Automotive Interior Applications Research Articles

Innovative CF/PVC Foam Applicated for Automotive Synthetic Leather with High-Performance and Reduced VOC Emissions.

Polyvinyl chloride (PVC) foam, valued for its mechanical and thermal properties along with cost-effectiveness, is extensively utilized across diverse industries. However, its high volatile organic compound (VOC) emissions hinder its adoption in eco-friendly synthetic leather. This study proposes a solution by optimizing the formulation design and foaming processes and achieving mechanical property enhancement via carbon-fiber-reinforced PVC composite foam (CF/PVC). The aim is to reduce PVC usage via enhancing its intrinsic properties. Systematic investigations were carried out on the impact of foaming raw materials, foaming processes, fiber content, and fiber length on the foaming performance, mechanical properties, and VOC emissions. The material formulation and process parameters were successfully optimized. Further assessment of various indicators such as the density, mechanical properties, and tear resistance of synthetic leather samples confirmed that the innovative CF/PVC foam developed in this study meets the requirements for automotive interior applications. Notably, the tensile strength and tear resistance of CF/PVC composite synthetic leather increased by 50% and 29%, respectively, compared to pure PVC, while VOC emissions decreased by 28%. It is anticipated that a more pronounced reduction in VOC emissions will be achieved in practical automotive interior leather applications when further considering the reinforcing effect of fibers, which leads to a reduction in PVC usage. The findings present a technical reference for innovative applications, aiming to enhance PVC foam performance and minimize emissions.

Avient launches automotive-specific grades within its reSound™ REC recycled content TPEs portfolio

On July 19, 2023, Avient Corporation announced the addition of two reSound™ REC Recycled Content Thermoplastic Elastomers (TPEs). The new grades for automotive interior applications are formulated with post-consumer recycled (PCR) content, reportedly offering a more sustainable TPE option with comparable performance to traditional TPEs.

Effect of SEBS Molecular Structure and Formula Composition on the Performance of SEBS/PP TPE for Automotive Interior Skin.

The hydrogenated styrene-butadiene-styrene block copolymer (SEBS)/Polypropylene (PP)-blended thermoplastic elastomer (TPE) is an ideal material for automotive interior skin applications due to its excellent elasticity, weather resistance, and environmentally friendly characteristics such as low odor and low volatile organic compounds (VOC). As a thin-wall injection-molded appearance skin product, it requires both high fluidity and good mechanical properties with scratch resistance. To optimize the performance of the SEBS/PP-blended TPE skin material, an orthogonal experiment and other methods were employed to investigate the impact of the formula composition and raw material characteristics, such as the styrene content and molecular structure of SEBS, on the TPE's final performance. The outcomes revealed that the ratio of SEBS/PP had the most significant influence on the mechanical properties, fluidity, and wear resistance of the final products. The mechanical performance was enhanced by increasing the PP content within a certain range. The degree of sticky touch on the TPE surface was increased as the filling oil content increased, causing the increase in sticky wear and the decrease in abrasion resistance. When the SEBS ratio of high/low styrene content was 30/70, the TPE's overall performance was excellent. The different proportions of linear/radial SEBS also had a significant effect on the final properties of the TPE. The TPE exhibited the best wear resistance and excellent mechanical properties when the ratio of linear-shaped/star-shaped SEBS was 70/30.

Synergistic effects of zinc borate and graphene on enhanced thermal stability and antimicrobial properties of poly(methyl methacrylate)

