To make products, Tokai Chemical Industries uses proprietary processes derived from a variety technologies at the core of which are plastic molding and urethane foaming.
Urethane Mixing
- Soft, semi-hard and hard
- Flame-retarding, incombustible, super-heat resistant
- Energy-absorption, sound- absorption
Urethane Foaming
- Automatic weighing and injection system
- Composite foaming system with sawing
- Flashless, mold release agent free process
Stamping&TcPM Molding
- Sheet stamping
- Injection and press molding
- Low-pressure injection molding
- Laminating
Trimming & Welding
- Heat and cut trimming
- Ultrasonic welding
- Ultrasonic trimming
- Vibration welding
Powder Mixing
- PVC
- TPU
Pattern Molding
- Heat and cut trimming
- Ultrasonic welding
- Ultrasonic trimming
- Vibration welding
- Injection molding
Mold-Making
- Epoxy resin molds
- Nickel electrocasting molds
- Aluminum casting molds
This section introduces some of the molding processes that Tokai Chemical Industries uses.
Powder Slush Molding
Powder slush molding enables us to make large foamed urethane products with a high degree of freedom.
[ Features ]
- Produces high grade surfaces by faithfully transferring the grain patterns of real leather.
- Works with stitching and localized pattern changes to create diverse expressions.
- Can produce complicated large-size shapes.
- Can render leather super-soft.
[ Example Products ]
Safety pads, door trim, console, etc.
Urethane Foaming with Vacuum-Molded Surfacing
This process produces soft pads at the lowest cost possible.
[ Features ]
- Applicable with small lot production owing to the low cost of surface patterning molds.
- Good productivity because vacuum-molding has a short molding cycle.
- Can mold large works with thin walls.
- Pattern changes are easy because surface patterning molds are made of resin.
[ Example Products ]
Safety pads, cushion pads, glove box doors, etc.
Injection Molding
Injection molding is wisest choice for producing small soft products at low costs as soft material is injected and molded to form surfacing skins.
[ Features ]
- Best process for high turnout because the surfacing cycle is super fast.
- Foamed products feature high dimensional stability as skin thickness is kept constant.
- Applicable for multiple-cavity molding.
- Molds can be designed to add handles.
[ Example Products ]
Armrests, glove box doors, etc.
