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Technical Paper

Variation in Corrosion Resistance of Trivalent Chromate Coating Depending on Type of Zinc Plating Bath

2006-04-03
2006-01-1671
Trivalent chromate coating is replacing the conventional hexavalent chromate coating applied on zinc plating. Zinc plating uses one of three types of plating baths (zincate, cyanide and chloride) according to the characteristics required of subject parts. It has been recognized that trivalent chromate coating provides different corrosion resistance depending on the type of zinc plating bath used. Zinc plating with chromate coating were analyzed to clarify the cause of the corrosion resistance variation with the type of zinc plating bath. It has been revealed that the chromate coating thickness and the condition of top SiO2 layer vary with the type of zinc plating bath, resulting in corrosion resistance variation.
Technical Paper

The Development of Toyota Fantasy Print System

1998-09-29
982344
Recently, the demands of vehicle owners have become more diversified. This is particularly true in the paint appearance of the vehicle. Responding to these demands Toyota has developed an ink jet painting system, Toyota Fantasy Print System. This system can illustrate practically any picture which the customer desires. The system utilized a subtractive method of paint mixture which mixes or piles up these four permeable inks. The development of durable ink as well as equipment which can efficiently and effectively apply the ink onto the required contoured surface.
Journal Article

Reduction of Heat Loss and Improvement of Thermal Efficiency by Application of “Temperature Swing” Insulation to Direct-Injection Diesel Engines

2016-04-05
2016-01-0661
The reduction of the heat loss from the in-cylinder gas to the combustion chamber wall is one of the key technologies for improving the thermal efficiency of internal combustion engines. This paper describes an experimental verification of the “temperature swing” insulation concept, whereby the surface temperature of the combustion chamber wall follows that of the transient gas. First, we focus on the development of “temperature swing” insulation materials and structures with the thermo-physical properties of low thermal conductivity and low volumetric heat capacity. Heat flux measurements for the developed insulation coating show that a new insulation material formed from silica-reinforced porous anodized aluminum (SiRPA) offers both heat-rejecting properties and reliability in an internal combustion engine. Furthermore, a laser-induced phosphorescence technique was used to verify the temporal changes in the surface temperature of the developed insulation coating.
Technical Paper

Post PVC Sound Insulating Underbody coating

2002-03-04
2002-01-0293
Underbody coating is used to prevent chipping damage of the automobile underbody and wheel well. Multi-functional material that gives sound insulating properties is called sound insulating underbody coating. This paper describes the development of underbody coating material with powdered acrylic composition as an alternative to polyvinyl chloride resin. The new material also has better foaming properties. It is possible to ensure excellent sound insulating performance with thin film. This multi-functional underbody coating is the first application in the world with weight reduction and cost saving, and in a more environmentally acceptable manner.
Technical Paper

Metallic Powder Coating for Aluminum Wheels

2004-03-08
2004-01-1671
From the viewpoint of measures for environmental issues, the amount of solvents in paint for aluminum wheels needs to be minimized. Environmentally friendly powder coatings have been used widely for primer coating and clear coating, but there is no precedent for its use for base coating. This time, we optimized the condition of surface treatment of pigment and hardening behavior of constituent resin in the melting process and succeeded in developing a metallic powder coating for aluminum wheels that fulfills the appearance and the quality requirements of aluminum wheels.
Technical Paper

Material Consolidation for Automotive Interior and Exterior Parts through Development of a High Performance Material

1998-09-29
982410
Through a polymer design and precise morphology control, The Super Olefin Polymer, TSOP-1 and TSOP-5 were developed for the material consolidation of interior and exterior parts, respectively. Due to a good balance of TSOP performance, several conventional materials were consolidated into one material for each application. Accordingly, considerable amounts of weight reduction and cost savings have been obtained. In addition to the excellent recyclability of TSOP, the coated bumpers collected from the market were re-utilized through paint decomposition technology. The first dashboard construction, molded partially with foam-padded skin, was also realized. The current amount of TSOP used in a vehicle is about 30% of the total amount of plastic materials. Through the usage of TSOP, 70% of the material consolidation has been achieved.
Technical Paper

