Circularity in polymers: addressing performance and sustainability challenges using dynamic covalent chemistries

Pigment removal from reverse-printed laminated flexible films by solvent-targeted recovery and precipitation

The solvent-targeted recovery and precipitation (STRAP) process separates and recovers the constituent resins in multilayer plastic packaging films by selective polymer dissolution. In this work, the cause of coloring in the STRAP-recycled polyethylene (PE) resins from postindustrial printed films was identified as decomposed diarylide pigments. Two different approaches are needed to completely remove the dissolved colorants during the STRAP process including (i) adding an activated carbon (AC) adsorbent to the solvent after polymer dissolution and (ii) proper mechanical filtration of the polymer-solvent cake to remove as much solvent from the cake as possible. Colorless recycled PE can be produced by a combination of the proposed approaches (choosing the proper solvent, adding an AC adsorbent, and doing proper mechanical filtration) with minimal accumulation of colorants in the recycled STRAP solvents. This study demonstrated that high-quality STRAP low-density PE can be obtained from printed plastic films, enhancing the potential circularity of these packaging materials.

Changes in Heat Resistance and Mechanical Properties of Peroxide Cross-Linking HDPE: Effects of Compounding Cross-Linkers

Due to excellent chemical resistance and impermeability, high-density polyethylene (HDPE) is widely used in petrochemical transportation, product packaging, sports equipment, and marine applications. Yet, with the wide variety of service environments, its mechanical and thermal properties do not meet the demand. In the present study, a compounding cross-linker comprising di-tert-butyl peroxide (DTBP) and triallyl isocyanurate (TAIC) is employed by combining with a two-step preparation process. High-quality cross-linking reactions are achieved for HDPE. In this study, the cross-linking of DTBP is first examined separately. A peak cross-linking degree of 74.7% is achieved, and there is a large improvement in thermal resistance and mechanical properties. Subsequently, the composite cross-linking system of DTBP and TAIC is investigated. The peak cross-linking degree is 82.1% (10% increase compared to DTBP). The peak heat deformation temperature is 80.1 °C (22% increase compared to DTBP). The peak impact strength is 104.73 kJ/m2 (207% increase compared to neat HDPE). The flexural strength is 33.6 MPa (22% increase compared to neat HDPE). The results show that this cross-linking system further improves the cross-linking degree, heat resistance, and mechanical properties of HDPE, indicating its potential application in engineering materials for high performance.

Activated Phenyl Ester Vitrimers

Aromatic esters are amongst the oldest known chemical motifs that allow for thermal (re)processing of thermosetting polymers. Moreover, phenyl esters are generally known as activated esters that do not require a catalyst to undergo acyl transfer reactions. Even though dynamic aromatic esters find applications in commercialized thermoset formulations, all-aromatic esters have found limited use so far in the design of covalent adaptable networks (CAN) as a result of their high glass transition temperature (Tg) and specific curing process. Here, a strategy to include partly aromatic esters as dynamic cross-links inside low Tg (-40 °C) thermosetting formulations, using aliphatic esters derived from para-hydroxybenzoic acid, which serves as a highly activated phenol or as a reactive "phenylogous anhydride" is reported. A small molecule study shows that the activated phenyl ester bonds can readily exchange with free phenol moieties at 200 °C under catalyst-free conditions, while the addition of a catalyst allows for a faster exchange. Robust and hydrophobic polymer networks are conveniently prepared via rapid thiol-ene UV-curing of unsaturated phenol esters. The obtained networks show high thermal stability (350 °C), fast processability, good water resistance, and low creep up to 120 °C, thus showing good promise as a platform for CAN.

