Functionalizable and Chemically Recyclable Thermoplastics from Chemoselective Ring-Opening Polymerization of Bio-renewable Bifunctional α-Methylene-δ-valerolactone

Mass-Produced Chemically Recyclable Aromatic Polymers with Exceptional Strength and Stability

Developing chemically recyclable polymers that offer ultrahigh mechanical strength, exceptional chemical stability, mild recycling conditions, and scalability for mass production remains a significant challenge. This study presents a novel class of chemically recyclable plastics, synthesized at kilogram scale in the laboratory, by reversibly cross-linking aromatic polyamide macromonomers with boroxines, imine bonds, and hydrogen bonds. These plastics, denoted as PA-B3O3, exhibit an impressive tensile strength of 142.1 MPa, a Young's modulus of 2.39 GPa, a glass transition temperature of ∼211.6 °C, and outstanding chemical resistance to acidic/basic aqueous solutions and organic solvents. PA-B3O3 plastics can be depolymerized in a mixed solvent of N,N-dimethylacetamide and aqueous HCl solution, allowing for efficient recovery of the original amino-terminated polyamide (PA-NH2) via precipitation in selective solvents, even when mixed with polymer waste streams. This study represents a significant advancement toward the practical application of mechanically robust, chemically resistant, and recyclable polymers.

Crystallization/Precipitation Driven Nonequilibrium Ring-Opening Polymerization of Thiovalerolactone Toward Closed-Loop Recyclable Polythioester with Excellent Barrier Properties

The development of closed-loop recyclable polymers with comparable performances with commodity plastics remains as a challenge to establish a circular plastic economy. In this contribution, we propose a precipitation/crystallization driven nonequilibrium ring-opening polymerization of δ-thiovalerolactone (δTVL) to produce high-molecular-weight PTVL in the presence of a strong base/urea binary catalyst. The obtained PTVL exhibits good thermal and mechanical performances as well as superior barrier properties comparable with some commodity plastics. Remarkably, the obtained PTVL can be depolymerized to recover pristine monomer with a high yield and purity by distillation from a commodity plastic waste mixture without tedious separation, highlighting its great potential as a closed-loop recyclable packaging material.

A General and Mild Two-Step Strategy Using Bioderived Diols and CO2 for Chemically Recyclable Polycarbonates and Closed-Loop CO2 Fixation

Developing chemically recyclable polymers using CO2 and sustainable co-feedstocks is an important strategy for achieving carbon-neutral production of new polymers and mitigating plastic pollution. Herein, a series of six-membered cyclic carbonate monomers with different alkyl α-substituents were synthesized using CO2 and bioderived 1,3-alkanediol as raw materials at room temperature and atmospheric pressure. The organocatalytic ring-opening polymerization was systematically studied using a range of common and readily available organocatalysts. Phosphazene base (t-BuP2) was identified as the most effective catalyst, offering excellent control over the entire polymerization. The regioselectivity of the synthesized polycarbonates, ranged from 0.74 to 0.99, with the highest value achieved when the side group was isopropyl (highest steric hindrance). Notably, the α-substituent in the monomers reduced the ring strains, allowing the resulting polycarbonates to be fully recycled to the monomers without decarboxylation. The recycling process effectively traps CO2 in a closed loop between monomers and polymers, preventing its release into the atmosphere. The alkyl side groups enhanced the hydrophobicity of the polycarbonates, thereby reducing the likelihood of CO2 release through hydrolysis during their lifecycle, achieving a robust CO2 closed-loop fixation. The utility of CO2-based aliphatic polycarbonates as adhesives and the ability of copolymerization with l-lactide were explored.

