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.
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It can also be used for vehicle interior parts.
A claimed 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% 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%.
In contrast to current petroleum-based polypropylene plastics, the new bioplastic also has comparatively higher rigidity, resulting in thinner moulds 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-moulding equipment.
Mazda will continue its research and development in this area for the next several years, with any new advances to be employed in its own products.
The newly-developed bioplastic is made of 88% corn and 12% petroleum.
Mainly using corn-based polylactic acids, Nishikawa Rubber, Hiroshima and Kinki Universities focused their efforts on developing a new nucleating agent for crystallisation and a compatibiliser 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 Revitalisation” programme, which began in 2004.
The joint research has the goals of fostering new industry, creating new business and revitalising regional economies in Japan.
The new bioplastic consortium project partners are Hiroshima University, Nishikawa Rubber, Western Hiroshima Prefecture Industrial Research Institute, GP Daikyo Corporation, Japan Steel Works, Kinki University School of Engineering, Nishikawa Kasei, National Research Institute of Brewing, Yasuhara Chemical, MANAC and Mazda Motor Corporation. The consortium consists 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 GP Daikyo Corporation are at the centre 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 organisations – 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 utilising any advances we achieve to make better products for our customers.”
2006 is the final year of the Mazda Momentum mid-term management plan. Apart from profit goals, a key measure of the plan is to strengthen research and development efforts.
Mazda will exhibit vehicle interior parts made with the newly-developed bioplastic at the Automotive Engineering Exposition at the Japan Society of Automotive Engineering (JASE) Annual Congress, in Yokohama from 24 May.