Biobased vitrimers: towards sustainability and circularity

In polymer science and technology, the distinction between thermoplastic and thermosetting materials has always been sharp, clear, and well-documented: indeed, the former can theoretically be reprocessed a potentially infinite number of times by heating, forming, and subsequent cooling. This cannot be done in the case of thermosetting polymers due to the presence of cross-links that covalently bind the macromolecular chains, giving rise to insoluble and infusible polymeric networks. In 2011, the discovery of vitrimers revolutionized the classification mentioned above, demonstrating the possibility of using new materials that consist of covalent adaptable networks (CANs): this way, they can change their topology through thermally-activated bond-exchange reactions. Recently, the increasing attention directed at green systems and circular economies has pushed the scientific community toward the synthesis and characterization of biobased materials, including vitrimers. Indeed, these latter represent a practical and reliable answer to the demanding issue of the eco sustainability of both materials and related technologies. The main advantage of using biobased vitrimers relies on their limited environmental impact as compared with the traditional systems deriving from fossil sources. Furthermore, biobased vitrimers exploit the same chemistries and plants already optimized for their fossil-based counterparts. The present work aims to review the current use of biobased vitrimers for advanced applications, highlighting their importance for designing novel, green, and sustainable materials that perfectly match the up-to-date circular economy concept.

Toward Sustainable Polydienes

The sustainable management of polydiene waste represents a formidable challenge in the realm of polymer chemistry, given the extensive industrial utilization of polydienes due to their superior elastomeric properties. This comprehensive Perspective addresses the multifaceted obstacles hindering efficient recycling of polydienes, encompassing environmental concerns, technical limitations, and economic disincentives. We systematically dissect the influence of polydienes' chemical structures on their recyclability, tracing the evolution of polydiene utilization and disposal practices while assessing the current landscape of waste management strategies. Our investigation reveals the primary technical challenges associated with polydiene recycling, notably the energy-intensive nature of modification processes and the environmental detriments of prevailing disposal techniques. Furthermore, we critically evaluate existing recycling methodologies─including mechanical recycling, energy recovery, and chemical recycling─highlighting their respective merits, constraints, and environmental implications. Pioneering advancements in recycling technology, such as topochemical polymerization and computational prediction models, are spotlighted for their potential to revolutionize polydiene recycling. Looking forward, we delineate an optimistic trajectory for polydiene waste management, advocating for innovative polymerization methods, the exploration of milder recycling conditions, and the adoption of interdisciplinary approaches to bolster recycling efficiency. The Perspective culminates in a discussion on the pivotal role of policy frameworks, life cycle assessments, and economic analyses in shaping the future of polydiene recycling. Through this scholarly examination, we aim to catalyze further research and development efforts aimed at mitigating the environmental impact of polydiene waste, thereby contributing to the broader objective of sustainable chemistry.

Soft-Rigid Construction of Mechanically Robust, Thermally Stable, and Self-Healing Polyimine Networks with Strongly Recyclable Adhesion

Reversible and recyclable thermosets have garnered increasing attention for their smart functionality and sustainability. However, they still face challenges in balancing comprehensive performance and dynamic features. Herein, silicon (Si)─oxygen (O) and imidazole units covalent bonds are coupled to generate a new class of bio-polyimines (Bio-Si-PABZs), to endow them with high performance and excellent reprocessing capability and acid-degradability. By tailoring the molar content of diamines, this Bio-Si-PABZs displayed both a markedly high glass transition temperature (162 °C) and a high char yield at 800 °C in an oxygen atmosphere (73.1%). These Bio-Si-PABZs with their favorable properties outperformed various previously reported polyimines and competed effectively with commercial fossil-based polycarbonate. Moreover, the scratch (≈10 µm) on the surface of samples can be self-healing within only 2 min, and an effective "Bird Nest"-to-"Torch" recycling can also be achieved through free amines solution. Most importantly, a bio-based siloxane adhesive derived from the intermediate Bio-Si-PABZ-1 by acidic degradation demonstrated broad and robust adhesion in various substrates, with values reaching up to ≈3.5 MPa. For the first time, this study lays the scientific groundwork for designing robust and recyclable polyimine thermosets with Si─O and imidazole units, as well as converting plastic wastes into thermal-reversibility and renewable adhesives.