Monomer Design Enables Mechanistic Mapping of Anionic Ring-Opening Polymerization of Aromatic Thionolactones

Degradable chalcogenide polyesters, e.g., polythioesters (PTEs), typically exhibit improved thermal, mechanical, and optical properties. Anionic ring-opening polymerization (ROP) of thionolactones, an intrinsically promising yet underexplored approach to accessing PTEs, however, is still limited by: intolerance of metal catalysts, inadequate control over chain growth, and the absence of aromatic system. Monomer design-boosted mechanistic studies may address the above challenges. Here, we present a new and highly reactive thionolactone synthesized from 1,1'-binaphthyl-2,2'-diol (BINOL). Our investigations into polymerization kinetics and thermodynamics have underscored the importance of rapid initiation, eventually leading to the discovery of tetrabutylammonium 2-naphthyl-thiocarboxylate as a distinctive initiator that enables genuinely controlled and living polymerization of thionolactones. Ultimately, the atropisomerism inherent in BINOL has resulted in the creation of axially chiral PTE materials with tailored molecular weights, enantiomeric compositions, and topologies.

Circular Polymer Designed by Regulating Entropy: Spiro-Valerolactone-Based Polyesters with High Gas Barriers and Adhesion Strength

Enthalpy is often the focal point when designing monomers for polymer circularity, but much less is explored on how entropy can be exploited to create polymers with synergistic circularity and properties. Here, we design a series of spiro-lactones (SLs) with closed-chain cycloalk(en)yl substituents at the α,α-position of δ-valerolactone (δVL), which, when combined with the parent δVL and gem-α,α-dialkyl-substituted δVL with open-chain alkyl groups, provide a desired platform for exploring the circular polymer design by focusing on the entropy change of polymerization. These SLs exhibit finely balanced (de)polymerizability that is regulated chiefly by entropy differentiation, allowing both the facile synthesis of polyester PSLs (Mn up to 1000 kg mol-1) in a living fashion and selective depolymerization of the PSLs to completely recover monomers under mild conditions (using a recyclable catalyst at 100 °C). One such PSL is semicrystalline (Tm = 134 °C), strong (ultimate strength = 43 MPa), hard (modulus = 1.85 GPa), and modestly flexible. These notable mechanical properties are bolstered by its superior barriers to oxygen and moisture permeation compared to common packaging materials. In addition, this PSL can be postfunctionalized to a recyclable OH-containing PSL that shows higher adhesion strength than the comparative commercial adhesives.

Chemoselective Ring-Opening Polymerization of α-Methylene-δ-valerolactone Catalyzed by a Simple Organoaluminum Complex to Prepare Closed-Loop Recyclable Functional Polyester

α-Methylene-δ-valerolactone (MVL) as a bio-renewable bifunctional monomer has shown great promise to prepare closed-loop recyclable polyester with pendent functionalizable double bond. However, the chemoselective ring-opening polymerization (ROP) of MVL still faces challenges including low polymerization temperature, expensive catalyst as well as high catalyst loading. In this contribution, we present the chemoselective and controlled ROP of MVL using a simple organoaluminum complex [MeAl(BHT)2] (BHT=2,6-di-tert-butyl-4-methylphenoxy), which can be easily prepared from commercially available trimethylaluminum and 2,6-di-tert-butyl-4-methylphenol without purification. MeAl(BHT)2 exhibits much higher catalytic activity (TOF=668 h-1) than that of MeAl[Salen] (TOF=89 h-1), a commonly used organoaluminum catalyst. The high chemoselectivity and activity of MeAl(BHT)2 is proposed to originate from the cooperative activation of propagating chain-ends and monomers via the "coordination-insertion" mechanism. Remarkably, high-molecular-weight P(MVL)ROP can be prepared in bulk using MeAl(BHT)2, which is not accessible by the previous catalysts. This study may advance the development of closed-loop recyclable polymers considering the easy preparation, low cost and good catalytic performance of MeAl(BHT)2.

