What INOAC can do for theautomotive industry
The history of the automotive industry in Japan stretches back over 100 years, but it has
been facing a major turning point in recent years.
Since the financial crisis following the bankruptcy of the Lehman Brothers, the global
economy has faced multiple crises, and the trade war between the US and China has
intensified this year. All of this has continued to greatly affect Japan’ s automotive industry.
A crucial challenge that automotive-related companies must take on in order to pave theway for the future of Japan’ s economy is to flexibly respond to external factors, such aschanging economic environments, and strive to achieve sustainable growth across theentire automotive industry. Aside from economic issues, the automotive industry must also
contend with environmental issues as represented by CO2 emission regulations.
As a manufacturing company with a division dedicated to automotive products, we at INOAC
believe it is our duty to be aware of how much our activities affect the earth’ s environment,
and at the same time, find a way to progress that is more in harmony with the environment.

Product name
Theme

“Gasoline tank cover” to reduce volatile fuelCompatibility with exhaust gas regulations

Keyword

Thermal insulation

Gasoline-fueled vehicles inevitably leak gasoline vapor, which is raised as one of thecauses of environmental pollution. Therefore, Japan and other countries are carrying out
measures (evaporative emission regulations) to reduce the amount of gasoline vapor thatescapes 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?
I t is a cover that insulates the gasoline tank to prevent the tanktemperature 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).
■ Measurement of surface temperature

Surface temperature (We promote the development of automotive components that are compatible withenvironmental regulations, such as those concerning CO2 emissions and exhaust gas.
Featured here are some of our products that are being used commercially.

Examples of environmentally compatible products 14038363432302826242220

Measurement method: The assessment
sample (material) was placed on a 60°Cplate and the surface temperature of theassessment sample was measured.
P・E-LITE
EPP℃)

0200

400
600
Time (sec)

800

Thermocouple(stuck onto the surface)
1000

Sample（150×150mm）
Connected to arecording instrument

Heated plate（160×160mm）*Representative values measured by our company

Rear door trim
Air intake hose

■Form superiority
The cover can be vacuum formed or bent to fit the shape of the tank for a better finish.
■Vacuum formed + injection molded product

Vacuum formed
P E-LITE
thermal insulator ・Injection molded
protective cover Polypropylene (PP)

Gasoline tank cover
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■ What INOAC can do for the automotive industry

Examples of environmentally compatible products 2
Product name
Theme

“Rear door trim” made lighter with large-scale injection molds

Compatibility with CO2 emission regulations

Keyword

Examples of environmentally compatible products 3
Product name

Lightweight

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

Theme“Air intake hose” made lighter with Thermoplastic
Olefinic Elastomer

Compatibility with CO2 emission regulations

KeywordLightweight

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

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

Characteristics

After the foamed resin is injected, the core back process* is applied to the die to expand thegas inside. This causes the foam to line the surface of the die, making it thicker and lighter.

■About the air intake hoseThis makes it possible to create a structure comprised of solid surface layers and afoam layer (in the middle). It furthermore increases the thickness of the plate, thereby
ensuring lightness and rigidity.
Cross-section
Solid layer

An intake hose that carries air from outside tothe engine.

■Effect on weight■Thermoplastic polyolefin elastomer(TPO)

350
300

Solid layer*Core backA 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.

Foaming agent

Product weight (g)Foam layer

315

250

25% lighter
235

200
150

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

100500EPDMTPO■ EPDM: vulcanized rubber■ TPO: thermoplastic polyolefin elastomer*Representative values measured by our company■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 dietemperature during the molding process therefore remains low, which keeps down
manufacturing energy and CO2 emissions during the manufacturing process.
Die expansion causes foam expansion

Initially filled thin

INOAC CSR REPORT 201914