Feasibility study for recycling of JVC compact discs for use in the manufacturing of Motorola plastic housings

In a joint research project between JVC Kurihama R&D Center and Motorola Advanced Technology Center-Europe the recycling of JVC compact discs (CDs) for use in the manufacturing of Motorola plastic housings was developed and evaluated. Returned CDs, made out of polycarbonate (PC), can potentially be used to mold housings of electronic products, also made out of PC. Closing the PC loop is not only technically feasible, but also a gain for the environment, reducing the resource and energy consumption comparing virgin versus recycled PC. To allow returned CDs to be processed into plastic housings, CDs have to be decoated of the aluminum layer, the lacquer and the label ink in order to serve as input material for producing recycled PC. Then the clear CDs are crushed, blended with virgin PC and pelletized to obtain defined material properties. The JVC Kurihama R&D Center developed decoating methods for returned CDs, based on extensive trials using mechanical and chemical decoating techniques, resulting in clean CD parts. The material properties of the plastic recyclate was tested and specified. After evaluating the promising test results by JVC Kurihama R&D Center on the recycled PC material, the Motorola Advanced Technology Center-Europe decided to run a trial mold of an actual housing at a molder in Germany. A two-way mobile radio cover was molded with recycled CD material. The material properties of the original versus recycled resin were evaluated. The cover made with recycled CDs was put through an ALT (Accelerated Life Test), yielding in more information on the possibilities to use recycled material. The joint research project shows that a high tech product such as the CD can serve as a basis for housings of electronic and electrical equipment after its useful life. With a sophisticated technology the PC loop is closed, benefiting ecology and economy.