Stress-induced phase separation in plastics drives the release of amorphous polymer micropollutants into water

Dunzhu Li (), Peijing Li, Yunhong Shi, Emmet D. Sheerin, Zihan Zhang, Luming Yang, Liwen Xiao (), Christopher Hill, Conall Gordon, Manuel Ruether, Joshua Pepper, John E. Sader, Michael A. Morris, Jing Jing Wang () and John J. Boland ()
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Dunzhu Li: Zhejiang A&F University
Peijing Li: The University of Melbourne
Yunhong Shi: Trinity College Dublin
Emmet D. Sheerin: Trinity College Dublin
Zihan Zhang: Trinity College Dublin
Luming Yang: Trinity College Dublin
Liwen Xiao: Trinity College Dublin
Christopher Hill: Trinity College Dublin
Conall Gordon: Trinity College Dublin
Manuel Ruether: Trinity College Dublin
Joshua Pepper: Trinity College Dublin
John E. Sader: California Institute of Technology
Michael A. Morris: Trinity College Dublin
Jing Jing Wang: Trinity College Dublin
John J. Boland: Trinity College Dublin

Nature Communications, 2025, vol. 16, issue 1, 1-12

Abstract: Abstract Residual stress is an intrinsic property of semicrystalline plastics such as polypropylene and polyethylene. However, there is no fundamental understanding of the role intrinsic residual stress plays in the generation of plastic pollutants that threaten the environment and human health. Here, we show that the processing-induced compressive residual stress typically found in polypropylene and polyethylene plastics forces internal nano and microscale segregation of low molecular weight (MW) amorphous polymer droplets onto the plastic’s surface. Squeeze flow simulations reveal this stress-driven volumetric flow is consistent with that of a Bingham plastic material, with a temperature-dependent threshold yield stress. We confirm that flow is thermally activated and stress dependent, with a reduced energy barrier at higher compressive stresses. Transfer of surface segregated droplets into water generates amorphous polymer micropollutants (APMPs) that are denatured, with structure and composition different from that of traditional polycrystalline microplastics. Studies with water-containing plastic bottles show that the highly compressed bottle neck and mouth regions are predominantly responsible for the release of APMPs. Our findings reveal a stress-induced mechanism of plastic degradation and underscore the need to modify current plastic processing technologies to reduce residual stress levels and suppress phase separation of low MW APMPs in plastics.

Date: 2025
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DOI: 10.1038/s41467-025-58898-w

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