Photoinduced Iron-Catalyzed ATRP of Renewable Monomers in Low-Toxicity Solvents: A Greener Approach

Vapor Deposition of Polymer Structures: From 2D Surface Coatings and Surface Microstructures to 3D Building Blocks and Structural Monoliths

Vapor deposition of polymers offers precise control over polymerization, enabling the creation of uniform thin films, conformal coatings, and complex geometries. These methods produce pinhole-free films with tailored physical and chemical properties while addressing the limitations of conventional solution-based techniques. Recent advancements have extended polymer fabrication beyond thin films to include surface patterns, microstructures, and 3D architectures. This review provides an overview of vapor deposition methods, polymerization mechanisms, and processes for fabricating microstructures and 3D architectures. This review highlights the progress of vapor-deposited polymers, from simple coatings to complex, multifunctional structures. By integrating precise structural control with chemical versatility, these advancements open new opportunities for innovative material design and address the growing demands of modern applications.

Toward Sustainable Materials: From Lignocellulosic Biomass to High-Performance Polymers

Lignocellulosic biomass is an ideal feedstock for the next generation of sustainable, high-performance, polymeric materials. Although lignin is a highly available and low-cost source of natural aromatics, it is commonly burned for heat or disposed of as waste. The use of lignin for new materials introduces both challenges and opportunities with respect to incumbent petrochemical-based compounds. These considerations are derived from two fundamental aspects of lignin: its recalcitrant/heterogeneous nature and aromatic methoxy substituents. This Account highlights four key efforts from the Epps group and collaborators that established innovative methods/processes to synthesize polymers from lignin deconstruction products to unlock application potential, with a particular focus on the polymerization of biobased monomer mixtures, development of structure-property-processing relationships for diverse feedstocks, functional benefits of methoxy substituents, and scalability of lignin deconstruction. First, lignin-derivable polymethacrylate systems were probed to investigate the polymerization behavior of methacrylate monomers and predict thermomechanical properties of polymers from monomer mixtures. Notably, the glass transition temperatures (T gs) of lignin-derivable polymethacrylates (∼100-200 °C) were comparable to, or significantly above, those of petroleum-based analogues, such as polystyrene (∼100 °C), and the T gs of the complex, biobased copolymers could be predicted by the Fox equation prior to biomass deconstruction. Second, an understanding of structure-property relationships in polymethacrylates was applied to create performance-advantaged pressure-sensitive adhesives (PSAs) using phenolic-rich bio-oil obtained from the reductive catalytic fractionation of poplar wood. The use of actual lignin-derived monomers as the starting material was an important step because it underscored that nanostructure-forming, multiblock polymers could be readily made despite the complexity of real lignin deconstruction products. This work also highlighted that lignin-based phenolics could be used to make colorless/odorless PSAs, without complex separations/purifications, and still perform as well as commercial adhesives. Third, an intensified reductive catalytic deconstruction (RCD) process was developed to deconstruct lignin at ambient conditions, and the deconstructed products were successfully employed in 3D printing. The reactive distillation-RCD process operated at ambient pressure using a low-volatility and biobased solvent (glycerin) as a hydrogen donor, which reduced capital/operating costs, energy use, and safety hazards associated with conventional RCD. Technoeconomic analysis showed that such optimization could lead to a 60% reduction in cost to make the PSAs described above. Fourth, lignin-derivable bisguaiacols/bissyringols were explored as potential alternatives to petroleum-derived bisphenol A (BPA) in diamine-cured epoxy resins. A distinguishing feature of the lignin monomers (vs. BPA/bisphenol F [BPF]) was the presence of methoxy groups on the aromatic rings, and these methoxy moieties enabled tuning of application-specific properties, such as T g, degradation temperature (T d), and glassy storage modulus (E'), to achieve improved processing and performance. The lignin-derivable thermosets exhibited T gs above 100 °C, T ds above 300 °C, and E's above 2 GPa, all values that were comparable to those of BPA-/BPF-based analogues. Moreover, the methoxy groups on these lignin-derivable compounds sterically hindered hormone receptor binding and could mitigate many of the toxicity concerns associated with BPA/BPF. This Account concludes with suggestions on future research needed to advance lignin-derived materials as sustainable and performance-advantaged alternatives by leveraging recycling/upcycling strategies and scaling-up/commercializing biomass waste.

