Girginer Ozunlu B, Guner FS. An Industrial Case for Polypropylene Nanocomposite Foams: Lightweight, Soundproof Exterior Automotive Parts.
Polymers (Basel) 2022;
14:1192. [PMID:
35335521 PMCID:
PMC8950144 DOI:
10.3390/polym14061192]
[Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/29/2021] [Revised: 02/17/2022] [Accepted: 02/20/2022] [Indexed: 11/23/2022] Open
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.
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