Melt Polycondensation Strategy to Access Unexplored l-Amino Acid and Sugar Copolymers

Biodegradable polymers from bioresources are highly in demand for the development of sustainable polymer platforms for commodity plastics and in the biomedical field. Here, an elegant one-pot synthetic strategy is developed, for the first time, to access unexplored hybrid polymers from two naturally abundant resources: carbohydrates (sugars) and l-amino acids. A bottleneck in the synthetic strategy is overcome by tailor-making d-mannitol-based six- and five-membered bicyclic acetalized diols, and their structures are confirmed by single-crystal X-ray diffraction and 2D NMR spectroscopy. l-Amino acids are converted into ester-urethane functional monomers, and they are polymerized with sugar-diols under solvent-free melt polycondensation to yield biodegradable poly(ester-urethane)s. Acid-catalyzed deprotection yielded amphiphilic polymers having exclusively alternating residues of sugar and l-amino acid in the polymer backbone. The polymer is self-assembled into 200 ± 10 nm sized nanoparticles that can encapsulate fluorescent dyes, are nontoxic to cells up to 250 μg/mL, and are readily endocytosed for lysosomal enzymatic biodegradation at the cellular level.

Cross-Linked Polyolefins: Opportunities for Fostering Circularity Throughout the Materials Lifecycle

Cross-linked polyolefins (XLPOs) constitute a significant portion of the plastics commercial market, with a market size of a similar order of magnitude to those of polystyrene and polyethylene terephthalate. However, few aspects of XLPO materials circularity have been examined relative to thermoplastic polyolefins. The cross-linking of polyolefins imparts superior performance properties, such as impact strength, chemical and electrical resistance, and thermal stability vs thermoplastic analogues, but it also makes the reprocessing of XLPOs to valuable products more challenging, as XLPOs cannot be molten. Thus, most XLPOs are incinerated or landfilled at the end of the first lifecycle, even though XLPO products are commonly collected as a relatively clean waste stream-providing a unique opportunity for valorization. In this review, we discuss approaches to improve XLPO circularity throughout the entire materials lifecycle by examining biobased feedstocks as alternative olefinic monomer sources and by assessing both traditional mechanical and advanced XLPO recycling methods based on industrial feasibility and potential product value. We also consider how advancing materials longevity can reduce environmental impacts and lifecycle costs and how recyclable-by-design strategies can enable better end-of-life opportunities for future generations of XLPO materials. Throughout this review, we highlight XLPO circularity routes that have the potential to balance the performance, circularity, and scalability necessary to impart economic and environmental viability at an industrial scale.

Closed-loop recyclable polymers: from monomer and polymer design to the polymerization-depolymerization cycle

The extensive utilization of plastic, as a symbol of modern technological society, has consumed enormous amounts of finite and non-renewable fossil resources and produced huge amounts of plastic wastes in the land or ocean, and thus recycling and reuse of the plastic wastes have great ecological and economic benefits. Closed-loop recyclable polymers with inherent recyclability can be readily depolymerized into monomers with high selectivity and purity and repolymerized into polymers with the same performance. They are deemed to be the next generation of recyclable polymers and have captured great and increasing attention from academia and industry. Herein, we provide an overview of readily closed-loop recyclable polymers based on monomer and polymer design and no-other-reactant-involved reversible ring-opening and addition polymerization reactions. The state-of-the-art of circular polymers is separately summarized and discussed based on different monomers, including lactones, thiolactones, cyclic carbonates, hindered olefins, cycloolefins, thermally labile olefin comonomers, cyclic disulfides, cyclic (dithio) acetals, lactams, Diels-Alder addition monomers, Michael addition monomers, anhydride-secondary amide monomers, and cyclic anhydride-aldehyde monomers, and polymers with activatable end groups. The polymerization and depolymerization mechanisms are clearly disclosed, and the evolution of the monomer structure, the polymerization and depolymerization conditions, the corresponding polymerization yield, molecular weight, performance of the polymers, monomer recovery, and depolymerization equipment are also systematically summarized and discussed. Furthermore, the challenges and future prospects are also highlighted.

