Closed-loop recycling of polyethylene-like materials

Selective deuteration along a polyethylene chain: Differentiating conformation segment by segment

To improve the circularity and performance of polyolefin materials, recent innovations have enabled the synthesis of polyolefins with new structural features such as cleavable breakpoints, functional chain ends, and unique comonomers. As new polyolefin structures become synthetically accessible, fundamental understanding of the effects of structural features on polymer (re)processing and mechanical performance is increasingly important. While bulk material properties are readily measured through conventional thermal or mechanical techniques, selective measurement of local material properties near structural defects is a major characterization challenge. Here, we synthesized a series of polyethylenes with selectively deuterated segments using a polyhomologation approach and employed vibrational spectroscopy to evaluate crystallization and melting of chain segments near features of interest (e.g., end groups, chain centers, and mid-chain structural defects). Chain-end functionality and defects were observed to strongly influence crystallinity of adjacent deuterated chain segments. Additionally, chain-end crystallinity was observed to have different molar mass dependence than mid-chain crystallinity. The synthesis and spectroscopy techniques demonstrated here can be applied to range of previously inaccessible deuterated polyethylene structures to provide direct insight into local crystallization behavior.

Catalytic Chemical Recycling of Post-Consumer Polyethylene

Among commercial plastics, polyolefins are the most widely produced worldwide but have limited recyclability. Here, we report a chemical recycling route for the conversion of post-consumer high-density polyethylene (HDPE) into telechelic macromonomers suitable for circular reprocessing. Unsaturation was introduced into HDPE by catalytic dehydrogenation using an Ir-POCOP catalyst without an alkene acceptor. Cross-metathesis with 2-hydroxyethyl acrylate followed by hydrogenation transformed the partially unsaturated HDPE into telechelic macromonomers. The direct repolymerization of the macromonomers gave a brittle material due to the low overall weight-average molecular weight. Aminolysis of telechelic macromonomers with a small amount of diethanolamine increased the overall functionality. The resulting macromonomers were repolymerized through transesterification to generate a polymer with comparable mechanical properties to the starting post-consumer HDPE waste. Depolymerization of the repolymerized material catalyzed by an organic base regenerated the telechelic macromonomers, thereby allowing waste polyethylene materials to enter a chemical recycling pathway.

Closed-loop chemical recycling of cross-linked polymeric materials based on reversible amidation chemistry

Closed-loop chemical recycling provides a solution to the end-of-use problem of synthetic polymers. However, it remains a major challenge to design dynamic bonds, capable of effective bonding and reversible cleaving, for preparing chemically recyclable cross-linked polymers. Herein, we report a dynamic maleic acid tertiary amide bond based upon reversible amidation reaction between maleic anhydrides and secondary amines. This dynamic bond allows for the construction of polymer networks with tailorable and robust mechanical properties, covering strong elastomers with a tensile strength of 22.3 MPa and rigid plastics with a yield strength of 38.3 MPa. Impressively, these robust polymeric materials can be completely depolymerized in an acidic aqueous solution at ambient temperature, leading to efficient monomer recovery with >94% separation yields. Meanwhile, the recovered monomers can be used to remanufacture cross-linked polymeric materials without losing their original mechanical performance. This work unveils a general approach to design polymer networks with tunable mechanical performance and closed-loop recyclability, which will open a new avenue for sustainable polymeric materials.

Recyclable and malleable thermosets enabled by activating dormant dynamic linkages

Chemical recycling of polymers is critical for improving the circular economy of plastics and environmental sustainability. Traditional thermoset polymers have generally been considered permanently crosslinked materials that are difficult or impossible to recycle. Herein, we demonstrate that by activating 'dormant' covalent bonds, traditional polycyanurate thermosets can be recycled into the original monomers, which can be circularly reused for their original purpose. Through retrosynthetic analysis, we redirected the synthetic route from forming conventional C-N bonds via irreversible cyanate trimerization to forming the C-O bonds through reversible nucleophilic aromatic substitution of alkoxy-substituted triazine derivatives by alcohol nucleophiles. The new reversible synthetic route enabled the synthesis of previously inaccessible alkyl-polycyanurate thermosets, which exhibit excellent film properties with high chemical resistance, closed-loop recyclability and reprocessing capability. These results show that 'apparently dormant' dynamic linkages can be activated and utilized to construct fully recyclable thermoset polymers with a broader monomer scope and increased sustainability.

