Polypropylene modification is commonly achieved through several methods, including mineral reinforcement and toughening, weathering treatment, glass fiber reinforcement, and flame retardant enhancement. These modified materials find widespread use in the household appliance industry, offering improved performance, cost efficiency, and versatility. Mineral reinforcement involves adding substances like calcium carbonate, talc, wollastonite, glass microbeads, or mica powder to polypropylene. This not only enhances mechanical properties and impact resistance but also reduces shrinkage, improving dimensional stability. The cost savings from using minerals instead of pure polypropylene make it a popular choice. For example, washing machine drums and inner cylinders are often made from this type of material, replacing traditional stainless steel. This change helps reduce weight and manufacturing costs. In addition, components like pulsators and fabric outlets in washing machines, as well as microwave oven parts, benefit from this modification. Haier alone uses around 1700 tons annually for this purpose. The heat resistance of these materials is also improved, making them suitable for high-temperature environments like microwaves, where parts such as door seals and speaker flares are commonly made from modified polypropylene. Refrigerator shelves are another common application, as they offer better integration with glass panels and avoid issues like panel sinking that were seen with older ABS materials. Weather-resistant polypropylene modifications address the inherent instability of polypropylene due to its tertiary carbon groups, which can lead to aging, discoloration, and reduced strength when exposed to light, heat, and oxygen. This limits its use in outdoor applications. By enhancing weather resistance, the material becomes more durable in harsh conditions. It is now widely used for outdoor parts of air conditioners, replacing traditional metal-coated plastics. This not only improves aesthetics and durability but also reduces production complexity, cost, and weight while preventing rust. This technology was pioneered by Japanese companies like Sumitomo and Mitsubishi Chemical in the early 1990s. Glass fiber-reinforced polypropylene is used when higher mechanical properties are required for structural components. While standard polypropylene has tensile strength between 20–30 MPa and flexural modulus between 800–1500 MPa, glass fiber reinforcement significantly boosts these values—tensile strength reaching 65–85 MPa, bending strength up to 70–95 MPa, and flexural modulus as high as 3,000–4,500 MPa. These properties make it comparable to reinforced ABS but with better heat resistance, reaching up to 135–145°C. It’s ideal for axial and cross-flow fans in refrigerators and air conditioners, offering a cost-effective alternative to ABS-based materials. It’s also used in high-speed washing machine drums, meeting strict mechanical demands. Flame-retardant polypropylene is essential for safety in electronic appliances. Many countries require materials to meet UL94 V0 standards. Since polypropylene is inherently flammable, bromine-antimony compounds are commonly used for flame retardancy. This ensures that products self-extinguish in case of fire and can withstand high temperatures, such as 650°C or even 750°C on a glow wire. Flame-retardant polypropylene is used in critical areas like washing machine control trays, wire controller housings, refrigerator evaporators, and ducts, where fire safety is crucial.
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