Recyclability of reversible polymer networks over a Dozen reprocessing cycles

Reversible polymer networks capable of reversible reactions along their backbone provide a promising strategy for addressing waste management challenges associated with conventional thermoset products. However, reversible polymer networks cannot be recycled infinitely. Unavoidable side reactions eventually cause significant degradation of mechanical properties or loss of recyclability. This study aims to answer a simple yet critical question on reversible polymer network systems: how many reprocessing cycles can be achieved before profound mechanical degradation or a loss of recyclability? The recyclability of Diels–Alder (DA) network samples was evaluated by repeating consistent reprocessing cycles until they were no longer reprocessable. To enhance their recyclability, the chemical structure of the maleimide precursor was tailored to mitigating side reactions by maleimide homopolymerization. Remarkably, by employing a maleimide precursor with alkyl substitutions on its phenyl group, the DA network system attained 12 reprocessing cycles using injection molding at 160 °C without significant degradation of mechanical properties. However, the 13th reprocessing cycle did not succeed. Rheological analysis revealed the accumulation of non-reversible bonds within the network structure during repeated reprocessing, despite fairly consistent mechanical properties under operating conditions. This study demonstrates that the rational design of the maleimide precursor is an effective means to enhance the reprocessability of DA networks.