Work

Upcycling waste commodity polymers into high-performance polyarylate materials with direct utilization of capping agent impurities

Year: 2025

Type: article

Abstract: Commodity polymers are ubiquitous in our society, having replaced many inorganic and metal-based materials due to their versatile properties. However, their functionality heavily relies on the addition of various components known as additives, making it challenging to recycle the polymer fraction of plastic materials effectively. Thus, it is crucial to develop efficient chemical recovery strategies for commodity polymers and additives to facilitate the direct utilization of recovered monomers and additives without additional purification. Here, we develop a strategy for co-upcycling two types of waste commodity polymers, polycarbonate, and polyethylene terephthalate into polyarylate, a high-performance transparent engineering plastic. By incorporating a highly active metal-free ionic liquids catalyst for methanolysis and a two-stage interface polymerization technique with variable temperature control, we successfully prepare polyacrylate film materials from real end-of-life plastics with direct utilization of capping agent impurities in recovered monomers. These materials exhibit excellent thermal performance (Tg = 192.8 °C), transmittance (reach up to 86.73%), and flame-retardant properties (V-0, UL-94), equivalent to those of commercial polyarylate (U-100, about $10000/ton), and could be further easily close-loop recycled. Demonstrated in kilogram-scale experiments and life cycle assessments, this approach offers a low-carbon, environmentally friendly, and economically feasible pathway for upcycling waste commodity polymers. Recycling of commodity plastics remains challenging due to the presence of additives and mixed waste streams. Here the authors develop a strategy for co-upcycling polycarbonate, and polyethylene terephthalate, two types of waste commodity polymers, into polyarylate, a high-performance transparent engineering plastic.

Source: Nature Communications

DOI: 10.1038/s41467-025-57821-7

Authors: Cheng Li, Guangming Yan, Zhongwen Dong, Gang Zhang, Fan Zhang

Institutions: Sichuan University, State Key Laboratory of Polymer Materials Engineering

Language: English

Topic: Polymer crystallization and properties

Subfield: Polymers and Plastics

Field: Materials Science

Domain: Physical Sciences

SDG: Responsible consumption and production

Open Access status: gold

Estimated APC paid: $6,990