Researchers make non-recyclable flame-retardant EV composites recyclable

Korean researchers at the Korea Research Institute of Chemical Technology have created a recyclable flame-retardant composite material that could revolutionize electric vehicle manufacturing. Led by Drs. Jin Chul Kim, Ji-Eun Jeong, and Young-Jae Jin, the team developed a self-reinforced composite (SRC) fabrication method that simultaneously enhances processability, flame resistance, and recyclability by incorporating a low-cost, low-molecular-weight polyolefin additive.

This innovation enables the use of lightweight, recyclable components in next-generation mobility applications, such as electric vehicles, which have traditionally relied on nonrecyclable thermoset fiber-reinforced composites. Fiber-reinforced composites, known for their high flame resistance, are commonly used in automotive components and electronic circuit boards but cannot be melted and remolded once cured, leading to landfill or incineration.

The new additive allows the material to flow more easily during recycling, ensuring uniform distribution of flame-retardant particles and facilitating their removal. Notably, the composite achieved the highest flame-retardant rating (UL 94 V-0) while maintaining its mechanical properties, even with 40% of the flame retardant content.

Additionally, over 90% of the additive could be removed during recycling, resulting in a high-purity recycled material with color and strength comparable to virgin plastic. The researchers plan to conduct further flame-retardancy tests and collaborate with industrial users to accelerate the commercialization of this sustainable composite technology for next-generation mobility applications.