Management of the plastic industry is a momentous challenge, one that pits enormous societal benefits against an accumulating reservoir of nearly indestructible waste. A promising strategy for recycling polyethylene (PE) and isotactic polypropylene ( i PP), constituting roughly half the plastic produced annually worldwide, is melt blending for reformulation into useful products. Unfortunately, such blends are generally brittle and useless due to phase separation and mechanically weak domain interfaces. Recent studies have shown that addition of small amounts of semicrystalline PE- i PP block copolymers (ca. 1 wt%) to mixtures of these polyolefins results in ductility comparable to the pure materials. However, current methods for producing such additives rely on expensive reagents, prohibitively impacting the cost of recycling these inexpensive commodity plastics. Here, we describe an alternative strategy that exploits anionic polymerization of butadiene into block copolymers, with subsequent catalytic hydrogenation, yielding E and X blocks that are individually melt miscible with PE and i PP, where E and X are poly(ethylene- ran -ethylethylene) random copolymers with 6 wt% and 90 wt% ethylethylene repeat units, respectively. Cooling melt blended mixtures of PE and i PP containing 1 wt% of the triblock copolymer EXE of appropriate molecular weight, results in mechanical properties competitive with the component plastics. Blend toughness is obtained through interfacial topological entanglements of the amorphous X polymer and semicrystalline i PP, along with anchoring of the E blocks through cocrystallization with the PE homopolymer. Significantly, EXE can be inexpensively produced using currently practiced industrial scale polymerization methods, offering a practical approach to recycling the world’s top two plastics.

We present an approach to photocrosslink bicontinuous microemulsions derived from ternary blends of poly(methoxyethyl acrylate) (PM, M n = 4200 g/mol), poly(hexyl methacrylate-co-coumarin methacrylate) (PHC, M n = 6800 g/ mol), and PM-b-PHC diblock polymer (M n = 19,400 g/mol) in a phase-selective manner, enabling structural characterization at an unprecedented level of detail. This strategy utilizes the [2 + 2] photodimerization reaction of coumarin derivatives to covalently crosslink blends without the use of harsh reagents or disruptive thermal treatment, thus preserving the intricate network structure throughout curing. The resulting crosslinked bicontinuous microemulsions exhibited rubbery behavior at elevated temperatures, achieving an elastic shear modulus of nearly 1 MPa at 70 °C, owing to the presence of the three-dimensional co-continuous network morphology. The dimensional stabilization afforded by crosslinking further allowed the microstructure to be directly imaged by scanning electron microscopy and atomic force microscopy. Contrary to recent theoretical findings, the BμE appears in a wide temperature and compositional window, suggesting that it is a robust feature of these blends. As a proof of concept demonstrating both the utility of bicontinuous microemulsion-derived materials and versatility of this strategy toward broader applications in energy storage and transport, the uncrosslinked portion of a cured blend was extracted by washing and replaced with an ionic liquid; the resultant heterogeneous solid electrolyte exhibited a room-temperature conductivity of 2 mS/cm, approximately one-quarter that of the pure ionic liquid.