Polypropylene Resin Composition with Cellulose Fiber Texture
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Solution Overview
Problem
Current methods for creating a fabric texture in vehicle interior components using polypropylene resins face challenges such as increased costs, environmental pollution, and degradation of quality due to the use of organic solvents and adhesives, as well as limitations in applying various embossing patterns and color variations, with cellulose fibers often being carbonized during injection molding.
Innovation Solution
A polypropylene resin composition comprising a blend of homopolypropylene, propylene-ethylene copolymer, high-crystalline polypropylene, polypropylene elastomer, ethylene-α-olefin copolymer, inorganic filler, and cellulose fibers, along with volcanic rock, which does not require additional processing steps and maintains fiber integrity at high temperatures, enabling consistent fabric texture creation across different embossing patterns and colors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cellulose fibers are directly added to polypropylene resin to create fabric texture, then additional processes are eliminated, but the cellulose fibers are carbonized at high temperatures during injection molding
Solution Approach 1:
The patent uses a core-sheath structured bicomponent fiber where a cellulose core is coated with a heat-resistant polymer sheath. This composite structure allows the cellulose fibers to withstand high injection molding temperatures without carbonization, while still providing the desired fabric texture when the sheath degrades or breaks down during processing.
Solution Approach 2:
The heat-resistant polymer coating is applied to the cellulose fibers before injection molding. This preliminary protective action prevents the cellulose from direct thermal exposure during the high-temperature processing, enabling the fibers to maintain their structural integrity throughout the manufacturing process.
2Adaptability or versatility
If cellulose fibers are added to create fabric texture, then the texture may vary with plastic part color, but this limits application to various embossing patterns
Solution Approach 1:
The bicomponent fiber structure with heat-resistant polymer coating enables consistent fabric texture formation independent of the plastic part's base color. The controlled degradation or breakage of the sheath material during molding creates uniform texture patterns that remain consistent across different colored components and various embossing designs.
3Manufacturing precision
If cellulose fibers are used to create fabric texture, then the texture is reduced due to fiber tangle and size reduction during processing
Solution Approach 1:
The heat-resistant polymer coating acts as a protective barrier that maintains fiber structure stability during high-temperature injection molding. This prevents premature fiber tangling and size reduction, ensuring that the cellulose fibers maintain their intended dimensions and arrangement throughout the processing sequence.
Solution Approach 2:
The pre-applied heat-resistant coating performs the protective function before thermal exposure occurs, preventing fiber degradation, tangle, and size reduction during the injection molding process. This preliminary protection ensures consistent fiber structure and fabric texture quality in the final product.
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 proposed resin composition achieves improved quality and durability for vehicle interior components by maintaining cellulose fiber integrity, reducing VOC emissions, and enhancing mechanical properties, thus addressing the limitations of existing methods while minimizing processing costs and environmental impact.
Implementation Method 1
a volcanic rock, in which the cellulose fibers are not carbonized even at a high temperature of about 250° C.
Implementation Method 2
a polypropylene resin composition for creating a fabric texture, the polypropylene resin composition comprising a polypropylene resin, a polypropylene elastomer, an ethylene-α-olefin copolymer, an inorganic filler, at least one cellulose fiber, and a volcanic rock
Data Source
AI summary
According to preferred aspects, the present invention provides a polypropylene resin composition for creating a fabric texture, the polypropylene resin composition comprising: a polypropylene resin containing at least two selected from the group consisting of a homopolypropylene, a propylene-ethylene copolymer, and a high crystalline polypropylene (HCPP); a polypropylene elastomer; an ethylene-α-olefin copolymer; an inorganic filler; a cellulose fiber; and a volcanic rock. A molded product prepared using the polypropylene resin composition of the present invention has matt properties, do not cause odor due to their excellent VOC adsorption capabilities, and have excellent properties such as low temperature impact resistance, scratch resistance, etc.