JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 45

Sustainable composite solution for new Toyota LQ concept car

The polyurethane composite offers a lightweight and
sustainable solution that is based on a combination
of Covestro's advanced Baypreg® F NF technology
and Toyota Boshoku's expertise in the use of kenaf
fibres. The new product is used in the LQ's door trim
panels.
(Source: Toyota)

Car component manufacturer Toyota Boshoku Corporation selected Covestro as partner to jointly develop a
new, particularly lightweight polyurethane composite material for Toyota Motor Corporation's new «LQ» electric concept car.
(Source: Toyota)

Main LQ specifications

Length/Width/Height
(metres)

4.53 / 1.84 / 1.48

Wheelbase (metres)

2.7

Occupancy

4

Powertrain

BEV (battery electric vehicle)

Vehicle weight (kg)

1,680

EV cruising range (km)

Approx. 300

"

interview

Hiroaki Ido,
Head of PUR Application Development for
Automotive Solutions Japan & Global Japanese
Transplants
Covestro's Innovation Center in Japan

JEC Composites Magazine: : How did the
project start? What was the initial target?

Hiroaki Ido: In 2018, Toyota Boshoku

High-tech materials
Lightweight materials will play an increasingly important role in future mobility. For
example, they will help to extend the range
of electric cars even further. As a provider
of material solutions, Covestro has a long
experience in the global automotive industry. This includes the market in Japan, where
Covestro's Innovation Centre has already
developed many sustainable solutions, for
instance components for low-density polyurethane foams. Toyota Boshoku Corporation, a car component manufacturer in the
Japanese Toyota Group, chose Covestro as
partner to jointly develop a new polyurethane composite material for the new electric

Light and stiff
The kenaf-fibre-reinforced polyurethane
foam composite is characterized by high
strength and a very low area density of less
than 1 kg/m2, making a door trim panel made of the foam 30% lighter than one
produced from conventional materials. The
lighter the material, the further the car can
travel on a single gas or battery charge. The
new composite material was developed in
close cooperation between Toyota Boshoku
and Covestro's recently renovated Japanese
Innovation Centre.

ration is an automotive interior Tier-1 supplier for Toyota.Covestro Japan joined the
new project when TB asked them to cooperate for the Toyota LQ door trim project in
March 2018. With the advanced technology,
we produced the door trim products for LQ
together with TB at the recently-renovated
Covestro Innovation Center in Japan.

Feature Automotive

nication platforms to provide the occupants
with information. The integrated lighting indicates if the car is in automated or manual
driving mode, and illuminates the floor beneath the passenger Yui is addressing.
The LED-lit dashboard uses organic
light-emitting diodes (OLED), a first at Toyota. The LQ also has a new air-purifying coating that was developed with Aisin Chemical
Co., Ltd. and Cataler Corporation.

The futuristic design includes a passenger
compartment that tapers sleekly towards
the front end. Yui sits right in the centre of
the dashboard, the "inside-out" lines of
which seem to connect the interior with
the exterior.

LQ concept car. The material is being used
in the door trim panels, where it makes its
world premiere in a Toyota model. Offering a lightweight and sustainable solution,
the material is based on a combination of
advanced Baypreg® F NF technology and
Toyota Boshoku's expertise in the use of kenaf fibres. Kenaf is a member of the hibiscus
family. It grows in regions such as South East
Asia, Bangladesh, India and Africa. The fibre,
which is obtained from the plant's bast fibres,
has recently attracted increasing attention as
a cost-effective alternative raw material with
good mechanical properties, including in the
automotive industry.

/ jec composites magazine

45

"More than 50% of the advanced
product consists of natural fibre"
(TB) focused on our new technology - Advanced Baypreg® F NF - as a lightweight
solution for the door trim of Toyota's new
concept car, the LQ.
After testing various materials, TB concluded that only our technology could achieve
their development target: an area density of
less than 1 kg/m2. Toyota Boshoku Corpo-

N°137 November - December 2020



JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020

Cover
Edito
“We can change the way we envision global shipping overall”
Contents
NEWS
In brief
Agenda
BUSINESS
Human ressources - Skills requirements in the composite materials sector – the French example
Startup - Make lightness and performance affordable without compromising the environment
Offshore - GWEC: Asia Pacific to become the largest offshore wind market by 2030
MANUFACTURING
Additive manufacturing - The METHOD platform expands to support more materials,applications, and markets
Automation - One-shot manufacturing of cylindrical lattice structures for satellite applications
Recycling - World’s first fully-recycled thermoplastic composite application in aerospace
Additive molding - From large-scale continuous thermoplastic composites to mass production
FEATURE AUTOMOTIVE - Is it possible to do better?
FRP - Fully coupled processstructure analysis for automotive center floor panel
Honeycomb - Composite materials for lighter vehicles
Additive manufacturing - Transforming composite production processes with FDM additive manufacturing
EV - All-composite EV wheel moves to next development phase with pilot production
Security - The world’s fastest armoured car
Natural fibre - Sustainable composite solution for new Toyota LQ concept car
SOLUTIONS
Defence - Drones as wingmen
City - Composites for tomorrow’s cities
Maintenance - Degradation mechanism and maintenance of GFRP hydrochloric acid storage tanks
TECHNOLOGY
Bonding - Adhesion properties of bonded composite-to-aluminium joints using peel tests
Inside the lab - The University of Southern Queensland - Centre for Future Materials
Method - Weight and cost reduction with double-double laminates
Index
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JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Cover
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 2
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Edito
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - “We can change the way we envision global shipping overall”
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 5
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Contents
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 7
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - In brief
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 9
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Agenda
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Human ressources - Skills requirements in the composite materials sector – the French example
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 12
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 13
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Startup - Make lightness and performance affordable without compromising the environment
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 15
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 16
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Offshore - GWEC: Asia Pacific to become the largest offshore wind market by 2030
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 18
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive manufacturing - The METHOD platform expands to support more materials,applications, and markets
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 20
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Automation - One-shot manufacturing of cylindrical lattice structures for satellite applications
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 22
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 23
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Recycling - World’s first fully-recycled thermoplastic composite application in aerospace
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 25
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 26
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive molding - From large-scale continuous thermoplastic composites to mass production
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 28
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 29
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - FRP - Fully coupled processstructure analysis for automotive center floor panel
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 31
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 32
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 33
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Honeycomb - Composite materials for lighter vehicles
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 35
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 36
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Additive manufacturing - Transforming composite production processes with FDM additive manufacturing
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 38
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - EV - All-composite EV wheel moves to next development phase with pilot production
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 40
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Security - The world’s fastest armoured car
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 42
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 43
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Natural fibre - Sustainable composite solution for new Toyota LQ concept car
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 45
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 46
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Defence - Drones as wingmen
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 48
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 49
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - City - Composites for tomorrow’s cities
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 51
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Maintenance - Degradation mechanism and maintenance of GFRP hydrochloric acid storage tanks
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 53
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Bonding - Adhesion properties of bonded composite-to-aluminium joints using peel tests
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 55
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 56
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 57
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 58
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 59
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 60
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 61
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Inside the lab - The University of Southern Queensland - Centre for Future Materials
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 63
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Method - Weight and cost reduction with double-double laminates
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 65
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 67
JEC COMPOSITES MAGAZINE - Issue #137 - November/December 2020 - 68
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