Rigid Polyurethanes, Polyesters, and Polycarbonates from Renewable Ketal Monomers

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.

Self-evolutionary recycling of flame-retardant polyurethane foam enabled by controllable catalytic cleavage

Polyurethane (PU) foams, pivotal in modern life, face challenges suh as fire hazards and environmental waste burdens. The current reliance of PU on potentially ecotoxic halogen-/phosphorus-based flame retardants impedes large-scale material recycling. Here, our demonstrated controllable catalytic cracking strategy, using cesium salts, enables self-evolving recycling of flame-retardant PU. The incorporation of cesium citrates facilitates efficient urethane bond cleavage at low temperatures (160 °C), promoting effective recycling, while encouraging pyrolytic rearrangement of isocyanates into char at high temperatures (300 °C) for enhanced PU fire safety. Even in the absence of halogen/phosphorus components, this foam exhibits a substantial increase in ignition time (+258.8%) and a significant reduction in total smoke release (-79%). This flame-retardant foam can be easily recycled into high-quality polyol under mild conditions, 60 °C lower than that for the pure foam. Notably, the trace amounts of cesium gathered in recycled polyols stimulate the regenerated PU to undergo self-evolution, improving both flame-retardancy and mechanical properties. Our controllable catalytic cracking strategy paves the way for the self-evolutionary recycling of high-performance firefighting materials.

Polymers without Petrochemicals: Sustainable Routes to Conventional Monomers

Access to a wide range of plastic materials has been rationalized by the increased demand from growing populations and the development of high-throughput production systems. Plastic materials at low costs with reliable properties have been utilized in many everyday products. Multibillion-dollar companies are established around these plastic materials, and each polymer takes years to optimize, secure intellectual property, comply with the regulatory bodies such as the Registration, Evaluation, Authorisation and Restriction of Chemicals and the Environmental Protection Agency and develop consumer confidence. Therefore, developing a fully sustainable new plastic material with even a slightly different chemical structure is a costly and long process. Hence, the production of the common plastic materials with exactly the same chemical structures that does not require any new registration processes better reflects the reality of how to address the critical future of sustainable plastics. In this review, we have highlighted the very recent examples on the synthesis of common monomers using chemicals from sustainable feedstocks that can be used as a like-for-like substitute to prepare conventional petrochemical-free thermoplastics.

End-of-life upcycling of polyurethanes using a room temperature, mechanism-based degradation

A major challenge in developing recyclable polymeric materials is the inherent conflict between the properties required during and after their life span. In particular, materials must be strong and durable when in use, but undergo complete and rapid degradation, ideally under mild conditions, as they approach the end of their life span. We report a mechanism for degrading polymers called cyclization-triggered chain cleavage (CATCH cleavage) that achieves this duality. CATCH cleavage features a simple glycerol-based acyclic acetal unit as a kinetic and thermodynamic trap for gated chain shattering. Thus, an organic acid induces transient chain breaks with oxocarbenium ion formation and subsequent intramolecular cyclization to fully depolymerize the polymer backbone at room temperature. With minimal chemical modification, the resulting degradation products from a polyurethane elastomer can be repurposed into strong adhesives and photochromic coatings, demonstrating the potential for upcycling. The CATCH cleavage strategy for low-energy input breakdown and subsequent upcycling may be generalizable to a broader range of synthetic polymers and their end-of-life waste streams.

Recent Advances in Lignocellulose-Based Monomers and Their Polymerization

Replacing fossil-based polymers with renewable bio-based polymers is one of the most promising ways to solve the environmental issues and climate change we human beings are facing. The production of new lignocellulose-based polymers involves five steps, including (1) fractionation of lignocellulose into cellulose, hemicellulose, and lignin; (2) depolymerization of the fractionated cellulose, hemicellulose, and lignin into carbohydrates and aromatic compounds; (3) catalytic or thermal conversion of the depolymerized carbohydrates and aromatic compounds to platform chemicals; (4) further conversion of the platform chemicals to the desired bio-based monomers; (5) polymerization of the above monomers to bio-based polymers by suitable polymerization methods. This review article will focus on the progress of bio-based monomers derived from lignocellulose, in particular the preparation of bio-based monomers from 5-hydroxymethylfurfural (5-HMF) and vanillin, and their polymerization methods. The latest research progress and application scenarios of related bio-based polymeric materials will be also discussed, as well as future trends in bio-based polymers.

Chemically Recyclable Poly(β-thioether ester)s Based on Rigid Spirocyclic Ketal Diols Derived from Citric Acid

Incorporating rigid cyclic acetal and ketal units into polymer structures is an important strategy toward recyclable high-performance materials from renewable resources. In the present work, citric acid, a widely used platform chemical derived from biomass, has been efficiently converted into di- and tricyclic diketones. Ketalization with glycerol or trimethylolpropane afforded rigid spirodiols, which were obtained as complex mixtures of isomers. After a comprehensive NMR analysis, the spirodiols were converted into the respective di(meth)acrylates and utilized in thiol–ene polymerizations in combination with different dithiols. The resulting poly(β-thioether ester ketal)s were thermally stable up to 300 °C and showed glass-transition temperatures in a range of −7 to 40 °C, depending on monomer composition. The polymers were stable in aqueous acids and bases, but in a mixture of 1 M aqueous HCl and acetone, the ketal functional groups were cleanly hydrolyzed, opening the pathway for potential chemical recycling of these materials. We envision that these novel bioderived spirodiols have a great potential to become valuable and versatile bio-based building blocks for several different kinds of polymer materials.

