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The recycling of cross-member composite (CMC) parts was studied using partial decrosslinking of the polyurethane (PUR) composite matrix by catalyzed glycolysis. The decrosslinked material, containing reactive OH and NH2 groups, was reacted with polymeric isocyanate in a molding operation to form a new composite product. In order to make the process economically feasible the smallest amounts of reactants (glycol, catalyst, isocyanate) were used in the process. The results of the laboratory study were verified in semi-pilot plant runs. The economic analysis showed that the process is feasible.

A method for recycling of mixed color automotive thermoplastic scrap into appearance automotive interior parts has been developed and shown to satisfy the following three requirements: 1) material performance 2) color appearance, and 3) economically sound. The technique developed is based on minimal separation of the colors into hues (groups of similar colors) and repigmenting to the desired color. The studies included computer formulations, laboratory verifications and plant runs. Plant runs were carried out to produce automotive interior doors (base level S-truck) with polypropylene (PP) regrind and B-pillar 325 parts with acrylonitrile-butadiene-styrene (ABS) regrind at the Delphi - Adrian plant. Two colors, ruby red and medium gray, were selected because they are the most difficult colors to match. The results of the plant runs demonstrated that color matching can be successfully achieved.

The recycling of polyurea-urethane (PUU) RIM materials, which are widely used in the automotive industry, was investigated. The process employed for the recycling PU-U RIM was based on the catalyzed chemical decrosslinking, using short chain diol as a reactant. The transesterification (decrosslinking reaction) was studied in the Haake mixer and twin screw extruder. The effect of various parameters (temperature, reactant/PU-U RIM ratio, rpm etc.), on the yield of liquid oligomers was determined. The resulting liquid oligomers were characterized using various analytical methods and used in the preparation of new products such as coatings, adhesives etc. The results showed that the catalyzed chemical decrosslinking of PU-U RIM can be a potential recycling method.