Plastic components and materials accelerating lightweighting in automobiles

Examples of usage for internal combustion engines, electrified powertrains, and door trim panels

2018/11/14

Summary

The concept of lightweighting can be considered as one of the important topics in the automotive industry today. There is no doubt that plastic is one of the materials accelerating the lightweighting of automobiles. This report presents the technological trends in automotive plastics, which have been increasing in importance in recent years. Firstly, the characteristics and usage of various plastics used in automobiles are summarized in a number of tables, and latest trends in materials development and processing technologies are presented.

Automotive components made using plastic are extensively adopted for usage on many parts of a vehicle. This report, however, presents various examples of the application of plastics in typical powertrain components and interior parts, supported with images and photographs taken during recent exhibitions. This report introduces some of the plastic components and materials adopted on ICE (Internal Combustion Engines) as well as electrified powertrains such as EVs, HVs, FCVs, as well as plastic materials adopted for various interior parts and door trim materials.

Plastic materials contribute to the lightweighting of batteries Intake manifold with complex shapes Door trims requiring impact resistance and designability

 

In this report, through the cooperation of Mr. Takeo Yasuda, director of Yasuda Polymer Research Institute and based on the information from CMC Research “The Latest Trends in the Development and Adoption of Automotive Plastic Parts 2018” authored by Mr. Yasuda himself, the latest trends in plastic related technologies that are gaining attention will be covered. Furthermore, the sequel to this report will present the latest trends in plastics processing technologies such as joining and bonding processes.

 

Related reports:
JSAE Exposition 2018: Lightweight processing technology and plastic materials (Jun. 2018)
Automotive World 2018: Joining of dissimilar materials, high function plastics exhibition (Feb. 2018)
Automotive World 2018: CFRP components and plastic molding technology (Feb. 2018)





Latest trends and characteristics of automotive plastics

Automotive plastics given in the order of their usage are: PP (Polypropylene), PA (Polyamide), ABS resin, PUR (Polyurethane), PBT/PET (Polybutylene terephthalate/ polyethylene terephthalate), POM (Polyacetal), PC (Polycarbonate), PE (polyethylene), PVC (polyvinyl chloride), PPS (Polyphenylene sulfide), and m-PPE (modified polyphenylene ether).

In Table 1, each material and the properties that are particularly important in automotive plastics are indicated by symbols. In Table 2, recent trends in automotive plastics are introduced with their respective usage examples. These tables can be used as reference as judgment criteria for selecting materials and investigating plastics for automotive applications.

 

Table 1: Characteristics of automotive plastics (overview)

自動車用プラスチックの特性

Source: Prepared from CMC Research’s “The Latest Trends in the Development and Adoption of Automotive Plastic Parts 2018” and various published materials

 

Table 2: Latest trends in major automotive plastics

Material Name Trends of major plastics
Polypropylene (PP) (1) The most highly used plastic material (approximately half of all plastics). Adopted mainly for large sized parts (bumpers, instrument panels).
(2) PP-LFT (Long fiber reinforced PP) is seeing an increase in its adoption for usage for modular parts, including CF (carbon fiber reinforced) parts for some of the module components.
Polyethylene (PE) Increasing usage of HDPE for fuel tanks (barrier layers mainly using EVOH)
ABS resin Due to its appearance and secondary processing features, the demand for this plastic is growing for vehicle interiors on premium class cars.
Polyamide (PA, nylon) (1) PA6, PA66 are mainly adopted for powertrain components and modular parts.
(2) PA11, PA12 expanding demand for fuel tubes (mostly on laminates with fluororesin)
(3) Adoption of high thermal resistance PA is increasing for sliding parts, cooling system components, and fuel system components.
Polyacetal (POM) (1) Expected to be increasingly used for fuel system components due to good eco-gasoline resistance.
(2) Due to the demand for clean vehicle cabin interiors, POM with Low VOC (Volatile Organic Compounds) grade is being adopted as standard.
Polybutyleneterephthalate (PBT) (1) Usage is increasing for PBT, which has excellent electrical properties and chemical resistance for parts such as ECUs and sensors.
(2) There is a growing demand for PBT due to increasing number of parts for wiring harness connectors.
Polycarbonate (PC) Widespread usage for glazing is receiving increased attention. Weather resistance and improvement of surface scratch resistance are items under investigation.
Polyphenylenesulfide (PPS) Demand is rapidly increasing for high volume usage in electrification related components (e.g. housings for PCU, inverters)
Others (1) Modified PPE is used for Lithium-Ion battery (LiB) related parts, reinforced PET for electrical parts, as well as PF, PU, and PMMA for these parts.
(2) CFR(T)P, with its high performance properties, is gradually being adopted more frequently for various parts on premium class vehicles.
(3) Bioplastics and thermoplastic elastomer characteristics are making them attractive for use in applications development.

Source: Prepared from CMC Research’s “The Latest Trends in the Development and Adoption of Automotive Plastic Parts 2018” and various published materials
Note:
HDPE: High Density Polyethylene
EVOH: Ethylene-vinylalcohol copolymer
PET: Polyethylene terephthalate
PF: Phenol Formaldehyde Resin
PU: Polyurethane
PMMA: Polymethyl methacrylate
CFR(T)P: Carbone fiber reinforced (Thermoplastic resin) and thermosetting plastics



Technology development trends of automotive plastics

Technology development of plastics of interest for automotive applications are categorized into 3 main areas: materials development, molding process technology development, and others.

 

Materials development

Materials development is categorized into the development of new polymers and the combination of existing materials. The former is further categorized into the development of new chemical structures for polymers, and the development of polymers with the same chemical structure but with modified properties. The latter is categorized into the materials development of polymers (polymer alloy/polymer blend) and the materials development by a combination (composite materials) of polymers and mainly inorganic materials (such as various reinforced fibers, metals, metal oxides).

Resin manufacturers that supply materials to the automotive industry select polymers according to its user needs and are utilizing the development techniques described above to develop various new grades of plastics. Table 3 shows the new grades of automotive plastics.

 

Table 3: New grades of major automotive plastics

Materials Functions and Usage
New grades common on various materials Electrical conductivity, high thermal conductivity, long fiber reinforcement, nanocomposites, biomass-type, etc.
New grades unique to PP High Crystallized polymer, high impact resistance (PP/PA11), non-coated cosmetics, PP adhesive resin, high fluidity, etc.
New grades unique to PMMA Ultra-heat resistance, high hardness, non-coated for exteriors, jet black tone, high fluidity, zero birefringence, etc.
New grade unique to ABS Countermeasure for squeaking noise, non-coating decorative, heat resistant for vehicle interiors, sustainable anti-static, etc.
New grade unique to PC High hardness, high transparency, high chemical resistance, bio-type, heat absorbent, improved surface hardness, for automotive lens, etc.
New grade unique to PA Electroless plating, high thermal conductivity, metal adhesiveness, thermal aging resistance, high sliding property PA, high rigidity/good appearance/reinforced moldability, used for blow-molded ducts, injection foam, etc.
New grade unique to POM Low VOC, metallic appearance, high performance, high electrical conductivity, high performance GF reinforced, creep resistance, high rigidity, flexibility, etc.
New grade unique to PBT Improved hydrolysis resistance, improved long term properties, ultra-high fluidity, applicable for laser welding, good appearance, low warpage, for direct deposition, and high toughness, etc.
New grade unique to Modified PPE For lithium-ion batteries, flexibility for wire harness coating, high inductivity
New grade unique to PPS Low fuel swelling, low gas/heat shock resistance, metallic adhesiveness, high thermal conductivity, applicable for blow molding, flexibility, etc.

Source: Prepared from CMC Research’s “The Latest Trends in the Development and Adoption of Automotive Plastic Parts 2018” and various published materials

 

Development of molding process technologies

The majority of plastics used for automotive applications are thermoplastics, and the most used molding process is the injection molding method. The molding process technologies for thermoplastics that have been recently gaining attention are heat and cool molding (capable of weldless molding and surface reforming of molded products), film insert molding (improves performance of molded products with decorative film inserts), and hybrid molding (provides high strength and high rigidity materials using CFRTP).

Other than the above processes, suction blow molding used for duct related products is also drawing attention. Furthermore, in sheet press molding, by press molding plastic sheets such as PP, the molding of parts with large surface areas is now possible. These products, if done through injection molding, require large-sized molding equipment, but in this process a relatively compact press molding machine is capable of molding large parts, which makes it an excellent molding process contributing to energy conservation.

 

Other related technologies

CAE, various secondary processing, Rapid Prototyping, and recycle-related technologies are also important technologies when using plastics for automotive applications.

Among these technologies, a few particular methods that are drawing attention recently are adhesion/bonding and mold decoration. Adhesion/bonding is a key technology used for lightweighting in automobiles, while mold decoration is drawing attention as a means of decorating interior components.

 

Table 4: Latest plastics-related technologies to watch

1. Materials development
1-1. Development of new polymers
(1) Polyolefin-based (2) Polystyrene-based (3) Polyamide-based (4) Polyester-based (5) Polyimide-based (6) Biomass raw materials-based (7) Special transparent polymers (8) Others
1-2. Polymer alloy, polymer blend
(1) Nanoalloy
1-3. Composite materials (hybrid materials)
(1) Long glass fiber reinforced thermoplastics (2) Composite reinforced thermoplastics (3) Nanocomposites (4) Improved moldable CFR(T)P (5) High thermally conductive composite materials (6) Electrically conductive composite materials (7) Laminates/UD tape (8) Others
2. Molding process technologies (thermoplastics)
2-1. Injection molding
(1) Gas-assist molding (2) Outsert molding (3) Low pressure molding (4) DSI (Die Slide Injection molding), DRI (Die Rotating Injection molding) (5) MID (Molded Interconnect Device) (6) Combination of multiple molding (such as injection compression molding) (7) Multi-color, multi-property molding (8) Heat and cool molding (9) Hot melt molding (10) Compound simultaneous molding (11) Film insert molding (12) Hybrid molding (13) Decoration molding (14) Others
2-2. Blow molding method
(1) Double-wall blow molding (2) Multi-dimensional blow molding (3) Suction blow molding (4) Others
3. Other technologies
(1) CAE (Computer Aided Engineering) (2) Secondary processing (Cutting/machining, bonding/joining, welding, painting, printing, metalizing, annealing treatment) (3) Rapid Prototyping (3D printing, simplified die molding, machining process, etc) (4) Environmental compliance technologies such as recycling

Source: Prepared from CMC Research’s “The Latest Trends in the Development and Adoption of Automotive Plastic Parts 2018” and various published materials



Plastic parts for ICE (Internal Combustion Engine)

シリンダーヘッドカバー
Cylinder head cover (Du Pont)
インテークマニホールド
Intake manifold (Mahle)
The cylinder head cover shown is made from GF Reinforced PA66. One merit that can be given during conversion of this part to plastic is noise suppression. The grade used on this part further reduced noise. Noise suppression was achieved by the addition of a third ingredient that absorbs sound. It appears that a rubber-like material is used in the additive, however simply adding rubber may impair the required product properties such as high rigidity, so it is assumed that a thorough material design review was done to optimize well-balanced material properties. The intake manifold introduces air into the combustion chamber of the internal combustion engine. Either a reinforced grade of PA6 or PA66 GF is used. PA is used for its heat resistance, mechanical properties, and chemical resistance. The manifold has a complex shape so injection molding is used. The DSI and DRI methods are used for welding during injection molding, while laser welding is used after the injection molding. This part is an alternative to aluminum parts, significantly contributing to lightweighting and low noise.

ラジエーター
Radiator
インタークーラー
Intercooler (Behr)
The radiator is a type of heat exchanger, a typical component of a cooling system. The upper and lower radiator tank requires anti-freeze solution resistance so PA66 or PA610 is used, and PP is used for components of fan system due to its high cost performance. Further, for the radiator fan, either PP or PA with GF reinforced grade is used. These are applications that require strength, rigidity, and durability. The intercooler is an accessory for internal combustion engines with turbochargers. It is a heat exchanger that cools the heated compressed air from the turbocharger. It improves the combustion efficiency and power output. Air-cooled types are common but recently water-cooled types are adopted to reduce the volume of the air induction system. Materials with thermal resistance, mechanical strength, and wear resistance are used, materials such as PA6T, PA9T, and PA66.

キャニスター
Canister (Aisan Industry)
エンジンマウントブラケット
Engine mount bracket (Du Pont)
A canister is a component that temporarily adsorbs the gasoline vapors generated in the fuel tank into the activated carbon to prevent release of hydrocarbon emissions into the atmosphere. The gasoline vapors adsorbed is burned in the engine during the combustion process. By adopting a thermal storage medium in the canister, even HVs can meet the zero evaporative emissions regulations in the US. It is assumed that PA66 is used based on the requirements for gasoline resistance and thermal resistance. Engine mounts are components for securing the engine to the vehicle chassis during assembly. Approximately 30% lightweighting is achieved by converting from aluminum diecast to plastics. Furthermore, by using plastics, heat transfer is reduced and thermal deterioration of vibration damping rubber components is reduced. The characteristics of the PA used on these components are strength for withstanding high static loads and engine torque stress, creep deformation resistance, wear characteristics, NVH absorption performance, and the reduction of heat transfer to the surrounding components.

オイルパン
Oil pan (BASF)
ディーゼルエンジン用ベンチレーター
Ventilator for diesel engine
The oil pan is an oil circulation system component, where the high chemical resistance property of PA can be applied. Recently PA has been used for oil pans on large engines. Compared to metal products such as steel and aluminum, in addition to having a high degree of freedom in being formed with complex shapes, it can also be integrated with the mount (parts for eliminating metal particles by magnetism) for oil fill, thereby making it possible to reduce weight and cost. The ventilator is the general term for devices to promote ventilation in closed spaces and the outside environment. This component complies with diesel engine emissions regulations. It integrates the oil mist separator function and the crankcase pressure regulating function. The material is assumed to be PA. It makes use of the thermal resistance, chemical resistance, mechanical strength characteristics, and also achieves lightweighting.

エンジン冷却モジュール
Engine cooling module (Toray)
吸気モジュール
Intake module (Keihin)
The part is a new type of cooling system component different from radiators and intercoolers, making use of the thermal resistance, mechanical strength and chemical resistance characteristics of PPS. The part shown is a modularized intake manifold, injector, and throttle body using PPA (PA6T). It has excellent thermal resistance, chemical resistance and mechanical characteristics.

サーマルマネジメントモジュール
Thermal magagement module (Schaeffler)
ブロー成形によるPPS製のダクト
PPS made duct by blow molding (Toray)
Used for temperature regulation of the vehicle interior, engine and transmission oils, cylinder blocks, and cylinder heads. It is a system connected within the cooling circuit performing temperature control of functional parts based on cooling requirements. An electro-mechanical rotary slide valve device controlled by a position sensor is used, which accurately controls the flow of the refrigerant. PPS is used for the housing which makes use of its thermal resistance and chemical resistance (LLC resistance) properties. Due to engine downsizing and the addition of turbochargers, the temperature of area surrounding the engine is becoming increasingly higher. GF reinforced PA materials were originally used on these parts but products with GF reinforced PPS are adopted for higher thermal resistance. These ducts are formed with material grades possessing the required melt tension and melt viscosity for low cost blow molding.

