Synthesis of Renewable Copolyacetals with Tunable Degradation

Solvent-Free Synthesis of Closed-Loop Recyclable Acetal Thermosets Derived from Biobased Resources

Thermosetting plastics are essential in industry and daily life due to their superior thermal and mechanical properties, however their nonrecyclability and reliance on petroleum resources pose environmental concerns. Developing biobased thermosets with efficient chemical recycling capabilities is therefore crucial for advancing a circular plastic economy and reducing environmental impact. Herein, this study reports the synthesis of recyclable acetal thermosets via the polycondensation of a biobased vanillin-derived aldehyde and diols, utilizing oxalic acid as a catalyst, which can be easily removed during thermal postcuring. The resulting thermosets exhibit excellent mechanical performance, with tensile strengths up to 95 MPa, Young's moduli of ≈3.3 GPa, and a glass transition temperature (Tg) of ≈70 °C. More importantly, the thermosets are efficiently depolymerized under mild acidic conditions into their original monomers, which are easily isolated in high purity, with yields of 72% and 98% for the diol and aldehyde, respectively. These monomers were subsequently reused to synthesize new, identical thermosets, achieving closed-loop recycling. This research addresses the environmental challenges posed by traditional thermosets, offering a practical solution for sustainable polymer recycling without compromising material performance. The solvent-free approach further enhances its industrial viability, making a promising step toward a more sustainable strategy for closed-loop recyclable thermosets.

Sustainable and Scalable Synthesis of Acetal-Containing Polyols as a Platform for Circular Polyurethanes

Polyurethanes (PUs) are highly versatile polymers widely utilized across industries. However, chemical recycling of PU poses significant challenges due to the harsh conditions required and the formation of complex mixtures of oligomers upon depolymerization. Addressing this inherent lack of recyclability, we developed closed-loop recyclable PU materials by integrating cleavable acetal groups. We present a sustainable and scalable synthesis method for acetal-containing polyols (APs) through aldehyde-diol polycondensation, utilizing reusable heterogeneous catalysts. Three APs with different hydrolytic stabilities depending on the structure of acetal groups were synthesized from formaldehyde, acetaldehyde, and propionaldehyde with 1,6-hexanediol (H16). These APs were employed alongside 4,4'-methylene diisocyanate (MDI) for preparation of PU materials. The resulting PUs exhibited mechanical properties comparable to or surpassing those of conventional PUs, while demonstrating excellent recyclability under acidic conditions. Notably, hydrolysis of PU materials based on acetaldehyde-derived APs yielded remarkable monomer recovery rates, with 89 % for H16 and 84 % for 4,4'-methylenedianiline, a precursor to MDI. Furthermore, we successfully demonstrated closed-loop recycling by synthesizing APs from recovered H16, resulting in PU materials with identical properties to the original PU. This achievement highlights the potential for establishing a closed-loop recycling system for acetal-containing PUs, contributing to the advancement of a sustainable and circular economy.

High Bio-Content Thermoplastic Polyurethanes from Azelaic Acid

To realize the commercialization of sustainable materials, new polymers must be generated and systematically evaluated for material characteristics and end-of-life treatment. Polyester polyols made from renewable monomers have found limited adoption in thermoplastic polyurethane (TPU) applications, and their broad adoption in manufacturing may be possible with a more detailed understanding of their structure and properties. To this end, we prepared a series of bio-based crystalline and amorphous polyester polyols utilizing azelaic acid and varying branched or non-branched diols. The prepared polyols showed viscosities in the range of 504–781 cP at 70 °C, with resulting TPUs that displayed excellent thermal and mechanical properties. TPUs prepared from crystalline azelate polyester polyol exhibited excellent mechanical properties compared to TPUs prepared from amorphous polyols. These were used to demonstrate prototype products, such as watch bands and cup-shaped forms. Importantly, the prepared TPUs had up to 85% bio-carbon content. Studies such as these will be important for the development of renewable materials that display mechanical properties suitable for commercially viable, sustainable products.

Renewable Polyurethanes from Sustainable Biological Precursors

Due to the depletion of fossil fuels, higher oil prices, and greenhouse gas emissions, the scientific community has been conducting an ongoing search for viable renewable alternatives to petroleum-based products, with the anticipation of increased adaptation in the coming years. New academic and industrial developments have encouraged the utilization of renewable resources for the development of ecofriendly and sustainable materials, and here, we focus on those advances that impact polyurethane (PU) materials. Vegetable oils, algae oils, and polysaccharides are included among the major renewable resources that have supported the development of sustainable PU precursors to date. Renewable feedstocks such as algae have the benefit of requiring only sunshine, carbon dioxide, and trace minerals to generate a sustainable biomass source, offering an improved carbon footprint to lessen environmental impacts. Incorporation of renewable content into commercially viable polymer materials, particularly PUs, has increasing and realistic potential. Biobased polyols can currently be purchased, and the potential to expand into new monomers offers exciting possibilities for new product development. This Review highlights the latest developments in PU chemistry from renewable raw materials, as well as the various biological precursors being employed in the synthesis of thermoset and thermoplastic PUs. We also provide an overview of literature reports that focus on biobased polyols and isocyanates, the two major precursors to PUs.

Catalyst-Free Metathesis of Cyclic Acetals and Spirocyclic Acetal Covalent Adaptable Networks

Due to the exchangeability of dynamic covalent bonds in the covalent adaptable networks (CANs) at elevated temperature, they possess recyclability while still maintaining many of the superior properties of thermosets. The exploration of dynamic covalent chemistry is of great significance to the expansion of CANs library and hence the sustainable development of thermosets. In this work, we discovered that, in absence of catalyst, the direct metathesis of the cyclic acetals proceeds while the acyclic acetals cannot. The metathesis kinetics of the cyclic acetals were fully revealed with model compounds. For the CANs demonstration, a series of cross-linked spirocyclic acetal polymers with excellent reprocessability, high thermal stability, and high refractivity were prepared via thiol-ene click polymerization. We envisage that the uncovering of the catalyst-free metathesis of cyclic acetals will enrich the dynamic chemistry of acetals and greatly promote the development of acetal-based CANs and their potential applications in optical devices.

Thermoplastic polyacetals: chemistry from the past for a sustainable future?

This review serves as a guide to the synthesis and applications of thermoplastic polyacetals, highlighting in particular sustainability and degradability aspects.

Sustainable polyvinyl acetals from bioaromatic aldehydes

Water-degradable polyvinyl acetals with high glass transition temperatures (114–157 °C) were made via acetalization of polyvinyl alcohol (PVA) with bioaromatic aldehydes.