Selecting the right polymer for manufacturing polymer products

The use of thermoplastic resins in the polymer industry is significantly increasing. This is particularly important in the automotive industry, which aims to reduce vehicle weight and increase production volume. Thermoplastics are used in the manufacture of various automotive components due to their unique properties. Some of the important applications of these materials in the automotive industry include:

– Seat frames
– Battery trays
– Bumpers
– Various vehicle floor mats
– Grilles
– Valve and cover trims
– Engine covers
– Lights
– Dashboard and steering wheel
– Controllers and other components

Thermosetting resins, such as epoxies, often cannot meet the expected needs in the automotive industry. In these cases, the use of thermoplastic resins as a suitable alternative proves to be satisfactory.

Advantages of Thermoplastics over Thermosets :

Thermoplastics have two major advantages over thermosetting resins:

1. Higher Impact Resistance: Thermoplastics offer greater resistance to impact compared to thermosets, with the difference in some cases reaching up to 10 times.

2. Property Modification: Thermoplastics can be modified and strengthened by adding fibers or additives under temperature and pressure without requiring chemical reactions. This capability allows these materials to be recycled and reintroduced into the consumption cycle after use.

Factors Influencing Polymer Selection:

Three key factors play a role in selecting polymers: cost, operating environment, and mechanical properties.

– Cost: For high-volume applications such as the automotive industry, the cost of thermoplastic resins is a significant and limiting factor. Therefore, resins with lower costs, such as polypropylene and polyamide, are suitable choices for manufacturers.

– Operating Environment: Environmental conditions such as temperature, humidity, and exposure to chemicals have a substantial impact on polymer selection. For example, polyamides are sensitive to moisture and may degrade or lose mechanical properties in humid environments. In such cases, polypropylene, which is not moisture-sensitive, is a better option.

– Operating Temperature: The temperature of the environment where the product will be used plays a crucial role in polymer selection. Resins like polypropylene and polybutylene terephthalate, which have lower operating temperature ranges, are not suitable for applications requiring temperatures above 100°C. In contrast, polymers like PEEK and PEI, which can be used at higher temperatures, are suitable options, although their higher cost limits their applications.

Comparison Table of Common Thermoplastics: