JSAE 2019 in Yokohama: Plastic Materials Exhibitions
Automotive plastics for a variety of uses including weight reduction, and thermal management
The Automotive Engineering Exposition 2019 Yokohama was held by the Society of Automotive Engineers of Japan (JSAE) from May 22 to 24 at the Pacifico Yokohama Conference Center Hall. The theme of this year’s event was “Redefined Communities Supported by Automotive Engineering” with the secondary theme of the “Direction of the Evolution of Cars Merged with Revolutionary Social Infrastructure.” According to the event organizer, 624 companies exhibited products, 95,900 visitors attended the event during the 3 show days (compared to 93,458 attendees in 2018), and the event was considered a great success.
This report describes some of the most noteworthy exhibitions by plastics-related material manufacturers and component suppliers. To seize opportunities related to the current trends of electrification and autonomous driving technologies in the automotive industry, exhibitors were seen to be actively promoting their products to the OEMs.
|Automotive Engineering Exposition 2019 venue||The plastic components display of Riken Technos|
Plastic components and materials accelerating lightweighting in automobiles (Nov. 2018)
JSAE Exposition 2018: Lightweight processing technology and plastic materials (Jun. 2018)
Interior, exterior, and other components: Asahi Kasei, Mitsubishi Chemical, Mitsui Chemicals, Teijin, Kaneka
Asahi Kasei: Engineering plastics, general-purpose thermoplastic resin-related products
High-strength and high-rigidity continuous glass fiber reinforced polyamide composites
Using PA66 (polyamide 66) creates continuous glass fiber reinforced polyamide composite material with increased high strength, high-rigidity, and impact resistance. The booth displayed samples where the material has been adopted for components such as frame materials, seat materials, or shock-absorbing part materials, as well as wheels.
Unpainted acrylic resin for exterior parts
The product displayed had a jet-black color, darker than that of general black acrylic resin, which maintained its color at the same level of weather resistance. The material is suitable for exterior parts such as pillar garnishes and front grilles.
The company also displayed product samples such as three-dimensional suction blow polyamide, polyamide rigid sound absorption foam, high-strength and high-rigidity polypropylene, modified polyphenylene ether (m-PPE) for lithium-ion battery (LiB), and metallic polyacetal.
*PA: polyamide, PP: polypropylene, m-PPE: modified polyphenylene ether, POM: polyacetal
|High strength, high-rigidity continuous glass fiber reinforced polyamide resin
Display panel: High strength, high-rigidity continuous glass fiber reinforced polyamide resin
|Unpainted acrylic resin for exterior parts
Display panel: Unpainted acrylic resin for exterior parts
(Photographs by author, including photographs to follow)
Mitsubishi Chemical Holdings Group: General-purpose thermoplastic resin and engineering plastics-related resins, etc.
Bio-based polycarbonate resin exterior decorative components
Leveraging this resin’s superior coloring and scratch-resistant properties, Mitsubishi Chemical Holdings product can be used to manufacture unpainted and uncoated exterior parts to reduce costs. The material also boasts high weather resistance and high optical transparency. Mazda utilizes this material for exterior components such as front grilles.
Reduction of weight in automotive components using prepreg compression molding (PCM) technology
PCM is used in CFRP mass-production technology, and bio-based polycarbonate resin has characteristics such as allowing it to be used for high-cycle molding, superior surface quality, and automation, and the material can be used in general-purpose hydraulic press molding. The manufacturer exhibited a Hyundai trunk lid, which was made of the material.
The group displayed a number of plastic components that are targeted at the automotive industry. For example, the manufacturer demonstrated how it can reduce the weight of seat frames by using long glass fiber mat reinforced thermoplastic resin and structural components made of long glass fiber reinforced polypropylene and high hardness polycarbonate resin, as well as reducing the weight of automotive components by using carbon fiber sheet molding compounds (C-SMC).
*PC: polycarbonate, PCM: prepreg compression molding, CFRP: carbon fiber reinforced plastics, PP:polypropylene, C-SMC: carbon fiber sheet molding compounds
|Mazda’s bio-based polycarbonate external decorative components
Display panel: Bio-based polycarbonate DURABIO
|Weight reduction of automotive components using prepreg compression molding technology
Display panel: Weight reduction of automotive components using prepreg compression molding technology
Mitsui Chemical: General-purpose thermoplastic resin, engineering plastics, thermosetting resin, etc.
PCT LED in-vehicle interior light
The PCT LED in-vehicle interior light is made of heat resistant polyester resin, making it highly resistant to high temperatures. It also possesses low discoloration and water absorption properties, and is superior in terms of long-term reliability. The material is expected to be used for LED-related products.
