On the Mechanism of the Inverse Vulcanization of Elemental Sulfur: Structural Characterization of Poly(sulfur-random-(1,3-diisopropenylbenzene))

A Thermally Stable, Infrared-Transparent High-Sulfur-Containing Polymer for High Aspect-Ratio Nanostructured MWIR Polarizer

Infrared (IR) polarizer is essential for thermal imaging applications such as mobility and military operations. High-sulfur-containing polymers have emerged as promising candidates for IR polarizers due to their mid-wave IR (MWIR) transparency, addressing the limitations of inorganic materials, including their brittleness and high cost. However, poor thermal stability and limited IR range restrict their applicability. This study introduces a glassy IR polarizer based on poly(sulfur-co-hexavinyl disiloxane) (pSHVDS), a highly crosslinked sulfur-rich polymer synthesized via sulfur chemical vapor deposition (sCVD). Self-crosslinking of pSHVDS at high temperatures provided thermal stability during nanoimprint lithography, enabling the fabrication of high-fidelity nano-grating patterns (400 nm pitch, 150 nm width, 300 nm height). The broad transmittance and high aspect ratio of the nanopattern enabled the glassy-pSHVDS MWIR polarizer to achieve over 50% transmittance of transverse magnetic field (TTM) and an extinction ratio (ER) exceeding 6000 across a broad IR range (3-8 µm). An additional pSHVDS anti-reflection coating further enhanced TTM to 84% and ER to 7200 at a wavelength of 4 µm, the highest ER reported for organic MWIR polarizers to date. The polarizer maintained its performance after 24 h at 100 °C, demonstrating exceptional thermal stability. These findings underscore the potential of glassy pSHVDS-based polarizers for IR applications.

Sulfur Conversion to Donor-Acceptor Ladder Polymer Networks through Mechanochemical Nucleophilic Aromatic Substitution for Efficient CO2 Photoreduction

The development of synthetic methods capable of converting elemental sulfur into conjugated porous sulfur-rich polymers remains a great challenge, although direct utilization of this readily available feedstock can significantly enrich its uses and circumvent environmental problems during sulfur storage. We report herein mechanochemical (MC) nucleophilic aromatic substitution (SNAr) that enables sulfur conversion into thianthrene-bridged porous ladder polymer networks with dense donor-acceptor (D-A) molecular junctions. We demonstrate that the key lies in the generation of bent thianthrene units through a solid-state ball-milling condensation reaction between 1,2-dihaloarenes and elemental sulfur. We also show that the assembling of D-A structural motifs into porous networks affords efficient visible-light-driven photocatalytic reduction of carbon dioxide (CO2) with water (H2O) vapor, in the absence of any additional photosensitizer, sacrificial agents or cocatalysts. Exceptional photoinduced charge separation along with boosted exciton dissociation results in a high-performance of carbon monoxide (CO) production rate of 306.1 μmol g-1 h-1 with near 100 % CO selectivity, which is accompanied by H2O oxidation to O2, as confirmed by both experimental and theoretical results. We anticipate this novel MC SNAr approach will advance processing techniques for direct sulfur utilization and facilitate new possibilities for the synthesis of D-A ladder polymer networks with promising potential in photocatalysis.

Static and Dynamic Assessments of a Sulfur-Triglyceride Composite for Antimicrobial Surface Applications

Over 80 MT of elemental sulfur, a byproduct of fossil fuel desulfurization, are generated annually. This has spurred the development of high sulfur content materials (HSMs) via inverse vulcanization as a productive pathway towards sulfur utilization. In this study, we evaluate the antimicrobial performance of SunBG90, an HSM made from brown grease and sulfur, as tiles or infused into fabric squares. The static antimicrobial activity of SunBG90 tiles was assessed, revealing excellent efficacy against Gram-positive bacteria, with reductions of 96.84% for Staphylococcus aureus and 91.52% for Listeria monocytogenes. The tiles also exhibited strong antifungal activity, reducing Candida auris by 96.20% and mold (fumigatus) by 83.77%. In contrast, efficacy against Gram-negative bacteria was more variable, with moderate reductions for Escherichia coli (61.10%) and Salmonella enteritidis (62.15%), lower activity against Campylobacter jejuni and Salmonella typhi, and no effect on Clostridium perfringens. Under dynamic conditions, SunBG90-infused fabrics achieved a near-complete inhibition of L. monocytogenes (99.91%) and high reduction of E. coli (98.49%), along with a 96.24% inhibition of Candida auris. These results highlight the potential and limitations of SunBG90 for antimicrobial applications, emphasizing the need for further optimization to achieve consistent broad-spectrum activity.

