Sustainability

Thermal insulation

Compatibility with exhaust gas regulations

"Gasoline tank cover" to reduce volatile fuel

Gasoline-fueled vehicles inevitably leak gasoline vapor, which is raised as one of the causes of environmental pollution. Therefore, Japan and other countries are carrying out measures (evaporative emission regulations) to reduce the amount of gasoline vapor that escapes from the tank. To tackle this issue, we developed a tank cover that prevents vapor leaking from the gasoline tank.

Characteristics

■What is a gasoline tank cover?

It is a cover that insulates the gasoline tank to prevent the tank temperature from rising.

■Thermal insulation

Our product uses P·E-LITE (foamed polyethylene), which demonstrates greater thermal insulation compared to the more commonly used polypropylene foam beads (EPP).

 

■Form superiority

The cover can be vacuum formed or bent to fit the shape of the tank for a better finish.

Lightweight

Compatibility with CO2 emission regulations

"Rear door trim" made lighter with large-scale injection molds

Improvements to resin foaming technologies have enabled us to produce lighter rear door trims, which are large-scale injection molded articles. We have succeeded in making them lighter than the previously used polypropylene-molded articles while maintaining the same strength and precision.

Characteristics

■Achieving both lightness and rigidity with large-scale injection molding technologies

After the foamed resin is injected, the core back process* is applied to the die to expand the gas inside. This causes the foam to line the surface of the die, making it thicker and lighter.
This makes it possible to create a structure comprised of solid surface layers and a foam layer (in the middle). It furthermore increases the thickness of the plate, thereby ensuring lightness and rigidity.

*Core back
A method used during foam injection molding, where the volume of the die cavity is increased to expand the foam bubbles and create a high magnification foam-molded article.

Lightweight

Compatibility with CO2 emission regulations

"Air intake hose" made lighter with thermoplastic olefinic elastomer

The intake hose requires a level of flexibility that can withstand the engine' s vibrations at engine room temperature. Vulcanized rubber (EPDM) has commonly been used, but we are currently making a switch-over to thermoplastic polyolefin elastomer to make the product more lightweight.

Characteristics

■About the air intake hose

An intake hose that carries air from outside to the engine.

■Effect on weight

■Thermoplastic polyolefin elastomer (TPO)

A material produced by physically mixing a polymer with plasticity and a polymer with elasticity.
The material can be used for regular injection molding and is also recyclable.

■Keeping down manufacturing energy

Producing vulcanized rubber requires a vulcanization reaction to occur within the die, necessitating high temperatures and a lengthy molding cycle. However, thermoplastic polyolefin elastomer is formed by cooling plasticized material inside the die. The die temperature during the molding process therefore remains low, which keeps down manufacturing energy and CO2 emissions during the manufacturing process.

Comfort

Thermal insulation and sound absorption improved with dual structure

Twin Composite Duct

A cylindrical duct that conducts air that is generated from the air conditioner of an automobile to the inside of vehicle's passenger compartment (the air blow-off port). Conventionally, a polyethylene blow-molded product was used. However, to meet the demand for improved fuel efficiency, a further decrease in weight and improved thermal insulation were required. We developed the "Twin Composite Duct," structured with double layers consisting of fiber and foam. The weight dropped to approximately half of that of the conventional product, thermal insulation improved to approximately 60%, sound absorption improved to reduce blower noise from the air conditioner, and further, dropping of dew condensation was reduced.

Development item: Twin composite duct. fiber + Firing PF 2 layer sheet.Weight reduction: Down by about 50% compared with the current level.

Building & Construction related products

Energy saving

Building heat insulator that can achieve both heat insulation and incombustibility

THERMAX RW

Recently, the demand for heat insulation materials has increased because of increasing interest in energy saving at residences; the demand for heat insulators for buildings that can achieve both heat insulation and incombustibility has also increased due to frequent large-scale fires. We developed THERMAX RW to respond to this demand. THERMAX RW is a rigid polyisocyanurate (PIR) foam board that prevents fire from entering inside due to a surface char layer formed by the isocyanurate structure; THERMAX RW has extremely high incombustibility even when burning on a burner at the temperature of 1200°C for 5 minutes as well as excellent thermal insulation performance.