PP injection foam material
Superior injection foam molding technology is used to reduce weight and heat loss through effective thermal management, increasing fuel efficiency.
Polyolefin-based materials such as transparent polyamide products, thermoplastic polyamide, denatured polyamide 6T, reinforced polypropylene, and polymethylpentene were exhibited. Mold materials for thermosetting resin such as polyurethane and unsaturated polyester were also displayed.
*PCT: Polycyclohexylenedimethylene terephthalate, PP: polypropylene
|PCT LED in-vehicle room light
Display panel: High heat-resistance polyester (PCT)
|PP injection foam material
Display panel: Injection foam material
Teijin Group: Polycarbonate resin grading, composite external components
Concept car using polycarbonate grading
Teijin exhibited a concept car fully utilizing its polycarbonate grading, the lineup of which the company has been actively expanding.
All-composite door module
Teijin used its original high-performance materials, engineering technology, and molding technology to create a lightweight, strong, multi-material composite (using C-SMC, etc.) door module with optimal design freedom.
Various molds using SMC, automotive nonwoven fabrics, and artificial leather.
*PC: polycarbonate, C-SMC: carbon fiber sheet molding compounds
|Concept car using polycarbonate grading||Fully-composite door module|
Kaneka: Polypropylene foam, engineering plastics-based mold materials, decorative sheets, etc.
Polypropylene foam components
With parts using noise controling polypropylene foam, the material itself can reduce unpleasant rubbing sounds that occur when driving, improving in-vehicle comfort. Polypropylene foam also helps reduce weight.
External parts using engineering plastics-based mold materials
Thermosetting resin for interior paint, high-texture decorative sheets, etc.
Thermosetting resin for interior paint, high-texture decorative sheets, etc.
*PP: polypropylene, PC: polycarbonate, PET: polyethylene terephthalate
|Molds for noise control polypropylene foam||External parts made from engineering plastics-based mold materials|
New grades, etc.: Sumitomo Chemical, Toray, Kuraray, DuPont, Daicel-Evonik, etc.
Sumitomo Chemical: General-purpose thermoplastic resins such as PP and PMMA, super engineering plastics including PES and LCP
Scratch-resistant black acrylic resin film
Scratch-resistant black acrylic resin film can be used for unpainted parts after injection molding, since the material itself is colored. Compared to general painted parts, the material has superior scratch resistance and can be repolished, making it ideal for exterior components.
Automotive components using short glass fiber reinforced polypropylene
Intake manifolds and accelerator pedals made from short glass fiber reinforced polypropylene were on display. These components originally used short glass fiber reinforced polyamide, which has been replaced by long glass fiber reinforced polypropylene to reduce weight and cost. At this year’s show, the manufacturer exhibited products made from short glass fiber reinforced polypropylene. This may be due to improvements made in the strength of the material, but it remains an improved material from the standpoint of reduced weight and cost.
LCP molds for EGR valves, high-rigidity and tough PMMA glazing, wavelength selective polycarbonate for sensors, heterogeneous wood adhesive, aliphatic polycarbonate, halogen-free flame-retardant elastomers, etc.
*PP: polypropylene, PA: polyamide, PMMA: polymethyl methacrylate, PES: polyethersulfone, LCP: liquid crystal polymer, PC: polycarbonate
|Scratch-resistant black acrylic resin film
Display panel: Scratch resistant gloss black PMMA Sumipex FJ series
|Automotive components made from short glass fiber reinforced polypropylene
Display panel: High-concentration glass fiber reinforced polypropylene
Toray: Fibers, resins (primarily engineering plastics), films (PET, etc.), carbon fiber products, etc.
Super flexible polypropylene ducts
The super flexible polypropylene duct uses polypropylene developed based on Toray’s unique nanoalloy technology to achieve a world-class elastic modulus of 1,200 MPa or less. The material can maintain its strength at 1700℃×1,000 hr (dry heat) or 150℃×1,000 hr (LLC) environments. The material also supports suction blow molding, making it possible for use in manufacturing turbo ducts or piping.
Transparent TPC (Thermoplastic polyester elastomer) molds
The material has high heat resistance, fade resistance, and weather resistance. Being highly transparent, it can be brightly colored. The material can also be thermally welded with hard resins such as ABS or PC (bi-color molding).
C-SMC molds, artificial leather, various components using engineering plastics, etc.
