Automotive Applications

 

Clean Energy Applications

Asahi Kasei in Automotive

Mobility has always been vital to human beings. Whether it be walking, riding horses, taking trains, or driving cars, mobility is based on the technology around us. And because this technology has changed drastically in the last decade, we are here to propose new solutions to the industry.

 

 

Automotive Exterior

DURANATETM (HDI-based polyisocyanate): body paint additives

DURANATETM is an HDI-based product with excellent weatherability, which is supplied worldwide in a broad spectrum of types and grades. Its outstanding properties and performance make it a class-leader in weather-resistant paints and coatings, printing inks, adhesives, pressure sensitive adhesives, resins, elastomers, and electric materials for automotive, architectural, electronic, industrial, and many other fields of application.

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DURANOLTM (polycarbonatediol): body paint additives

DURANOLTM is a high performance polyol which provides high flexibility, excellent durability, abrasion resistance, chemical resistance and better appearance for automotive exterior coatings.

In terms of processbility, DURANOLTM has a good solubility to various solvents and low viscosity character, especially the liquid type. Due to these features, DURANOLTM contributes to reducing the amounts of solvents in both solvent-borne and water-borne coatings. DURANOLTM is the choice for Green Technology.

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Asahi Kasei Aluminium Paste: body paint raw materials

“For Designs that shine…” a palette of brilliance and sparkle, glint and gleam, light and shade, nuance and tone.

Asahi Kasei Aluminium Paste provides a broad range of metallic pigments, which differentiate in brightness, sparkle, smoothness, flip-flop, hiding-power, and chemical resistance. We are the global leader in terms of high design grades and particle treatment technology for highly distinctive and pleasing coated surface optical effects and designs.

Through our advanced technology, we respond to the expanding and diverse demands of today’s market.

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Automotive Interior

ELTAS (polyester, nylon spunbond synthetic continuous-filament Nonwovens): sheet skin lining

ELTAS is used in automotive applications such as backing cloth for seats, due to its light weight, high degree of elasticity, superiority in low load elasticity based on polymer blend technology, and outstanding track record in Japan.

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DURANOLTM (polycarbonatediol): polyurethane raw material

DURANOLTM is a high performance polyol which provides excellent durability for car interior parts, while optimizing softness and toughness.
This Duranol-based polyurethane has excellent hydrolysis resistance, chemical resistance and abrasion resistance, thus contributing to improved durability of car sheets and interior parts.

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TENACTM (POM) - Lightweight material with the world's lowest VOC emission class

TENACTM is the brand name of Asahi Kasei's polyacetal (POM) product group. The Japanese technology group is the only POM manufacturer to produce both homopolymers and copolymers. The engineering plastic is characterized, above all, by its dimensional stability, chemical resistance, ease of molding and extremely low emissions and is used in a large number of applications – including especially interior fittings in the automotive sector.

The material's high brightness metallic-colored grades make it possible to have a good appearance without using paint. This material is used in automotive interior parts such as inside door handles due to its good appearance and low emission characteristics. Eliminating the painting process also contributes to the reduction of production costs and environmental load.

Its various mechanical usages, and the durability of ultra-high viscosity homopolymer grades allow us to replace metal carrier plates, while improving the product characteristics and life-spans. In addition, reduction of thickness and weight with this grade provides the flexibility of product designs.

Due to its direct impact on passenger safety and comfort, the issue of in-vehicle air quality is becoming increasingly important in the automotive industry. In this context, the reduction of VOCs (Volatile Organic Compounds) significantly contributes to an improvement of the cabin air quality. VOCs are carbon-based gases that can evaporate from plastic materials into the air at room temperature, especially in newly produced cars. In closed environments, these gases can lead to discomfort and health issues, such as headaches or nausea.

Especially China – the world’s biggest automotive market – is addressing this issue by tightening the government’s GB regulations (“Guobiao” – “National Standards”), which regulate the air quality in the vehicle as well as the allowed level of VOCs. Therefore, VOC requirements by the automobile manufacturers worldwide have become increasingly stricter in the recent years.

Asahi Kasei – a diversified global supplier of materials and technologies that contribute to the overall safety and comfort of vehicles – provides OEMs with solutions to this challenge. First and foremost with the company’s TENAC™-C Z4520 copolymer polyacetal (POM) resin. Low VOC grades are widely used in interior parts, such as seat belt retractors, buckles and clips.

TENAC™-C Z4520 has been manufactured at the plant in Mizushima, Japan, since 2004, and at Asahi Kasei POM Zhangjiagang Co., Ltd., a subsidiary in China, since 2014. Widely acknowledged to provide the world’s lowest VOC emission level in the industry, the special TENACTM grade has been adopted around the globe as material for automobile interiors, for example for clips and lumbar support. In addition, it is also used for office equipment.

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THERMYLENE® (polypropylene compounds, PP-GF) - Glass-reinforced polypropylene for advanced lightweight solutions

Thermylene represents our family of specialty chemically coupled glass reinforced polypropylenes (PP). When chemical coupling technology is applied to glass fiber reinforced polypropylene, significant improvements are seen across a number of key physical attributes. The enhanced properties of these polymers yield an extremely attractive cost/performance balance when compared to traditional engineering thermoplastics.