Biodegradation: the best solution to the world problem of discarded polymers

The widespread use of polymers has made our lives increasingly convenient by offering a more convenient and dependable material. However, the challenge of efficiently decomposing these materials has resulted in a surge of polymer waste, posing environment and health risk. Currently, landfill and incineration treatment approaches have notable shortcomings, prompting a shift towards more eco-friendly and sustainable biodegradation approaches. Biodegradation primarily relies on microorganisms, with research focusing on both solitary bacterial strain and multi-strain communities for polymer biodegradation. Furthermore, directed evolution and rational design of enzyme have significantly contributed to the polymer biodegradation process. However, previous reviews often undervaluing the role of multi-strain communities. In this review, we assess the current state of these three significant fields of research, provide practical solutions to issues with polymer biodegradation, and outline potential future directions for the subject. Ultimately, biodegradation, whether facilitated by single bacteria, multi-strain communities, or engineered enzymes, now represents the most effective method for managing waste polymers.

Perspective on the Development of Monomer Recovery Technologies from Plastics Designed to Last

In order to prevent the current unsustainable waste handling of the enormous volumes of end-of-use organic polymer material sent to landfilling or incineration, extensive research efforts have been devoted toward the development of appropriate solutions for the recycling of commercial thermoset polymers. The inability of such cross-linked polymers to be remelted once cured implies that mechanical recycling processes used for thermoplastic materials do not translate to the recycling of thermoset polymers. Moreover, the structural diversity within the materials from the use of different monomers as well as the use of such polymers for the fabrication of fiber-reinforced polymer composites make recycling of these materials highly challenging. In this Perspective, depolymerization strategies for thermoset polymers are discussed with an emphasis on recent advancements within our group on recovering polymer building blocks from polyurethane (PU) and epoxy-based materials. While these two represent the largest thermoset polymer groups with respect to the production volumes, the recycling landscapes for these classes of materials are vastly different. For PU, increased collaboration between academia and industry has resulted in major advancements within solvolysis, acidolysis, aminolysis, and split-phase glycolysis for polyol recovery, where several processes are being evaluated for further scaling studies. For epoxy-based materials, the molecular skeleton has no obvious target for chemical scission. Nevertheless, we have recently demonstrated the possibility of the disassembly of the epoxy polymer in fiber-reinforced composites for bisphenol A (BPA) recovery through catalytic C-O bond cleavage. Furthermore, a base promoted cleavage developed by us and others shows tremendous potential for the recovery of BPA from epoxy polymers. Further efforts are still required for evaluating the suitability of such monomer recovery strategies for epoxy materials at an industrial scale. Nonetheless, recent advancements as illustrated with the presented chemistry suggest that the future of thermoset polymer recycling could include processes that emphasize monomer recovery in an energy efficient manner for closed-loop recycling.

Polymer design for solid-state batteries and wearable electronics

Solid-state batteries are increasingly centre-stage for delivering more energy-dense, safer batteries to follow current lithium-ion rechargeable technologies. At the same time, wearable electronics powered by flexible batteries have experienced rapid technological growth. This perspective discusses the role that polymer design plays in their use as solid polymer electrolytes (SPEs) and as binders, coatings and interlayers to address issues in solid-state batteries with inorganic solid electrolytes (ISEs). We also consider the value of tunable polymer flexibility, added capacity, skin compatibility and end-of-use degradability of polymeric materials in wearable technologies such as smartwatches and health monitoring devices. While many years have been spent on SPE development for batteries, delivering competitive performances to liquid and ISEs requires a deeper understanding of the fundamentals of ion transport in solid polymers. Advanced polymer design, including controlled (de)polymerisation strategies, precision dynamic chemistry and digital learning tools, might help identify these missing fundamental gaps towards faster, more selective ion transport. Regardless of the intended use as an electrolyte, composite electrode binder or bulk component in flexible electrodes, many parallels can be drawn between the various intrinsic polymer properties. These include mechanical performances, namely elasticity and flexibility; electrochemical stability, particularly against higher-voltage electrode materials; durable adhesive/cohesive properties; ionic and/or electronic conductivity; and ultimately, processability and fabrication into the battery. With this, we assess the latest developments, providing our views on the prospects of polymers in batteries and wearables, the challenges they might address, and emerging polymer chemistries that are still relatively under-utilised in this area.