Picture of the material

Clean

Low-VOC, heat insulation and light shielding sheet

PureCell 'CELL SHADE'

PureCell "CELL SHADE" is a heat insulation and light shielding sheet made from the low-VOC and eco-friendly foam material PureCell. It excels in thermal resistance and light stability, and has self-adhesive and shock absorption properties as well. With these properties utilized, the surface strength of CELL SHADE is enhanced further by being laminated with PET film. It provides heat insulation and light shielding from outside air if put on window glasses, and therefore has an effect on indoor temperature control (thermal insulation).

Ultraviolet cut in the summer, adiabatic effect in the winter
Perform air conditioning using renewable energy

Clean

Developed version of 'U-Poly Pipe' that utilizes natural energy

Spiral heat exchanger for geothermal heat

Heat Exchange Equipment That Utilizes Geothermal System is a system that performs air conditioning and snow melting by utilizing stable heat (approximately 15 centi degree) 10 m to 100 m underground. "U-Poly Pipe" is a system used for air conditioning by exchanging liquid in the pipes installed underground with geothermal heat. The system utilizes natural energy, and thereby achieves low-consumption power.


Implementation at the same time as pile construction shortens construction period

Buried Work Condition

Further, the "Spiral Heat Exchange Equipment" which was developed based on the "U-Poly Pipe" shortens construction periods and reduces cost through the installation of spiral underground tubes when pile-driving, a part of foundation work, is done. The amount of heat exchange per depth unit of spiral tube is approximately three times greater than when using conventional U-Poly Pipe. The efficiency of heat dissipation and collecting is drastically improved.


Comparison of Heat Exchange Performance

Heat exchange amount 3 times. Increase heat dissipation and heat extraction efficiency
Use to vibration proof / sound proof of construction heavy machinery. Control 10dB Driving amplitude.

Comfort

Anti-vibration mat

CELLDAMPER

CELLDAMPER is a foamed polyurethane elastomer developed for use as an anti-vibration material to reduce oscillation. It provides excellent anti-vibration, and its production process includes no silicone or sulfur. It is a clean product with a low environmental load. Among other things, CELLDAMPER is an eco-friendly anti-vibration mat. Large-scale construction generates diverse types of oscillation that continue for a long period of time, which is likely to be an annoyance to others in the neighborhood. Accordingly, countermeasures against noise or vibration source should be taken at construction sites by improving heavy machinery and reducing noise, among other things. The CELLDAMPER mat effectively reduces oscillation just by spreading it out under iron plates at the site. It can reduce running vibration caused by heavy machine by 10 dB. This product is used as anti-vibration material on heliports, roof-top decks, and so on, as well as with equipment and automobiles that generate oscillation.


Material expansion photo

Benefits

  • Vibration reduction due to an excellent damping effect
  • Long-term performance due to low compressive set
  • Clean material without silicone or sulfur
  • Suitable to anywhere because of no rubber odor
  • Cleared flame retardant regulations in each field.

Composite Materials

Energy saving

Composite with excellence in heat insulation, processability and flexibility

Flexible aerogel

Aerogel is a dried porous gel with low density and high porosity, which is notably weak as a simple substance. Therefore, impregnating a nonwoven fabric base material with it or the like is required for commercialization, as a heat insulation material, due to weak points such as gel falling (powder falling) during use and insufficient heat insulation. Aerogel becomes an excellent product featuring extremely rare powder falling, high heat insulation, processability and flexibility by making a composite (filling in cell) with a special foamed body with a skin layer having a fine cell structure. Aerogel is expected to be utilized in various fields such as automobiles and construction materials in the future.

Material expansion photo of FOLEC Double-sided Tape

Clean

Eco-friendly with no chemical foaming agent used

FOLEC Double-sided Tape

FOLEC is a micro-celled clean roll-sheet product manufactured by INOAC's original foaming technology without using a chemical foaming agent. FOLEC Double-sided Tape is produced using FOLEC as the base material, and therefore provides excellent dust-proofing, water-proofing, and shock absorption. It will lead to a reduction of the chemical substances used and never breed* chemicals even when used for a long period of time, because it does not contain a chemical foaming agent.

*Breed: phenomenon of chemical substances oozing out to the surface.

No use of chemical substances. VOC Generation amount 132ppm.

Sustainability