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Journal of Polymer & Composites Review Article

Recycling and Reinforcement of Retired EV Battery Materials in Polymer Composites for Sustainable Engineering Applications

  1. Rajkumar K. Chougale Department of Electrical Engineering, Bharati Vidyapeeth’s College of Engineering, Kolhapur
  2. Pralhad B. Patole Department of Mechanical Engineering, Bharati Vidyapeeth’s College of Engineering, Kolhapur
  3. Amit A. Desai Department of Mechanical Engineering, Bharati Vidyapeeth’s College of Engineering, Kolhapur
  4. Gayatri S. Ghorpade Department of Environmental science, Bharati Vidyapeeth’s College of Engineering, Kolhapur
  5. Balaji T. Mohite Department of Mathematics, Bharati Vidyapeeth’s College of Engineering, Kolhapur
  6. Jayant C. Thorat Department of Chemistry, Bharati Vidyapeeth’s College of Engineering, Kolhapur

Abstract

The rapid proliferation of electric vehicles (EVs) has led to a substantial increase in lithium-ion battery waste, necessitating sustainable strategies for material recovery and reuse. This review explores the valorization of retired Electrical Vehicle batteries within polymer and composite systems, highlighting second-life applications as a promising pathway toward circular material utilization. Batteries retaining 70–80% of their original capacity remain suitable for extended use; however, beyond conventional energy storage, their constituent materials—including electrode powders, current collectors, and separators—can be effectively incorporated into polymer matrix composites for both functional and structural applications. This study critically examines battery degradation mechanisms, material recovery processes, and the transformation of recovered components into composite fillers and reinforcements. Particular emphasis is placed on polymer–battery material interactions, processing techniques such as melt blending and solution casting, and the resulting mechanical, electrical, and thermal properties of the developed composites. Techno-economic analysis demonstrates the feasibility of cost-effective material substitution, while life cycle assessment highlights significant environmental benefits, including reduced carbon footprint and conservation of critical raw materials. Emerging strategies, including hybrid composite systems, conductive polymers, and multifunctional materials, are discussed alongside key challenges such as material heterogeneity, interfacial compatibility, and large-scale scalability. Finally, This strategy not only mitigates the environmental burden associated with battery waste but also promotes resource circularity by converting end-of-life materials into value-added functional components. the integration of retired EV battery materials into polymer composites represents a novel and high-impact approach, advancing sustainable materials engineering and efficient energy resource management for future technologies

Keywords

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