not only 2.5 lb lighter than the traditional GOR of metal stampings overmolded with plastic, but the new part's aesthetic quality prompted Ford to forgo the "beauty cover" to hide the GOR, saving another 1.9 lb for a 45% weight reduction overall. Meanwhile, Polyscope's main focus is on interior structural parts. Says Muezers,"We are aiming to achieve performance proper- ties that bridge the gap between nylon 6 and nylon 66 in applica- tions such as instrument-panel supports, structural consoles, audio components, and interior trim." Since 2013, its Xiran IZ terpolymers—based on SMA and N-phenylmaleimide, have made significant commercial strides with several OEMs in sunroof frames. Applications such as this require a high degree of functional integration, high-precision molding, and greater stiff- ness. Xiran products replace glass-filled PBT/ ASA blends, which can have warpage issues, cost more, and are more diffi- cult to process. Polyscope is also targeting instrument-panel carriers where SMA can meet a broader temperature range (-35 C to 120 C or 31-248 F) than the widely used PP. In particular, PP does not have comparable low-temperature performance, which is important for airbag deployment. At the K 2016 show in Dusseldorf, Ineos Styrolution, Aurora, Ill. (styrolution.com), launched what are believed to be the first styrenic thermoplastic composites, called Stylight, with mechanical proper- ties that reportedly exceed composites of nylon 6 or PC (see Februry 2017 feature). In cooperation with German engineering company KTM Technologies, the company has developed a selection of concept studies of StyLight in exterior and interior applications like body panels, tailgates, door modules, and consoles. Celanese has continued to reduce volatile emissions in inte- riors with a novel family of acetals that boast formaldehyde emission levels as low as 2 ppm. These Hostaform XAP2 grades reportedly are now the benchmark for acetals in vehicle interiors. They are used in locks, head-rest guide sleeves, HVAC components, buttons, speaker grilles, etc. Speaker grilles represent a fairly large interior acetal part where its contribution to interior emissions is more heavily weighted. Celanese is continuing to push emission levels down with a next-generation XAP3 acetal line that promises formaldehyde emissions of 1 ppm. In the area of aerodynamics, active grille shutters play a role in increasing fuel efficiency by as much as 1.1 mpg, but weight and warpage can be an issue. To address this, Lanxess' new Durethan XF (Xtreme Flow) easy-flowing nylon 6 is being evaluated for reduced warpage and improved cycle times. LIGHTWEIGHTING ALL AROUND Each of these, and other, material suppliers, are targeting light- weighting with certain materials: • Lanxess' Durethan XF is gaining in structural parts such as front ends, cross-car beams, rear bumpers, and door modules. • Solvay's lightweighting materials include Amodel PPA and Omnix HPP nylon with 30-60% long fiber, aimed at gears , structural parts on interior panels and chassis components. • A. Schulman has compounds based on innovative reinforce- ments and polymer alloys that have lower density than conven- tional compounds, including Polyfort impact-modified PP and Shulamid nylon 6 and RD nylon 66 • SABIC sees Stamax long-glass PP (LGF-PP) replacing metal in structural applications like front-end modules, door modules, inner tailgate components, and instrument panels. • Trinseo has worked with long-standing partner Renault to con- vert semi-structural parts to LGF-PP. Targets have included lift- gates, front-end and door modules, air-flow systems, IPs, under- vehicle belly pans, and seat structures. Car makers are focusing on making premium interiors more affordable, putting emphasis on materials with improved aesthetics and haptics, as well as low volatile emissions. Torlon PAI thrust washer developed by Solvay and Freudenberg- NOK was an SPE Innovation Awards finalist. @plastechmag 47 Plastics Technology Materials Innovations in Automotive

Articles in this issue

Links on this page

Archives of this issue

view archives of Plastics Technology - JUN 2017