This paper reports a method for upcycling depolluted, dismantled, and shredded end-of-life vehicle waste plastic into flash graphene using flash Joule heating. The process requires no plastic separation or sorting and uses no solvents or water. The resulting graphene is used as a reinforcing agent in automotive polyurethane foam composites, improving tensile strength and low-frequency noise absorption. The study demonstrates process continuity by upcycling the foam composite back into flash graphene. A prospective life cycle assessment suggests that this method may offer lower cumulative energy demand, water use, and global warming potential compared to traditional graphene synthesis.

Kevin M. Wyss, Robert D. De Kleine, Rachel L. Couvreur, Alper Kiziltas, Deborah F. Mielewski, James M. Tour