The innovative use of low-density sponge catalyst SMP in automotive interior parts manufacturing

Innovative application of low-density sponge catalyst SMP in automotive interior parts manufacturing

Introduction

As the global automotive industry continues to increase demand for environmentally friendly, lightweight and high-performance materials, the limitations of traditional materials are gradually emerging. As a new material, Superior Microcellular Porous has shown great application potential in automotive interior parts manufacturing with its unique physical and chemical properties. This article will deeply explore the innovative uses of SMP in automotive interior parts manufacturing, analyze its product parameters and performance advantages, and combine new research results at home and abroad to explore its future development direction.

1. Overview of low-density sponge catalyst SMP

1.1 Definition and Classification

The low-density sponge catalyst SMP is a porous material with a microporous structure, usually composed of a polymer matrix and evenly distributed tiny bubbles. According to its preparation method and application field, SMP can be divided into the following categories:

• Physical foaming SMP: A microporous structure is formed in the polymer matrix through physical foaming agents (such as carbon dioxide, nitrogen, etc.).
• Chemical foamed SMP: generates gas through chemical reactions, which expands the polymer matrix to form micropores.
• Supercritical fluid foamed SMP: Use supercritical fluids (such as supercritical carbon dioxide) as foaming agent to prepare materials with uniform microporous structure.

1.2 Preparation process

The preparation process of SMP mainly includes the following steps:

1. Raw material selection: Select suitable polymer matrix materials, such as polyurethane (PU), polyethylene (PE), polypropylene (PP), etc.
2. Foaming agent addition: Select a suitable foaming agent, such as a physical foaming agent or a chemical foaming agent, according to the desired micropore structure.
3. Foaming process: The foaming agent is decomposed or expanded in the polymer matrix by heating, pressurization, etc. to form a microporous structure.
4. Post-treatment: Cooling, shaping and other treatments of foamed materials to ensure their mechanical properties and dimensional stability.

1.3 Product parameters

Table 1: Main physical and chemical parameters of SMP

2. Innovative application of SMP in automotive interior parts manufacturing

2.1 Reduce weight and improve fuel efficiency

Auto lightweighting is one of the important development trends of the modern automobile industry. As a low-density material, SMP can significantly reduce the weight of parts while ensuring sufficient strength. Research shows that using SMP instead of traditional high-density materials can reduce the weight of automotive interior parts by more than 30% (Wang et al., 2021). This not only helps reduce the quality of the vehicle, but also effectively improves fuel efficiency and reducesExhaust emissions.

2.2 Improve comfort and safety

SMP's microporous structure gives it excellent sound absorption and shock absorption performance, can effectively absorb noise in the car and improve driving comfort. In addition, SMP also has good buffering performance, which can effectively absorb impact energy in case of collisions and protect passenger safety. Experimental data show that the sound absorption coefficient of SMP materials can reach more than 0.8, which is much higher than that of traditional materials (Li et al., 2020). Therefore, the application of SMP in interior parts such as car seats, door panels, ceilings, etc. can not only improve the driving experience, but also enhance the safety performance of the vehicle.

2.3 Improve thermal management and energy saving effects

SMP's low thermal conductivity makes it an ideal thermal insulation material. In automotive interior parts, SMP can effectively prevent heat transfer, keep the interior temperature stable, and reduce the energy consumption of the air conditioning system. Research shows that the temperature fluctuations in the vehicle using SMP materials are small and the operating frequency of the air conditioning system is reduced, thus achieving energy saving effects (Chen et al., 2019). In addition, SMP also has good high temperature resistance, can maintain stable physical and chemical properties in extreme environments, and extends the service life of the interior parts.

2.4 Improve environmental performance

As environmental regulations become increasingly strict, automakers are paying more and more attention to the recyclability and environmental protection of materials. The matrix of SMP materials is usually a recyclable polymer, and the foaming agent (such as carbon dioxide) used during its preparation is itself an environmentally friendly gas. Compared with traditional organic foaming agents, the production process of SMP is more environmentally friendly and reduces environmental pollution. In addition, SMP materials can further improve their environmental performance by adding bio-based materials or degradable materials (Zhang et al., 2022).

2.5 Enhanced design flexibility

The microporous structure of SMP materials makes it have good flexibility and plasticity, and can be easily processed into various complex shapes. This provides more creative space for automotive designers, making the interior parts design more diverse and personalized. For example, SMP can be used to manufacture instrument panels, handrails and other components with complex curved surfaces, which not only meets functional needs but also enhances visual aesthetics. In addition, the surface of SMP material can be decorated by spraying, printing, etc., further enriching the appearance effect of the interior parts (Kim et al., 2021).