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LEONATM (PA 66) - Lightweight material with class-A surface appearance

Polyamide 66 is one of the most important engineering plastics in the world due to its strength, heat-, oil-, and abraision resistance, and workability.

Asahi Kasei is market leader for PA 66 in Japan, and one of only four fully integrated PA 66 manufacturers worldwide. The LEONA 90G series is a semi-aromatic glass-fiber reinforced PA66/6I material with excellent surface appearance and high mechanical strength. Though filled with 60 percent of glass fiber, its Class A surface makes it possible to omit the whole painting process, thereby saving time and costs. Additionally, LEONA 90G brings the enormous advantage during the injection process of being able to mold at a lower mold temperature than is the case with competitors’ materials.

As the newest development following the LEONA 90G series, Asahi Kasei introduced the LEONA SG material. It is characterized by its superior strength, stiffness and impact with higher creep resistance long term. This is combined with a higher flowability, a better dimensional stability, lower warpage and lower water absorption. The material also contributes to an excellent gloss of injection moulded parts. Therefore, it is perfectly suited as replacement for metal parts – whereby weight is reduced.

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Automotive Battery

Hipore (wet process lithium-ion battery separator)

Hipore™ is a high-performance microporous polyolefin flat membrane. With its wide range of thicknesses and highly uniform and microscopic pores, it is widely used as a separa-tor in lithium-ion batteries.

The wet-process separator Hipore™ is used in automotive lithium-ion batteries, but also for consumer electronics, such as smartphones or portable music players. Its high porosity enables an outstanding liquid holding capacity, while its high puncture strength contributes to an enhanced safety and reliability.

Asahi Kasei is the world’s leading manufacturer and supplier of lithium-ion battery separators.

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Celgard (dry process lithium-ion battery separator)

Asahi Kasei's group company Celgard offers products for a variety of battery separator applications that balance the competing demands of EDV performance criteria, including safety, chemical and dimensional stability, and cycle life.

Celgard® Traditional Trilayer lithium ion battery separators with medium porosity and Celgard® H-Series lithium ion battery separators with high porosity are microporous trilayer membranes consisting of polypropylene outer layers and a polyethylene inner layer.

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XYRONTM (modified PPE): Lightweight material with excellent electrical properties and UL94 V-0 flame retardance

XYRON™ – the brand name of Asahi Kasei’s mPPE – is an engineering plastic with very unique properties, created by blending with other resins such as polystyrene (PS), polyamide (PA), polypropylene (PP), polyphenylene sulfide (PPS) or other polymeric materials. The modification of PPE to mPPE can be realized in different locations, for example in Thailand or the USA.

Applications for XYRON are to be found to a large extent in the automotive sector. Thanks to its low density – the lowest among engineering plastics – mPPE is suitable for a wide range of lightweight components, that are used, for example, for relay blocks, hood panels and brackets. However, concerning the current period of upheaval in the automotive sector, XYRON™ is especially used in the context of structural battery parts in the field of e-mobility. In this regard, the material contributes to a compact and weight saving battery design, at the same time leading to more efficiency as well as safety.

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SunForceTM (modified PPE particle foam): Unique particle foam with UL94 V-0 flame retardance

The automotive industry is facing serious challenges, as requirements regarding safety and CO2 emissions are getting increasingly tighter. Lithium-ion batteries are an essential component for the electrification of vehicles. As lithium-ion batteries show their full performance only at a stable temperature, both heating and cooling units are installed to the automotive battery pack, especially for PHEVs (plug-in hybrid electric vehicles) and BEVs (battery electric vehicle). However, creating the right temperature environment for the battery consumes a significant amount of energy, so an optimized thermal management of battery packs will become increasingly important. At the same time, safety issues such as fire protection and crash behavior stand on top position at the OEMs' agenda.

Asahi Kasei has developed SunForce™ – a particle foam based on the engineering plastic m-PPE (modified polyphenylene ether) – as a solution to these challenges. Compared to standard foams made of polystyrene or polyolefin, the use of m-PPE equips this foamed material with unique properties, opening new doors for applications in thermal management and fire protection. The material is certified with UL 94 V-0 (Standard for Safety of Flammability of Plastic Materials for Parts in Devices and Appliances) fire protection class by the Underwriters Laboratories safety certification organization and thus contributes to an overall product safety.

SunForce™ is the first-of-its-kind material certified with the UL94 V-0 standard. In addition to this outstanding flame retardancy, the material provides superior heat insulation properties while at the same time functions as a lightweight shock-absorbing material for automotive battery packs. The aforementioned properties and features allow functions and applications fields beyond those of conventional foams. The material is suitable for applications in automotive battery packs, lightweight shock absorbers, sandwich composite cores with carbon fiber, as well as for thermal insulation applications.

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Engine

LEONATM (polyamide 66 based compounds)

While the automotive industry turns towards electric motors, internal combustion engines will continue to dominate the market, especially in developing countries. Our LEONA product portfolio fully matches to ICE related applications requirements, and widely enjoys a very high reputation from automotive manufacturers and parts manufacturers.

