ABS+PA INNOVATION FOR AUTOMOTIVE INTERIORS

Robert Hooker and Vineet Kapila,, BASF Corporation, Wyandotte, MI

Dr. Marko Blinzler, BASF SE, Ludwigshafen, Germany


Abstract

The need for automotive interior molded-in-color
(MIC) low gloss, rigid plastic components with good
scratch and mar resistance is well known. Typical
interior product gloss targets of automotive Original
Equipment Manufacturers (OEMs) now range from 1.5 -
2.5 units for sixty degree Gardner gloss. Interior scratch
objectives require a scratch width of less then four tenths
of a millimeter with slight whitening when a 15 Newton
load is applied via a one millimeter hemispherical tip.
Strength and rigidity requirements now range from
1.0mm to 3.0mm max deflection on high touch interior
areas when subjected to an arm or finger loading.
Recent advancements in the field of Acrylonitrile-
Butadiene-Styrene + Polyamide (ABS+PA) blends by
BASF Corporation have allowed for such a copolymer
that with the proper design and tooling considerations
allows one to meet these specifications.

Introduction

Mold-in-color (MIC) is now the primary direction for
interior automotive applications when considering doors
panels, consoles systems, instrument panels, and other
interior trim areas. Paint, film, and skin are now only
primarily considered in areas that are highly visible and
contactable by customers on mid-grade to luxury models
for styling, quality, and tactile perception. While the trend
in the industry is to continue to use products such as
polypropylene or thermoplastic polyolefins (TPO) to fit
this need for low gloss MIC, compromises in quality
relating to fit and finish, impact resistance, rigidity, and
scratch resistance are being made. As a result, automotive
OEMs continue to look for innovative materials that are
not only MIC with low gloss, but that can also improve
part quality by providing a rigid and durable appearance
surface. Recently, BASF Corporation has developed such
a product line. This paper will detail tooling and design
considerations when using different grades of ABS+PA to
meet OEM interior automotive component specifications
for gloss, scratch, and strength and rigidity.


Main Section

Three grades of ABS+PA in standard black were used
in two different injection molding plaque tools for gloss
measurements, scratch ratings, and rib/wall ratio
performance. The grades included a standard unfilled and
UV stabilized grade (ABS+PA Standard), an easy flow
unfilled and UV stabilized grade (ABS+PA Easy Flow),
and an 8% glass filled and UV stabilized grade (ABS+PA
8%GF). Basic physical, mechanical, impact, and thermal
properties generated from International Organization of
Standardization (ISO) methods for the three grades of
ABS+PA used in this study are shown below in Table 1.

Table 1: Material properties for ABS+PA Standard,
ABS+PA Easy Flow, and ABS+PA 8%GF (ISO Test
Methods).
Units
ABS+PA
Standard
ABS+PA
Easy Flow
ABS+PA
8%GF
Physical Units
Mold Shrink, Linear Flow % 0.5-0.7 0.5-0.8 0.3-0.6
Specific Gravity - 1.07 1.07 1.12
Mechanical Units
Tensile Modulus, 23 C MPa 2000 2100 3200
Tensile Strength, 23 C MPa 43 46 55
Flexural Modulus, 23 C MPa 1800 2000 2800
Flexural Strength, 23 C MPa 62 66 80
Impact Units
Notched IZOD @ 23C KJ/m
2
65 65 10
Notched IZOD @ -30C KJ/m
2
14 11 5
Thermal Units
Vicat B/50 C 103 110 108


Gloss Measurements

The molded plaques for gloss measurements and
scratch rating were 200mm x 150mm x 2.5mm and
contained grains of the following types: stipple,
geometric, and leather as illustrated in Figure 1. These
grains were selected as variations of them are widely used
in the automotive industry on MIC plastic components.








Figure 1: Grain types: stipple, geometric, and leather (left
to right).

Gardner 60
o
gloss measurements were taken on these
three distinct grains. Table 2 shows the average gloss
measurements for three plaques of each grain/grade
combination molded on an injection molding plaque tools
ANTEC 2009 / 1027
surface finished with a high loading of glass beading.
Additionally, Table 3 shows the average of the same
grain/grade combinations with the addition of an advanced
graining technique called SGE designed by Tenibac-
Graphion, Inc. to further reduce the gloss level.