Bifunctional and recyclable polyesters by chemoselective ring-opening polymerization of a δ-lactone derived from CO2 and butadiene

When aiming at the direct use of CO2 for the preparation of advanced/value-added materials, the synthesis of CO2/olefin copolymers is very appealing but challenging. The δ-lactone 3-ethylidene-6-vinyltetrahydro-2H-pyran-2-one (EVP), synthesized by telomerization of CO2 with 1,3-butadiene, is a promising monomer. However, its chemoselective ring-opening polymerization (ROP) is hampered by unfavorable thermodynamics and the competitive polymerization of highly reactive C=C double bonds under usual conditions. Herein, we report the chemoselective ROP of EVP using a phosphazene/urea binary catalyst, affording exclusively a linear unsaturated polyester poly(EVP)ROP, with a molar mass (Mn) up to 16.1 kg·mol-1 and a narrow distribution (Ð < 1.6), which can be fully recycled back to the pristine monomer, thus establishing a monomer-polymer-monomer closed-loop life cycle. In these polyesters, the CO2 content reaches 33 mol% (29 wt%). The reasons for the unexpected chemoselectivity were investigated by Density-functional theory (DFT) calculations. The poly(EVP)ROP features two pendent C=C double bonds per repeating unit, which show distinct reactivity and thus can be properly engaged in sequential functionalizations towards the synthesis of bifunctional polyesters. We disclose here a methodology providing a facile access to bifunctional and recyclable polyesters from readily available feedstocks.

Closed-loop recyclable polymers: from monomer and polymer design to the polymerization-depolymerization cycle

The extensive utilization of plastic, as a symbol of modern technological society, has consumed enormous amounts of finite and non-renewable fossil resources and produced huge amounts of plastic wastes in the land or ocean, and thus recycling and reuse of the plastic wastes have great ecological and economic benefits. Closed-loop recyclable polymers with inherent recyclability can be readily depolymerized into monomers with high selectivity and purity and repolymerized into polymers with the same performance. They are deemed to be the next generation of recyclable polymers and have captured great and increasing attention from academia and industry. Herein, we provide an overview of readily closed-loop recyclable polymers based on monomer and polymer design and no-other-reactant-involved reversible ring-opening and addition polymerization reactions. The state-of-the-art of circular polymers is separately summarized and discussed based on different monomers, including lactones, thiolactones, cyclic carbonates, hindered olefins, cycloolefins, thermally labile olefin comonomers, cyclic disulfides, cyclic (dithio) acetals, lactams, Diels-Alder addition monomers, Michael addition monomers, anhydride-secondary amide monomers, and cyclic anhydride-aldehyde monomers, and polymers with activatable end groups. The polymerization and depolymerization mechanisms are clearly disclosed, and the evolution of the monomer structure, the polymerization and depolymerization conditions, the corresponding polymerization yield, molecular weight, performance of the polymers, monomer recovery, and depolymerization equipment are also systematically summarized and discussed. Furthermore, the challenges and future prospects are also highlighted.

Fully recyclable and tough thermoplastic elastomers from simple bio-sourced δ-valerolactones

While a large number of chemically recyclable thermoplastics have been developed in recent years, technologically important thermoplastic elastomers (TPEs) that are not only bio-based and fully recyclable but also exhibit mechanical properties that can rival or even exceed those petroleum-based, non-recyclable polyolefin TPEs are critically lacking. The key challenge in developing chemically circular, bio-based, high-performance TPEs rests on the complexity of TPE's block copolymer (BCP) structure involving block segments of different suitable monomers required to induce self-assembled morphologies responsible for performance as well as the control and monomer compatibility in their synthesis and the selectivity in their depolymerization. Here we demonstrate the utilization of bio-sourced δ-valerolactone (δVL) and its simple α-alkyl-substituted derivatives to produce all δVL-based polyester tri-BCP TPEs, which exhibit not only complete (closed-loop) chemical recyclability but also excellent toughness that is 2.5-3.8 times higher than commercial polyolefin-based TPEs. The visualized cylindrical morphology formed via crystallization-driven self-assembly in the new all δVL tri-BCP is postulated to contribute to the excellent TPE property.