Adding Value into Elementary Sulfur for Sustainable Materials

Sulfur-rich copolymers, characterized by high sulfur contents and dynamic disulfide bonds, show significant promise as sustainable alternatives to conventional carbon-based plastics. Since the advent of inverse vulcanization in 2013, numerous synthesis strategies have emerged - ranging from thermopolymerization and photoinduced polymerization to the use of crosslinkers such as mercaptans, episulfides, benzoxazines, and cyclic disulfides. These advancements coupled with the rising demand for degradable plastics have driven research for diverse applications, including optical windows, metal uptake, and adhesives. Due to the unique electronic properties of sulfur-rich materials, they are promising candidates for cathodes in Li-S batteries and triboelectric nanogenerators. This review highlight the latest exciting ways of synthesis strategy in which sulfur and sulfur-based reactions are bing utilized to produce sustainable materials in energy, optics, engeneering material, environemtal, and triboelectric nanogenerators. Finally, this review provides a forward-looking perspective on the opportunities and challenges shaping this rapidly evolving field.

Sodium Thiophenolate Initiated Polymerization of Methacrylate with Sulfur (S8): High-Refractive-Index and -Transparency Polymers for Lithography

A simple and effective strategy for introducing sulfur into a polymethacrylate matrix at room temperature has been developed, allowing for the polymerization of a variety of methacrylate derivatives with sulfur. The resulting S-containing polymers exhibited a high refractive index of up to 1.72 while retaining over 90% transmittance in the visible region. Additionally, when mixed with 3% photo acid generator (PAG) as photoresist, the formulation demonstrated excellent patterning capabilities. Furthermore, the scalable preparation of high-refractive-index polymers (HRIPs) indicates significant potential for fabrication.

Inverse Vulcanization of Aziridines: Enhancing Polysulfides for Superior Mechanical Strength and Adhesive Performance

This study introduces a novel approach to inverse vulcanization by utilizing a commercially available triaziridine crosslinker as an alternative to conventional olefin-based crosslinkers. The model reactions reveal a self-catalyzed ring-opening of "unactivated" aziridine with elemental sulfur, forming oligosulfide-functionalized diamines. The triaziridine-derived polysulfides exhibit impressive mechanical properties, achieving a maximum stress of ~8.3 MPa and an elongation at break of ~107 %. The incorporation of silicon dioxide (20 wt %) enhances the composite's rigidity, yielding a Young's modulus of ~0.94 GPa. Furthermore, these polysulfides display excellent adhesion strength on various substrates, such as aluminum (~7.0 MPa), walnut (~9.6 MPa), and steel (~11.0 MPa), with substantial retention of adhesion strength (~3.3 MPa on steel) at -196 °C. The straightforward synthetic process, combined with the accessibility of the triaziridine crosslinker, emphasizes the potential for further innovations in sulfur polymer chemistry.

Probe-Based Mechanical Data Storage on Polymers Made by Inverse Vulcanization

Big data and artificial intelligence are driving increasing demand for high-density data storage. Probe-based data storage, such as mechanical storage using an atomic force microscope tip, is a potential solution with storage densities exceeding hard disks. However, the storage medium must be modifiable on the nanoscale. While polymers are promising storage media, they face challenges with synthesis, erasing temperatures, and stability. Here, a low-cost and robust polymer system is reported that allows repeated writing, reading and erasing. The polymer is made by inverse vulcanization, providing a network of S─S bonds that can be broken and re-formed repeatedly. This property is leveraged in mechanical indentation to encode information, and thermal S─S metathesis and polymer re-flow to erase. Exquisite control of indentation depth is possible over 1-30 nm. This control enables data encoding not just as a function of the presence or absence of an indent, but also indentation depth. This ternary coding increases the data density four-fold over binary coding. Furthermore, the coding can be done at room temperature which is rare for mechanical information storage. The low cost, ease of synthesis, and dynamic S─S bonds in these polymers are a promising advance in polymer storage media for probe-based data storage.

Optimizing Superhydrophobic Coatings: The Role of Catalysts, Additives, and Composition on UV and Thermal Stability of Inverse Vulcanization Polymers

Inverse vulcanization (IV) enables the production of sustainable polymer from sulfur waste, offering hydrophobic, fluorine-free, and superhydrophobic coatings. However, these materials need adhesion improvements for enhanced durability. This study has developed an epoxy-, fluorine-, and metal-free superhydrophobic coating using the spray-coating of carbon nanofibers (CNFs), silica nanoparticles, and IV polymers on glass. An optimized formula of 28% sulfur, 20 mg/mL CNFs, 25 mg/mL silica, and 80 mg/mL polymer-was established. Zn(DTC)2-catalyzed coatings retained superhydrophobicity for 150 tape peeling cycles, up to 250 °C, and 6 h of UV-C exposure, demonstrating a straightforward, eco-friendly approach to durable, versatile superhydrophobic coatings.