Table 2: Gardner 60
o
gloss by grade and grain for three
ABS+PA grades.
Grade
Stipple Geometric Leather
ABS+PA Standard 1.9 1.2 1.8
ABS+PA Easy Flow 1.7 1.1 1.6
ABS+PA 8%GF 1.9 1.4 2.1
Grain Type


Table 3: Gardner 60
o
gloss by grade and grain (w/SGE)
for three ABS+PA grades.
Grade
Stipple Geometric Leather
ABS+PA Standard 1.7 1.1 1.6
ABS+PA Easy Flow 1.5 1.0 1.5
ABS+PA 8%GF 1.6 1.2 1.8
Grain Type


Table 2 and Table 3 illustrate that all three grades of
ABS+PA met or exceeded the 1.5 - 2.5 unit sixty degree
Gardner gloss range targeted by OEMs in the standard
grain as well as when the advanced SGE graining
technique was applied.

In addition to the three grades of ABS+PA, a standard
black mineral-filled thermoplastic elastomeric olefin
(TEO+MF) and two standard black TPOs commonly used
for interior and exterior MIC applications were also
molded in the same tooling for gloss comparison purposes
as shown in Table 4.

Table 4: Gardner 60
o
gloss by grade and grain for olefin
based materials TEO+MF and TPO.
Grade
Stipple Geometric Leather
TEO+MF 2.9 2.0 3.1
TPO-1 3.0 2.0 3.3
TPO-2 2.8 2.0 2.9
Grain Type


Notice in Table 4 that the olefin based materials did
not achieve the gloss target of 1.5 2.5 units when run in
the plaque tooling finished with a high glass bead content
blast media. In order for olefin based materials to achieve
the 1.5 2.5 unit range, a high content of Aluminum
Oxide in the finishing media is required to create
additional microscopic peaks and valleys in the tool steel
to help disperse reflected light. High content Aluminum
Oxide blast media is not required to reduce the gloss of
ABS+PA as ABS+PA grades reproduce the tool surface
very well. In fact when an ABS+PA grade is run in a tool
finished with Aluminum Oxide, the achieved 60 degree
Gardner gloss is typically below 1.0 units. Although from
an aesthetic standpoint this may be desired, surface
performance with respect to mar is compromised as the
microscopic peaks and valleys are easily deformed
through surface contact.

Scratch Performance

Scratch testing was completed using a Taber 710 5-
Finger scratch tester to apply a 15N load via a 1mm
hemispherical tip onto the same three distinct grains
without SGE shown in Figure 1 in all three grades of
ABS+PA. The same TEO+MF and two TPOs on which
gloss measurements were taken were also tested for
comparison purposes. Post testing, scratch widths were
measured with a scaled microscope and a rating was made
based on the 5 point scale shown in Table 5.

Table 5: Point scale for scratch performance rating.
Rating Scratch Width Whitening
1 (best)
Less than 0.2mm wide,
almost invisible None
2
0.2 - 0.3 mm wide,
visible at close range None
3
0.3 - 0.4 mm wide,
clearly visible Slight Whitening in places
4 0.4 - 0.5 mm wide
Whitening over the entire
scratch
5 (worst)
Greater than 0.5 mm
wide
Whitening over the entire
scratch with debris


Table 6 below shows the measured scratch widths and
subsequent ratings for the three tested grades of ABS+PA
including ABS+PA Standard, ABS+PA Easy Flow, and
ABS+PA 8%GF. Similarly Table 7 shows the measured
scratch width and subsequent ratings for the TEO+MF and
TPOs tested.

Table 6: Scratch width and ratings for ABS+PA.
Grade
Stipple Geometric Leather
ABS+PA Standard
Scratch Width (mm) 0.35 0.35 0.40
ABS+PA Standard
Scratch Rating 3 3 3
ABS+PA Easy Flow
Scratch Width (mm) 0.35 0.30 0.40
ABS+PA Easy Flow
Scratch Rating 3 2 3
ABS+PA 8%GF
Scratch Width (mm) 0.30 0.30 0.30
ABS+PA 8%GF
Scratch Rating 2 2 2
Grain Type







