pps proceeding - Abstract Preview
pps proceeding
Symposium: S03 - Injection Molding and Micromolding
Keynote Presentation
 
 

Surface Replication of Automotive Polypropylene in Injection Molding Process

Ito Hiroshi (1)*, Kuroda Shinichi (2), Mizutani Atsushi (2)

(1) Yamagata University - Yamagata - Japan, (2) Nissan Motor Co., Ltd - Kanagawa - Japan

Talc-containing polypropylene (PP) resin is extensively employed in automobiles. Considering microstructure transfer process in injection molding, the effect of the talc’s dispersibility and particle size on this process and its impact on the gloss level of the product were investigated. The results show that a fine unevenness of about several ìm was self-formed by the shrinkage of PP in non-transferred areas due to the blending of talc. Additionally, the amount of self-formed unevenness tended to increase as the average particle size of talc increased. Furthermore, it was observed that a fine tiger-stripe pattern was self-formed using special molds with modified microstructure due to PP shrinkage and density differences of talc. This self-formed fine unevenness changes the gloss level because of the effect of diffused light reflection. This study proposes a new perspective that this change can be controlled by the average particle size of talc and the structure of the mold. Furthermore, the effect of fine mold structure and talc particle size on the microstructure transfer and impact on the wettability and scratchability of products was investigated considering the microstructure transfer in injection molding of talc-containing polypropylene (PP) resin. Consequently, it was observed that a fine tiger-stripe structure caused by PP shrinkage and differences in talc density was self-formed when using a unique mold with a varying microstructure. It was suggested that the self-formed fine irregularities formed an air layer at the boundary between the resin surface and water droplets to enhance water repellency. Furthermore, it was confirmed that the fine tiger-stripe structure had the same or higher scratchability than other shapes. Herein, we revised new methods of controlling the microstructure via the average talc particle size and mold structure.