Utilization of Isocyanate-based Binders in Recycling of Automotive Composite Headliners

Recycling of automotive headliners has been carried out by grinding them and forming composites with isocyanate-based binders. Rear-seat-to-back-window trim panels have been prepared. Composites with 80-90 wt.% of scrap manufactured in plant runs exhibited mechanical properties comparable to the existing products. The rear-seat-to-back-window trim panel composites were produced by compression molding ground scrap-binder pre-preg sheets for 30 seconds at moderate temperatures, with no postcuring. This is the best indication that the utilization of the scrap headliners is both technically and economically sound. The plant runs have confirmed the feasibility of production of large parts with relatively complex shapes such as headliners. The adhesion of decorative materials to the composite substrates was excellent. More importantly, the decorative materials can be applied to the substrate during compression molding without any additional adhesive.