PP/PS Nanocomposite Reaches Final Round of SPE-Award
(Mar 20, 2006)
MUNICH -- Only six months after being launched onto the market, the newly developed nanocomposite Elan XP, an alloy of polypropylene (PP) and polystyrene (PS), reached the round of the finalists in the "Materials" category of the "Best in Automotive Plastics Award" of the Automotive Division of the Society of Plastics Engineers (SPE). The criterion for the jury's choice was the high user benefit afforded by this material, for it combines "a uniformly matt surface finish with very good scratch resistance and an in-mould shrinkage of less than 1%. This material can replace painted interior parts hitherto moulded in styrene polymers and at the same time achieve a cost saving of 50%. Besides its aesthetically appealing matt surface, this material features the tactile appeal necessary for passenger compartment components."The newly developed PP/PS nanocomposite Elan XP reached the final round of the SPE Award. One of the first parts to be mass-produced in this blend is an injection moulded footwell heater vent for various Volkswagen and Audi models. This passenger compartment component does not have to be painted.
A decisive role in optimizing the properties of this PP/PS blend for passenger compartment applications was played by Nanofil® SE 3000, a nano additive belonging to a newly developed generation of nano additives from the Moosburg/ Germany plant of Süd-Chemie AG. Its large surface area-weight ratio of around 700 m2/g is the decisive factor in ensuring an extremely fine and stable distribution of PS particles in the PP matrix. The ready-to-process pigmented and stabilized PP/PS blend is produced by Putsch GmbH, Nuremberg/Germany, on a twin-screw extruder using a processing technology specially optimized for this application.
The first parts to be mass-produced in the new Elan XP PP/PS blend include an injection moulded footwell heater vent for various Volkswagen and Audi models. For other passenger compartment components, e.g. seat trims, development work has progressed to such an extent that mass production can commence in the immediate future. The footwell heater vent is manufactured by Dr. Haubitz GmbH & Co. KG, Solingen/Germany, a highly efficient processor specializing in the production of components and systems for the automotive industry.
Although the award went to another innovation at the award ceremony in Livonia, MI/USA, on 16th November 2005, the fact that this PP/PS nanocomposite almost won the SPE innovation award so shortly after its introduction into the market indeed testifies to the outstanding and innovative properties of this material.
"As this PP/PS blend shows," Dr. Joachim Grossmann of Süd-Chemie explains, "the development of nano additives opens up completely new possibilities for optimizing the properties of polymer blends for specific applications." Michael Putsch adds: "Working together on a very close basis, we have succeeded in developing an innovative material which in this case is distinguished by its special surface properties. It offers high efficiency potential for both the processor and the user and hence contributes to a safeguarding of jobs in Germany." Werner Schirmer, General Manager of Dr. Haubitz GmbH & Co. KG, comments from the standpoint of a medium-sized supplier: "Precisely for us suppliers to the automotive industry, which is now heavily globalized, it is vital for our survival and for the safeguarding of jobs to play an innovative part in the development of new materials and processes, the additional benefits of which - in this case waiving the need for a painted finish - help us to reduce costs."
Süd-Chemie is an independent specialty chemical company headquartered in Munich and operating on a worldwide scale. Key markets served by its Adsorbents Division include the consumer-goods, packaging and foundry industries, as well as the paper and plastics industries. Products manufactured by the Catalysts Division offer solutions for water treatment, petrochemicals processing, energy storage and hydrogen production, as well as off-gas purification. The common denominator for all its products and innovations is the efficient and sparing use of natural resources to enhance the quality of life for humans and the environment. Sales of € 862 million were generated in 2004, 80% of these outside Germany. Süd-Chemie employs more than 5,100 people at its 70 sales and production sites around the world.
Source: Süd-Chemie