Polyolefin Compatibilization through Dynamic Covalent Crosslinking

Recycling polyethylene (PE) and polypropylene (PP), the two most common plastics accounting for more than 40% of global plastic consumption, has been a big challenge because of the quality deficiency of the recycled materials. PE and PP cannot be sorted cleanly and are often recycled as a mixture due to their similar chemical compositions and densities. However, PE and PP are immiscible and their simple blends have poor mechanical properties. RockyTech has developed compatibilizer additives to improve the quality of post-consumer or post-industrial recycled polyolefin blends, primarily PE and PP. This innovation promotes the reuse of these materials, advancing our mission to "upcycle plastic waste for the circular economy." The key strategy involves incorporating reversible covalent bonds into polyolefin linear chains to enable their crosslinking at the particle interface, thus achieving polymer fusion and quality enhancement with minimal micro-and macroscopic phase separation. We have developed various compatibilizer prototypes that enhance the quality of PE and PP blends, achieving tensile properties similar to or even surpassing those of virgin high-density polyethylene (HDPE). We have validated the technology, filed for PCT and US patents, and developed two MVPs, RevLink-202 and RevLink-M202, which are currently undergoing customer testing and evaluation. We will refine our initial MVPs based on customer feedback and develop production-ready compatibilizer formulations. This includes conducting industry-specific tests, streamlining our in-house semi-pilot scale manufacturing process, and continuously expanding our product offerings through ongoing R&D. Our polyolefin compatibilizers transform recycled polyolefins into value-added products, enabling a circular lifecycle and reducing plastic waste accumulation. Our technology efficiently upcycles cheap, low-quality, and mixed polyolefins, addressing the quality issues faced by recyclers and processors. The resulting upcycled polyolefins, made from post-consumer or post-industrial waste, are suitable for various applications including 3D printing, auto parts, sports equipment, and packaging. Additionally, our compatibilizers enhance virgin PE properties by incorporating PP, creating a superior PE/PP alloy that merges PP's strength with PE's flexibility. This innovation is poised to revolutionize industries like geotextiles, which require both strength and flexibility. Thus, we are developing manufacturing processes and technologies that could benefit the whole plastic recycling and processing ecosystem.