New Advances in Covalent Network Polymers via Dynamic Covalent Chemistry

Covalent network polymers, as materials composed of atoms interconnected by covalent bonds in a continuous network, are known for their thermal and chemical stability. Over the past two decades, these materials have undergone significant transformations, gaining properties such as malleability, environmental responsiveness, recyclability, crystallinity, and customizable porosity, enabled by the development and integration of dynamic covalent chemistry (DCvC). In this review, we explore the innovative realm of covalent network polymers by focusing on the recent advances achieved through the application of DCvC. We start by examining the history and fundamental principles of DCvC, detailing its inception and core concepts and noting its key role in reversible covalent bond formation. Then the reprocessability of covalent network polymers enabled by DCvC is thoroughly discussed, starting from the significant milestones that marked the evolution of these polymers and progressing to their current trends and applications. The influence of DCvC on the crystallinity of covalent network polymers is then reviewed, covering their bond diversity, synthesis techniques, and functionalities. In the concluding section, we address the current challenges faced in the field of covalent network polymers and speculates on potential future directions.

Sustainable Vat Photopolymerization-Based 3D-Printing through Dynamic Covalent Network Photopolymers

Vat photopolymerization (VPP) based three-dimensional (3D) printing, including stereolithography (SLA) and digital light projection (DLP), is known for producing intricate, high-precision prototypes with superior mechanical properties. However, the challenge lies in the non-recyclability of covalently crosslinked thermosets used in these printing processes, limiting the sustainable utilization of printed prototypes. This review paper examines the recently explored avenue of VPP 3D-printed dynamic covalent network (DCN) polymers, which enable reversible crosslinks and allow for the reprocessing of printed prototypes, promoting sustainability. These reversible crosslinks facilitate the rearrangement of crosslinked polymers, providing printed polymers with chemical/physical recyclability, self-healing capabilities, and degradability. While various mechanisms for DCN polymer systems are explored, this paper focuses solely on photocurable polymers to highlight their potential to revolutionize the sustainability of VPP 3D printing.

Covalent Adaptable Networks with Tailorable Material Properties Based on Divanillin Polyimines

Covalent adaptable networks (CANs) are being developed as future replacements for thermosets as they can retain the high mechanical and chemical robustness inherent to thermosets but also integrate the possibility of reprocessing after material use. Here, covalent adaptable polyimine-based networks were designed with methoxy and allyloxy-substituted divanillin as a core component together with long flexible aliphatic fatty acid-based amines and a short rigid chain triamine, yielding CANs with a high renewable content. The designed series of CANs with reversible imine functionality allowed for fast stress relaxation and tailorability of the thermomechanical properties, as a result of the ratio between long flexible and short rigid amines, with tensile strength (σb) ranging 1.07-18.7 MPa and glass transition temperatures ranging 16-61 °C. The CANs were subsequently successfully reprocessed up to three times without determinantal structure alterations and retained mechanical performance. The CANs were also successfully chemically recycled under acidic conditions, where the starting divanillin monomer was recovered and utilized for the synthesis of a recycled CAN with similar thermal and mechanical properties. This promising class of thermosets bearing sustainable dynamic functionalities opens a window of opportunity for the progressive replacement of fossil-based thermosets.