*PET: polyethylene terephthalate, PPS: polyphenylene sulfide, TPC: thermoplastic copolyester, ABS resin: acrylonitrile butadiene styrene copolymer resin, PC: polycarbonate, C-SMC: carbon fiber sheet molding compounds
|Super flexible PPS ducts
Display panel: Super flexible PPS grades
|Transparent TPC molds
Display panel: Thermoplastic polyester elastomer
Kuraray: Heat-resistant polyamide resin (PA9T), gas-barrier resin (EVOH, PA9T), etc.
PA9T power module case
Power module cases for EVs and HVs primarily use PPS, which has high heat resistance and electrical properties. PA9T allows the material has a heat resistance similar to PPS and has a smaller specific gravity, making it possible to reduce weight.
Intercoolers serve as auxiliary equipment for internal combustion engines with forced induction, as well as heat exchangers to help cool down the air that becomes hot during the compression cycle. PA9T’s heat resistance and gasoline-resistance, as well as its strength make the material well-suited for this purpose.
Other automotive functional components such as gears made from PA9T and various tubes using PA9T and EVOH.
*PA9T: polyamide 9T, EVOH: ethylene-vinylalcohol copolymer, PPS: polyphenylene sulfide
|PA9T power module case||PA9T intercooler tanks|
DuPont: Various polyamide, PBT, TPC, etc.
Timing belt covers using silent PA66
Silent PA66 consists of polyamide 66 with additives to reduce noise. The material can replace metal parts to reduce component weight and minimize noise caused by the reduction in weight.
Lightweight resin body mount vulcanization adhesion
PA66, rubber, and metal composite components are bonded via vulcanization during molding. Replacing metal parts with resin can help reduce weight and improve productivity by eliminating press processing and welding.
High heat resistant PA66 functional components, replacing various piping for cooling tubes with resin, upgraded anti-tracking grade, next-generational automotive adhesives, etc.
|Timing belt cover made from silent PA66
Display panel: Reducing noise of automotive components
|Vulcanization of lightweight resin body mounts
Display panel: Vulcanization of lightweight resin body mounts
Daicel-Evonik: PA12, transparent PA, PEEK, PMMA, etc.
Various PA12-based tubes
Tubes utilizing PA12’s elasticity and anti-kink properties are used in fueling and cooling. In situations where PA12 lacks the barrier properties necessary due to the fluid contained in the tubes or the usage environment, PA6T, PA9T, and EVOH are stacked. These tubes were conventionally made of metal, but replacing them with resin tubes helps reduce weight.
Carbon fiber cloth-reinforced PEEK hybrid molds
As can be seen in the image to the lower right, carbon fiber cloth is impregnated with PA to make pre-preg sheets, which are inserted into molds, upon which other resins (PA) are later formed to make hybrid molds. The molding manufacturer is Yakiguma Co., Ltd. Current molds use PA, but Yakiguma plans to manufacture molds using PEEK from July 2019. High-strength CF-reinforced PEEK is expensive, but using the material selectively in places where strength is required can help combat increasing mold processing costs.
Metal/plastic composite component adhesives, polymethacrylimide foaming materials, thermoplastic composites, etc.
*PA12: polyamide 12, PEEK: polyether ether ketone, PMMA: polymethyl methacrylate, EVOH: ethylene vinyl alcohol copolymer resin, CF: carbon fiber
|Various PA12-based tubes||Carbon fiber cloth-reinforced PEEK hybrid molds|
EMS-CHEMIE (Japan): Assorted polyamide product families
|High-heat resistant polyamide|
High heat resistant polyamide “Grivory high heat resistant HT”
Grivory is a PA6T-based copolymer that possesses superior properties under high temperatures in comparison to other general polyamides. It boasts high-strength and high rigidity with a high load deflection temperature, as well as good chemical resistance.
The company also exhibited various reinforced-grade molds based on general PA6 and 66 as well as heat resistant PPA, elastic PA12, and transparent PA.
*PA6T: polyamide 6T, PPA: polyphthalamide
Riken Technos: Compound products (primarily elastomers) and film materials
Lineup of elastomers and molds
Riken Technos provides a range of elastomer products to meet the needs of its customers (lower left image). The company also exhibited how its materials are used in various types of automotive components based on their oil and heat resistance requirements (lower right image).
High heat-resistant and flame-retardant PP (polypropylene) colgate compounds, decorative film for vacuum pressure forming, etc.
|Lineup of thermoplastic elastomers (TPE)||Automotive components made from TPE|
Ministry of the Environment: NCV project
Nanocellulose fibers (CNF) are a next-generation plant-based material that is lightweight with high strength and a high elastic modulus. They are expected to be used in a wide range of applications, with research and development actively underway. The Ministry of the Environment’s NCV (Nano Cellulose Vehicle) project is a consortium composed of 22 industry, academia, and government organizations, led by Kyoto University as the representative organization. The consortium is working on product development of materials, components, automobile parts, etc. using CNF, conducting performance evaluations at various stages, and evaluations and verifications of the effects on reducing CO2. The consortium aims to exhibit a final prototype vehicle at the Tokyo Motor Show in the fall of 2019.