AbstractThe use of graphene nanoplatelets (GnP) as reinforcing material for thermoplastic polymer matrices, polymethyl methacrylate (PMMA) and zinc borate (ZnB), as an antimicrobial and fire‐retardant agent was studied. PMMA‐ZnB and PMMA‐GnP‐ZnB (ZG) composite films were fabricated with different ZnB concentrations (2.5, 5, 10 wt%) by solvent casting method using acetone. The effect of additives on the antimicrobial activity, thermal and mechanical properties, and surface morphologies of the composites were investigated. Antimicrobial surface activity tests were conducted against seven microorganisms, including bacterial and fungal species. An improvement in antimicrobial activity by up to 99.99% with increasing ZnB content was observed. Thermal stability was increased with increasing concentration of ZnB and a combination of ZnB and GnP additions. 10% ZG‐based composites increased the % char residue value of PMMA from 0.5% to 9.3%. The incorporation of the ZnB and GnP into the PMMA matrix resulted in an increase in the calculated limiting oxygen index (LOI). 10% and 50% weight loss temperature increased by 11.7°C and 3.7°C, respectively, for 10% ZG composites. The Young's modulus of the composites increased with increasing ZnB and a combination of ZnB and GnP loading (increasing by 16% to 2033 MPa with the addition of 10 wt% ZG). The commercial application for this study would be in high touch and piano black automotive interior, construction, and medical applications.

Development and application of nonwovens based on palm fiber as reinforcements of unsaturated polyester

This work aims to investigate the potential of nonwovens made from untreated (U) and alkaline/bleaching treated (T) palm, wool, and polyester fibers as reinforcing materials in polyester matrix for automotive interior applications. Four needle-punched nonwovens were developed and used with and without chloropropyltriethoxysilane (CPTS) treatment as polyester matrix fillers. Eight composite panels were made using the resin transfer molding machine process and compared to the matrix panel in terms of physical, mechanical, thermal, and climate resistance. The produced composite materials have smooth surfaces and provide consumers with four different aesthetically pleasing finishes. The physical results reveal that the UPalm/Wool and UPalm/Polyester nonwovens lower matrix density from 1223.3 Kg/m3 to 1022.3 and 1040.7 Kg/m3, respectively. The SEM images show that palm fibers are more adherent to the matrix after being treated with an alkaline/bleaching solution. This adhesion is also improved after nonwovens are treated with the CPTS precursor. The composite reinforced with CPTS-treated TPalm/Polyester nonwoven has the highest tensile strength and modulus (72.1 MPa and 3.76 GPa), which are 127% and 36% greater than those of the polyester matrix, respectively. The matrix’s flexural strength and modulus are also enhanced by 148% and 59%, respectively, after reinforcing with CPTS-treated TPalm/Polyester nonwoven. The use of TPalm/Wool and TPalm/Polyester nonwovens as polyester matrix fillers reduces their thermal conductivity from 0.125 W/(m.K) to 0.081 and 0.095 W/(m.K), respectively. Moreover, the climate aging results indicate that composites reinforced with CPTS-treated nonwovens are more stable to climate, implying their applicability and durability in automotive interior applications.

Sound absorbing and thermal insulating properties of recycled cotton/polyester selvedge waste chemical bonded nonwovens

This research study reports on acoustics insulation properties of six samples made from recycled Cotton/polyester (PET) selvedge waste for automotive interior applications. The selvedge waste recycled from Cotton/PET fibers has a possible source of raw material that can be measured for sound insulation purposes, but its amounts are limited. While the amounts are limited, selvedge waste recycled cotton fiber was mixed with recycled PET fiber in 50/50, 70/30, 30/70, 60/40, and with 100/0 recycled selvedge cotton and 0/100% recycled selvedge PET mass ratios in the procedure of different-layer nonwoven sheets is prepared with a chemical bonding method. The entire samples were tested for thermal and acoustics insulation according to their physical properties as per the ASTM standard. The sound absorption coefficients (SAC) were measured according to ASTME1050 by an impedance tube method, the SAC over six frequencies 125, 250, 500, 1000, 2000, and 4000 Hz were calculated. The result revealed that nonwoven mats that are prepared from recycled/PET/cotton selvedge waste have confirmed more than 70% of the SAC and the recycled nonwoven mats provided the best insulation, sound absorption, moisture absorption, and fiber properties. The recycled selvedge waste cotton/PET nonwoven mats have adequate moisture resistance at high humidity conditions without affecting the insulation and sound-absorbing properties. The reused waste cotton/PET selvedge nonwoven mats have satisfactory moisture resistance at high humidity situations without disturbing the insulation properties.