1028 / ANTEC 2009
Table 7: Scratch width and ratings for olefin based
materials TEO+MF and TPO.
Grade
Stipple Geometric Leather
TEO+MF
Scratch Width (mm) 0.75 0.45 0.50
TEO+MF
Scratch Rating 5 4 4
TPO-1
Scratch Width (mm) 0.40 0.45 0.40
TPO-1
Scratch Rating 4 4 3
TPO-2
Scratch Width (mm) 0.70 0.65 0.70
TPO-2
Scratch Rating 5 5 5
Grain Type


Table 6 above shows that all three grades of ABS+PA
tested met the standard automotive interior requirement of
a rating of 3 or better as only slight or no whitening was
observed and the scratch widths were measured to be less
then 0.40mm. In contrast, Table 7 shows that the
TEO+MF and TPO-2 did not meet the scratch
requirements in any grain and that TPO-1 only met the
requirement in the leather grain. The rating of 3 or better
was not achieved because scratch widths on the Olefin
based polymers ranged from 0.40mm to 0.75mm and
visible whitening over the entire scratch accompanied by
debris was observed. Figure 2 below illustrates the
scratch lines on the stipple, geometric, and leather grains
for ABS+PA 8%GF and for TPO-2 when subjected to 5N,
10N, 15N, and 20N loadings via the 1mm scratch tip.
Illustration of these two grades has been shared as they
represent the highest and lowest ratings with respect to
scratch testing completed for this study.
















Figure 2: Illustration of scratch performance for ABS+PA
8%GF (left) and TPO-2 (right) for stipple, geometric, and
leather grains (top to bottom).



Design for Strength and Rigidity

Strength and rigidity requirements for high touch
interior areas when subjected to an arm or finger loading
are being targeted by OEMs at 1.0mm to 3.0mm max
deflection when subjected to a 25N to 75N load. In order
to meet these standards, product design engineers typically
add structural ribbing in critical areas to components
affected by these requirements. Although this is a good
practice with respect to design, it can lead to surface
defects such as sinks and filling issues such as short shots.
In order to minimize potential appearance defects
resulting from ribbing and other design features,
manufacturing engineers enforce design guidelines. For
example, on Olefin based materials, manufacturing
engineers advise rib/wall ratios of 30-40% and minimum
rib thicknesses of 1.0mm. As a result, components
produced with TEO or TPO are typically produced with a
minimum wall stock of 3.0 mm. In the case of ABS+PA,
rib/wall ratios are recommended at 50-60% which allows
for base wall stock to range from 2.0mm to 2.5mm
without concern for sinks or short shots. Figure 3 below
illustrates a 90mm x 120mm plaque tool that is edge gated
with varying rib/wall ratios of 40%, 60%, 80%, and 100%.
ABS+PA Standard, ABS+PA Easy Flow, and ABS+PA
8%GF were injection molded in this tool at standard
processing conditions (See Table 8). Figure 4 illustrates
the resultant sink depths measured for ABS+PA unfilled,
ABS+PA Easy Flow, and ABS+PA 8%GF at the different
rib/wall ratios. Additionally an automotive industry
standard black Polycarbonate / Acrylonitrile-Butadiene-
Styrene (PC/ABS) and a standard black 20% talc filled
polypropylene (PP+20%TF) were molded in the same tool
for comparison purposes. These results are shown below
in Figure 5 and processing conditions for these two
materials are shown in Table 9.




















5N 10N 15N 20N 5N 10N 15N 20N
ANTEC 2009 / 1029





















Figure 3: Illustration of rib/wall ratio plaque used for sink
depth study.

ABS+PA Sink Depth verses Rib/Wall Ratio
0.000
0.005
0.010
0.015
0.020
0.025
0.030
ABS+PA
Standard
ABS+PA Easy
Flow
ABS+PA 8%GF
S
i
n
k

D
e
p
t
h

(
m
m
)
Sink Depth 40% Rib (mm)
Sink Depth 60% Rib (mm)
Sink Depth 80% Rib (mm)
Sink Depth 100% Rib (mm)

Figure 4: ABS+PA sink depth verse rib/wall ratio

The bar chart in Figure 4 shows that ABS+PA
Standard and ABS+PA Easy Flow did not have a
measureable sink on the grained surface over the rib
pattern while ABS+PA 8%GF had a measureable sink
over both the 80% and 100% ribs.
PC/ABS and PP+20%TF Sink Depth verses Rib/Wall Ratio
0.000
0.010
0.020
0.030
0.040
0.050
0.060
PC/ABS PP+20%TF
S
i
n
k

D
e
p
t
h

(
m
m
)
Sink Depth 40% Rib (mm)
Sink Depth 60% Rib (mm)
Sink Depth 80% Rib (mm)
Sink Depth 100% Rib (mm)

Figure 5: PC/ABS and PP+20%TF sink depth verse
rib/wall ratio.

