Mazda devises corn-based plastic for auto interior parts
The new material is made mainly from corn and can be mass-produced, according to Mazda, which is planning to start commercial production within a few years.
Tokyo, Japan, May 11, 2006 - (JCN Newswire) - Mazda Motor Corporation has
announced that an industry-government-academia joint research project in
Hiroshima Prefecture, in which it is participating, has achieved an
improved exterior surface quality, high-strength, heat-resistant plastic
(bioplastic) made of natural materials. It can also be used for vehicle
interior parts. An automotive sector first, this new bioplastic is made
from natural materials and is carbon neutral because of the reduced amounts
of fossil fuels used to make it and the consequent lowered amount of carbon
dioxide (CO2) emissions.
This newly-developed bioplastic features is
stronger - it has three times the shock impact resistance along with 25
percent higher heat resistance when compared to contemporary bioplastics
used for items such as electrical appliances. In addition, it is made with
a fermentation process that includes natural materials such as fermented
starches and sugars which, compared with the process to make polypropylene,
reduces energy use by 30 percent. In contrast to current petroleum-based
polypropylene plastics, the new bioplastic also has comparatively higher
rigidity, resulting in thinner molds and fewer materials used. These
attributes hold great promise for better productivity in the mass
production of vehicle parts, since parts manufacture frequently involves
injection-molding equipment. Mazda will continue its research and
development in this area for the next several years, with any new advances
being employed in Mazda products.
Bioplastic
This
newly-developed bioplastic is made of 88 percent corn and 12 percent
petroleum. Mainly using corn-based polylactic acids, Nishikawa Rubber Co.
Ltd, Hiroshima and Kinki Universities focused their efforts on developing a
new nucleating agent for crystallization and a compatibilizer compound to
raise the strength and heat resistance of the new plastic, dramatically
increasing the amount of applications for automobile
manufacturing.
This research was the result of joint
industry-academia-government collaboration, promoted under the auspices of
the Japanese Ministry of Economy, Trade and Industry's (METI) "Consortium
R&D Projects for Regional Revitalization" program, which began in 2004. The
joint research conducted under this rubric has the goals of fostering new
industry, creating new business and revitalizing regional economies in
Japan.
The new bioplastic consortium project partners are Hiroshima
University, Nishikawa Rubber Co. Ltd., Western Hiroshima Prefecture
Industrial Research Institute, G.P. Daikyo Corporation, Japan Steel Works
Ltd., Kinki University School of Engineering, Nishikawa Kasei Co. Ltd.,
National Research Institute of Brewing, Yasuhara Chemical Co. Ltd., MANAC
Incorporated and Mazda Motor Corporation. This is a consortium consisting
of two universities, seven companies and two research
institutes.
Seita Kanai, senior managing executive officer in charge
of Mazda's R&D, said, "Mazda and G.P. Daikyo Corporation are at the center
of a world-class accumulation of automotive plastic module parts makers
here in the Hiroshima area. Based on our rich tradition of sake brewing in
this region, we've been accumulating fermentation biotechnology for a long
time and Hiroshima University, Nishikawa Rubber Company and the Western
Hiroshima Prefecture Industrial Research Institute - among other
organizations - have an extensive history of research into the practical
uses of biodegradable plastics than can be broken down by microorganisms.
In particular, great results have been achieved through joint international
research into lactic acid copolymers. So it's safe to say the Hiroshima
area is fertile ground in terms of research achievements. Together with our
regional partners over the next few years, Mazda intends to continue its
bioplastics research for the purpose of utilizing any advances we achieve
to make better products for our customers."
2006 marks the final
year of the Mazda Momentum mid-term management plan. Two of the plan's
goals were to achieve 100 billion yen in operating profit and a
net-debt-to-equity ratio of less than one hundred percent by the end of
fiscal year 2006; these were achieved one year earlier than projected.
Another key measure of the plan is to strengthen research and development
efforts. As a company that values its social contributions now and into the
future, Mazda will keep up its proactive technical research on eco-friendly
and safe products for its customers.
Mazda will exhibit vehicle interior parts made with the newly-developed
bioplastic in its booth at the Automotive Engineering Exposition at the
Japan Society of Automotive Engineering (JASE) Annual Congress, to be held
at the Pacifico Yokohama complex from May 24-26, 2006.
Notes:
1)
Carbon neutral
As an example, carbon neutral can be characterized as CO2
gases released during plant decomposition or combustion being absorbed
during the growth phase of photosynthesis, so any emitted CO2 gases are
offset and end up producing a negligible impact on CO2 levels in the
atmosphere.
2) Nucleating agents for crystallization
An additive
to stimulate crystallization
A "stimulus" nucleating agent added to
crystal acts as a catalyst and makes it easier to form the crystals.
Polylactic acid has properties which make for comparatively slower
crystallization when compared to other plastics and this negatively impacts
on production efficiency when molding bioplastics for car parts. Given this
factor, it is necessary to carry out the crystallization earlier by means
of a nucleating agent. When the molecular chain is arranged in a systematic
way, the plastic's strength is increased and its heat-resistant properties
are improved.
3) Compatibilizer
An additive is needed for a
material that has two or more different types of properties, and when
distributed uniformly, it improves the physical properties of the material.
It is necessary to mix the polylactic acids with a combination of
polylactic acid and an added element that is not chemically
compatible.
4) Lactic acid copolymers
This is a plastic material
derived by partly replacing some of the elements of polylactic acids with
other ingredients.
5) International collaboration
-Participating
organizations: Hiroshima University (the representative research
institute); University of Massachusetts and Tufts University (US);
University of Liege (Belgium), Zhejiang University (China).
-Research
content: The aforementioned research institutions worked together to
conduct research and development into lactic acid copolymers for general
use as well as use in medical treatments.