Sumika Polymer Compounds (Sumika), a leader in the development and manufacturing of high-quality polyolefin thermoplastic compounds and elastomers, and Flex-N-Gate Europe combined expertise to manufacture the world’s first short glass fibre reinforced polypropylene (PP) inner tailgate trim for Stellantis’ new DS4 hatchback.
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Flex-N-Gate has over six decades of experience with auto OEMs offering a full range of design services from initial concept renderings to fully functional prototypes for the development of world-class automotive applications.
The rising e-mobility trend has increased the need for light-weighting solutions as balancing the vehicle’s load and axle weight distribution is important for performance and fuel efficiency. Battery powered electric vehicles (BEVs) and hybrid electric vehicles (HEVs) bring new challenges to automakers concerning trunk weight balancing.
The material choice to mould a complex, large inner tailgate part for Stellantis’ DS4 hatchback allowing for metal inserts and fixtures had to provide a homogenous glass fibre dispersion in very long flow lengths, provide outstanding mechanical performance, and offer a Class-A surface finish that also included the OEM’s colour and UV specifications.
Sumika, who has over 40 years’ experience in manufacturing compounds for demanding automotive applications, combined a high fluidity PP from parent company Sumitomo Chemical and unique short glass fibres with advanced sizing and binding technology to develop a customized THERMOFIL HP® compound which ultimately provided higher mechanical properties than long glass fibre filled PP compounds.
Sumika’s THERMOFIL HP® short glass fibre reinforced PP compound allowed easy processing during injection with fewer nozzles, a perfectly smooth and outstanding surface aesthetic with no visible weld lines, and a shorter cycle time of up to 5%, thereby saving energy. The part is also fully recyclable at end-of-life.
The Stellantis DS4 inner tailgate will be displayed at Sumika Polymer Compounds’ stand at K2022 in Düsseldorf, Germany (Oct. 19-26).
® THERMOFIL HP is a registered trademark of Sumika Polymer Compounds
