Initial samples were a bit too flexible, Korczynski recalls, but this was overcome with some minor design changes that added stiffness and, today, after 18 months on the market, the GEP power-distribution box is meeting all performance expectations – even in off-road service on the frozen North Slope of Alaska.

In parallel, Asahi Kasei will introduce its solvent-based recycling process for the first time in Europe. By applying dissolution recycling, high-quality PA 66 can be obtained from process scraps and post-consumer-recycled (PCR) materials such as airbags.

The company will also present its comprehensive solutions for establishing a sustainable life cycle for PA 66. In the field of chemical recycling, the company works with Japanese partner company Microwave Chemical, utilizing a microwave process to depolymerize automotive airbags and other PA 66–based parts and directly obtain the monomers hexamethylenediamine (HMD) and adipic acid (ADA). Currently undergoing trials, the process is expected to achieve high yields with low energy consumption. The monomers obtained can then be used to manufacture new PA 66.

The Japanese resin supplier will highlight polymers that support sustainability, comfort and performance in automobiles at the plastics-focused trade show in southern Germany.

At Fakuma, Asahi Kasei also will show multilayer cooling pipes that do not require an adhesive layer. These two-layer pipes employ the company’s Leona polyamide (PA) on the outside and Xyron mPPE on the inside. This product offers excellent bending properties, hydrolysis resistance, and low ion elution properties.

Bonding to the polypropylene (PP) core layer is possible in the same or separate injection molding step. The strong chemical bonding between all layers eliminates the need for additional adhesive layers. Asahi Kasei's new SEBS contributes to reducing the total number of materials, simplifying the manufacturing process, and improving the recyclability of interior components.

Balancing sustainability and functionality without sacrificing cost-competitiveness is a major issue for car manufacturers. To tackle this challenge, Asahi Kasei is currently developing a thermoplastic styrene block copolymer (SEBS) grade for automotive interior surfaces, which require good haptics and soft touch. Conventional approaches use different materials and production technologies for the skin, foam, and core layers in automotive instrument panels, door panels, armrests, or center consoles. The new SEBS material is suitable for both skin and foam layers, which can be molded in one step by utilizing a core back injection molding process.

Japanese technology company Asahi Kasei will exhibit its range of diversified material solutions at Fakuma 2024 from Oct. 15 to 19 in Friedrichshafen, Germany. Highlights include polymers for thermal management applications in EVs, a novel thermoplastic elastomer for improved recyclability of automotive interior parts, and a cellulose nanofiber composite for high-performance 3D printing.

GEP grew out of Precision Cable Assemblies, which started in business some 30 years ago, producing wire and cable for the automotive and truck industry. GEP was formed about 8 years ago to make and market other electrical products like the power-distribution box. "We cater to the mid-market," explains Rich Horky, President. "We’re structured to deliver the customization and rapid-product development that larger competitors can’t provide. Our customers expect us to be innovative and responsive and we appreciate suppliers, like Clariant, that exhibit those same qualities."

A novel transparent polymer reportedly outperforms incumbents such as polycarbonate and acrylic in automotive head-mounted displays. Image courtesy of Asahi Kasei/Business Wire.

From automotive head-up displays to head-mounted displays and smart glasses, requirements related to the weight and design of optical devices have become increasingly demanding. Asahi Kasei’s transparent AZP polymer features almost zero birefringence, overcoming the challenges of conventional transparent polymers in applications with polarizing light. Its superior processability compared to glass enables the large-scale production of injection-molded optical components that fulfill demanding customer requirements.

"The problem with most toughened nylons," says Robert Wick, Clariant Specialty Compounding Product Manager, "is that they tend to develop a swirled or mottled surface during the injection-molding process as a side-effect of the impact modifying additives. This would be unacceptable to GEP and so we suggested RENOL® 6608LLT, an impact-modified nylon 66 that is formulated to minimize that effect."

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and a proud dachshund owner.

Asahi Kasei will also showcase a bio-based and biodegradable cellulose nano fiber (CNF) at Fakuma. This material is made from cotton linter and features high heat resistance and a network-forming capability. CNF-reinforced PA exhibits thixotropic behavior, making it highly suitable for 3D-printing applications requiring dimensional accuracy, a smooth appearance, and mechanical performance. Furthermore, CNF exhibits superior material recyclability compared to glass fibers.

At the battery island, the company will showcase Xyron modified polyphenylene ether (mPPE) featuring high non-halogenic flame retardance and low ion elution properties. This material is suitable for thermal management applications in EV batteries.

Muttenz, March 26, 2014 - Clariant, a world leader in Specialty Chemicals, today announced it is supplying a special Nylon 66 compound for a molded power distribution box manufactured by GEP Power Products, Milwaukee, Wisconsin, USA. The company supplies standard and custom electrical components to some of the world’s leading manufacturers of trucks, buses and off-road vehicles. Brands like FreightLiner, Thomas, John Deere and International rely on GEP for cost effective products and custom engineered solutions that perform in harsh environments that are typical of transportation and outdoor power applications. When they needed a plastic material with superior low-temperature impact resistance and durability, good dimensional stability and uniform surface finish, they turned to Clariant Specialty Compounding.

A dual-layer polyamide/mPPE cooling pipe for EV battery thermal management offers excellent bending properties, hydrolysis resistance, and low ion elution properties. Image courtesy of Asahi Kasei/Business Wire.

"We were trying to develop an enclosure to protect an electrical fuse block," explains Jacek "Jack" Korczynski, GEP’s Vice President – Design Development. "Because this device is normally installed on the underside of large commercial vehicles, it can be subject to terrible abuse in extreme heat and cold. We test these boxes by freezing them to -40°C and firing 3/4-inch rocks and gravel at them, so we knew we needed a really tough plastic and asked Clariant for their recommendation."

Clariant Masterbatches’ specialty compounding business is structured to formulate and compound a wide-range of engineering grade thermoplastic resins, reinforcements and additives, in a wide variety of colors, to meet demanding application requirements for companies like GEP Power Products. Clariant specialty compounding experts draw on decades of experience with resins, colorants and additives to deliver an ideal solution, whether it is a standard product or a custom compound formulated to meet unique application requirements.

Asahi Kasei will present its materials and solutions in three different areas: Compact & Safe EV Batteries, Improved Connectivity & Lightweighting, and Sustainable Material Life Cycle at its location in hall B5, booth 5319.