Overcoming the low reactivity of biobased, secondary diols in polyester synthesis

Shifting away from fossil- to biobased feedstocks is an important step towards a more sustainable materials sector. Isosorbide is a rigid, glucose-derived secondary diol, which has been shown to impart favourable material properties, but its low reactivity has hampered its use in polyester synthesis. Here we report a simple, yet innovative, synthesis strategy to overcome the inherently low reactivity of secondary diols in polyester synthesis. It enables the synthesis of fully biobased polyesters from secondary diols, such as poly(isosorbide succinate), with very high molecular weights (M_n up to 42.8 kg/mol). The addition of an aryl alcohol to diol and diacid monomers was found to lead to the in-situ formation of reactive aryl esters during esterification, which facilitated chain growth during polycondensation to obtain high molecular weight polyesters. This synthesis method is broadly applicable for aliphatic polyesters based on isosorbide and isomannide and could be an important step towards the more general commercial adaption of fully biobased, rigid polyesters.

Block Poly(carbonate-ester) Ionomers as High-Performance and Recyclable Thermoplastic Elastomers

Thermoplastic elastomers based on polyesters/carbonates have the potential to maximize recyclability, degradability and renewable resource use. However, they often underperform and suffer from the familiar trade-off between strength and extensibility. Herein, we report well-defined reprocessable poly(ester-b-carbonate-b-ester) elastomers with impressive tensile strengths (60 MPa), elasticity (>800 %) and recovery (95 %). Plus, the ester/carbonate linkages are fully degradable and enable chemical recycling. The superior performances are attributed to three features: (1) Highly entangled soft segments; (2) Fully reversible strain-induced crystallization and (3) Precisely placed Zn^II -carboxylates dynamically crosslinking the hard domains. The one-pot synthesis couples controlled cyclic monomer ring-opening polymerization and alternating epoxide/anhydride ring-opening copolymerization. Efficient convresion to ionomers is achieved by reacting vinyl-epoxides to install Zn^II -carboxylates.

In Vivo Olefin Metathesis in Microalgae Upgrades Lipids to Building Blocks for Polymers and Chemicals

Sustainable sources are key to future chemicals production. Microalgae are promising resources as they fixate carbon dioxide to organic molecules by photosynthesis. Thereby they produce unsaturated fatty acids as established raw materials for the industrial production of chemical building blocks. Although these renewable feedstocks are generated inside cells, their catalytic upgrading to useful products requires in vitro transformations. A synthetic catalysis inside photoautotrophic cells has remained elusive. Here we show that a catalytic conversion of renewable substrates can be realized directly inside living microalgae. Organometallic catalysts remain active inside the cells, enabling in vivo catalytic olefin metathesis as new-to-nature transformation. Stored lipids are converted to long-chain dicarboxylates as valuable building blocks for polymers. This is a key step towards the long-term goal of producing desired renewable chemicals in microalgae as living "cellular factories".

Scalable Production of Self-Toughening Plant Oil-Based Polyurethane Elastomers with Multistimuli-Responsive Functionalities

Plant oils are becoming of high industrial importance due to the persisting challenges befalling with the utilization of fossil fuels. Thus, developing methodologies to produce multifunctional materials by taking advantage of the unique structure of plant oil is highly desired. In this study, castor oil served as a cross-linker and soft segments, by incorporating scalable rhodamine 6G derivatives, to systematically synthesize a series of smart polymers that possess self-toughening and multistimuli-responsive capabilities. The polyurethane elastomers showed 10 times and 60 times increases in tensile strength and toughness, respectively, in comparison with the unmodified polyurethane due to the existence of large amounts of hydrogen bonding, dynamic C-N spiro bonds, rigid benzene ring, and high cross-link densities. The novel polyurethane elastomers exhibited excellent reversible multichromic behaviors in response to light, pH, and mechanics. Notably, the resulting polyurethane elastomers exhibited ultrasensitive sustained photochromism with tunable white emission and rapid reversibility. This study provides a simple and effective strategy to utilize plant oil for multifunctional material preparation and paves the way to open access for application of plant oil-based products in a variety of industry applications, such as sensors, self-fitting tissue scaffolds, and switchable devices.