Hydrolyzable Poly(β-Thioether Ester Ketal) Thermosets via Acyclic Ketal Monomers

Hydrolytically degradable poly(β-thioether ester ketal) thermosets are synthesized via radical-mediated thiol-ene photopolymerization using three novel dialkene acyclic ketal monomers and a mercaptopropionate based tetrafunctional thiol. For all thermoset compositions investigated, degradation behavior is highly tunable based on the structure of the incorporated ketal and pH. Complete degradation of the thermosets is observed upon exposure to acidic and neutral pH, and under high humidity conditions. Polymer networks comprised of crosslink junctions based on acyclic dimethyl ketals degrade the quickest, whereas networks containing acyclic cyclohexyl ketals undergo hydrolytic degradation on a longer timescale. Thermomechanical analysis revealed low glass transition temperatures and moduli typical of thioether-based thermosets. This article is protected by copyright. All rights reserved.

Synthesis of Mono Ethylene Glycol (MEG)-Based Polyurethane and Effect of Chain Extender on Its Associated Properties

This study depicts the investigations of the effect of composition of aromatic polyester polyol produced from terephthalic acid (TPA) and different concentrations of mono ethylene glycol (mEG) as a chain extender on the mechanical properties of polyurethane (PU) elastomer. Aromatic polyester polyols are prepared via the poly-esterification of adipic acid, terephthalic acid, catalyst, and mono ethylene glycol; while a polyurethane elastomer is formulated via the pre-polymerization of polyol with pure monomeric Methylene diphenyl diisocyanate (MDI.) Mechanical properties of polyurethane elastomers are examined, such as hardness via shore A hardness, apparent density via ASTM (American Society for Testing and Materials) D1622–08, and abrasion wear resistance via a Deutches Institut fur Normung (DIN) abrasion wear resistance tester. Structural properties are investigated through Fourier-transform infrared spectroscopy (FTIR) analysis. Results reveal that the shore A hardness of the PU elastomer increases with an increasing concentration of mEG from 4g to 12g. Nevertheless, the elastomer’s density depicts a reduction with an increasing extender content. The abrasion wear resistance of polyurethane, however, increases with an increasing concentration of glycol. A structural analysis through FTIR confirms the formation of polyurethane elastomer through the characteristic peaks demonstrated.

Degradable Spirocyclic Polyacetal-Based Core-Amphiphilic Assemblies for Encapsulation and Release of Hydrophobic Cargo

Polymeric nanomaterials that degrade in acidic environments have gained considerable attention in nanomedicine for intracellular drug delivery and cancer therapy. Among various acid-degradable linkages, spirocyclic acetals have rarely been used to fabricate such vehicles. In addition to acid sensitivity, they benefit from conformational rigidity that is otherwise not attainable by their non-spirocyclic analogs. Herein, amphiphilic spirocyclic polyacetals are synthesized by Cu-catalyzed alkyne-azide "click" polymerization. Unlike conventional block copolymers, which often form core-shell structures, these polymers self-assemble to form core amphiphilic assemblies capable of encapsulating Nile red as a hydrophobic model drug. In vitro experiments show that while release from these materials can occur at neutral pH with preservation of their integrity, acidic pH accelerates efficient cargo release and leads to the complete degradation of assemblies. Moreover, cellular assays reveal that these materials are fully cytocompatible, interact with the plasma membrane, and can be internalized by cells, rendering them as potential candidates for cancer therapy and/or drug delivery.

Synthesis and melt-spinning of partly bio-based thermoplastic poly(cycloacetal-urethane)s toward sustainable textiles

Partly bio-based thermoplastic poly(cycloacetal-urethane)s synthesized and melt-spun into textile fibres that can be potentially chemically recycled.

Synthesis and characterization of BPA-free polyesters by incorporating a semi-rigid cyclobutanediol monomer

A trans-1,3-cyclobutane-containing diol (CBDO-1) has been synthesized and introduced to materials science as a versatile monomer and a possible phenol-free BPA replacement.

Synthesis, Thermal Properties, and Rheological Characteristics of Indole-Based Aromatic Polyesters

Currently, there is an intensive development of bio-based aromatic building blocks to replace fossil-based terephthalates used for poly(ethylene terephthalate) production. Indole is a ubiquitous aromatic unit in nature, which has great potential as a bio-based feedstock for polymers or plastics. In this study, we describe the synthesis and characterization of new indole-based dicarboxylate monomers with only aromatic ester bonds, which can improve the thermal stability and glass-transition temperature (T _g) of the resulting polyesters. The new dicarboxylate monomers were polymerized with five aliphatic diols to yield 10 new polyesters with tunable chemical structures and physical properties. Particularly, the T _g values of the obtained polyesters can be as high as 113 °C, as indicated by differential scanning calorimetry and dynamic mechanical analysis. The polyesters showed decent thermal stability and distinct flow transitions as revealed by thermogravimetric analysis and rheology measurements.

