Toray Industries, Sumitomo Chemical and other agencies in Japan have jointly launched an electric vehicle prototype that is approximately 40% lighter than existing similar vehicles and has achieved greater mileage Potential breakthrough. The car can carry three people.
Almost the entire body is made of carbon fiber reinforced plastic (CFRP). In fact, except for the battery and drive system, ItoP cars are basically free of metal and glass. The weight of the plastic single-shell structure is 147 kg (half the weight of the steel frame), and the entire vehicle body weighs 850 kg, of which 47% are plastic. The car was developed in collaboration with the University of Tokyo as part of a project supported by the Japanese government.
The body of this car is made of carbon fiber reinforced thermosetting resin composite material developed by Toray, which is about 50% lighter than similar metal structures. This design is said to prevent stress from being concentrated on any one component. It has been reported that the car's body durability has been improved by about 200% compared to conventional cars using carbon fiber reinforced plastics.
The thermosetting resin developed by Toray has good flexibility. As a composite matrix material, it also combines the sliding crosslinkability of polyrotaxane. Polyrotaxane is a mechanical interlocking molecule composed of strings and rings. There are multiple rings on the molecular axis. Two large end groups prevent the rings from falling off.
Sumitomo Chemical has developed a plastic windshield made of a mixture of two resins. Sumitomo Chemical is a company that produces acrylic resins and polycarbonate resins.
In addition, the suspension system uses the same polyrotaxane crosslinked CFRP coils, leaf springs and suspension arms. Mass production of the car may have to wait until 2028.
Impact-resistant crushing box is made of modified glass fiber polyamide
Polyrotaxane is also used in impact-resistant "shred boxes" made of glass fiber reinforced polyamide resin and placed on the front and sides of vehicles. The battery case and base are also made of carbon fiber reinforced material, which achieves a 30% weight reduction and improves impact resistance.