Mechanical and aging performances of Palm/ Wool and Palm/ Polyester nonwovens coated by waterborne polyurethane for automotive interiors

The Washingtonia palm (Arecaceae) is a fast-growing species. Their management generates a large amount of biomass each year, which is generally disposed of in landfills or burned on-site without being valorized. In this work, the petiole part of Washingtonia palm was introduced in the automotive industry for interior applications through the production of soft feel eco-friendly bio-composite nonwovens made of Palm, Wool, and Polyester fibers through a needle-punching process. Initially, palm microfibrils were extracted in a solution containing sodium hydroxide (NaOH) and hydrogen peroxide (H2O2) at concentrations equal to 0.70 %. Subsequently, composite nonwovens were manufactured from the Palm/ Wool (P/W) and Palm/ Polyester (P/PES) blends with a weight proportion of 3/1. Afterwards, nonwovens were coated with different percentages of WPU (2.5, 5, 10, 15, and 20 wt%), dried at 120 °C and hot calendered between two rolls at 20 K N pressure and 140 °C temperature. Developed nonwovens were tested for physical, morphological, mechanical, climatic, and abrasion resistance performance. The findings revealed that Washingtonia palm-based biocomposite nonwovens treated with WPU proportions equal to/or higher than 10 wt% had excellent tensile strength and abrasion resistance. The climate aging test, on the other hand, confirmed their durability. The FTIR and SEM data indicated that WPU polymer adheres well to P/W and P/PES nonwovens. Furthermore, they provide aesthetically pleasing fabrics with a golden color appearance, low raw material costs, and environmental benefits, suggesting that they could be a suitable candidate for automotive interior applications.

Highly flexible displays for automotive interior applications

Highly flexible displays for automotive interior applications

Static analysis on Malaysian Yankee’s pineapple leaf fiber/epoxy composite

The static analysis on pineapple leaf fibre (PALF) reinforced epoxy composites was carried out in this study. The effect of fiber alignment in X and Y axis were studied while maintaining total fiber loading of 10% by weight. The bending and compression strength were analyzed by performing flexural and compression test. The composite properties was strongly influence by the fiber orientation where Y axis shows improvement about 97% in bending and 5.3% in compressive strength compared to neat epoxy. However, as for X orientation bending test shows lower bending strength compared to neat epoxy but improve 4% in compressive strength. It can be concludedthat the fiber alignment in Y-direction is more suitable to be utilized for automotive interior or household applications that demand high strength properties.

Novel Lightweight Semi-Finished Products Made of Poplar Veneer Plywood with Basalt Fibre Reinforcement

Veneer plywood is established in building construction, interior finishing and vehicle construction. Particularly in automotive or ship interior applications, the requirements with regard to strength and stiffness properties are increasing. At the same time, the weight of the panel materials used is to be reduced. The development presented here is a new type of lightweight basalt fibre-reinforced poplar veneer plywood and at the same time rigid alternative to the established birch veneer plywood. By adapting the adhesive and the reinforcing semi-finished products, the material and manufacturing costs are comparatively low. The bonding of the fibre reinforcement to the carrier material is achieved by means of adapted wood adhesives (e.g. polyvinyl acetates), which are also used as matrix material for the fibre reinforcement. An application of the reinforcement layer is integrated into the coating process (e.g. with High Pressure Laminate HPL decorative fabrics) of the carrier material. Essential advantages compared to conventional board materials are shown in this paper. The research results were achieved at the Institute for Structural Lightweight Construction of the TU Chemnitz in cooperation with the company Toms Gerber GmbH within the ZiM cooperation project FuBa.

Polymeric feedstock from post-consumer and post-industrial plastic wastes for automotive interior applications

In this study, an economically-viable methodology is discussed where a blend of post-consumer recycled (PCR) plastics and post-industrial scrap (PIS) polymers is refined and used as the feedstock for manufacturing of interior structural products for automotive industry. A comprehensive thermo-mechanical characterisation suggest that feedstock obtained using a melt-filtering based refining process, offers performance on par with the virgin materials with reduced cost and environmental impact. Using both lab-scale prototyping and pilot plant trials, interior trim parts have successfully been produced to demonstrate the viability of using this new feedstock in mainstream polymer production processes such as injection moulding and thermoforming for automotive applications.