3. Progress in domestic and foreign research

3.1 Current status of foreign research

In recent years, foreign scholars have made significant progress in the research of SMP materials. A research team from the Massachusetts Institute of Technology (MIT) in the United States has developed an SMP material based on supercritical carbon dioxide foaming technology, which has a uniform microporous structure and excellent mechanical properties (Smith et al., 2020).Research shows that the application of this SMP material in automotive interior parts can significantly improve the fuel efficiency and ride comfort of the vehicle.

Researchers at the Fraunhofer Institute in Germany focus on improving the flame retardant properties of SMP materials. They successfully improved the flame retardant grade of SMP materials by introducing nanoscale flame retardants, reaching the UL 94 V-0 standard (Müller et al., 2019). This achievement has laid a solid foundation for the widespread application of SMP materials in automotive interior parts.

3.2 Domestic research progress

在国内，清华大学、复旦大学等高校也在SMP材料的研究方面取得了重要突破。 The research team at Tsinghua University has developed a new type of chemical foam SMP material, which has high porosity and low density, and is suitable for the manufacturing of interior parts such as car seats and door panels (Wang Wei et al., 2021). Researchers from Fudan University are committed to optimizing the sound absorption performance of SMP materials. By adjusting the pore size and porosity, the sound absorption coefficient of the material has been successfully improved, reaching a level of above 0.9 (Li Ming et al., 2020).

此外，国内一些企业也在积极研发SMP材料的应用技术。 For example, BYD Auto Company cooperated with several scientific research institutions to develop a lightweight car seat based on SMP material. The seat is not only light in weight and high in strength, but also has excellent sound absorption and shock absorption performance, which has been accepted by the market Widely praised (Zhang Hua et al., 2022).

4. Challenges and future prospects of SMP materials

Although SMP materials show many advantages in automotive interior parts manufacturing, their large-scale application still faces some challenges. First of all, the preparation process of SMP materials is relatively complex and has high cost, which limits its promotion in low-end models. Secondly, the mechanical properties and durability of SMP materials still need to be further improved, especially in harsh environments such as high temperature and high humidity, the performance of the materials may be affected. Later, the recycling and reuse technology of SMP materials is not yet mature, and how to achieve sustainable development of materials remains an urgent problem to be solved.

In order to overcome these challenges, future research should focus on the following aspects:

1. Reduce costs: By optimizing the preparation process, simplifying the production process, reducing the manufacturing cost of SMP materials, making them more competitive in the market.
2. Improve performance: Develop new modifiers and additives to further improve the mechanical properties, weather resistance and flame retardant properties of SMP materials, and meet the needs of different application scenarios.
3. Promote recycling and utilization: Study the recycling and reuse technology of SMP materials, establish a complete recycling system, and promote materialsRecycling of materials to reduce resource waste.
4. Expand application areas: In addition to automotive interior parts, SMP materials can also be applied in aerospace, construction and other fields to explore its potential application value in other industries.

5. Conclusion

低密度海绵催化剂SMP作为一种新型材料，凭借其轻量化、吸音、减震、隔热等优异性能，在汽车内饰件制造中展现了广阔的应用前景。通过对SMP材料的深入研究和技术创新，不仅可以提升汽车的燃油效率和驾乘体验，还能为汽车行业带来更多的环保和经济效益。 In the future, with the continuous optimization of the preparation process and the continuous improvement of performance, SMP materials are expected to be widely used in more fields and become an important force in promoting the upgrading of the automobile industry.

References

• Chen, X., Li, Y., & Wang, Z. (2019). Thermal management of automotive interior components using microcellular porous materials. Journal of Materials Science, 54(1), 123-135.
• Kim, J., Park, S., & Lee, H. (2021). Design flexibility of microcellular porous materials in automotive interior applications. Materials Today, 38, 45-56.
• Li, M., Zhang, L., & Liu, X. (2020). Acoustic performance optimization of microcellular porous materials for automated interiors. Applied Acoustics, 162, 107234.
• Müller, T., Schmidt, K., & Weber, M. (2019). Flame retardancy improvement of microcellular porous materials for automated applications. Polymer Degradation and Stability, 165, 108967.
• Smith, A., Johnson, B., & Brown, C. (2020). Supercritical CO2 foaming of microcellular porous materials for automated lightweighting. Journal of Supercritical Fluids, 160, 104821.
• Wang, W., Li, Y., & Zhang, H. (2021). Development of chemical foaming microcellular porous materials for automated seats. Composites Part A: Applied Science and Manufacturing, 144 , 106285.
• Zhang, H., Chen, X., & Liu, Y. (2022). Environmental performance enhancement of microcellular porous materials through bio-based additives. Green Chemistry, 24(1), 123-134.

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