New ABS/PC for exterior pillar cover

A leading supplier of interior and exterior automotive parts has selected a new ABS/polycarbonate blend from ELIX Polymers for the production of exterior pillar covers to be used in an upcoming premium class car from a well-known German manufacturer. Maier S. Coop., in Vizcaya, Spain, is using ELIX Ultra HH4115HI in a two-component part that combines the ABS/PC with a polymethylmethacrylate (PMMA).

The central pillar cover is a technically highly demanding part that forms part of a complex assembly with other components. ELIX Ultra HH 4115 HI was chosen particularly for its high strength and temperature resistance, and for its low density. The technical departments of Maier and ELIX Polymers worked intensively together to find the best possible solution and optimize the injection conditions of the parts (one on each side of the car).

ELIX Ultra HH4115HI ABS/PC, which was introduced late last year, has several advantages over a PC/ABS: these advantages include a 5% lower density (1.07 g/cm³ vs 1.13 g/cm³), as well as low emission and odour (VDA 278 VOC = 8 / FOG = 3 ppm, VDA 270 = 3.0). Its high flow rate (MVR is 14 cm³/10min under 5 kg force at 260°C) helps to reduce cycle times, increasing productivity. A further advantage is its very high impact strength (58 kJ/m² at 23°C, 41 kJ/m² at -30°C, according to ISO 180-1A). Significant cost savings are possible thanks to its better paintability versus PC/ABS, which leads to a reduced scrap rate.

Puncture impact behaviour tests carried out according to ISO 6603-2 confirm the very good performance of ELIX Ultra HH4115HI at different temperatures for crash-relevant parts such as the exterior pillar covers produced by Maier and also for interior trim and parts that may be subject to knee or head impacts. The appearance and structure of fractures produced in the test has been evaluated very positively by several premium car manufacturers.

ELIX Polymers envisages a wide range of applications for this innovative material, including door panel parts, instrument panel parts, centre console trim, seating parts, luggage compartment trim, and interior as well as exterior pillar covers. As with other grades from ELIX Polymers, pre-coloured material in OEM colours is possible, as are tailor-made solutions with special additive packages for very demanding part and environment requirements.

ELIX Ultra HH4115HI has been tested and approved at several Automotive OEMs. Among them, Audi noted its low emissions and odor, and considers the material as very interesting for lower instrument panel parts, center console parts and door panel parts according to its TL 52231 specification. BMW has approved it under its GS 93016 specification, and first serial projects are now running. GM has approved Ultra HH4115HI under GMW 15572-T4, and Daimler has approved it under DBL 5404 AA83.