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Cost-saving solutions for weightsensitive parts

Source:Ringier Release Date:2011-06-17 929
Plastics & Rubber
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 Glass fibre reinforced PP has been on the market for many years, but since the first introduction of such material, technology has progressed in many areas that vast improvements in properties have been achieved. The glass fibres used has improved – by having obtained a better surface treatment. The result is that the glass fibres are dispersed better within the compound whilst maintaining the fibre length. The glass fibres of today also connects substantially better to the "chemical couplers" that is used to connect it to the surrounding PP.
 In this area, Polykemi's POLYfill HC is a reflection of how high-technology solutions can also become a price-optimised challenger. This new generation of glass fibre reinforced PP offers processors the possibility of decreasing their material costs whilst achieving weight reductions at lower energy consumption during production. "Our new material – POLYfill HC – has a great potential when used in all kinds of weight sensitive parts, but it should be especially interesting within the automotive industry," reveals Henrik Eriksson, Development Manager at Polykemi.
 Engine covers are often produced in glass fibre – or mineral reinforced PA. However some leading car producers have found that a PP-compound in many cases can fulfill the requirements even for this types of parts. Such a solution of course results in substantial cost savings.
 Incases where there is a scepticism towards a conventional PP-material not having "what it takes" for this kind of application, POLYfill HC can bridge the gap in heat properties historically having divided PP & PA6 to a large extent. "The results obtained during our research and development work also shows that a POLYfill HC indeed has what it takes to withstand the tough high heat conditions within under hood applications," Patrik Axrup at Polykemis Market Department points out.

 Delivering better performance
 Also the chemical couplers of today deliver better performance resulting in an improved mechanical characteristic. Eriksson stressed. PP-polymerisation technology has made major improvements and the high performing PP-types currently available – act as another factor to spice up and maximise the material properties.
 What happens when adding all this improved technology together - into the new generation glass fibre reinforced PP? The answer is a material of a truly new level with unimagined new fields of usage. The property profile of the material is entering areas previously reserved for much more expensive materials. "At the same time also cost optimisations towards older types of glass fibre reinforced PP is possible. In cases where POLYfill HC can replace a PA6 GF, or PBT GF, the possibilities of cost savings are substantial," adds Eriksson.
 He however also notes that sometimes there can be obstacles to overcome for the mentioned type of highly cost saving material changes. When changing materials whilst keeping the "old" mould, there is a need to closely monitor and ensure that there is sufficient cooling capacity when wanting to maintain the existing cycle times. Despite that, POLYfill HC is possible to injection mould considerably faster than a traditional PP GF, still there is a difference in process temperature and freeze temperature compared to PA6 and PBT. Many customers of today are actively exploring the possibilities of using PA GF eller PBT GF based on secondary raw material so called "industrial grades" to maintain their competitive edge.

 Price advantage stressed
 Even when comparing to that type of raw materials, the POLYfill HC is a highly interesting alternative. Instead of possibly gambling with the quality and having to accept decreased productivity that the usage of industrial gOriginals

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