Abstract
Over the last two to three years, the automotive industry has recognised the benefits of low density structural reaction injection moulding (LDSRIM) materials in automotive interior applications. Low part weights, consolidation of parts, and improved design freedom associated with this technology help reduce material and labour costs, improve productivity and help engineers meet specific objectives such as CAFE standards.
ICI Polyurethanes has actively participated in the development of LDSRIM technology and has developed a series of resins designed for automotive interior application. These CFC-free polyurethane foams are processable on conventional RIM equipment. The resin systems are differentiated for open pour and closed mould processing techniques.
Unique processing features allow glass reinforced substrates to be moulded directly behind various vinyl composites, carpeting and fabrics, to produce parts with an aesthetically pleasing look and feel. Excellent adhesion to these substrates eliminates the need for secondary adhesive bonding operations, thereby improving productivity and lowering assembly costs. Composite door panels containing 20% by weight glass mat reinforcement weigh approximately half as much as competitive materials, such as ABS and polypropylene, with comparable physical properties. Typical door panel composite materials have flexural modulus 2370 MPa at 0.55 specific gravity. Unreinforced sections of the part, such as ribs and attachment points, are filled with a durable rigid foam material. Attachment inserts can be moulded in place to eliminate the need for post-mould assembly. Manufacturing mould residence times of 45 seconds are achievable in door panels.
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