Reductive Amination/Cyclization of Methyl Levulinate with Aspartic Acid: Towards Renewable Polyesters with a Pendant Lactam Unit

Environmental regulation and depletion of fossil resources are boosting the search for new polymeric materials produced from biomass. Here, the synthesis of a new diester bearing a pendant lactam unit from methyl levulinate and aspartic acid is reported. The palladium-catalyzed reductive amination/cyclization sequence was carefully optimized to afford the diacid with high yield (>95 %). In a second step, the compound was esterified to give the corresponding diester. The latter monomer was copolymerized with α-ω linear diols, yielding polyesters with molecular weights up to 20.5 kg mol^-1 .

Designing Biobased Recyclable Polymers for Plastics

Several concurrent developments are shaping the future of plastics. A transition to a sustainable plastics system requires not only a shift to fossil-free feedstock and energy to produce the carbon-neutral building blocks for polymers used in plastics, but also a rational design of the polymers with both desired material properties for functionality and features facilitating their recyclability. Biotechnology has an important role in producing polymer building blocks from renewable feedstocks, and also shows potential for recycling of polymers. Here, we present strategies for improving the performance and recyclability of the polymers, for enhancing degradability to monomers, and for improving chemical recyclability by designing polymers with different chemical functionalities.

Copolycarbonates Based on a Bicyclic Diol Derived from Citric Acid and Flexible 1,4-Cyclohexanedimethanol: From Synthesis to Properties

Octahydro-2,5-pentalenediol (OPD), is a compelling citric acid-based bicyclic diol with excellent rigidity and thermal stability. Herein, a series of copolycarbonates (co-PCs) were synthesized, starting from OPD, 1,4-cyclohexanedimethanol (CHDM), and diphenyl carbonate (DPC). All polycarbonates are amorphous with glass transition temperatures increased when increasing the content in OPD units. Dynamic mechanical analysis (DMA) revealed the sub T_g β-relaxations at low temperatures originating from the CHDM conformational transition, indicative of the possibility of impact-resistance. Morphological analysis of the fracture surfaces revealed the toughening mechanism under tensile was shear yielding of the matrix triggered by internal cavitation. The incorporation of OPD steadily increased the Young's modulus, from 482 to 757 MPa, with the OPD fraction increased from 0 to 30 mol %. As the OPD content further increased, a "ductile-to-brittle" transition occurred due to the low number-average molecular weight (M_n) and the low entangled strand density (high entanglement molecular weight).

Hydrolytically degradable poly(β-thioether ester ketal) thermosets via radical-mediated thiol–ene photopolymerization

Poly(β-thioether ester ketal) networks are reported that undergo complete degradation with tuneable degradation profiles under acid and/or basic conditions.

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.

Polycycloacetals via polytransacetalization of diglycerol bisacetonide

Diglycerol bisacetonide sourced from renewable, abundant and inexpensive glycerol is introduced as a building block for polycycloacetal (co)polymers, which cover a range in thermal and mechanical properties and degradability profile.

Vanillin derived a carbonate dialdehyde and a carbonate diol: novel platform monomers for sustainable polymers synthesis

Vanillin has been regarded as one of the important biomass-based platform chemicals for aromatic polymers synthesis. Herein, novel symmetric bis(4-formyl-2-methoxyphenyl)carbonate (BFMC) and bis(4-(hydroxymethyl)-2-methoxyphenyl)carbonate (BHMC) polymeric monomers have been synthesized in high yields using vanillin as a raw chemical, which have been submitted for polymer synthesis via well-established polymeric strategies. A new class of poly(carbonate ester)s oligomers with amide moieties in their side chain can be prepared by using the BFMC as one of monomers via the Passerini three compound reaction (3CR). A new class of poly(carbonate ester)s oligomers and poly(carbonate urethane)s can be prepared via reactions between BHMC with dicarboxylic acid chlorides and diisocyanates, respectively. Their structure have been confirmed by ¹H NMR, ¹³C NMR and FTIR, and the gel permeation chromatograph (GPC) analysis shows that the Mn of poly(carbonate ester)s oligomers ranges from 3100 to 7900 with PDI between 1.31 and 1.65, and the Mn of poly(carbonate urethane)s ranges from 16 400 to 24 400 with PDI ranging from 1.36 to 2.17. The DSC analysis shows that the poly(carbonate ester)s oligomers have relative low T_g ranging from 37.4 to 74.1 °C, and the poly(carbonate urethane)s have T_g ranging from 97.3 to 138.3 °C, mainly correlating to the structure of dicarboxylic acid chlorides and diisocyanates used.

Novel classes of lignin-derived poly(carbonate ester)s, poly(carbonate ester)s pending amide moiety oligomers, and poly(carbonate urethane)s have been designed and synthesized.