Noise Reduction and Lightweight Design
Asahi Kasei Develops Polyamide Foam
Asahi Kasei Corp., Tokyo, Japan, is a fully integrated polyamide manufacturer who is able to produce PA 66 completely from monomer to compound. Based on this expertise, the company is currently developing a foam bead material based on polyamide. The material features the typical heat, chemical and oil resistant properties of polyamide, mixed with an outstanding rigidity or noise reducing quality – depending on the shape of the beads.
The so-called PA Foam consisting of round-shaped beads features a strong rigidity, making it an alternative material for aluminum and metal in structural applications, as well as for use for insulators, ducts, spacers, or other lightweight parts of the battery case of electrified vehicles.
Noise Reducing through C- and Macaroni-Shaped Beads
The foam bead material PA Foam with a C- or macaroni-shape provides noise insulation in addition to the typical polyamide properties. Possible applications can be found everywhere around the car, especially in the engine compartment. With Regulation No. 51-031 issued by the United Nations in 2016, the noise level emitted to the outside must be continuously reduced in newly manufactured vehicles.
Used for engine covers, it does not only contribute to lightweight, but also significantly reduces the radiating engine noise, making the car quieter in total. These noise reduction qualities of the foam also contribute to an enhanced comfort inside the car. The PA Foam can serve as insulation and reduction of noise radiating from the car itself, but also to reduce noise coming from the outside. Possible applications can be found in the roof and bonnet, but also in the seat and floor structure.
Foam beads made of polyamide can be processed in a steam molding process on standard polystyrene molding equipment. Furthermore, a significant reduction of resin for the production process can be achieved, contributing to an overall cost reduction.
Asahi Kasei Corporation
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