Fiber reinforced polypropylene composite interior trim cover panels

A fiber reinforced composite interior trim cover panel, said interior trim cover panel which comprises a composition comprising at least 30 wt % polypropylene based resin having a melt flow rate of from about 80 to about 1500 g/10 min, from 10 to 15 wt % of polyester fiber, and 50 to 60 wt % of talc, said weight percents based on the total weight of the composition, said talc having a specific surface area of at least 14 m2/gram of said talc, said interior trim cover panel having an outer surface and an underside surface, wherein said composition comprises no lubricant, has a flexural modulus of 850,000 to 1,200,000 psi, does not shatter during instrumented impact testing (15 mph, −29° C., and 25 lbs), and has a heat distortion temperature ranging from 130° C. to 140° C.

A fiber reinforced composite interior trim cover panel, said interior trim cover panel which comprises a composition comprising at least 30 wt % polypropylene based resin having a melt flow rate of from about 80 to about 1500 g/10 min, from 10 to 15 wt % of polyester fiber, and 50 to 60 wt % of talc, said weight percents based on the total weight of the composition, said talc having a specific surface area of at least 14 m2/gram of said talc, said interior trim cover panel having an outer surface and an underside surface, wherein said composition comprises no lubricant, has a flexural modulus of 850,000 to 1,200,000 psi, does not shatter during instrumented impact testing (15 mph, −29° C., and 25 lbs), and has a heat distortion temperature of greater than 100° C.

A process for producing an interior trim cover panel for a vehicle, the process comprising the step of injection molding a composition to form the interior trim cover panel for a vehicle, the interior trim cover panel having at least an outer surface and an underside surface, wherein the composition comprises at least 30 wt % polypropylene based resin having a melt flow rate of from about 20 to about 1500 g/10 min, from 20 to 60 wt % organic fiber which comprises a polyester fiber, and 15 to 25 wt % of talc, said weight percents based on the total weight of the composition, said talc having a specific surface area of at least 14 m2/gram of said talc, wherein said composition comprises no lubricant, has a flexural modulus of at least 300,000 psi, exhibits no splintering during instrumented impact testing (15 mph, −29° C., and 25 lbs), and has a heat distortion temperature ranging from 130° C. to 140° C.