In response to escalating demand across aerospace, energy and transport sectors, Toray Industries is scaling up its carbon-fibre composite materials business under the Torayca banner. The company has announced the development of a recycling technology that can decompose diverse carbon fiber reinforced plastics (CFRP) made from thermosetting resins while retaining the strength and surface quality of those fibers. The company drew on this technology to create a nonwoven fabric employing recycled carbon fibers.
CFRP applications include aircraft and wind turbines. Toray applied its accumulated expertise in organic synthesis and polymer polymerization to innovate a decomposition agent that breaks down degradation-resistant, three-dimensionally crosslinked thermosetting resins at lower temperatures than conventional methods. The recycled carbon fiber from this process retains over 95% of the single-fiber tensile strength of petroleum-derived virgin carbon fiber. Toray expects carbon dioxide emissions from this technology to be less than half those from manufacturing virgin carbon fiber.
The recycled carbon fibers exhibit controllable water dispersibility, allowing for the fabrication of uniform nonwoven structures as well as those with distinctive texture reminiscent of washi (traditional Japanese paper). This fabric combines the functionality of carbon fiber, including radio frequency shielding and thermal conductivity, with aesthetic appeal. This innovative fabric features in the interior and exterior components of a concept car that Mazda Motor Corporation exhibited at the Japan Mobility Show.
Toray developed its recycling technology as part of a fiscal 2024–2025 Ministry of the Environment program to promote establishment of a decarbonized and circular economy.
Source: www.toray.com