ターボチャージャー用エアバイパス弁
Air bypass valve for turbocharger (Fujikoshi)
モーターコントロールバルブ
Motor control valve (Nippon Thermostat)
Shown is a thin-type air bypass valve for turbochargers to improve the drivability of turbo engines. The part is composed of PEEK, PPS, and PA66 from the inside in the order of high thermal resistance, corrosion resistance. The part requires a complex and high level of molding technique to mold three types of materials. (1) Improved mountability due to downsizing and lightweighting technologies, (2) high corrosion resistance by plastic molding By optimized control of the flow rate of the engine coolant according to external environmental conditions, the motor control valve aims to improve the warm-up speed, reduce mechanical losses, and improve the combustion efficiency of the engine. PPS or PPA which have excellent thermal and hot water resistance are used for the housing.


Plastic components for ICE (internal Combustion Engine) other than the ones listed above are cited below.

  • Inter cooler end cap (PA)
  • Thermostat housing (PPS, PA6T, PA9T)
  • Chain lever guide (PA)
  • Water jacket spacer (PA6T)
  • Turbocharger impeller (PEEK)
  • Engine oil pump rotor (PEEK)
  • Engine cooling module (PF)
  • Camshaft pully (PF)
  • Water jacket (PA6T)
  • Electric oil pump (PA)
  • EGR valve (PBT)
  • Throttle body (PA)
  • Turbo actuator (PPS)
  • Flow switching valves (engine coolant) (PPS)


Plastic parts and materials for electrified powertrains such as EV/HV/FCV

LiB関連材料
Plastic materials for LiB (Asahi Kasei)
電気二重層キャパシター
Electrical double-layer capacitors (TPR)
For the frames, busbars, and spacers used on Lithium-Ion batteries (LiB), the power source of electric vehicles, m-PPE (modified polyphenylene ether) is used. In addition to having excellent alkali resistance properties, flame retardance of UL 94V-0 for non-halogen-based flame retardants, and thin-walled flowability, it contributes to the lightweighting of products due to its low specific gravity. Electrical double-layer capacitors have small capacity compared to secondary batteries, but because of their high-power output feature, they are suitable as a power source during vehicle launch start and uphill climbing. This product is a plate-like cartridge type of which the housing is made of PP with outstanding thermal resistance and electrical properties.

HV用燃料タンク
Fuel tank for HEV (Yachiyo Industry)
インバーター
Inverter
A tank with combined HDPE and EVOH. Yachiyo developed and adopted self-contained technologies for functional parts that reduce fuel evaporation, such as installation of the valve by welding it inside the tank, eliminating the drilling of holes. For vehicles with a high degree of quietness like HVs, the unpleasant sound of fuel sloshing inside the fuel tank can resonate to reach the passenger cabin. The structures used to reduce the unpleasant sound are made by insert blow molding. The inverter converts the direct current (DC) power stored in the battery into alternating current (AC) power. During conversion by generating the required frequency for vehicle speed and system control, it controls the speed, driving torque, and power of the motor to perform vehicle acceleration and deceleration. The housing is assumed to be made of PBT (or PPS) that has an outstanding balance between electrical properties, thermal resistance, and mechanical strength.

フィルムコンデンサー
Film capacitor (Shizuki Electric)
HV用電源ボックス
Power supply box for HEV
A film capacitor that assists functions of the EV inverter. PPS is used for the housing. This application makes use of the PPS material’s outstanding electrical properties, thermal resistance, and chemical resistance. Shown is an application that makes use of PBT properties such as electrical characteristics, thermal resistance, moldability, dimensional characteristics, and low humidity absorption.