Monomer-Recyclable Polyester from CO2 and 1,3-Butadiene

Synthesis of monomer-recyclable polyesters solely from CO2 and bulk olefins holds great potential in significantly reducing CO2 emissions and addressing the issue of plastic pollution. Due to the kinetic disadvantage of direct copolymerization of CO2 and bulk olefins compared to homopolymerization of bulk olefins, considerable research attention has been devoted to synthesis of polyester via the ring-opening polymerization (ROP) of a six-membered disubstituted lactone intermediate, 1,2-ethylidene-6-vinyl-tetrahydro-2H-pyran-2-one (𝜹-L), obtained from telomerization of CO2 and 1,3-butadiene. However, the conjugate olefin on the six-membered ring of 𝜹-L leads to serious Michael addition side reactions. Thus, the selective ROP of 𝜹-L, which can precisely control the repeating unit for the production of polyesters potentially amenable to efficient monomer recycling, remains an unresolved challenge. Herein, the first example of selective ROP of 𝜹-L is reported using a combination of organobase and N,N'-Bis[3,5-bis(trifluoromethyl)phenyl]urea as the catalytic system. Systematic modifications of the substituent of the urea show that the presence of electron-deficient 3,5-bis(trifluoromethyl)-phenyl groups is the key to the extraordinary selectivity of ring opening over Michael addition. Efficient monomer recovery of oligo(𝜹-L) is also achieved under mild catalytic conditions.

Heteroatom Substitution Strategy Modulates Thermodynamics Towards Chemically Recyclable Polyesters and Monomeric Unit Sequence by Temperature Switching

In this paper, we proposed a heteroatom substitution strategy (HSS) in the δ-valerolactone (VL) system to modulate thermodynamics toward chemically recyclable polyesters. Three VL-based monomers containing different heteroatoms (M1 (N), M2 (S), and M3 (O)), instead of C-5 carbon, were designed and synthesized to verify our proposed HSS. All three monomers undergo organocatalytic living/controlled ROP and controllable depolymerization. Impressively, the resulting P(M1) achieved over 99 % monomer recovery under both mild solution depolymerization and high vacuum pyrolysis conditions without any side reactions, and the recycled monomers can be polymerized again forming new polymers. The systematic study of the relationship between heteroatom substitution and recyclability shows that introducing heteroatoms does change the thermodynamics of the monomers (ΔHp o, ΔSp o and Tc values), thereby adjusting the polymerizability and depolymerizability. DFT calculations found that the introduction of heteroatoms adjusts the ring strain by changing the angular strain of the monomers, and the order of their angular strain (M2>M1>M3) is consistent with the order of the experimentally obtained enthalpy change. Notably, the one-pot/one-step copolymerization of two of each of the three monomers enables the synthesis of sequence-controlled copolymers from gradient to random to block structures, by simply switching the copolymerization temperature.

Enabling Closed-Loop Circularity of "Non-Polymerizable" α, β-Conjugated Lactone Towards High-Performance Polyester with the Assistance of Cyclopentadiene

Chemical recycling of polymers to monomers presents a promising solution to the escalating crisis associated with plastic waste. Despite considerable progress made in this field, the primary efforts have been focused on redesigning new monomers to produce readily recyclable polymers. In contrast, limited research into the potential of seemingly "non-polymerizable" monomers has been conducted. Herein, we propose a paradigm that leverages a "chaperone"-assisted strategy to establish closed-loop circularity for a "non-polymerizable" α, β-conjugated lactone, 5,6-dihydro-2H-pyran-2-one (DPO). The resulting PDPO, a structural analogue of poly(δ-valerolactone) (PVL), exhibits enhanced thermal properties with a melting point (Tm) of 114 °C and a decomposition temperature (Td,5%) of 305 °C. Notably, owing to the structural similarity between DPO and δ-VL, the copolymerization generates semi-crystalline P(DPO-co-VL)s irrespective of the DPO incorporation ratio. Intriguingly, the inherent C=C bonds in P(DPO-co-VL)s enable their convenient post-functionalization via Michael-addition reaction. Lastly, PDPO was demonstrated to be chemically recyclable via ring-closing metathesis (RCM), representing a significant step towards the pursuit of enabling the closed-loop circularity of "non-polymerizable" lactones without altering the ultimate polymer structure.