The Ministry of the Environment exhibited components such as engine hoods (CNF paper/epoxy resin) at its booth. Additionally, Toyota Auto Body and Asahi Kasei’s CNF reinforced plastic was also on display.
|Engine hood (CNF paper/epoxy resin)
(Ministry of the Environment exhibition)
|CNF-reinforced polypropylene and wood powder-reinforced polypropylene
(Toyota Auto Body exhibition)
Plastic reinforcement materials: Nitto Boseki, Shin-Etsu Chemical
Nitto Boseki: Various glass fibersspan
Flat fibers (low warpage molding glass fiber)
Standard glass fibers have a circular cross-section, but this glass fiber has an irregular, oval-shaped cross-section. The material suppresses warping and twisting in molds and is used for products for which even the slightest amount of distortion cannot be allowed. The material is a crystalline engineering plastic such as PBT (polybutylene terephthalate) and is expected to be used in materials with molds that can easily become warped or twisted. The company also exhibited a roadmap for increasing the performance of flat fibers.
Low dielectric constant and low dielectric loss tangent glass fibers that will be of great importance in the 5G era, thermoplastic semipreg (thermoplastic sheet made from roving cloth coated with resin), etc.
|Low warpage glass fiber (flat fibers)||Increased performance of flat fibers|
Shin-Etsu Chemical/Shin-Etsu Polymer: Low dielectric materials, etc.
Ultra-low dielectric quartz cloth
Ultra-low dielectric quartz cloth, which is optimal for the 5G era, is shown in the explanatory panel to have far smaller dielectric properties than other materials. Used as laminate base materials, the cloth can be used as reinforcement for materials such as epoxy resin and to create dielectric substrates. However, it’s important that the utilized resin also have low dielectric properties, and so the company is currently engaged in the development of a low dielectric resin.
Fluorine-based heat dissipation materials, vision control film, high sliding compounds, silicone-acrylic copolymer resin, high heat resistant and high pressure resistant sealing material for power devices.
|Ultra-low dielectric quartz cloth||Low dielectric materials/quartz cloth explanatory panel|
Analysis of plastics: Mitsui Chemical Analysis & Consulting Service, Nissan Arc
Mitsui Chemical Analysis & Consulting Service: Analysis support for weight reduction
The company held a panel exhibition and provided documentation on its analysis and evaluation technology for weight reduction, batteries, durability, and recycling.
Analysis support for automobile weight reduction
Mitsui Chemical Analysis & Consulting Service analyzes the dispersion of composites as metal substitutes, conducts interface observations, observes the bonding state of resin and metal interfaces, and analyzes the elastic modulus temperature dependence to help reduce weight.
Visualization of polymer surfaces and internal structures
The company exhibited its expertise in visualization technology (visualization of the phase separation structure through staining, element distribution, composition/functional group distribution, and elastic modulus distribution).
Analysis of fuel cells and lithium-ion rechargeable batteries.
|Analysis support for automobile weight reduction||Visualization of polymer surfaces and internal structures|
Nissan Arc: Analysis of dissimilar material bonding and welding structures
The company exhibited its analysis of lithium-ion rechargeable batteries and all-solid-state batteries. It held a panel exhibition on its analysis technology to improve the quality of dissimilar material bonding.
State analysis of metal-resin junction parts
The company provided examples of its analysis and the key points in the expression of bonding strength in metal-resin junction parts, and analysis and verification of a PPS-Al joint product.
Analysis of ultrasonic welding structure and welding strength through the observation of the bonding interface
The company was able to analyze the mechanism of how welding strength decreases, in products with different shapes, in ultrasonic welding using 40% GF reinforced polypropylene.
Analysis of the dispersion structure of CNF composite materials, analysis of the crystallinity of forming conditions affecting the welding strength, etc.
*PPS: polyphenylene sulfide, Al: alluminum, GF: glass fibers, CNF: nanocellulose fibers
|Bonded state analysis of metal and resin parts||Analysis of ultrasonic welding structure and welding strength through the observation of the bonding interface|
JSAE, Lightweighting, plastic, Plastic Injection molding, CFRP, Wheel, Radiator Grille, Interior Lighting, Molding, Door Panel, Intake Manifold, Inter Cooler, Duct, tube, power module case, timing belt cover, body mount, engine hood
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