Automotive interior systems manufacturer Toyota Boshoku (Tokyo / Japan; www.toyota-boshoku.com) and Toyota Central R&D Labshave developed technology to create a bio-based plastic alloy with high impact strength. The bioalloy is produced from PA 11, a 100% bio-based resin originating from plants and synthesised by castor oil as a raw material, and PP derived from petroleum-based resin. The performance of this high impact bioalloy is claimed to surpass that of polycarbonate alloys.

The improved impact strength has been achieved by controlling the phase structure of PP and PA 11 at the nano level through a “salami structure” dispersion. A reactive compatibiliser is added to the raw materials and a molten blended technology is carried out to lead to a chemical reaction between the raw materials.

By utilising the technology, the manufacturer has created a bioalloy claimed to have an impact strength 10 times greater than that of PP conventionally used in car interior decoration parts and 13 times greater than that of bio-based plastic (PP/PLA).

Potential applications include interior decoration parts such as automotive door trims, panels and as a collision energy absorber. Exterior automotive parts made from the resin, such as fenders and bumpers, can also be produced.