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About 11 million vehicles are scrapped each year in the United States. Most of these vehicles are recycled by automotive dismantlers and shredders. Presently, about 95% of the ferrous and non-ferrous metals present in vehicles (75% of the total vehicle weight) are recovered. The remainder of the scrapped vehicles (non-metal portion known as automotive shredder residue-ASR) is landfilled, generating up to 3 million tons of waste per year. In order to increase the efficiency of recovery of both ferrous and non-ferrous metals from the shredded vehicles, numerous developments have been made by the shredders in separation technology recently. This paper is an update of our previous paper and contains in-depth characterization of the various ASR streams.

The recycling of cross-member composite (CMC) parts was studied using partial decrosslinking of the polyurethane (PUR) composite matrix by catalyzed glycolysis. The decrosslinked material, containing reactive OH and NH2 groups, was reacted with polymeric isocyanate in a molding operation to form a new composite product. In order to make the process economically feasible the smallest amounts of reactants (glycol, catalyst, isocyanate) were used in the process. The results of the laboratory study were verified in semi-pilot plant runs. The economic analysis showed that the process is feasible.

A number of prototype automotive interior trim products were developed from polyurethane-cored headliner scrap by utilization of isocyanate-based binders: 1) rear-seat-to-back-window trim panels (Deville and Eldorado Chimsl covers), 2) package trays (Neon PL-tray, Buick/Oldsmobile G-trays), and 3) sun-shades (Accord/Acura sun-shades). The technology for the manufacture of these products is outlined in this paper as well as their mechanical, acoustical, and other properties relevant to the automotive interior trim applications.

A method for recycling of mixed color automotive thermoplastic scrap into appearance automotive interior parts has been developed and shown to satisfy the following three requirements: 1) material performance 2) color appearance, and 3) economically sound. The technique developed is based on minimal separation of the colors into hues (groups of similar colors) and repigmenting to the desired color. The studies included computer formulations, laboratory verifications and plant runs. Plant runs were carried out to produce automotive interior doors (base level S-truck) with polypropylene (PP) regrind and B-pillar 325 parts with acrylonitrile-butadiene-styrene (ABS) regrind at the Delphi - Adrian plant. Two colors, ruby red and medium gray, were selected because they are the most difficult colors to match. The results of the plant runs demonstrated that color matching can be successfully achieved.

Recycling of automotive headliners has been carried out by grinding them and forming composites with isocyanate-based binders. Rear-seat-to-back-window trim panels have been prepared. Composites with 80-90 wt.% of scrap manufactured in plant runs exhibited mechanical properties comparable to the existing products. The rear-seat-to-back-window trim panel composites were produced by compression molding ground scrap-binder pre-preg sheets for 30 seconds at moderate temperatures, with no postcuring. This is the best indication that the utilization of the scrap headliners is both technically and economically sound. The plant runs have confirmed the feasibility of production of large parts with relatively complex shapes such as headliners. The adhesion of decorative materials to the composite substrates was excellent. More importantly, the decorative materials can be applied to the substrate during compression molding without any additional adhesive.