EV用電源コネクタ
Charger coupler for EV (Yazaki)
IPMハウジング
IPM housing (Hitachi Chemical)
For EV power supply applications that require high voltage resistance and high current resistance, the use of PBT is adequate. PBT is used for the black portion, however the white portion uses a PC/PBT alloy since it needs to withstand impact if dropped. This is an application making use of PBT’s excellent electrical characteristics and dimensional characteristics. The IPM (Intelligent Power Module) is a module that incorporates self-protection functions and driver circuits in semiconductors for power applications. It is used for power control in EVs and HVs. PPS material that can withstand heat generated by various semiconductor components is adopted for the housing. This is an application making use of the excellent electrical characteristics, mechanical strength, dimensional stability, and moldability of the PPS.

PTCヒーター
PTC heater (BorgWarner)
HV制御システム
HEV control system (Denso)
This is a type of electrical heater that self-regulates the heat according to the temperature of the surrounding environment. It is adopted on EVs as the main cabin heater. Because they are equipped on EVs that do not have heat sources, they have the disadvantage of directly consuming the electrical power also used for electric driving. PBT and engineering plastics are used as insulating materials for the housing. Shown is the control system comprised of the HV ECU, battery monitoring unit, and system main relays. PBT and PPS with excellent electrical characteristics, mechanical strength, thermal resistance, and dimensional stability are used for parts such as housing.

FCV用水素タンク
FCV hydrogen tank (Toyota)
FCスタック
Fuel cell stack (Toyota)
Fuel Cell Vehicle (FCV) hydrogen tank. CFRP is wrapped around the aluminum inner shell to make it lightweight. This is also an application that makes use of the high strength/rigidity properties of CFRP. It should also be noted that PA-based material is used for the tank liner. The fuel cell stack is an electric generator device that utilizes the chemical reaction between hydrogen and oxygen in the air. Thermoplastic CFRP is used on the frame. The CFRP is jointly developed between Toyota and Toray, capable of being press molded within a short time period, which is suited to mass production. This product is a world’s first adoption for structural components of mass production vehicles.

FCVのエアバルブモジュール
Air valve module for FCV (Aisin Group)
FCV用水素ディテクター
Hydrogen detector for FCV (FIS)
Shown is a modular part that has the control functions to regulate pressure, divide or bypass the flow, and stop the flow of air. During power generation, the module separates the flow of the supplied air, regulates the pressure, and shuts off the air during power shutdown. PPS, PA66, and rubber are used according for the parts of the system. Shown is a hydrogen detector adopted on the Toyota FCV “Mirai”, installed at two locations. The device immediately detects hydrogen gas leaks and alerts the driver. The MLIT (Ministry of Land, Infrastructure and Transport) requires installation of hydrogen gas leak detection devices as standard equipment for FCVs. The housing is made of reinforced PBT/PC.


Other plastic products for electrified powertrain not in the above list are cited below.

  • Motor controller (PC)
  • Hydrogen injector (PA)
  • Hydrogen fuel refill nozzle (PA)
  • ECU for HV (PBT)
  • Inverter busbar for HV (PBT)
  • Alternator (PPS)
  • Motor stator for HV (PPS)
  • Harness module for HV (PP)
  • IPU (Intelligent Power Unit) for HV (PPS)
  • Electric water pump for inverter cooling (PPS)
  • Terminal blocks for HV (SPS)


Plastic materials for door trim panels

Door trims are important parts of the vehicle’s interior space, comprised of a three-layer structure, the skin material, cushion sheets, and core materials. In addition to ensuring passenger safety from side impact, consideration is required for the environment such as lightweighting and design considerations for decorative purposes.

PP製ドアトリム
PP made door trim (Kasai Kogyo)
ナノコンポジット使用ドアトリム
Door trim using PP nanocomposite (Kasai Kogyo)
This part makes use of PP with excellent properties such as lightweighting and moldability. It also provides added value by applying surface decorative technologies as shown on the section with metallic gloss. Shown is a door trim made by injection molding using PP nanocomposite. It is the most commonly used mass production nanocomposite PP for automotive applications.