  • LEONA 14G series:

Standard glass-fiber reinforced PA66 material with excellent high strength, fatigue strength, creep resistance and heat aging resistance. Major applications include cylinder head covers, torque rods, engine mounts, bush and knocking sensor housing.

  • LEONA 53G series:

Glass-fiber reinforced PA66/PA612 material with low water absorption, hydrolysis resistance and calcium chloride resistance. Major applications include radiator tanks, cooling pipes, and thermos valves.

  • LEONA Durelia series:

Glass-fiber reinforced PA66 materials with further improved long-term heat resistance to be used in the high temperature range of 150C to 230C. Major applications include turbo ducts, turbo cooling pipes, and intercooler tanks.

  • LEONA BG series:

Glass-fiber reinforced PA610 containing plant-derived component with low water absorption, hydrolysis resistance and calcium chlorides resistance. Major applications include radiator tanks and oil pumps.

  • LEONA high performance sliding series:

PA66/PTFE alloy material with improved significantly low friction coefficient and wear resistance. This series was developed for chain guides and various gear applications.

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THERMYLENE® (polypropylene compounds): fan shrouds, fan blades, air cleaner boxes and other under-the-hood parts

Thermylene represents our family of specialty chemically coupled glass reinforced polypropylenes (PP). When chemical coupling technology is applied to glass fiber reinforced polypropylene, significant improvements are seen across a number of key physical attributes. The enhanced properties of these polymers yield an extremely attractive cost/performance balance when compared to traditional engineering thermoplastics.

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System

In-Car Communication (echo and noise canceller technology)
Asahi Kasei DSP products support stress free conversations between the front seats and rear seats in passenger cars. Asahi Kasei’s In-car Communication solution not only provides high quality sound, but also robustness to changes in the cabin environment caused by opening and closing of windows, doors and hatchbacks.

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Hands-free communication
Asahi Kasei’s high-performance audio DSP products have over 15 years of market presence in worldwide automotive markets. Asahi Kasei offers innovative solutions complying with international automotive quality assurance while fulfilling the latest industry standards such as Era-Glonass.

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IR Sensor
Asahi Kasei takes gas sensing to another level with its cutting-edge IR sensor. Asahi Kasei offers the world’s smallest IR sensor while maintaining the highest sensitivity in the market, allowing users to adapt low power light sources to conserve energy.

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Green Hydrogen

Alkaline Water Electrolyser System

Asahi Kasei launched an alkaline water electrolyser system which transforms power from renewable energy sources into green hydrogen. In combination with captured CO2 from industrial emissions, the hydrogen can further be transformed into alternative fuels such as green methane, green methanol, green diesel etc.

Asahi Kasei is a leading company in the fields of ion exchange membranes and chlor-alkali electrolysis, and is developing water electrolyser technologies leveraging many years of experience in the chlor-alkali electrolyser business. Asahi Kasei's water electrolyser system can be scaled-up and has high energy efficiency. With this technology, Asahi Kasei contributes to the reduction of carbon footprints in the fields of transportation, power generation, etc. and provides effective solutions to energy transition.

 

PV (Photovoltaic)

XYRONTM (modified PPE resin): PV junction box / connector
XYRON (modified polyphenylene ether, or "mPPE") is an engineering plastic with very unique properties, which is used as a polymer alloy in combination with other materials such as PS, PA, PP, PPS. As the 2nd largest manufacturer, we are able to provide reliable products to our customers all over the world. We offer the best grades for PV application to enhance product safety with its high heat aging (RTI: relative thermal index), electric resistance (CTI: comparative tracking index), cold impact, hydrolysis resistance and halogen-free flammability.

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LEONATM (PA66 compounds): PV connector

Polyamide 66 is one of the most important engineering plastics in the world due to its strength, heat-, oil-, and abrasion resistance, and workability. LEONA specialty grade is suitable for PV connector parts especially those requiring super-tough properties such as connector nuts.

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Rechargeable Battery

Hipore (wet process lithium-ion battery separator)

Hipore is Asahi Kasei’s polyolefin flat-film membrane, used in a wide range of high-technology fields, such as lithium ion battery separators.
Flat-film membranes look like plastic films, but are actually filled with microscopic pores. The Hipore is a high-performance microporous film membrane with a wide range of thicknesses and highly uniform pores.

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Celgard (dry process lithium-ion battery separator)

Celgard separators are used in a broad range of energy storage applications including rechargeable lithium-ion batteries, disposable lithium batteries and specialty energy storage technologies.
Celgard's microporous membrane separators provide specific benefits ideal for Electric Drive Vehicle (EDV) applications. We understand how characteristics such as strength, resistance, chemical permeability, uniformity and other factors can affect the development of efficient, high-performance separator products. Our solutions deliver unique advantages for safety and optimal combinations of energy and power performance in a wide variety of lithium-ion cell designs for EDV systems.

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Coreless current sensor

Asahi Kasei has developed the world's smallest coreless current sensors. Asahi Kasei’s current sensors achieve high accuracy of less than 1% and response time of less than 1 microsecond, allowing users to develop sufficient and extremely effective applications.

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