Initiators for Continuous Activator Regeneration (ICAR) Depolymerization

Chemical recycling of polymers synthesized by atom transfer radical polymerization (ATRP) typically requires high temperatures (i.e., 170 °C) to operate effectively, not only consuming unnecessary energy but also compromising depolymerization yields due to unavoidable end-group deterioration. To overcome this, the concept of initiators for continuous activator regeneration (ICAR) depolymerization is introduced herein as a broadly applicable approach to significantly reduce reaction temperatures for ATRP depolymerizations. Addition of commercially available free radical initiators enables the on-demand increase of depolymerization efficiency from <1% to 96%, achieving monomer generation at 120 °C, with conversions on par with thermal reversible addition-fragmentation chain transfer (RAFT) depolymerizations. Incubation studies confirm the elimination of deleterious side reactions at the milder temperatures employed, while the methodology can be scaled up to 1 g. The robustness and versatility of ICAR depolymerization is further demonstrated by the possibility to effectively depolymerize both chlorine and bromine terminated polymers and its compatibility with both copper and iron catalysts.

RAFT solution polymerisation of bio-based γ-methyl-α-methylene-γ-butyrolactone monomer in DMSO and Cyrene

Reversible addition fragmentation chain transfer (RAFT) solution polymerisation of the bio-based lactone monomer γ-methyl-α-methylene-γ-butyrolactone (γMeMBL) has been demonstrated in DMSO and Cyrene. RAFT control was evidenced by control over molecular weights, low disperisites, and kinetic evaluation. Purified P(γMeMBL) homopolymers exhibited high glass transition temperatures (206-221 °C) and excellent thermal stabilities. This work demonstrates the first RAFT solution polymerisation of γMeMBL and the first example of RAFT polymerisation in Cyrene.

Hydrophobic Aerogels from Vinyl Polymers Derived from Radical Polymerization: Proof-of-Concept

Hydrophilicity is one important drawback of bio-based aerogels. To overcome this issue, a novel approach for the preparation of mesoporous, water repellent aerogels is introduced, which combines synthesis of cross-linked bio-based copolymers from methacrylate copolymerizations, followed by solvent exchange and supercritical drying steps. The influence of monomers with different nonpolar ester groups (methyl, vanillin, tetrahydrofurfuryl) on textural properties and water contact angles of the dry products is assessed. Final aerogels show generally high overall porosities (≈96%), low densities (0.07-0.11 g cm-3) as well as fine, mainly mesoporous networks, and specific surface areas in the range of 120-240 m2 g-1. Hereby, choice of the methacrylate ester groups results in differences of the resulting pore-size distributions. Water repellency tests show stable static water contact angles in the hydrophobic range (≈100°) achieved for the substrate containing the vanillin ester group. On the contrary the other substrates absorb water quickly, which indicates a decisive role of the ester group. The presented approach opens up a new pathway to bio-based aerogels with intrinsic hydrophobicity. It is suggested that the properties are tailored by the choice of the monomer structure, hence enabling further adaption and optimization of the products.

Chemical recycling of bromine-terminated polymers synthesized by ATRP

Chemical recycling of polymers is one of the biggest challenges in materials science. Recently, remarkable achievements have been made by utilizing polymers prepared by controlled radical polymerization to trigger low-temperature depolymerization. However, in the case of atom transfer radical polymerization (ATRP), depolymerization has nearly exclusively focused on chlorine-terminated polymers, even though the overwhelming majority of polymeric materials synthesized with this method possess a bromine end-group. Herein, we report an efficient depolymerization strategy for bromine-terminated polymethacrylates which employs an inexpensive and environmentally friendly iron catalyst (FeBr2/L). The effect of various solvents and the concentration of metal salt and ligand on the depolymerization are judiciously explored and optimized, allowing for a depolymerization efficiency of up to 86% to be achieved in just 3 minutes. Notably, the versatility of this depolymerization is exemplified by its compatibility with chlorinated and non-chlorinated solvents, and both Fe(ii) and Fe(iii) salts. This work significantly expands the scope of ATRP materials compatible with depolymerization and creates many future opportunities in applications where the depolymerization of bromine-terminated polymers is desired.

