Lightweight Molded Foam Door Trims with High Impact-resistance

TOYOTA BOSHOKU CORPORATION

Outline

This door trim utilizes Toyota Boshoku’s high impact-resistant plastic,
a plastic material featuring world-class impact resistance. Our foam
molding technologies enable us to create a door trim that reduces weight by approximately 20% compared to conventional base materials while maintaining high impact resistance. As weight lightening of vehicle,
can improve fuel economy and reduce CO2 emissions. It can realize a
decarbonized society through challenge enhancement of technology and expand sales.

Description

“Lightweight Molded Foam Door Trims with High Impact-resistance” is door trim resin material based on the world-class lightweight technology.
The point is taking a material design method as the countermeasure against decline of the impact resistance due to the weight reduction, which results in the high robustness. Developed nano-order-controlled base material showing the salami structure(※) as an impact resistance enhancer and used it at foam-molded door trim. (The Salami Structure: Type of phase structure structured from multiple materials. About the salami structure, there are few reports in the world at this time. By giving the salami structure into the material, the impact strength is incredibly improved. It derived from the resemblance to the cross-section of salami in food.) A high foam ratio injection molding is necessary to achieve the target stiffness. And to put to practical use, development of method is also necessary. To combine the salami structure and a high foam ratio injection, it can be compatible with lightweight and impact resistance.
Currently, it is continuing to develop the material to cost reduction and to process for the sales expansion.