Automotive paint sludge char-reinforced polypropylene molded parts
AssigneeMagna Exteriors Inc.
InventorsAlexis Baltazar-y-Jimenez, Parvinder S. Walia
Life of this patent
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Abstract
An expanded polymer product which includes a milled pyrolysis char material. A vehicle part produced from a polymer including from about 5-50% by weight pyrolysis char material used as a sustainable filler which reduces the carbon footprint of the subsequent vehicle part.
Claims20
A molded vehicle manufacturing component comprising polypropylene, polyamide or mixtures thereof which is at least partially reinforced with paint sludge char particles after pyrolysis at loadings between 1-10% by weight, wherein the molded component is produced by steam molding to produce Expanded PP (EPP) or Expanded Polyamide (EPA) applications relating to vehicle sound insulation, crumple zones for energy absorption, or dunnage for in-plant logistic applications.
A foam material comprising a foamable polymer selected from the group consisting essentially of expanded polypropylene, expanded polyamide, and mixtures thereof which includes a pyrolyzed paint char material having a particle size of less than about 10 microns in an amount of from about 1-10% by weight and suitable fillers and dyes and colorants for making a foamed part.
A molded automotive component based on polypropylene, polyamide or mixtures thereof which is at least partially reinforced with paint sludge char particles after pyrolysis at loadings between 1-50% by weight, wherein the molded component is produced by co-injection molding, and the paint sludge char is mixed with an additive such as thermoplastic elastomer olefins or with thermoplastic polyolefins in the core layer.
A molded automotive component comprising:
- a co-injection molded automotive part having an outer class A show surface layer co-injection over molded over a solid or foamed polyolefin substrate containing 2-5% by weight of a paint sludge char filler material having a particle size of 10 microns or less.
Dependencies are inferred from the claim text.