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Development of Weight Reduction Technology for Door Trim using Foamed PP

Article of Honda R&D Technical Review Vol.12 No.2


To reduce vehicle weight, a foaming PP resin was developed as a substrate for the injection molding of door trim. This material was formed by mixing a PP resin that acts as a base with a master batch of foaming agent. The PP resin used as the base is low viscosity to reduce the amount of the injected resin. Non-filled PP resin is also used to lower the specific gravity. Impact-resistance is improved by adding an elastomer. The foaming agent was selected after considering such factors as the uniformity of foam cells, effects on pollution, and the associated work environment. The ratio of foaming agent was selected for a balance between product stiffness and low-temperature impact-resistance. The result is a weight reduction of approximately 25% compared to conventional door-trim substrate material.


(1) K. Ichikawa: Foaming Agent, Plastic Age, June, p.159 (1991) (Written in Japanese).

Author (organization or company)

Kenji HIKITA(Tochigi R&D Center)

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