Light-Induced Ring-to-Chain Transformations of Elemental Sulfur: Nonadiabatic Dynamics Simulations

The emergence of high-sulfur content polymeric materials and their diverse applications underscore the need for a comprehensive understanding of the ring-to-chain transformation of elemental sulfur. In this study, we delve into the ultrafast transformation of the elemental sulfur S8 ring upon photoexcitation employing advanced nonadiabatic dynamics simulations. Our findings reveal that the bond breaking of the S8 ring occurs within tens of femtoseconds. At the time of bond breaking, most molecules are in the lowest singlet excited state S1. S1 survives for 40-450 fs before relaxing to the quasi-degenerate manifolds formed by the T1 and S0 states of the S8 chain. This suggests that upon photoexcitation the polymerization of the S8 chains might proceed before the chains relax to their lowest energy states. The derived temporal resolution provides a detailed perspective on the dynamics of S8 rings upon photoexcitation, shedding light on the intricate processes involved in its excited-state transformations.

Closed-loop chemically recyclable covalent adaptive networks derived from elementary sulfur

The development of sulfur-rich polymers derived from elementary sulfur provides an innovative approach to industrial waste valorization. Despite significant advancements in polymerization techniques and promising applications beyond traditional polymers, polysulfide networks are still primarily stabilized by diene crosslinkers, forming robust C-S bonds that hinder the degradation of sulfur-based polymers. In this study, the anionic ring-opening copolymerization of chemically homologous S8 and cyclic disulfides was explored to yield robust sulfur-rich copolymers with high molecular weight. The incorporation of polysulfide segments not only efficiently activated the crosslinked networks for excellent reprocessability and mechanical adaptability but also endowed the resulting copolymer with high optical transparency in the near-infrared region. More importantly, the dynamic disulfide crosslinking sites promoted the chemical closed-loop recyclability of the polysulfide networks via reversible S-S cleavage. This innovative inverse vulcanization strategy utilizing dynamic disulfide crosslinkers offers a promising pathway for the advanced applications and upcycling of high-performance sulfur-rich polymers.

Synthesis of Polycyclic Olefinic Monomers from Norbornadiene for Inverse Vulcanization: Structural and Mechanistic Consequences

The preparation of high-sulfur content organosulfur polymers has generated considerable interest as an emerging area in polymer science that has been driven by advances in the inverse vulcanization polymerization of elemental sulfur with organic comonomers. While numerous new inverse vulcanized polysulfides have been made over the past decade, insights into the mechanism of inverse vulcanization and structural characterization of the high-sulfur-content copolymers remain limited in scope. Furthermore, the exploration of new molecular architectures for organic comonomer synthesis remains an important frontier to enhance the properties of these new polymeric materials. In the current report, the first detailed study on the synthesis and inverse vulcanization of polycyclic rigid comonomers derived from norbornadiene was conducted, affording a quantitative assessment of polymer microstructure for these organopolysulfides and insights into the inverse vulcanization polymerization mechanism for this class of monomers. In particular, a stereoselective synthesis of the endo-exo norbornadiene cyclopentadiene adduct (Stillene) was achieved, which enabled direct comparison with the known exo-exo norbornadiene dimer (NBD2) previously used for inverse vulcanization. Reductive degradation of these sulfur copolymers and detailed structural analysis of the recovered sulfurated organic fragments revealed that remarkable exo-stereospecificity was achieved in the inverse vulcanization of elemental sulfur with both these polycyclic dienyl comonomers, which correlated to the robust thermomechanical properties associated with organopolysulfides made from NBD2 previously. Melt processing and molding of these sulfur copolymers were conducted to fabricate free-standing plastic lenses for long-wave infrared thermal imaging.

Structural evolution during inverse vulcanization

Inverse vulcanization exploits S8 to synthesize polysulfides. However, evolution of products and its mechanism during inverse vulcanization remains elusive. Herein, inverse vulcanization curves are obtained to describe the inverse vulcanization process in terms of three stages: induction, curing and over-cure. The typical curves exhibit a moduli increment before declining or plateauing, reflecting the process of polysulfide network formation and loosing depending on monomers. For aromatic alkenes, in the over-cure, the crosslinked polysulfide evolves significantly into a sparse network with accelerated relaxation, due to the degradation of alkenyl moieties into thiocarbonyls. The inverse vulcanization product of olefins degrades slowly with fluctuated relaxation time and modulus because of the generation of thiophene moieties, while the inverse vulcanization curve of dicyclopentadiene has a plateau following curing stage. Confirmed by calculations, the mechanisms reveal the alkenyl groups react spontaneously into thiocarbonyls or thiophenes via similar sulfur-substituted alkenyl intermediates but with different energy barriers.