Hexagonal Cell Ceramic Substrates for Lower Emission and Backpressure

2008-04-14
2008-01-0805
Stringent emission regulations call for advanced catalyst substrates with thinner walls and higher cell density. However, substrates with higher cell density increase backpressure, thinner cell wall substrates have lower mechanical characteristics. Therefore we will focus on cell configurations that will show a positive effect on backpressure and emission performance. We found that hexagonal cells have a greater effect on emission and backpressure performance versus square or round cell configurations. This paper will describe in detail the advantage of hexagonal cell configuration versus round or square configurations with respect to the following features: 1 High Oxygen Storage Capacity (OSC) performance due to uniformity of the catalyst coating layer 2 Low backpressure due to the large hydraulic diameter of the catalyst cell 3 Quick light off characteristics due to efficient heat transfer and low thermal mass
Journal Article

Development of a Highly Anti-Corrosive Organic-Inorganic Hybrid Paint

2016-04-05
2016-01-0540
A highly anti-corrosive organic-inorganic hybrid paint for automotive steel parts has been developed. The inorganic component included in the paint is silicon dioxide (SiO2), which has the capability to passivate zinc. By application of the paint on a trivalent chromatetreated zinc-plated steel sheet or a trivalent chromate-treated zinc-nickel-plated steel sheet, high anti-corrosion protection can be provided to steel materials. Particularly in the case of application over a zinc-nickel-plated steel sheet, 0 mm corrosion depth after a cyclic corrosion test (CCT) of 450 cycles was demonstrated.
Journal Article

Development of Paint Booth: “New Paint Mist Collection Method”

2016-04-05
2016-01-1258
1 Inside a paint booth to spray paint on vehicle bodies, bumpers, and other parts (hereinafter referred to as “works”), air whose temperature and humidity are controlled by air-conditioner is supplied by blower fans through filters. Dust-eliminated and regulated air flow is sent downward from top to bottom (hereinafter referred to as “downflow”) in the painting booth. Conventionally, paint which does not adhere to work in spraying (hereinafter referred to as “paint mist”) is collected while flowing at a high speed through a slit opening called venturi scrubber in a mixture of air and water. However, this mist collecting system using venturi scrubber requires a large space with a large amount of pressure loss while consuming substantial energy. By radically changing the mist collecting principle, we developed a new compact system with less pressure loss aiming to reduce energy consumption by 40% in a half-size booth.
Technical Paper

Development of Instantaneous Temperature Measurement Technique for Combustion Chamber Surface and Verification of Temperature Swing Concept

2016-04-05
2016-01-0675
To improve the thermal efficiency of an internal combustion engine, the application of ceramics to heat loss reduction in the cylinders has been studied [1-2]. The approach taken has focused on the low heat conductivity and high heat resistance of the ceramic. However, since the heat capacity of the ceramic is so large, there is a problem in that the wall temperature increases during the combustion cycle. This leads to a decrease in the charging efficiency, as well as knocking in gasoline engines. To overcome these problems, the application of thermal insulation without raising the gas temperature during the intake stroke has been proposed [3-4]. As a means of achieving this, we developed a "temperature swing heat insulation coating" [5, 6, 7, 8, 9]. This reduces the heat flux from the combustion chamber into the cooling water by making the wall temperature follow the gas temperature as much as possible during the expansion and exhaust strokes.
Technical Paper

Development of High Chroma TiO2 Pigment

2006-04-03
2006-01-0753
Color design is playing a more important role recently when establishing automotive commercial value. High chroma TiO2 pigments which have less than 1/3 the aspect ratio of the current interfere pigments have been developed. Anatase type TiO2 pigments, which have high photo-catalytic activity can now also be used for automotive paints.
Technical Paper

Development of Anti Scratch Clear Coat

2008-04-14
2008-01-1461
“Anti-scratch performance” is the highest in customer's needs of paint. To achieve anti-acid and anti-scratch performance, we selected 2K-urethane because of a high degree of freedom in paint design. In addition, we have done a precise molecular design of the acrylic polyol and the isocyanate. As a result, “a highly durable, soft, fine-crosslinking paint film” was achieved, and “anti-scratch clear coat” that surpassed the current clear coats was developed.
Technical Paper

Application of Structural Color Technology for Automotive Paint

2005-04-11
2005-01-0617
Currently, to achieve the desired design in automotive paint, absorption pigments, such as organic pigments, are used in combination with brilliant pigments (ex. aluminum or mica etc.). However, many beautiful colors exist in the world, especially in the natural world. Until now, automotive paints have not been able to replicate those colors. In this project, by first analyzing the coloring principles of the natural world, we have focused on the development of a previously non-existent coloring technology (structural color). By combining this with nanostructure control technology, we have established a radically new coloring process enabling the design of hues, chromaticity and reflection intensity. This technology has tangible results, as new pigments are available for paint formulations.
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