Development of polycarbonate/acrylonitrile–butadiene–styrene copolymer based composites with functional fillers for car audio chassis

Environmental regulations require the improvement of automobile fuel efficiency. This can be achieved mainly by reducing the weight of automobile components. In this study, polycarbonate/acrylonitrile–butadiene–styrene copolymer (PC/ABS) based composite mixed with glass fibers and metal fibers was developed and its suitability of application into car audio chassis was investigated. The test materials were prepared with various contents of metal fibers because of the fibers’ excellent mechanical and electrical properties. In this study, the morphologies of the materials were investigated to confirm the dispersion of the fillers and the interfacial characteristics between the fillers and the base material. In addition, the mechanical and electrical characteristics of the PC/ABS based composites, which depended on the metal fiber content, were evaluated using key mechanical (impact, tensile and flexural) and electrical tests such as electromagnetic interference (EMI) and surface resistance. The proper proportion of the metal fibers in PC/ABS based composites was determined from the test results. Finally, the applicability of PC/ABS based composites in car audio chassis was evaluated through weight reduction analysis and cost-benefit analysis.