Simple Iron Halides Enable Electrochemically Mediated ATRP in Nonpolar Media

An electrochemically controlled atom transfer radical polymerization (eATRP) was successfully carried out with a minimal amount (ppm-level) of FeBr3 catalyst in a nonpolar solvent, specifically anisole. Traditionally, nonpolar media have been advantageous for Fe-based ATRP, but their low conductivity has hindered any electrochemical application. This study introduces the application of electrocatalytic methods in a highly nonpolar polymerization medium. Precise control over the polymerization was obtained by employing anhydrous anisole with only 400 ppm of FeBr3 and applying a negative overpotential of 0.3 V. Additionally, employing an undivided cell setup with two simple iron wire electrodes resulted in a significant 15-fold reduction in electrical resistance compared to traditional divided cell setups. This enabled the production of polymers with a dispersity of ≤1.2. Lastly, an examination of kinetic and thermodynamic aspects indicated that the ppm-level catalysis was facilitated by the high ATRP equilibrium constant of Fe catalysts in nonpolar environments.

Photocatalytic ATRP Depolymerization: Temporal Control at Low ppm of Catalyst Concentration

A photocatalytic ATRP depolymerization is introduced that significantly suppresses the reaction temperature from 170 to 100 °C while enabling temporal regulation. In the presence of low-toxicity iron-based catalysts and under visible light irradiation, near-quantitative monomer recovery could be achieved (up to 90%), albeit with minimal temporal control. By employing ppm concentrations of either FeCl2 or FeCl3, the depolymerization during the dark periods could be completely eliminated, thus enabling temporal control and the possibility to modulate the rate by simply turning the light "on" and "off". Notably, our approach allowed preservation of the end-group fidelity throughout the reaction, could be carried out at high polymer loadings (up to 2M), and was compatible with various polymers and light sources. This methodology provides a facile, environmentally friendly, and temporally regulated route to chemically recycle ATRP-synthesized polymers, thus opening the door for further opportunities.

Oxygen-Enhanced Atom Transfer Radical Polymerization through the Formation of a Copper Superoxido Complex

In controlled radical polymerization, oxygen is typically regarded as an undesirable component resulting in terminated polymer chains, deactivated catalysts, and subsequent cessation of the polymerization. Here, we report an unusual atom transfer radical polymerization whereby oxygen favors the polymerization by triggering the in situ transformation of CuBr/L to reactive superoxido species at room temperature. Through a superoxido ARGET-ATRP mechanism, an order of magnitude faster polymerization rate and a rapid and complete initiator consumption can be achieved as opposed to when unoxidized CuBr/L was instead employed. Very high end-group fidelity has been demonstrated by mass-spectrometry and one-pot synthesis of block and multiblock copolymers while pushing the reactions to reach near-quantitative conversions in all steps. A high molecular weight polymer could also be targeted (DP_n = 6400) without compromising the control over the molar mass distributions (Đ < 1.20), even at an extremely low copper concentration (4.5 ppm). The versatility of the technique was demonstrated by the polymerization of various monomers in a controlled fashion. Notably, the efficiency of our methodology is unaffected by the purity of the starting CuBr, and even a brown highly-oxidized 15-year-old CuBr reagent enabled a rapid and controlled polymerization with a final dispersity of 1.07, thus not only reducing associated costs but also omitting the need for rigorous catalyst purification prior to polymerization.

Excitation Dependence in Photoiniferter Polymerization

We report on a fundamental feature of photoiniferter polymerizations mediated with trithiocarbonates and xanthates. The polymerizations were found to be highly dependent on the activated electronic excitation of the iniferter. Enhanced rates of polymerization and greater control over molecular weights were observed for trithiocarbonate- and xanthate-mediated photoiniferter polymerizations when the n → π* transition of the iniferter was targeted compared to the polymerizations activating the π → π* transition. The disparities in rates of polymerization were attributed to the increased rate of C-S photolysis which was confirmed using model trapping studies. This study provides valuable insight into the role of electronic excitations in photoiniferter polymerization and provides guidance when selecting irradiation conditions for applications where light sensitivity is important.

