Precision Polymer Design in Microstructured Flow Reactors: Improved Control and First Upscale at Once

Continuous Polymer Synthesis and Manufacturing of Polyurethane Elastomers Enabled by Automation

Connecting polymer synthesis and processing is an important challenge for streamlining the manufacturing of polymeric materials. In this work, the automated synthesis of acrylate-capped polyurethane oligomers is integrated with vat photopolymerization 3D printing. This strategy enabled the rapid manufacturing of a library of polyurethane-based elastomeric materials with differentiated thermal and mechanical properties. The automated semicontinuous batch synthesis approach proved enabling for resins with otherwise short shelf lives because of the intimate connection between synthesis, formulation, and processing. Structure-property studies demonstrated the ability to tune properties through systematic alteration of cross-link density and chemical composition.

One-step flow synthesis of size-controlled polymer nanogels in a fluorocarbon microfluidic chip

Synthetic polymer nanoparticles (NPs) with biomimetic properties are ideally suited for different biomedical applications such as drug delivery and direct therapy. However, bulk synthetic approaches can suffer from poor reproducibility and scalability when precise size control or multi-step procedures are required. Herein, we report an integrated microfluidic chip for the synthesis of polymer NPs. The chip could sequentially perform homopolymer synthesis and subsequent crosslinking into NPs without intermediate purification. This was made possible by fabrication of the chip with a fluorinated elastomer and incorporation of two microfluidic mixers. The first was a long channel with passive mixing features for the aqueous RAFT synthesis of stimuli-responsive polymers in ambient conditions. The polymers were then directly fed into a hydrodynamic flow focusing (HFF) junction that rapidly mixed them with a crosslinker solution to produce NPs. Compared to microfluidic systems made of PDMS or glass, our chip had better compatibility and facile fabrication. The polymers were synthesized with high monomer conversion and the NP size was found to be influenced by the flow rate ratio between the crosslinker solution and polymer solution. This allowed for the size to be predictably controlled by careful adjustment of the fluid flow rates. The size of the NPs and their stimuli-responses were studied using DLS and SEM imaging. This microfluidic chip design can potentially streamline and provide some automation for the bottom-up synthesis of polymer NPs while offering on-demand size control.

Inverse Miniemulsion Enables the Continuous-Flow Synthesis of Controlled Ultra-High Molecular Weight Polymers

We report the controlled synthesis of ultra-high molecular weight (UHMW) polymers (Mn ≥ 106 g/mol) via continuous flow in a tubular reactor. At high monomer conversion, UHMW polymers in homogeneous batch polymerization exhibit high viscosities that pose challenges for employing continuous flow reactors. However, under heterogeneous inverse miniemulsion (IME) conditions, UHMW polymers can be produced within the dispersed phase, while the viscosity of the heterogeneous mixture remains approximately the same as the viscosity of the continuous phase. Conducting such IME polymerizations in flow results in a faster rate of polymerization compared to batch IME polymerizations while still providing excellent control over molecular weight up to 106 g/mol. Crucial emulsion parameters, such as particle size and stability under continuous flow conditions, were examined using dynamic light scattering. A range of poly(N,N-dimethylacrylamide) and poly(4-acryloylmorpholine) polymers with molecular weights of 104-106 g/mol (Đ ≤ 1.31) were produced by this method using water-soluble trithiocarbonates as photoiniferters.

Review of quantitative and qualitative methods for monitoring photopolymerization reactions

Authomatic in-situ monitoring and characterization of photopolymerization.

One-Pot Multifunctional Polyesters by Continuous Flow Organocatalysed Ring-Opening Polymerisation for Targeted and Tunable Materials Design

Targeted and tunable access to biodegradable polymers will be vital for their continued adoption and use in modern materials applications. Herein we report a platform for the synthesis of well-defined,...

Comprehensive studies of continuous flow reversible addition–fragmentation chain transfer copolymerization and its application for photoimaging materials

Thorough studies of RAFT copolymerization in a continuous flow to gain deeper insights into kinetics, reactivity, and applicability were conducted with monomers and solvents utilizable for chemically amplified resist systems.

Design, Fundamental Principles of Fabrication and Applications of Microreactors

This study highlights the development of small-scale reactors, in the form of microstructures with microchannel networking. Microreactors have achieved an impressive reputation, regarding chemical synthesis ability and their applications in the engineering, pharmaceutical, and biological fields. This review elaborates on the fabrication, construction, and schematic fundamentals in the design of the microreactors and microchannels. The materials used in the fabrication or construction of the microreactors include silicon, polymer, and glass. A general review of the application of microreactors in medical, biological, and engineering fields is carried out and significant improvements in these areas are reported. Finally, we highlight the flow patterns, mixing, and scaling-up of multiphase microreactor developments, with emphasis on the more significant industrial applications.

