Advances in Chlorinated Polyethylene: Properties, Applications, and Future Directions

Elastomeric chlorinated polyethylene (CM or E-CPE) integrates the thermoplastic's dynamic processing properties with the elastomer's behavioral characteristics. It is a hybrid thermoplastic–thermoplastic elastomer (TPE) material derived from resin-type CPE (R-CPE), which is synthesized by partially substituting hydrogen in high- or low-density polyethylene with chlorine (Cl) via various methods. Because of its distinct combination of properties, which are mostly ascribed to Cl, CPE is an active ingredient in the manufacture of numerous domestic and industrial products, including floor lamination, window strips, cable sheathing, and conveyor belt covers. This hybrid thermoplastic-TPE material is cost-effective, noncarcinogenic, versatile, comprises a network structure that allows for easy interpenetration of different substrates (e.g., polymers, elastomers, and additives), and offers a long service life while maintaining optimal performance. Accordingly, research efforts have recently intensified, focusing primarily on the sustainable alternatives to conventional copolymer processing, the integration of occupational safety considerations in line with regulatory frameworks like Occupational Safety and Health Administration and Registration, Evaluation, Authorization and Restriction of Chemicals, and the improved management of end-of-life CPE-based polymer products. This, in turn, is expected to cause several sectors to undergo a dramatic shift to employing CPE, which will become one of the reasons for its rapid market expansion. This review paper aims to provide a broader overview of CPE status in the field of materials science and engineering, emphasizing its past innovations, current properties-based applications, and future developments. In particular, the applications are believed to be reasonably well-established to date, while the prospects remain promising, as continued demand for CPE is anticipated across sectors, with growth spurred by ongoing advancements in the field, processing technologies, and sustainability.