Light-accelerated depolymerization catalyzed by Eosin Y

Retrieving the starting monomers from polymers synthesized by reversible deactivation radical polymerization has recently emerged as an efficient way to increase the recyclability of such materials and potentially enable their industrial implementation. To date, most methods have primarily focused on utilizing high temperatures (typically from 120 °C to 180 °C) to trigger an efficient depolymerization reaction. In this work, we show that, in the presence of Eosin Y under light irradiation, a much faster depolymerization of polymers made by reversible addition-fragmentation chain-transfer (RAFT) polymerization can be triggered even at a lower temperature (i.e. 100 °C). For instance, green light, in conjunction with ppm amounts of Eosin Y, resulted in the accelerated depolymerization of poly(methyl methacrylate) from 16% (thermal depolymerization at 100 °C) to 37% within 1 hour, and finally 80% depolymerization after 8 hours, as confirmed by both 1H-NMR and SEC analyses. The enhanced depolymerization rate was attributed to the activation of a macroCTA by Eosin Y, thus resulting in a faster macroradical generation. Notably, this method was found to be compatible with different wavelengths (e.g. blue, red and white light irradiation), solvents, and RAFT agents, thus highlighting the potential of light to significantly improve current depolymerization approaches.

Cu(0)-RDRP of acrylates using an alkyl iodide initiator

In the vast majority of atom transfer radical polymerizations, alkyl bromides or alkyl chlorides are commonly employed as initiators. Herein, alkyl iodides are demonstrated as ATRP initiators.

Open-air green-light-driven ATRP enabled by dual photoredox/copper catalysis

Photoinduced atom transfer radical polymerization (photo-ATRP) has risen to the forefront of modern polymer chemistry as a powerful tool giving access to well-defined materials with complex architecture. However, most photo-ATRP systems can only generate radicals under biocidal UV light and are oxygen-sensitive, hindering their practical use in the synthesis of polymer biohybrids. Herein, inspired by the photoinduced electron transfer-reversible addition-fragmentation chain transfer (PET-RAFT) polymerization, we demonstrate a dual photoredox/copper catalysis that allows open-air ATRP under green light irradiation. Eosin Y was used as an organic photoredox catalyst (PC) in combination with a copper complex (X-CuII/L). The role of PC was to trigger and drive the polymerization, while X-CuII/L acted as a deactivator, providing a well-controlled polymerization. The excited PC was oxidatively quenched by X-CuII/L, generating CuI/L activator and PC˙+. The ATRP ligand (L) used in excess then reduced the PC˙+, closing the photocatalytic cycle. The continuous reduction of X-CuII/L back to CuI/L by excited PC provided high oxygen tolerance. As a result, a well-controlled and rapid ATRP could proceed even in an open vessel despite continuous oxygen diffusion. This method allowed the synthesis of polymers with narrow molecular weight distributions and controlled molecular weights using Cu catalyst and PC at ppm levels in both aqueous and organic media. A detailed comparison of photo-ATRP with PET-RAFT polymerization revealed the superiority of dual photoredox/copper catalysis under biologically relevant conditions. The kinetic studies and fluorescence measurements indicated that in the absence of the X-CuII/L complex, green light irradiation caused faster photobleaching of eosin Y, leading to inhibition of PET-RAFT polymerization. Importantly, PET-RAFT polymerizations showed significantly higher dispersity values (1.14 ≤ Đ ≤ 4.01) in contrast to photo-ATRP (1.15 ≤ Đ ≤ 1.22) under identical conditions.

Poly(2,3-Dihydrofuran): A Strong, Biorenewable, and Degradable Thermoplastic Synthesized via Room Temperature Cationic Polymerization

Creation of strong and tough plastics from sustainable and biorenewable resources is a significant challenge in polymer science. This challenge is further complicated when attempting to make these materials using an economically viable process, which is often hindered by the production and availability of chemical feedstocks and the efficiency of the monomer synthesis. Herein, we report the synthesis and characterization of a strong thermoplastic made from 2,3-dihydrofuran (DHF), a monomer made in one step from 1,4-butanediol, a bioalcohol already produced on the plant scale. We developed a green, metal-free cationic polymerization to enable the production of poly(2,3-dihydrofuran) (PDHF) with molecular weights of up to 256 kg/mol at room temperature. Characterization of these polymers showed that PDHF possesses high tensile strength and toughness (70 and 14 MPa, respectively) comparable to commercial polycarbonate, high optical clarity, and good barrier properties to oxygen, carbon dioxide, and water. These properties make this material amenable to a variety of applications, from food packaging to high strength windows. Importantly, we have also developed a facile oxidative degradation process of PDHF, providing an end-of-life solution for PDHF materials.