Surface characterization and analysis of textured injection moulded PC-ABS automotive interior components

Abstract

Automotive interior components are produced by injection moulding due to its cost effectiveness in mass production. The surfaces of these components are textured to control the appearance and other surface functional properties such as wear and scratch resistance. Key challenges lie in replicating the features of mould tool with high aspect ratio which are influenced by the polymer and large number of process variables. Hence, to control the aesthetic properties, it is important to improve the understanding of the replication of textured surfaces and its relationship with measured gloss. In this study, the surface topography of PC-ABS samples is investigated using coherence scanning interferometry. Replication of two types- coarse and fine grain surface texture are investigated to identify the effects of tool temperature, injection speed and holding pressure. Areal surface parameters are scrutinized for the quantitative characterization and discrimination of study samples surface topographies. The correlations between process parameters, measured gloss and areal surface parameters are discussed. The results show significant influence of process variables on the replication of surface topography and measured gloss. The grain pattern governed the set of surface parameters selected and the variation in gloss. The process variables are observed to influence different region or distribution of specific surface features represented by surface parameters.

Advanced Injection Molding Methods: Review

“…Subsequently, surface properties were also determined in automotive interior components produced by ABS injection molding. They discussed the correlations between process parameters and the measured gloss and surface properties of the resulting products [75].…”

A low pollution surface pretreatment of PC‐ABS under acidic conditions

“…Polycarbonate‐acrylonitrile butadiene styrene (PC‐ABS) is one of the most popular engineering copolymers in the world today. Compared with a single polycarbonate (PC), PC‐ABS has various important properties, such as a high impact and thermal stability 1–3 . It can, therefore, be used in many industrial areas, including printed circuits and lightweight automotive parts 4 .…”

“…In addition, the electrode potential of permanganate can reach +1.51 V under acidic conditions by adjusting the acidity of the solution. In addition, H 2 SO 4 provides an acidic atmosphere, and the micro‐etching of the ABS phase in PC‐ABS will be improved under acidic conditions 2 …”

“…Compared with a single polycarbonate (PC), PC-ABS has various important properties, such as a high impact and thermal stability. [1][2][3] It can, therefore, be used in many industrial areas, including printed circuits and lightweight automotive parts. 4 Surface pretreatment can improve the surface roughness of PC-ABS.…”

“…In addition, H 2 SO 4 provides an acidic atmosphere, and the micro-etching of the ABS phase in PC-ABS will be improved under acidic conditions. 2 Based on literature data, reasonable swelling conditions have been investigated in the present study by using a micro-etching volume ratio, V H 2 O :V H 2 SO 4 , of 1:2, a MnO 2 content of 30 g/L, and a temperature of 70 C. 23 After the swelling of the PC-ABS, the micro-etching ability of the KMnO 4 -H 2 SO 4 micro-etching system on the PC-ABS was, thereafter, investigated. The peel strength between PC-ABS and copper film can meet the test standard of ASTM D 5229 after the acid system micro-etching treatment.…”