Role of External Field in Polymerization: Mechanism and Kinetics

The past decades have witnessed an increasing interest in developing advanced polymerization techniques subjected to external fields. Various physical modulations, such as temperature, light, electricity, magnetic field, ultrasound, and microwave irradiation, are noninvasive means, having superb but distinct abilities to regulate polymerizations in terms of process intensification and spatial and temporal controls. Gas as an emerging regulator plays a distinctive role in controlling polymerization and resembles a physical regulator in some cases. This review provides a systematic overview of seven types of external-field-regulated polymerizations, ranging from chain-growth to step-growth polymerization. A detailed account of the relevant mechanism and kinetics is provided to better understand the role of each external field in polymerization. In addition, given the crucial role of modeling and simulation in mechanisms and kinetics investigation, an overview of model construction and typical numerical methods used in this field as well as highlights of the interaction between experiment and simulation toward kinetics in the existing systems are given. At the end, limitations and future perspectives for this field are critically discussed. This state-of-the-art research progress not only provides the fundamental principles underlying external-field-regulated polymerizations but also stimulates new development of advanced polymerization methods.

Polymerizations in Continuous Flow: Recent Advances in the Synthesis of Diverse Polymeric Materials

The number of reports using continuous flow technology in tubular reactors to perform precision polymerizations has grown enormously in recent years. Flow polymerizations allow highly efficient preparation of polymers exhibiting well-defined molecular characteristics, and has been applied to a slew of monomers and various polymerization mechanisms, including anionic, cationic, radical, and ring-opening. Polymerization conducted in continuous flow offers several distinct advantages, including improved efficiency, reproducibility, and enhanced safety for exothermic polymerizations using highly toxic components, high pressures, and high temperatures. The further development of this technology is thus of relevance for many industrial polymerization processes. While much progress has been demonstrated in recent years, opportunities remain for increasing the compositional and architectural complexity of polymeric materials synthesized in a continuous fashion. Extending the reactor processing principles that have heretofore been focused on optimizing homopolymerization to include multisegment block copolymers, particularly from monomers that propagate via incompatible mechanisms, represents a major challenge and coveted target for continuous flow polymerization. Likewise, the spatial and temporal control of reactivity afforded by flow chemistry has and will continue to enable the production of complex polymeric architectures. This Viewpoint offers a brief background of continuous flow polymerization focused primarily on tubular (micro)reactors and includes selected examples that are relevant to these specific developments.

Activation of homogenous polyolefin catalysis with a machine-assisted reactor laboratory-in-a-box (μAIR-LAB)

Catalysis discovery is typically limited to specialized labs – this work demonstrates an Artificially Intelligent Microreactor Lab in a Box applied to investigate the chemistry of different co-catalysts for zirconocene-catalyzed olefin polymerization.

Rapid production of block copolymer nano-objects via continuous-flow ultrafast RAFT dispersion polymerisation

Continuous-flow reactors are exploited for conducting ultrafast RAFT dispersion polymerisation for the preparation of diblock copolymer nanoparticles.

Enabling technologies in polymer synthesis: accessing a new design space for advanced polymer materials

This review discusses how developments in laboratory technologies can push the boundaries of what is achievable using existing polymer synthesis techniques.

Flow chemistry controls self-assembly and cargo in Belousov-Zhabotinsky driven polymerization-induced self-assembly

Amphiphilic block-copolymer vesicles are increasingly used for medical and chemical applications, and a novel method for their transient self-assembly orchestrated by periodically generated radicals during the oscillatory Belousov-Zhabotinsky (BZ) reaction was recently developed. Here we report how combining this one pot polymerization-induced self-assembly (PISA) method with a continuously stirred tank reactor (CSTR) strategy allows for continuous and reproducible control of both the PISA process and the chemical features (e.g. the radical generation and oscillation) of the entrapped cargo. By appropriately tuning the residence time (τ), target degree of polymerization (DP) and the BZ reactants, intermediate self-assembly structures are also obtained (micelles, worms and nano-sized vesicles). Simultaneously, the chemical properties of the cargo at encapsulation are known and tunable, a key advantage over batch operation. Finally, we also show that BZ-driven polymerization in CSTR additionally supports more non-periodic dynamics such as bursting.

