Covestro: Post-consumer recycling polycarbonate/ABS f?r interior components of the Lexus ES used

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With the material "Bayblend T85X R35 CQ", Covestro supplies a polycarbonate/ABS blend with a proportion of 35 percent post-consumer recyclate (PCR) for selected interior components of the Lexus ES. The application is considered an early example of the use of a mechanically recycled plastic with a high PCR content in visible components of a premium vehicle.

The material is part of Covestro's circular intelligence portfolio and, according to the company, reduces the global warming possible compared to comparable fossil-based substitutes by around 25 percent, measured in CO₂ equivalents. The research takes place against the background of rising standards to recycling in vehicles and the expected regulatory standards in connection with the European End-of-Life Vehicle Ordinance (ELV).

The implementation was created in cooperation between Toyota Motor Corporation, Toyota Motor Kyushu, Kojima Industries Corporation and Covestro. The partners carried out extensive tests to demonstrate the suitability of the material to visible interior applications. The aim was to enable the integration of recycled material without restrictions on condition and performance standards.

According to Covestro, "Bayblend T85X R35 CQ" meets the durability, surface condition, dimensional stability and processability standards required to high-condition vehicle interiors. At the same time, the material can be integrated into existing manufacturing processes. In addition to pre-colored applications, the material is also suitable to lacquerable components and thus opens up possible uses both in the interior and in the exterior.

The integration of high proportions of post-consumer recyclates into visible premium components has so far been considered a technical challenge. With their consumption in the Lexus ES, the companies involved demonstrate the manufacturing feasibility of such concepts in series applications.

to the supply of recycled material, Covestro refers to certified and established sources of post-consumer plastics as well as its global production and supply network. This is to ensure consistent material condition and security of supply.

The consumption is part of Covestro's circular economy strategy. The company is continuously expanding its portfolio of recycled materials, including the recently introduced "RV line", which includes recycled plastics from end-of-life vehicles, to instance from headlight systems. The developments are intended to support vehicle manufacturers in meeting future recycling and recycling standards and at the same time meet standards to product condition and component performance.

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