Mechanical, thermal, and burning properties of viscose fabric composites: Influence of epoxy resin modification

ABSTRACTThe influence of epoxy resin modification by 3‐aminopropyltriethoxysilane (APTES) on various properties of warp knitted viscose fabric is reported in this study. Dynamic mechanical, impact resistance, flexural, thermal properties, and burning behavior of the epoxy/viscose fabric composites are studied with respect to varying content of silane coupling agent. The results obtained for APTES‐modified epoxy resin based composites reinforced with unmodified viscose fabric composites are compared to unmodified epoxy resin based composites reinforced with APTES‐modified viscose fabric. The dynamic mechanical behavior of the APTES‐modified resin based composites indicates improved interfacial adhesion. The composites prepared from modified epoxy resin exhibited a twofold increase in impact resistance. The improved adhesion between the fiber and modified resin was also visible from the scanning electron microscope analysis of the impact fracture surface. There was less influence of resin modification on the flexural properties of the composites. The 5% APTES modification induced early degradation of composites compared to all other composites. The burning rate of all the composites under study is rated to be satisfactory for use in automotive interior applications. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018, 135, 46673.

A case for closed-loop recycling of post-consumer PET for automotive foams

Striving to utilize sustainable material sources, polyester polyols made via glycolysis and esterification of recycled polyethylene terephthalate (rPET) scrap were used to synthesize flexible polyurethane (PU) foams typically found in automotive interior applications. The objective of this endeavor was to ascertain if a closed-loop model could be established with the discarded PET feedstock. In five separate formulations, up to 50% of the total polyol content (traditionally derived from petroleum-based feedstock) was replaced with the afore-mentioned sustainable recycled polyols. These foams underwent mechanical, thermal, morphological, and physical characterization testing to determine feasibility for use in an automotive interior. Young’s modulus, tensile stress at maximum load, tear resistance, and compression modulus all increased by combined averages of 121%, 67%, 32%, and 150% over the control petroleum-based formulation, respectively, in foams possessing 50% rPET polyol content. Thermal stability also increased with sustainable polyol content; thermogravimetric analysis showed that 50% mass loss temperature increased by an average of 20 °C in foams containing 30% recycled polyol. Properties of density and SAG factor remained within 5% of the control petroleum-based reference foams. After comparing these findings to traditional polyols, a compelling argument can be made for the use of post-consumer automotive and industrial feedstocks in developing high-performing interior automotive PU foams.

Eco-solutions for automotive interior applications by way of thermoplastic biocomposites: cost, weight and green advancements

This paper discloses viable eco-solutions concerning the formulation and the performance of biocomposites and bioblends formulated based on polypropylene (PP), polyamide (PA6), and acrylonitrile-butadiene-styrene (ABS) and designated for the fabrication of interior automotive parts. Biocomposites containing up to 40 wt.% of cellulosic fibres were first formulated and compounded. Bioblends containing up to 30 wt.% polylactide (PLA) were also obtained. Different formulations of biocomposites were also compounded based on PLA-containing alloys and cellulosic fibres. Tensile strength, tensile modulus, and heat deflection temperature (HDT) of obtained bioblends and biocomposites presented at least equivalent values comparing to their commercial counterparts currently used in the fabrication of automotive interior parts. Parts obtained by foaming through injection-moulding process presented similar properties as the unfoamed and commercial grades while being up to 25 wt.% lighter, up to 37% less expensive, and up to 50 wt.% greener.

