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Development of three-layer instrument panel crust recycling technology
Our soft instrument panel crust was composed of three layers: barrier layer (PP), cushion layer (foam PP), and skin layer (PVC). For efficient recycling, the different materials should be separated. Toyoda Gosei recycles the three-layer instrument panel crust by using material with the same nature (all olefin) and a multilayer plastic sorting device to separate the existing materials of different types that are produced in parallel. The materials were developed for effective, efficient separation of different material types to enhance recyclability by recovering the separated materials in highly pure form and mixing them in high concentrations.
Five processes are involved in the separation and sorting: crushing, air sorting, cleaning separation, air sorting, and plastic sorting. We established a high-purity, high-efficiency recycling system by developing and improving the key equipment, such as the cleaning separator (that separates multilayer plastics) and the hydro cyclone (that sorts mixed plastics). The improvements to the equipment result in successful recovery of about 70% of the plastic materials with a purity of 99.99 % or more. This technology has been developed through joint research with Hitachi, Ltd. |
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•Establishment of the recycling system for a variety of different types of crust ends that are generated during the instrument panel production process
•Improvement of the technology to separate and sort compound component materials for reuse in the original products |
•Product specifications and treatment process
•Technical points
(1) High-purity, high-recovery recycling technology
(•Cleaning separator •Hydro cyclone)
(2) Technology to apply recycled materials to products in high concentration
(•Crust compounding design •Injection, stamping, molding (ISM)
•Performance and purposes
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