An Industrial Case for Polypropylene Nanocomposite Foams: Lightweight, Soundproof Exterior Automotive Parts

Abstract

Lightweighting is a challenge for the automotive industry, and foaming is a key technology used to address this problem. A new practical approach is studied to regulate the cell formation of copolymer polypropylene (co-PP) by utilizing graphene nanoplatelets (xGnP) as a process aid during foam injection molding. The approach was designed to enable process freedom to tune part performance by adjusting the amount of xGnP masterbatch. Two different levels of 1–2 wt % xGnP and 0.25–0.35 wt % supercritical fluid (SCF) were investigated. Prepared samples were compared with samples prepared by the traditional method (twin-screw extrusion followed by foam injection molding). The nanocomposite with 2 wt % xGnP comparatively showed about twofold reduction in cell size magnitude. Although the increment in SCF amount resulted in a 47% and 122% enhancement in flexural modulus and strength, respectively, and a 45% loss in Izod unnotched impact strength, the cell size was prone to increasing with regard to low melt strength as compared to neat foams. In conclusion, a 12% weight reduction fulfilled the desired performance parameters in terms of mechanical and sound insulation by utilizing 2 wt % xGnP as a process aid.

Enhancing the Sound and Thermal Insulation Properties of Polypropylene Foam by Preparing High Melt Strength Polypropylene

“…Self‐polymerization products destroy the aggregation of PP molecular chains and make PP molecular chains slip more easily during compression. [ 47 ]…”

Morphology Distribution in Injection Molded Parts

“…Isotactic polypropylene is one of the most used polymers in transportation due to its low density, which allows for the production of lightweight materials [5,6]. The possibility to control the properties of isotactic polypropylene (iPP) parts in the injection molding process can be a way to reduce the environmental impact of plastic.…”

Estudo da predição de propriedades mecânicas de compósitos poliméricos de polipropileno e grafeno utilizando redes neurais artificiais

“…[1], [2] Different studies have shown that in the case of a 10 % in car weight reduction, fuel consumption, and emissions may be decreased by 6 % to 8 % and 5 % to 6 %, respectively. [3] Using polymer help to reduce the vehicle weight, impacting directly in the reduction of fuel consumption and gas emissions. [4] Polyolefins are polymer materials that are vastly used in the automotive industry, both in interior and exterior applications.…”