Polyolefin Compounds, Masterbatches and Elastomers

Automotive  

Polypropylene Compounds

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PolyPacific has extensive experience in supplying the automotive industry with its range of polypropylene compounds and is dedicated to support the total needs of this industry.

Product range

Applications and grades for PolyPacific's compounds and thermoplastic elastomers in the automotive industry are extensive. They include but not limited to:

Polypropylene Compounds

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  • Heater Cases
  • Lamp Housings
  • Bumper Fascias
  • Instrument Panels
  • Rocker Panels
  • Interiors Trims
  • Interior Pillar Trims
  • Scuff Plates
  • Cowl Grills
  • Boot Liners
  • Fans and Shrouds
  • Lighting
  • Electrical Housings
  • Splash Shields
  • Fender Liners
  • Seating Components
  • Door Trims

 

 

 

Grades include:CortonTalc filled Polypropylene compounds
  Talc filled PP UL listed
  Mar resistant PP
 ExtronGlass fibre reinforced polypropylene
  Glass Fibre & mineral filled polypropylene
  High heat polypropylene compounds
 PolycompUV stabilised polypropylene
  Custom coloured PP

Previously restricted to PVC, the development of modified elastomers (Seblex) at PolyPacific has allowed further interior trim options:

  • Soft feel over-moulding of grip handles
  • Console mats
  • Handbrake covers

PolyPacific's comprehensive grade range has been established as a result of many years of experience in the automotive industry and through the use of our own extensive R & D facility. With the advent of combined filler technology, such as mineral and glass fibre reinforcement and also impact modification all in the one compound, has led to a wider range of products with improved physical properties.

Polypropylene Compounds

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Applications

PolyPacific's polypropylene compounds are used extensively for automotive parts and components. In addition to polypropylene being inherently light-weight, the modification and reinforcement enables a wide variety of properties to be achieved.

It is not intended to detail all the grades currently in use, but the chart highlights the spread of uses and typical product groups. These cost effective materials are increasingly being specified for automotive applications to keep pace with productivity, quality and lower costs.

Standards

The central focus of PolyPacific's Quality Policy is continuous improvement. All aspects of its products, services and internal processes are constantly under review. Throughout its history, the company has continually sought and achieved significant milestones.

After initially attaining both the Ford Q1 status and the GMH/Toyota B+ rating, the company then went on to achieve certification to the international Quality Standard ISO 9001. In June 1997, PolyPacific was one of the first raw material suppliers in Australia to achieve certification to QS9000, the global automotive industry Quality Standard, and in April 2006 has upgraded to the latest Automotive Standard TS16949.

TS 16949 is a highly demanding standard which fully embraces the requirements of QS9000 and emphasises continuous improvement, customer satisfaction, defect prevention and the reduction of variation and waste.

Coloured Compounds

Alongside the continued introduction of new model cars is the need for new interior colour schemes which require colour matching expertise essential in establishing colour masters. PolyPacific can assure the industry that it supplies through coloured polypropylene compounds that meet industry standards.

Polypropylene Compounds

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Grade Selection

The motor vehicle industry uses a wider range of polypropylene applications than any other industry, all of which exploit the fundamental advantages of polypropylene.

Applications range from bumper facias weighing several kilograms to control knobs weighing a few grams.

Processes include injection moulding, low pressure moulding, blow moulding, sheet extrusion and thermoforming and profile extrusions.

Grades range from custom colours/stabilised homopolymer resin through to fully chemically coupled glass reinforced compounds, with many newer applications requiring tailor-made properties to optimise performance and minimise cost.

Design Parameters

Colour

Generally, custom coloured polypropylene compounds are the preferred option over masterbatch addition. This ensures colour consistency and dispersion. PolyPacific can match colour masters or, if necessary, use an existing moulding or colour sample to develop a customer specific colour.

It is important to define the required colour tolerance for production purposes (method of testing, light source, visual or instrumental etc.) especially for touching components where appearance is critical.

Polypropylene Compounds

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Weatherability

The UV weathering requirement for both exterior and interior components should be clearly specified. Generally this is nominated as a set time at a weathering site (e.g. Allunga, Australia or Arizona, USA etc.) with the component showing no loss of colour or surface degradation and a colour rating, for example, as specified on the AATCC Grey Scale.

As this specified time can be in excess of 12 months, "accelerated" weathering is also specified and the type of weatherometre and conditions should be clearly defined. Typically, the number of hours is specified, with the same pass criteria as for "normal" weathering. UV stability of both the polymer and the pigment needs to be considered.

Surface Appearance

For interior trim, grained surfaces are preferred and the trend to matte finish is readily achievable with polypropylene compounds which have the added benefit of fewer squeaks and rattles when compared to styrenic resins.

Where possible, the grain surface (type and number) should be specified as this can assist with colour development and initial colour matching. Care should be exercised across the various tools to ensure equal depth of grain and equal degree of polish, as otherwise a difference in colour may be noted from the same batch of material. Also, the tool draft angle should be sufficient to prevent scuffing of grain surfaces during part ejection

Polypropylene Compounds

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Painting

Interior

Sometimes it is necessary to paint interior trim to either mask off areas (e.g. black surround) or to achieve surface appearance uniformity between different surfaces/materials etc. Several paint systems are available and the types depend upon the level of wear that might be encountered.

Exterior

The major proportion of bumper facias (rubber modified polypropylene, unfilled and filled grades) are now painted body colour (fully or partially). Several technologies are available to achieve surface finish, durability and conformance to automotive standards. It should be emphasised that the final paint film performance depends upon the overall "system" used; i.e. the type of base polypropylene compound influences adhesion, flexibility etc., as well as the cleaning, priming and painting steps.

PolyPacific is proud of our relationship with the automotive industry and endeavours to keep at the forefront of innovation in polypropylene manufacture. To find out how we can service the needs of the automotive industry call PolyPacific +613 9793 6000 or email us at customerservice@polypacific.com.au

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