Modification of Polysulfide Surfaces with Low-Power Lasers

The modification of polymer surfaces using laser light is important for many applications in the nano-, bio- and chemical sciences. Such capabilities have supported advances in biomedical devices, electronics, information storage, microfluidics, and other applications. In most cases, these modifications require high power lasers that are expensive and require specialized equipment and facilities to minimize risk of hazardous radiation. Additionally, polymer systems that can be easily modified by lasers are often complex and costly to prepare. In this report, these challenges are addressed with the discovery of low-cost sulfur copolymers that can be rapidly modified with lasers emitting low-power infrared and visible light. The featured copolymers are made from elemental sulfur and either cyclopentadiene or dicyclopentadiene. Using a suite of lasers with discreet wavelengths (532, 638 and 786 nm) and powers, a variety of surface modifications could be made on the polymers such as controlled swelling or etching via ablation. The facile synthesis and laser modification of these polymer systems were exploited in applications such as direct laser lithography and erasable information storage.

Converting inorganic sulfur into degradable thermoplastics and adhesives by copolymerization with cyclic disulfides

Converting elementary sulfur into sulfur-rich polymers provides a sustainable strategy to replace fossil-fuel-based plastics. However, the low ring strain of eight-membered rings, i.e., S8 monomers, compromises their ring-opening polymerization (ROP) due to lack of an enthalpic driving force and as a consequence, poly(sulfur) is inherently unstable. Here we report that copolymerization with cyclic disulfides, e.g., 1,2-dithiolanes, can enable a simple and energy-saving way to convert elementary sulfur into sulfur-rich thermoplastics. The key strategy is to combine two types of ROP-both mediated by disulfide bond exchange-to tackle the thermodynamic instability of poly(sulfur). Meanwhile, the readily modifiable sidechain of the cyclic disulfides provides chemical space to engineer the mechanical properties and dynamic functions over a large range, e.g., self-repairing ability and degradability. Thus, this simple and robust system is expected to be a starting point for the organic transformation of inorganic sulfur toward sulfur-rich functional and green plastics.

Ring-Opening Terpolymerisation of Elemental Sulfur Waste with Propylene Oxide and Carbon Disulfide via Lithium Catalysis

Elemental sulfur, a waste product of the oil refinement process, represents a promising raw material for the synthesis of degradable polymers. We show that simple lithium alkoxides facilitate the polymerisation of elemental sulfur S8 with industrially relevant propylene oxide (PO) and CS2 (a base chemical sourced from waste S8 itself) to give poly(monothiocarbonate-alt-Sx) in which x can be controlled by the amount of supplied sulfur. The in situ generation of thiolate intermediates obtained by a rearrangement, which follows CS2 and PO incorporation, allows to combine S8 and epoxides into one polymer sequence that would otherwise not be possible. Mechanistic investigations reveal that alkyl oligosulfide intermediates from S8 ring opening and sulfur chain length equilibration represent the better nucleophiles for inserting the next PO if compared to the trithiocarbonates obtained from the competing CS2 addition, which causes the sequence selectivity. The polymers can be crosslinked in situ with multifunctional thiols to yield reprocessable and degradable networks. Our report demonstrates how mechanistic understanding allows to combine intrinsically incompatible building blocks for sulfur waste utilisation.

Porous sulfur polymers for effective aqueous-phase organic contaminant removal

Sulfur polymers produced through 'inverse vulcanization' exhibit various attributes, such as photocatalytic activity and a high capacity to adsorb heavy metals. Nevertheless, there is a lack of research investigating the use of sulfur polymers as materials for the removal of organic contaminants. In this work, porous sulfur polymers (PSPs) were synthesized from elemental sulfur and 1,3-diisopropenylbenzene, with porosity introduced via salt templating. The result is a material that can strongly adsorb and chemically neutralize a model organic contaminant (caffeine). PSPs show adsorption up to 5 times higher than a leading adsorption material (activated carbon). Furthermore, either the adsorption or degradation processes can govern the removal efficiency depending on the synthesis parameters of PSPs. This is the first-ever report demonstrating sulfur polymers as effective materials for removing emerging contaminants from water. The versatile synthesis of sulfur polymers offers variation, which means that there is much more to explore in this exciting research area.

