Polymer Blend Composition for Automotive Flooring
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Solution Overview
Problem
Existing non-carpeted automotive flooring materials made from blends of impact modified polypropylene and high melt strength polypropylene have a narrow temperature range for thermoforming, increased gloss at elevated forming temperatures, and do not meet manufacturer requirements for scratch and mar resistance, durability, and low modulus elasticity.
Innovation Solution
A polymer blend composition comprising an impact modified polypropylene copolymer and low density polyethylene, with a weight ratio between 6:4 to 9:1, which is thermoformable, colorable, and includes up to 50% recycled material, maintaining low gloss and excellent hot strength, and can be embossed during or after forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high melt strength polypropylene (partially crosslinked) is used in the blend, then scratch and mar resistance is improved, but the temperature range for thermoforming becomes narrow and gloss increases at elevated temperatures
Solution Approach 1:
The patent changes the polymer composition parameters by replacing high melt strength polypropylene with low density polyethylene, which has different thermal and rheological properties. This substitution broadens the thermoforming temperature window while maintaining scratch and mar resistance through the impact modified polypropylene component.
Solution Approach 2:
The patent creates a composite polymer blend combining impact modified polypropylene copolymer (60-90 wt%) with low density polyethylene (10-40 wt%). This composite material integrates the scratch resistance of polypropylene with the thermal stability and broad processing window of polyethylene, resolving the temperature range limitation.
2Strength
If high melt strength polypropylene is used to provide adequate strength during thermoforming, then forming strength is improved, but gloss significantly increases as forming temperatures are increased
Solution Approach 1:
The patent changes the material composition to low density polyethylene, which maintains forming strength at elevated temperatures without the gloss increase problem associated with polypropylene. The LDPE component allows adequate forming strength while maintaining low gloss appearance even at higher forming temperatures.
3Ease of operation
If impact modified polypropylene is used to create flexibility for installation, then ease of installation is improved, but the temperature range for thermoforming is limited
Solution Approach 1:
The patent combines impact modified polypropylene copolymer (providing flexibility and ease of installation) with low density polyethylene (providing broad thermoforming temperature range). The synergistic composite material achieves both ease of installation through flexibility and wide processing temperature window.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The polymer blend composition achieves low gloss, excellent hot strength, and flexibility down to -30°F, while allowing up to 50% recycled material without affecting aesthetics or physical properties, meeting automotive manufacturer requirements.
Implementation Method 1
heating the polymer blend to a temperature of about 340° F. to about 380° F.
Implementation Method 2
extruding the heated polymer blend to form a sheet of automotive flooring material
Implementation Method 3
cooling the sheet of automotive flooring material
Data Source
AI summary
A polymer blend composition, in an exemplary embodiment, includes an impact modified polypropylene copolymer, and a low density polyethylene polymer. The ratio of an amount, by weight, of the impact modified polypropylene copolymer to an amount, by weight, of the low density polyethylene polymer is between about 6:4 to about 9:1.