Kraft (Nano)Lignin as Reactive Additive in Epoxy Polymer Bio-Composites

The demand for high-performance bio-based materials towards achieving more sustainable manufacturing and circular economy models is growing significantly. Kraft lignin (KL) is an abundant and highly functional aromatic/phenolic biopolymer, being the main side product of the pulp and paper industry, as well as of the more recent 2nd generation biorefineries. In this study, KL was incorporated into a glassy epoxy system based on the diglycidyl ether of bisphenol A (DGEBA) and an amine curing agent (Jeffamine D-230), being utilized as partial replacement of the curing agent and the DGEBA prepolymer or as a reactive additive. A D-230 replacement by pristine (unmodified) KL of up to 14 wt.% was achieved while KL-epoxy composites with up to 30 wt.% KL exhibited similar thermo-mechanical properties and substantially enhanced antioxidant properties compared to the neat epoxy polymer. Additionally, the effect of the KL particle size was investigated. Ball-milled kraft lignin (BMKL, 10 μm) and nano-lignin (NLH, 220 nm) were, respectively, obtained after ball milling and ultrasonication and were studied as additives in the same epoxy system. Significantly improved dispersion and thermo-mechanical properties were obtained, mainly with nano-lignin, which exhibited fully transparent lignin-epoxy composites with higher tensile strength, storage modulus and glass transition temperature, even at 30 wt.% loadings. Lastly, KL lignin was glycidylized (GKL) and utilized as a bio-based epoxy prepolymer, achieving up to 38 wt.% replacement of fossil-based DGEBA. The GKL composites exhibited improved thermo-mechanical properties and transparency. All lignins were extensively characterized using NMR, TGA, GPC, and DLS techniques to correlate and justify the epoxy polymer characterization results.

State-of-the-Art Polyurea Coatings: Synthesis Aspects, Structure-Properties Relationship, and Nanocomposites for Ballistic Protection Applications

This review presents polyurea (PU) synthesis, the structure-properties relationship, and characterization aspects for ballistic protection applications. The synthesis of polyurea entails step-growth polymerization through the reaction of an isocyanate monomer/prepolymer and a polyamine, each component possessing a functionality of at least two. A wide range of excellent properties such as durability and high resistance against atmospheric, chemical, and biological factors has made this polymer an outstanding option for ballistic applications. Polyureas are an extraordinary case because they contain both rigid segments, which are due to the diisocyanates used and the hydrogen points formed, and a flexible zone, which is due to the chemical structure of the polyamines. These characteristics motivate their application in ballistic protection systems. Polyurea-based coatings have also demonstrated their abilities as candidates for impulsive loading applications, affording a better response of the nanocomposite-coated metal sheet at the action of a shock wave or at the impact of a projectile, by suffering lower deformations than neat metallic plates.

Dynamic covalent synthesis

Dynamic covalent synthesis aims to precisely control the assembly of simple building blocks linked by reversible covalent bonds to generate a single, structurally complex, product. In recent years, considerable progress in the programmability of dynamic covalent systems has enabled easy access to a broad range of assemblies, including macrocycles, shape-persistent cages, unconventional foldamers and mechanically-interlocked species (catenanes, knots, etc.). The reversibility of the covalent linkages can be either switched off to yield stable, isolable products or activated by specific physico-chemical stimuli, allowing the assemblies to adapt and respond to environmental changes in a controlled manner. This activatable dynamic property makes dynamic covalent assemblies particularly attractive for the design of complex matter, smart chemical systems, out-of-equilibrium systems, and molecular devices.

The thermodynamics and kinetics of depolymerization: what makes vinyl monomer regeneration feasible?

Depolymerization is potentially a highly advantageous method of recycling plastic waste which could move the world closer towards a truly circular polymer economy. However, depolymerization remains challenging for many polymers with all-carbon backbones. Fundamental understanding and consideration of both the kinetics and thermodynamics are essential in order to develop effective new depolymerization systems that could overcome this problem, as the feasibility of monomer generation can be drastically altered by tuning the reaction conditions. This perspective explores the underlying thermodynamics and kinetics governing radical depolymerization of addition polymers by revisiting pioneering work started in the mid-20th century and demonstrates its connection to exciting recent advances which report depolymerization reaching near-quantitative monomer regeneration at much lower temperatures than seen previously. Recent catalytic approaches to monomer regeneration are also explored, highlighting that this nascent chemistry could potentially revolutionize depolymerization-based polymer recycling in the future.