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ThermHex Technology for Latest Prius Model

Lightweight Honeycomb Solution

Japanese automotive OEM Toyota has adopted an interior part using unique honeycomb material solution for its new hybrid model Prius PHV launched earlier this year. The solution, based on ThermHex thermoplastic honeycomb core technology developed by EconCore, is implemented in the trunk cover of the car. Due to its combination of strength and rigidity and optimized material performance, the ultra-low weight honeycomb delivers weight savings of 50 % as a core part inside the trunk cover compared to previous conventional material set-ups based on cardboard and metal.

The lightweight honeycomb solution, based on EconCore’s ThermHex technology, is implemented in the trunk cover of the car (© EconCore)

This specific trunk cover part was developed by Gifu Plastics Industry Co. from Japan together with its local automotive supplier partners. Gifu Plastic, a licensee of EconCore started out using the ThermHex process to make thermoplastic honeycomb products for packaging and logistics applications, achieving notable success in these areas. Recently Gifu Plastic has extended its portfolio to include automotive interiors.

“We are very pleased to see such a prominent leader in automotive innovation and responsibility moving forward with our honeycomb materials which have minimal weight and minimal environmental impact,” says Jochen Pflug, CEO of EconCore and inventor of the ThermHex technology. Pflug says the efficiency of the unique and patented continuous ThermHex process enables the naturally optimized honeycomb structure to be brought to more cost sensitive applications, ultimately saving natural resources by replacing heavier sub-optimal designs.

EconCore’s ThermHex technology is a continuous process for the production of thermoplastic honeycombs integrated with an in-line lamination of skin layers. Due to the efficient process, the resulting sandwich panels are not only exceptionally strong and lightweight but also very cost-effective. EconCore has licensed the technology to several companies operating within packaging, automotive, furniture, building and transportation markets. Furthermore, the versatility of the technology allows direct lamination of thermoplastic skins as well as other facing layers (including for instance composites and metal) onto the thermoplastic honeycomb core to offer lightweight sandwich panels suitable for different applications. The list of EconCore licensees is growing and includes, amongst others, Renolit Group, Gifu Plastic, Tata Steel, Röplast, ThermHex Waben GmbH, Fynotej and Wabash National.

Additional information
  • Published in Kunststoffe international 2017/08

    Lightweight Polymer Solar Panel

    Polyamide Honeycomb Technology

    Dupont's Zytel and Vizilon were materials of choice for the development of an ultra-light photovoltaic panel.   more

    EconCore N.V.

Company profile

EconCore N.V.

Ambachtenlaan 25
Tel.: +32 16 381060

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