Automotive Trunk Spacer/Tool Box
	Brand Owner: Nihon Tokushu Toryo Co., Ltd Designer: Sekisui Plastics Co., Ltd Machinery Manufacturer: Sekisui Plastics Co., Ltd Materials: Sekisui Plastics Co., Ltd Molder: Sekisui Plastics Gunma Co., Ltd Moldmaker: Sekisui Plastics Gunma Co., Ltd
Company Entering Design - Materials: Sekisui Plastics Co., Ltd Product Description: A new automotive trunk spacer / tool box was designed utilizing a new moldable foam bead material. The new foam material is a hybrid PS/PO (polystyrene/polyolefin) composition. Similar parts today are made from other materials/methods; however the properties of the new hybrid foam (higher compression and flexural strength, fire reducing) allow its use at lighter weight/density. Existing hybrid foam materials do not exhibit sufficient heat resistance for automotive interior applications. However, this new hybrid composition utilizes a different olefin which provides for the heat resistance and also improved physical and flammability properties over other hybrid foam grades and other materials used for such automotive trunk spacer / tool box type parts. This part exhibits the following advantages over previous materials: a) Weight reduction – approximately 20% or 1/4lb based upon only reduction in density from 2.25pcf to 1.78pcf. Additional weight reduction obtained via part redesign utilizing superior properties of the new foam b) Size / volume reduction – part volume decreased via part redesign c) Cost reduction – approximately 20-25% cost reduction mainly due to weight reduction, other costs (processing, molding, etc.) are similar to previous material d) Functionality due to durability, acoustic (sound deadening) and intricate shape (easily possible via molding process)
Why is the product innovative? A combination of factors contributes to make the new Automotive Trunk Spacer / Tool Box innovative. Solid plastic materials, such as thermoformed parts, have previously been used in this application; however, they suffer from relatively heavy weight. Molded foams were introduced, and EPP (expanded polypropylene has gained popularity due to its light weight, ease in molding into intricate shapes, dimensional stability, durability and cost. Existing hybrid PS/PO molded foam compositions, such as Piocelan-O, have been utilized in certain automotive applications like energy absorption and sub-carpet spacers, because of weight reduction, increase in strength and dimensional tolerance improvements over EPP. However, it lacks the thermal resistance at low foam densities to withstand the heat exposure requirements for interiors in today’s automobile industry. Piocelan-T, moldable foam bead material, was developed after extensive research efforts utilizing similar PS/PO hybrid technology as previous grades like Piocelan-O and Piocelan-S. However, it is composed of a higher heat olefin component which affords increased elevated temperature stability along with higher compressive, flexural and tensile strength and the ability to meet stringent flammability standards of the automotive industry. The newly designed part incorporates the following improvements over previous similar parts: a) Part weight is reduced approximately 20%, resulting in lower vehicular mass contributing to fuel economy and the environment b) Part size is reduced via design utilizing the higher strength properties of the new PS/PO hybrid foam, contributing to more spacious interior in the automobile c) Part cost is reduced through lower mass of foam material needed due to lower foam density and reduced part size. Further, the PS/PO foam material is able to be molded with any desired grain or texture surface for more appealing appearance and improved noise reduction performance. It is “colored” black and also meets the needed flammability requirements for automotive interior parts. It is designed so that it easily holds tools, a tire-jack and other accessories securely and without rattling or noise generation. Besides the benefit to the environment from the improved fuel efficiency, the foam part of PS/PO hybrid foam material is recyclable under the PS (polystyrene) classification symbol, 6. It can be reprocessed into other foam parts, and also reprocessed and used in solid applications such as injection molded or extruded articles.
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