Hybrid Organosulfur Network/MWCNT Composite Cathodes for Li-S Batteries

Lithium-sulfur (Li-S) batteries hold a promising position as candidates for next-generation high-energy storage systems. Here, we combine inverse vulcanization of sulfur with multiwalled carbon nanotubes (MWCNTs) to increase the conductivity of cathode materials for Li-S batteries. The mixing process of inversely vulcanized sulfur copolymer networks with MWCNTs is aided by shear in a two-roll mill to take advantage of the soft nature of the copolymer. The high-throughput mixing method demands a source of conductive carbon that can be intimately mixed with the S copolymer, rendering MWCNTs an excellent choice for this purpose. The resulting sulfur copolymer network-MWCNTs composites were thoroughly characterized in terms of structure, chemical composition, thermal, and electronic transport properties, and finally evaluated by electrochemical benchmarking. These promising hybrids yielded electrodes with high sulfur content and demonstrate stable electrochemical performance exhibiting a specific capacity of ca. 550 mAh·gsulfur-1 (380 mAh·gelectrode-1) even after 500 charge-discharge cycles at specific current of 167 mA·g-1 (corresponds to 0.1C discharge rate), and thus are superior to melt-infiltrated reference samples.

The Role of Dithiocarbamate Catalysts in the Diversification of Sulfur Speciation Towards Anionic Sulfur

Recently, there has been growing interest in the implementation of various "catalysts" to further diversify the substrate scope for inverse vulcanization reactions. While there have been several proposals on the mechanism of how these catalysts work, the speciation of sulfur in these mixtures has remained elusive. As a key component to understanding when and if these catalysts are appropriate, we sought to elucidate the role of dithiocarbamate species in inverse vulcanization reactions by attempting to characterize the speciation of sulfur. The reaction efficacy for various substrates containing different functional groups with sulfur, either with or without a metal dithiocarbamate, potassium diethyldithiocarbamate (K-DTC), suggests the formation of a rapidly fluctuating sulfur speciation and, most importantly, the presence of anionic sulfur. The work concludes with some suggestions on best practices for the utilization of dithiocarbamate catalysts based on our results.

Synthesis of Deuterated and Sulfurated Polymers by Inverse Vulcanization: Engineering Infrared Transparency via Deuteration

The synthesis of deuterated, sulfurated, proton-free, glassy polymers offers a route to optical polymers for infrared (IR) optics, specifically for midwave IR (MWIR) photonic devices. Deuterated polymers have been utilized to enhance neutron cross-sectional contrast with proteo polymers for morphological neutron scattering measurements but have found limited utility for other applications. We report the synthesis of perdeuterated d14-(1,3-diisopropenylbenzene) with over 99% levels of deuteration and the preparation of proton-free, perdeuterated poly(sulfur-random-d14-(1,3-diisopropenylbenzene)) (poly(S-r-d14-DIB)) via inverse vulcanization with elemental sulfur. Detailed structural analysis and quantum computational calculations of these reactions demonstrate significant kinetic isotope effects, which alter mechanistic pathways to form different copolymer microstructures for deutero vs proteo poly(S-r-DIB). This design also allows for molecular engineering of MWIR transparency by shifting C-H bond vibrations around 3.3 μm/3000 cm-1 observed in proteo poly(S-r-DIB) to 4.2 μm/2200 cm-1. Furthermore, the fabrication of thin-film MWIR optical gratings made from molding of deuterated-sulfurated, proton-free poly(S-r-d14-DIB) is demonstrated; operation of these gratings at 3.39 μm is achieved successfully, while the proteo poly(S-r-DIB) gratings are opaque at these wavelengths, highlighting the promise of MWIR sensors and compact spectrometers from these materials.

Unraveling the rheology of inverse vulcanized polymers

Multiple relaxation times are used to capture the numerous stress relaxation modes found in bulk polymer melts. Herein, inverse vulcanization is used to synthesize high sulfur content (≥50 wt%) polymers that only need a single relaxation time to describe their stress relaxation. The S-S bonds in these organopolysulfides undergo dissociative bond exchange when exposed to elevated temperatures, making the bond exchange dominate the stress relaxation. Through the introduction of a dimeric norbornadiene crosslinker that improves thermomechanical properties, we show that it is possible for the Maxwell model of viscoelasticity to describe both dissociative covalent adaptable networks and living polymers, which is one of the few experimental realizations of a Maxwellian material. Rheological master curves utilizing time-temperature superposition were constructed using relaxation times as nonarbitrary horizontal shift factors. Despite advances in inverse vulcanization, this is the first complete characterization of the rheological properties of this class of unique polymeric material.