Eco-solutions for automotive interior applications by way of thermoplastic biocomposites: cost, weight and green advancements

Eco-solutions for automotive interior applications by way of thermoplastic biocomposites: cost, weight and green advancements

Innovative Waterborne and UV Resins for Plastics and Automotive Interior Applications

Plastics EngineeringVolume 69, Issue 7 p. 50-56 Cover Story Innovative Waterborne and UV Resins for Plastics and Automotive Interior Applications Robert Harrer, Robert Harrer Allnex (formerly Cytec Coating Resins of Cytec Industries)Search for more papers by this authorPhilippe De Groote, Philippe De Groote Allnex (formerly Cytec Coating Resins of Cytec Industries)Search for more papers by this authorAnton Artz, Anton Artz Allnex (formerly Cytec Coating Resins of Cytec Industries)Search for more papers by this authorMouhcine Kanouni, Mouhcine Kanouni Allnex (formerly Cytec Coating Resins of Cytec Industries)Search for more papers by this author Robert Harrer, Robert Harrer Allnex (formerly Cytec Coating Resins of Cytec Industries)Search for more papers by this authorPhilippe De Groote, Philippe De Groote Allnex (formerly Cytec Coating Resins of Cytec Industries)Search for more papers by this authorAnton Artz, Anton Artz Allnex (formerly Cytec Coating Resins of Cytec Industries)Search for more papers by this authorMouhcine Kanouni, Mouhcine Kanouni Allnex (formerly Cytec Coating Resins of Cytec Industries)Search for more papers by this author First published: 01 July 2013 https://doi.org/10.1002/j.1941-9635.2013.tb01041.xAboutPDF ToolsExport citationAdd to favoritesTrack citation ShareShare Give accessShare full text accessShare full-text accessPlease review our Terms and Conditions of Use and check box below to share full-text version of article.I have read and accept the Wiley Online Library Terms and Conditions of UseShareable LinkUse the link below to share a full-text version of this article with your friends and colleagues. Learn more.Copy URL Share a linkShare onFacebookTwitterLinkedInRedditWechat Volume69, Issue7July-August 2013Pages 50-56 RelatedInformation

Next Generation UV Stabilized, Impact Modified Polyacetal Copolymer (POM) for Automotive Interior Applications

Next Generation UV Stabilized, Impact Modified Polyacetal Copolymer (POM) for Automotive Interior Applications

Comparison of Ultrasonic Welding and Vibration Welding of Thermoplastic Polyolefin

Thermoplastic polyolefin (TPO) is widely used in automotive interior applications including instrument panel, doors, and centre console. Ultrasonic welding and vibration welding are two common joining techniques used in the industry. The goal of this study was to use design of experiments (DOE) to evaluate the ultrasonic welding and vibration welding of a TPO. This study included ultrasonic energy director welding using American Welding Society (AWS) standard test samples and vibration welding of two AWS Tee samples in butt joint geometry. The weld strength was compared to bulk material tensile strength of moulded AWS I-beams. Ultrasonic welding results indicated that amplitude was the most dominant factor in affecting the welding strength and both time and weld pressure had minimum impact on weld strength. The maximum achievable weld strength using ultrasonic welding was 40% of the base material strength. Vibration welding results indicated that amplitude was the most dominant factor in affecting the weld strength and high weld pressure resulted in lower weld strength. The maximum achievable weld strength using vibration welding was 66% of the base material strength.

Coir fiber reinforced polypropylene composite panel for automotive interior applications

In this study, physical, mechanical, and flammability properties of coconut fiber reinforced polypropylene (PP) composite panels were evaluated. Four levels of the coir fiber content (40, 50, 60, and 70 % based on the composition by weight) were mixed with the PP powder and a coupling agent, 3 wt % maleic anhydride grafted PP (MAPP) powder. The water resistance and the internal bond strength of the composites were negatively influenced by increasing coir fiber content. However, the flexural strength, the tensile strength, and the hardness of the composites improved with increasing the coir fiber content up to 60 wt %. The flame retardancy of the composites improved with increasing coir fiber content. The results suggest that an optimal composite panel formulation for automotive interior applications is a mixture of 60 wt % coir fiber, 37 wt % PP powder, and 3 wt % MAPP.

Material and Design Innovation Techniques for Expanded Polypropylene (EPP) Products Used in Automotive Interior Applications

Material and Design Innovation Techniques for Expanded Polypropylene (EPP) Products Used in Automotive Interior Applications