Selection and Validation of a Bio-Waste-Based Composite Material with Thermoplastic Properties for Automotive Applications

Abstract

The European automotive sector has been going through deep changes lately. Besides the electrification of vehicles, OEMs are adapting to comply with the carbon neutrality goals of the continent and are being required to significantly increase the content of post-consumer recycled materials in all their products. The present work, which is the result of a 6-month research internship at Toyota Motor Europe, tackles two different initiatives that can increase the material circularity in the brand’s activities: the smell improvement of an ELV recycled PP grade to be used in vehicles’ interiors and the viability study of adopting a new household biowaste-based composite with thermoplastic properties in the material portfolio of the OEM. Injection moulding of material samples containing additives and smell reducing treatments were conducted, as well as smell tests and emissions tests. The results showed significant improvements on the smell of the ELV recycled PP grade tested, indicating the possibility of using the material in automotive interior parts. The biowaste- based composite was technically investigated, including compounding tests, injection moulding of samples, microscopic observation of structure, alongside with mechanical performance testing and evaluation of the sustainability benefits associated. Preliminary results showed a negative impact in mechanical performance by the addition of the composite material to PP resins, but still a possible adoption to benefit from the sustainable advantages of such material.