Quality evaluation and development of automotive parts for the application of recycled materials to automotive interior and exterior parts
Principal Organization
Toyoda Gosei Co., Ltd.
Research and Development Overview
With the ELV (End-of-Life Vehicles) regulations in Europe and other initiatives, there is an urgent need to develop systems and plastic recycling technologies that support a circular economy.
This R&D project focuses on Polypropylene (PP), which accounts for approximately 60% of all plastic materials used in automobiles. We are promoting the development of materials and products with an increased ratio of recycled content. By evaluating product characteristics, processing properties, and reliability for interior and exterior components, we aim to build a circular economy through the development of automotive parts using recycled materials.
FY2026 Research Summary
- Review of FY2024 and FY2025
Regarding PP compounds mixed with recycled materials, it was determined that interior and exterior parts can satisfy initial performance requirements if their material properties align with the JAMA (Japan Automobile Manufacturers Association) target values for "Composite Reinforced PP (1)" and "Composite Reinforced PP (2)." - FY2026 Plan
To further expand the scope of recycled material application this fiscal year, we have added the "Console" - which corresponds to the JAMA target value "General-Purpose PP (1)" - to our target components to verify its suitability for production.
Figure 1. Examples of Automotive Interior PP Parts and Target Components for Evaluation
Evaluation Items
In applying recycled materials, we will focus on the following four evaluation items:
- Moldability:
Can a cycle time equivalent to virgin material be ensured in injection molding? Are there any changes in odor during molding or mold-releasing properties? - Appearance:
Are there any issues such as foreign particles or visual inconsistencies? - Impact Resistance:
Does it satisfy the performance standards required for each product? - Assemblability:
Does any defect occur during the assembly of the product?
Future Outlook
Automotive products are composed of various parts with different characteristics, such as general-purpose PP and composite reinforced PP. Therefore, we will verify the visual quality of the entire unit, remaining mindful of the consistency in texture and color with adjacent components.