Toray develops technology recycling carbon fiber plastics, preserving strength and quality, enabling diverse nonwoven applications, reducing emissions, supporting sustainability.
Toray Industries, Inc., a global leader in advanced materials, has announced the development of a groundbreaking recycling technology capable of decomposing various carbon fiber reinforced plastics (CFRP) produced from thermosetting resins, while maintaining the inherent strength and surface integrity of the recovered fibers. Leveraging this innovative method, Toray has successfully created nonwoven fabrics using recycled carbon fibers, opening new possibilities for high-performance and decorative applications.
The company has begun supplying prototype samples to its clients, enabling them to explore and develop materials for a broad spectrum of sectors, including the automotive industry, construction, electrical and electronic devices, and daily consumer goods. Toray plans to work closely with its customers to conduct technical assessments and refine the materials according to specific application requirements, ensuring optimal performance and versatility.
CFRP materials are widely used in high-performance applications such as aerospace components and wind turbine structures. Recycling methods for CFRP are evolving rapidly, with chemical recycling processes increasingly used as reducing agents in steel furnaces. Additionally, technologies employing pyrolysis at elevated temperatures are being developed to recover fibers for reuse, particularly in injection molding applications. However, broadening the applicability of recycled carbon fibers requires advanced techniques capable of minimizing thermal damage, controlling residual resin content, and accommodating diverse CFRP waste types.
Toray applied its extensive expertise in organic synthesis and polymer chemistry to design a novel decomposition agent that effectively breaks down highly crosslinked, degradation-resistant thermosetting resins at lower temperatures than conventional recycling methods. Using this agent, Toray successfully decomposed CFRP waste originating from aircraft, wind turbines, automobiles, and other industrial sources. Remarkably, the recycled carbon fibers produced through this process retain over 95% of the single-fiber tensile strength of virgin carbon fiber derived from petroleum, making them suitable for high-performance applications.
Beyond performance benefits, this technology also contributes to environmental sustainability. Toray estimates that carbon dioxide emissions associated with this recycling method are less than half of those generated during the production of virgin carbon fiber. By combining performance retention with significant environmental benefits, Toray鈥檚 approach represents a major advancement in the circular economy for carbon fiber materials. The company aims to further develop the technology, optimize it for industrial-scale applications, and expand the range of materials and sectors that can benefit from high-quality recycled carbon fibers.
In summary, Toray鈥檚 innovative recycling technology not only enables the recovery of high-strength, high-quality carbon fibers but also supports diverse applications, reduces environmental impact, and encourages the wider adoption of recycled materials in advanced industrial sectors.
