Enhancing the recyclability of ELV plastic bumpers: Characterization of molecular, morphological, rheological, mechanical properties and ageing degradation

While the automotive industry has traditionally prioritized metal recycling, the increasing use of plastics in vehicles underlines the need for sustainable management of these materials. Recycling rates of plastics from end-of-life vehicles (ELVs) in Europe are low, but recent EU legislation requires 25 % of the plastics in new vehicles to be recycled, forcing innovative designs and strategies to enhance the recovery and quality of recycled resins. This study focuses on post-consumer bumpers, a significant recoverable component of ELVs, by assessing their molecular, morphological, rheological, and mechanical properties to investigate their homogeneity and quality from various sources to assess their suitability for recycling. Since the aging of these materials, caused by thermo-oxidative and thermo-mechanical degradation processes, can compromise the quality of recycled bumpers, we propose a blend of recycled PP from different bumper cars with virgin resin, representing a realistic scenario where the post-consumer ELV bumpers are collected. Interestingly, this blend, which can replace up to 50 % of the virgin resin without additional compatibilizers or additives, mitigates the degradation effects. Furthermore, the study evaluates the degradation resistance of these blends through multiple extrusion cycles and accelerated weathering tests in a temperature-controlled UV chamber to ascertain the number of cycles the material can tolerate without significant quality degradation, and to determine its suitability for long-term applications. Our results not only support the feasibility of using recycled PP for automotive components but also contribute to meeting the EU's recycling targets. This research highlights the potential for significant advances in the circularity of automotive plastics, providing a sustainable pathway for integrating recycled materials into new vehicle production.