Recyclable and (Bio)degradable Polyesters in a Circular Plastics Economy

Polyesters carrying polar main-chain ester linkages exhibit distinct material properties for diverse applications and thus play an important role in today's plastics economy. It is anticipated that they will play an even greater role in tomorrow's circular plastics economy that focuses on sustainability, thanks to the abundant availability of their biosourced building blocks and the presence of the main-chain ester bonds that can be chemically or biologically cleaved on demand by multiple methods and thus bring about more desired end-of-life plastic waste management options. Because of this potential and promise, there have been intense research activities directed at addressing recycling, upcycling or biodegradation of existing legacy polyesters, designing their biorenewable alternatives, and redesigning future polyesters with intrinsic chemical recyclability and tailored performance that can rival today's commodity plastics that are either petroleum based and/or hard to recycle. This review captures these exciting recent developments and outlines future challenges and opportunities. Case studies on the legacy polyesters, poly(lactic acid), poly(3-hydroxyalkanoate)s, poly(ethylene terephthalate), poly(butylene succinate), and poly(butylene-adipate terephthalate), are presented, and emerging chemically recyclable polyesters are comprehensively reviewed.

A recyclable polyester library from reversible alternating copolymerization of aldehyde and cyclic anhydride

Our society is pursuing chemically recyclable polymers to accelerate the green revolution in plastics. Here, we develop a recyclable polyester library from the alternating copolymerization of aldehyde and cyclic anhydride. Although these two monomer sets have little or no thermodynamic driving force for homopolymerization, their copolymerization demonstrates the unexpected alternating characteristics. In addition to readily available monomers, the method is performed under mild conditions, uses common Lewis/Brønsted acids as catalysts, achieves the facile tuning of polyester structure using two distinct monomer sets, and yields 60 polyesters. Interestingly, the copolymerization exhibits the chemical reversibility attributed to its relatively low enthalpy, which makes the resulting polyesters perform closed-loop recycling to monomers at high temperatures. This study provides a modular, efficient, and facile synthesis of recyclable polyesters using sustainable monomers.

Chemically Recyclable Polyethylene-like Sulfur-Containing Plastics from Sustainable Feedstocks

The green revolution in plastics should be accelerated due to growing sustainability concerns. Here, we develop a series of chemically recyclable polymers from the first reported cascade polymerization of H₂ O, COS, and diacrylates. In addition to abundant feedstocks, the method is efficient and air-tolerant, uses common organic bases as catalysts, and yields polymers with high molecular weights under mild conditions. Such polymers, structurally like polyethylene with low-density in-chain polar groups, manifest impressive toughness and ductility comparable to high-density polyethylene. The in-chain ester group acts as a breaking point, enabling these polymers to undergo chemical recycling through two loops. The structures and properties of these polymers also have an immeasurably expanded range owing to the versatility of our method. The readily available raw materials, facile synthesis, and high performance make these polymers promising prospects as sustainable materials in practice.

Ring-Opening Polymerization for the Goal of Chemically Recyclable Polymers

A crucial modern dilemma relates to the ecological crisis created by excess plastic waste production. An emerging technology for reducing plastic waste is the production of "chemically recyclable" polymers. These polymers can be efficiently synthesized through ring-opening polymerization (ROP/ROMP) and later recycled to pristine monomer by ring-closing depolymerization, in an efficient circular-type system. This Perspective aims to explore the chemistry involved in the preparation of these monomer/polymer systems, while also providing an overview of the challenges involved, including future directions.