Adsorption and photocatalytic removal of Ibuprofen by activated carbon impregnated with TiO2 by UV-Vis monitoring

The removal of Ibuprofen was investigated by activated carbon impregnated with TiO₂. Emphasis was given on the effect of different parameters, such as composite type, initial Ibuprofen concentration (5-25 mg/L), temperature (22-28 °C) and pH (acidic and alkaline solution). The experiment was carried out in a self-made tubular flow reactor, with one 15 W monochromatic UV lamp (254 nm). The composite AC90T10 gives the highest removal degree of 92% of Ibuprofen solution under UV light within 4 h, due to synergy of adsorption and photodegradation. It was found that weight ratio of composite/Ibuprofen has limited effect on the removal degree within the concentration range (5-25 mg/L), but reaction time under UV light (4 h) and pH (acidic solution) are very important. The kinetic experimental data obtained at pH 4.3 at 25 °C on different composites were fitted to pseudo-first, pseudo-second and Elovich models, obtaining a high accuracy based on R² values. From the results, composites of granular activated carbon and TiO₂ can enhance removal of Ibuprofen effectively, making recycle process much easier and less costly, which can be a promising method in future water treatment.

All-aqueous continuous-flow RAFT dispersion polymerisation for efficient preparation of diblock copolymer spheres, worms and vesicles

A continuous-flow platform enables rapid kinetic profiling and accelerated production of block copolymer nano-objects via RAFT aqueous dispersion polymerization.

Continuous flow synthesis of core cross-linked star polymers via photo-induced copper mediated polymerization

A convenient method to synthesize core cross-linked star polymers via a continuous flow photopolymerization process is developed.

Flow-facilitated ring opening metathesis polymerization (ROMP) and post-polymerization modification reactions

Continuous flow facilitates ROMP reactions to prepare homopolymers and block copolymers and allows for in-line post-polymerization click modifications.

Alcohol-based PISA in batch and flow: exploring the role of photoinitiators

Polymerization-induced self-assembly (PISA) via PhotoRAFT (photoinduced reversible addition–fragmentation radical transfer) was investigated in polar solvents via continuous flow reactors.

Continuous-flow chemistry for the determination of comonomer reactivity ratios

Continuous-flow chemistry provides an operationally simple and reproducible method for the determination of comonomer reactivity ratios in a single afternoon.

The Light at the End of the Tunnel-Second Generation HPMA Conjugates for Cancer Treatment

It is almost four decades since N-(2-hydroxypropyl)methacrylamide (HPMA) - based copolymers arose as drug carriers. Although fundamentals have been established and significant advantages have been proved, the commercialization of this platform technology was hampered due to modest outcome of clinical trial initiated with PK1, the symbol of first generation polymer-drug conjugates. In this review, we illustrate the exciting progress and approaches offered by more effective 2^nd generation HPMA-based polymer-drug conjugates in cancer treatment. For example, a new synthetic strategy endorses inert HPMA polymer with biodegradability, which permitted to prepare high molecular weight HPMA-drug conjugates with simple linear architecture while maintaining good biocompatibility. As expected, extended long-circulating pharmacokinetics and enhanced antitumor activities were achieved in several preclinical investigations. In addition, greater inhibition of tumor growth in combination regimes exhibits the remarkable capability and flexibility of HPMA-based macromolecular therapeutics. The review also discusses the main challenges and strategies for further translation development of 2^nd generation HPMA-based polymer-drug conjugates.

A photochemical flow reactor for large scale syntheses of aglain and rocaglate natural product analogues

Herein, we report the development of continuous flow photoreactors for large scale ESIPT-mediated [3+2]-photocycloaddition of 2-(p-methoxyphenyl)-3-hydroxyflavone and cinnamate-derived dipolarophiles. These reactors can be efficiently numbered up to increase throughput two orders of magnitude greater than the corresponding batch reactions.

Photo-induced ring-closure via a looped flow reactor

Looped flow processes are an efficient and versatile tool to synthesize cyclic macromolecular materials.

RAFT multiblock reactor telescoping: from monomers to tetrablock copolymers in a continuous multistage reactor cascade

Well-defined multiblock copolymers were synthesized via reversible addition-fragmentation chain transfer radical polymerization in a fully continuous multireactor cascade.

Visible light-induced iniferter polymerization of methacrylates enhanced by continuous flow

Visible-light induced photoiniferter polymerization in continuous flow reactors is very efficient in yielding low dispersity methacrylate block copolymers.

High-throughput polymer screening in microreactors: boosting the Passerini three component reaction

The Passerini three-component reaction (Passerini-3CR) has been studied via on-line microreactor/electrospray ionisation mass spectrometry (MRT/ESI-MS) reaction monitoring to demonstrate the high-throughput screening potential of microreactors for macromolecular design.