高耐衝撃プラスチック製ドアトリム
Door trim using high impact resistant plastic (Toyota Boshoku)
CNF/PP製ドアトリム
CNF/PP made door trim (Toyota Boshoku)
The door trim shown uses a high impact resistant plastic with world-leading impact strength featuring a “salami” structure that controls the dispersion of the natural resin components PP and PA11 at the nano-level. The high impact-resistant plastic can be added to the PP using dry blending methods. Addition of high-impact resistant plastic to PP makes it possible to improve impact strength while maintaining rigidity. The door trim shown is using the CNF (Cellulose nanofiber) that is gaining attention as a plant-derived reinforcement material. This is a material being studied by the Ministry of Environment as part of the NCV (Nano Cellulose Vehicle) project. It is being studied as door trim technology material for automotive interior components. The material is required to possess both rigidity and impact-resistant properties. The key point in the development is the compatibility of the PP/CNF materials with respect to base material rigidity and moldability.

PP製ドアトリム
PP made door trim (Sekisui Chemical)
高機能フィラー配合ドアトリム
Door trim incorporating high performance filler (Ube Industries)
Door trim products applying high expansion foam molding technology. This technology uses the company’s original blend of raw materials, achieving lightweighting by high expansion foam molding (weight reduction of 50% on flat panels, and 25~35% on interior door trims). It possesses the equivalent appearance, strength and rigidity of high impact products. The materials used for this product was developed by an affiliate company of Ube Industries using high performance magnesium sulfate filler. The PP is reinforced with talc and magnesium sulfate, but the filler content is low so that lightweighting is also achieved.


Plastic parts and materials for interiors

インストルメントパネルコア
Core component for instrument panel (Celanese Japan)
オートヒーターコンローラー
Auto climate control (U-SHIN)
Due to its use as the core component for instrument panels, the long fiber-reinforced PP (PP-LFT) is used due to its outstanding properties such as high rigidity/strength, impact-resistance, thermal resistance, dimensional accuracy, dimensional stability, and lightweight. Shown is a switch that operates switching of the A/C outlet, switching of Fresh Air Mode/Recirculation Mode, A/C temperature and air flow regulation. It makes use of the balanced properties of ABS resin (such as mechanical strength, electrical properties, thermal resistance, dimensional stability, decorative, and appearance).

スピーカーグリル
Speaker grill (Celanese)
DURABIO製表示パネル
DURABIO made display panel (Mitsubishi Chemical)
Because the part is commonly touched by passengers that may result in poor appearance due to scratches, POM with outstanding friction and wear properties is used. Durabio is a plant-derived bio-polycarbonate based on isosorbide as the main raw material developed by Mitsubishi Chemical. Compared to conventional PC, it features high transparency and outstanding optical properties. It also demonstrates impact resistance comparable to PC.

電子ミラー
Electronic mirror (Nippon Seiki)
バックドアインナープレート
Back door inner plate (Mitsubishi Chemical)
Electronic mirror that can switch between mirror mode and camera monitor mode. It is assumed that PC/ABS-based materials are used. As an alternative for metals, LFT-PP with outstanding high rigidity/strength and lightweight properties is used. This material is being considered for applications on automotive sub-structural components and other parts.


Other plastic interior parts are also given below.

  • Overhead console (PP)
  • Glove box (PP)
  • Seat pan (PP-LFT)
  • Air conditioner ventilator (ABS resin)
  • Thin resist (PC/ABS resin)
  • Meter panel (PC)
  • Air duct control beam (POM)
  • Ventilator (m-PPE)
  • Headliner module (PP)
  • Steering switch (ABS resin)
  • Lever combination switch (PA, POM, ABS resin)
  • Console box (PP-LFT)

 


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Keywords
lightweight, electrification, resin, plastic, CFRP, carbon fiber, composite, metal substitution, high rigidity, heat resistance, high strength, thermoplastic, thermosetting, heat conduction, molding, injection molding, interior, housing, intake manifold, door trim

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