Rapid Ring-Opening Polymerization of γ-Butyrolactone toward High-Molecular-Weight Poly (γ-butyrolactone) by an Organophosphazene Base and Bisurea Binary Catalyst

The low temperature condition, long reaction time and associated high energy inputs involved in the polymerization process still hampered the scalable production of poly(γ-butyrolactone) (PγBL) via ring-opening polymerization (ROP) of low strained γBL due to its unfavorable thermodynamics. In this contribution, we presented the rapid ROP of γBL using a bisurea in combination with an organophosphazene base as the binary catalyst. Well-defined PγBL samples with various terminal groups were prepared by using different alcohol initiators. The bisurea as a co-catalyst exhibited much higher catalytic activity even compared to the most active monourea in previous report as supported by the kinetic experiments. A moderate monomer conversion of 61% was achieved within 10 mins, producing high-molecular-weight PγBL with M_n up to 37.5 kDa and good mechanical properties. The short polymerization time considerably reduced the energy cost for the ROP of γBL conducted at low temperature condition. This study may clear away obstacles for the scalable production and practical applications for PγBL.

Synthesis and Post-Functionalization of Poly(conjugated ester)s Based on 3-Methylene-1,5-dioxepan-2-one

Poly(α-methylene ester)s are an attractive type of functional aliphatic polyesters that represent a platform for the fabrication of various biodegradable and biomedical polymers. Herein, we report the controlled ring-opening polymerization (ROP) of a seven-membered α-methylene lactone (3-methylene-1,5-dioxepan-2-one, MDXO) that was synthesized based on the Baylis-Hillman reaction. The chemoselective ROP of MDXO was catalyzed by diphenyl phosphate (DPP) at 60 °C or stannous octoate (Sn(Oct)₂) at 130 °C, generating α-methylene-containing polyester (PMDXO) with a linear structure and easily tunable molar mass. The ring-opening copolymerization of MDXO with ε-caprolactone or 1,5-dioxepan-2-one was also performed under the catalysis of DPP or Sn(Oct)₂ to afford copolymers with different compositions and sequence structures that are influenced by the kinds of monomers and catalysts. PMDXO is a slowly crystallizable polymer with a glass transition temperature of ca. -33 °C, and its melting temperature and enthalpy are significantly influenced by the thermal history. The thermal properties of the copolymers are dependent on their composition and sequence structure. Finally, the post-modification of PMDXO based on the thiol-Michael addition reaction was briefly explored using triethylamine as a catalyst. Given the optimized condition, PMDXO could be dually modified to afford biodegradable polyesters with different functionalities.

Block Poly(carbonate-ester) Ionomers as High-Performance and Recyclable Thermoplastic Elastomers

Thermoplastic elastomers based on polyesters/carbonates have the potential to maximize recyclability, degradability and renewable resource use. However, they often underperform and suffer from the familiar trade-off between strength and extensibility. Herein, we report well-defined reprocessable poly(ester-b-carbonate-b-ester) elastomers with impressive tensile strengths (60 MPa), elasticity (>800 %) and recovery (95 %). Plus, the ester/carbonate linkages are fully degradable and enable chemical recycling. The superior performances are attributed to three features: (1) Highly entangled soft segments; (2) Fully reversible strain-induced crystallization and (3) Precisely placed ZnII -carboxylates dynamically crosslinking the hard domains. The one-pot synthesis couples controlled cyclic monomer ring-opening polymerization and alternating epoxide/anhydride ring-opening copolymerization. Efficient convresion to ionomers is achieved by reacting vinyl-epoxides to install ZnII -carboxylates.

Ring-Opening Polymerization of a Bicyclic Lactone: Polyesters Derived from Norcamphor with Complete Chemical Recyclability

Chemical recycling of polymers is an elegant approach to achieve a circular economy and address the sustainability and end-of-life issues of plastics. Herein, we report the ring-opening polymerization of a bicyclic lactone that is easily accessible from norcamphor. High molecular weight polyesters (M_n up to 164 kg mol^-1) are obtained using ZnEt₂ as catalyst, while the polymerizability of the monomer is good even at high temperatures. More importantly, the polymers can be completely depolymerized under thermolysis conditions to selectively recover the pristine monomer. Thus, the monomer design strategy of using ring-fused/hybridized lactones enables an innovative monomer-polymer system that shows both high polymerizability and high depolymerizability.