B1-02 Development of recycled- and bio-plastic composites utilizing dry-defibrated post-consumer paper and garment waste
Principal Investigator
SEKI Shunichi (SEIKO EPSON CORPORATION)
Research and Development Overview
We aim to establish fiber composite material technology and molding technology that will resolve the mechanical performance issues that recycled- and bioplastics have, and to put them into practical use in society.
The goal is to realize material technology and molding processes that can achieve both the elastic modulus and impact resistance of recycled- and bio-plastics and ensure moldability through fiber composite technology. In addition, we will build a value chain that connects the results of technological development to social implementation, derive traceability requirements for the widespread use of these composite materials, and reflect them in the Plastics Information Distribution Platform (PLA-NETJ).
Specific initiatives include characterizing composite materials using advanced analytical techniques such as synchrotron radiation and simulation technologies for fiber-reinforced plastics. This involves selecting the optimal types of plastics and fiber materials to improve the performance of composite materials, and deriving optimal conditions such as fiber length, thickness, aspect ratio, density, dispersibility, orientation, and compatibility with resins. In addition, the mixing and pelletizing conditions and injection molding conditions for product implementation will be derived. Using these technological development results, we will establish systems for raw material procurement, pellet manufacturing, and quality assurance, and conduct demonstrations with our own products, as well as automotive and home appliance components.
As a contribution to the SIP, we will establish the foundation for composite materials and molding technologies that achieve the performance of recycled- and bio-plastics required for a wide range of products, and provide them as core technologies for the circular economy system. Furthermore, through product demonstration activities for this technology, we will promote the social implementation of the system by putting into practice a manufactures-recyclers collaboration model. In addition, we will accumulate a database that includes quality data such as the physical properties of recycled- and bio-plastics and composite materials, as well as historical data on recycling, thereby contributing to the construction of the PLA-NETJ system. By utilizing tracer technology for material properties obtained during this material development process and informatics technology, we will contribute to the development of a platform for improving and visualizing circularity in this SIP.
Progress and Achievements
Based on the research and development system established at the Co-creation Research Institute within Tohoku University's Green Cross Tech Research Center, we promoted the establishment of fundamental technologies for fiber-reinforced plastics materials and molding processes by fully utilizing advanced analytical and evaluation technologies, material informatics and process informatics.
First, we investigated the effects of compounding virgin polypropylene (PP) with natural fibers such as cellulose and general-purpose fibers used in clothing. By designing the composite with separate functions for the added fibers, we were able to exceed the target mechanical properties of ABS resin and achieve elastic modulus and impact strength that meet the target range set by the Japan Automobile Manufacturers Association. In particular, the impact strength exceeded that of glass fiber reinforced resin, and in-situ observation using NanoTeras showed that the shape and length of the fibers were effective in increasing the strength.
Towards social implementation, we have begun concrete studies on application to automotive parts and home appliance parts, in addition to our own products. As for the X to Car model, we investigated the effects of fiber composites on various PPs (homo, random, and block), including recycled materials. We understood the differences in improvement effects depending on the type of PP and found that it is possible to improve properties to the elastic modulus and impact strength targets set by the Japan Automobile Manufacturers Association. Furthermore, to verify scale-up capabilities, we have introduced and commenced operation of the twin screw compounding extruder facility with a processing capacity of 100 kg/h.
We are continuing to explore fiber suppliers to build a value chain that will lead to social implementation, and to search for and consider co-creation with external compounders to expand pellet production.