The bar chart in Figure 5 shows that PC/ABS had a
measureable sink on the grained surface over the ribs
designed at both 80% and 100% of the wall thickness and
that PP+20%TF had a measureable sink over the 60%,
80% and 100% structural ribs.

Table 8. Injection molding conditions for PA+ABS
rib/wall ratio plaque samples.
Product
ABS+PA
Standard
ABS+PA
Easy Flow
ABS+PA
8%GF
Temp Rear Zone,
o
F 480 480 480
Temp Middle Zone,
o
F 490 490 490
Temp Front Zone,
o
F 490 490 490
Temp Nozzle,
o
F 490 490 490
Actual Melt
Screw % , 80 rpm 80 rpm 80 rpm
Recovery time, sec 8.07 8.06 7.88
Shot size, in 2.6 2.6 2.6
Cushion, in 0.22 0.16 0.19
Position- actual, in 0.4 0.4 0.4
Pressure - actual, psi 783 770 749
Time set \ Fill Time 2.64 2.64 2.64
Hold pressure, psi 600 600 600
Hold time, sec 15 15 15
Cure time, sec 20 20 20
Velocity ( %ss ) 1 .85 in/sec .85 in/sec .85 in/sec
Velocity ( %ss ) 2 .85 in/sec .85 in/sec .85 in/sec
Velocity ( %ss ) 3 .85 in/sec .85 in/sec .85 in/sec
Velocity ( %ss ) 4 .85 in/sec .85 in/sec .85 in/sec
Mold temperture A plate 140 140 160
Mold temperture B plate 140 140 160
MACHINE: TK 110 ton TK 110 ton TK 110 ton






1030 / ANTEC 2009
Table 9. Injection molding conditions for PC/ABS and
PP+20%TF rib/wall ratio plaque samples
Product PP+20%TF PC/ABS
Temp Rear Zone,
o
F 410 500
Temp Middle Zone,
o
F 420 510
Temp Front Zone,
o
F 420 510
Temp Nozzle,
o
F 420 510
Actual Melt
Screw % , 80 rpm 80 rpm
Recovery time, sec 8.06 6.39
Shot size, in 2.5 2.5
Cushion, in 0.16 0.29
Position- actual, in 0.55 0.4
Pressure - actual, psi 443 816
Time set \ Fill Time 1.68 3.46
Hold pressure, psi 600 600
Hold time, sec 15 15
Cure time, sec 20 20
Velocity ( %ss ) 1 1.25 in/sec .65 in/sec
Velocity ( %ss ) 2 1.25 in/sec .65 in/sec
Velocity ( %ss ) 3 1.25 in/sec .65 in/sec
Velocity ( %ss ) 4 1.25 in/sec .65 in/sec
Mold temperture A plate 100 140
Mold temperture B plate 100 140
MACHINE: TK 110 ton TK 110 ton


Conclusions

ABS+PA is a copolymer that can be used by
injection molders to create a molded-in-color, low gloss,
scratch resistant, interior plastic component with good
strength and rigidity. All three grades of ABS+PA
evaluated for gloss met or exceeded the 1.5-2.5 unit
target for 60 degree Gardner gloss. Additionally, all
three grades of ABS+PA evaluated for scratch
performance met or exceeded the automotive industry
standards of a scratch width of less then 0.4mm and
slight whitening when subjected to a 15N load over a
1mm tip. Finally, ABS+PA allow for higher rib to wall
ratios then industry standard olefin based materials and
comparable ratios for industry standard PC/ABS.

References

1. BASF Plastic Design Guide, Wyandotte, MI (2008).
2. BASF Terblend N Product Literature, Ludwigshafen,
Germany (2007).
3. A.H. Sharma and J.H. Botkin, Additive approaches to
improving scratch and mar resistance in automotive
polyolefins, SPE Automotive TPO Global Conference
Geneva, Switzerland (2005).

ANTEC 2009 / 1031