Closed-Loop Recycling of Poly(Imine-Carbonate) Derived from Plastic Waste and Bio-based Resources

Closed-loop recycling of polymers represents the key technology to convert plastic waste in a sustainable fashion. Efficient chemical recycling and upcycling strategies are thus highly sought-after to establish a circular plastic economy. Here, we present the selective chemical depolymerization of polycarbonate by employing a vanillin derivative as bio-based feedstock. The resulting di-vanillin carbonate monomer was used in combination with various amines to construct a library of reprocessable poly(imine-carbonate)s, which show tailor-made thermal and mechanical properties. These novel poly(imine-carbonate)s exhibit excellent recyclability under acidic and energy-efficient conditions. This allows the recovery of monomers in high yields and purity for immediate reuse, even when mixed with various commodity plastics. This work provides exciting new insights in the design of bio-based circular polymers produced by upcycling of plastic waste with minimal environmental impact.

Revealing and modeling of fire products in gas-phase for epoxy/black phosphorus-based nanocomposites

This work aims at revealing and optimizing the mechanism, to promote the design of phosphorus-based flame retardants (PFRs) for controlling the spread of fire risk caused by the continuous spread of polymers. Herein, we synthesized about 10 nm TiO₂ grown in situ on the surface of BP through a simple hydrothermal procedure to introduce it into epoxy (EP/BP-TiO₂). In the first place, EP/BP-TiO₂2.0 nanocomposite achieves a reduction of 58.96% and 50.35% in PHRR and THR, respectively. Secondly, the pyrolysis of BP from P_n to P₄, P₃ and P₂ is revealed. As a guide, P₄ is established as a characteristic product of the analytical model for evaluating the effects in the gas phase for BP-based hybrids. Finally, this work clarifies the enhancement path for BP-TiO₂ is optimized for the capturing of OH· and H· radicals by P₄(PO_x). Crucially, this study reveals and controls the mechanism of the BP-based hybrids at the molecular level, which is expected to provide a promising analytical model for broad market PFRs design to address the risks and challenges of casualties and ecology caused by composites fire.

A Chemically Recyclable Crosslinked Polymer Network Enabled by Orthogonal Dynamic Covalent Chemistry

Chemical recycling of synthetic polymers offers a solution for developing sustainable plastics and materials. Here we show that two types of dynamic covalent chemistry can be orthogonalized in a solvent-free polymer network and thus enable a chemically recyclable crosslinked material. Using a simple acylhydrazine-based 1,2-dithiolane as the starting material, the disulfide-mediated reversible polymerization and acylhydrazone-based dynamic covalent crosslinking can be combined in a one-pot solvent-free reaction, resulting in mechanically robust, tough, and processable crosslinked materials. The dynamic covalent bonds in both backbones and crosslinkers endow the network with depolymerization capability under mild conditions and, importantly, virgin-quality monomers can be recovered and separated. This proof-of-concept study show opportunities to design chemically recyclable materials based on the dynamic chemistry toolbox.

Cascade degradation and upcycling of polystyrene waste to high-value chemicals

Plastic waste represents one of the most urgent environmental challenges facing humankind. Upcycling has been proposed to solve the low profitability and high market sensitivity of known recycling methods. Existing upcycling methods operate under energy-intense conditions and use precious-metal catalysts, but produce low-value oligomers, monomers, and common aromatics. Herein, we report a tandem degradation-upcycling strategy to exploit high-value chemicals from polystyrene (PS) waste with high selectivity. We first degrade PS waste to aromatics using ultraviolet (UV) light and then valorize the intermediate to diphenylmethane. Low-cost AlCl₃ catalyzes both the reactions of degradation and upcycling at ambient temperatures under atmospheric pressure. The degraded intermediates can advantageously serve as solvents for processing the solid plastic wastes, forming a self-sustainable circuitry. The low-value-input and high-value-output approach is thus substantially more sustainable and economically viable than conventional thermal processes, which operate at high-temperature, high-pressure conditions and use precious-metal catalysts, but produce low-value oligomers, monomers, and common aromatics. The cascade strategy is resilient to impurities from plastic waste streams and is generalizable to other high-value chemicals (e.g., benzophenone, 1,2-diphenylethane, and 4-phenyl-4-oxo butyric acid). The upcycling to diphenylmethane was tested at 1-kg laboratory scale and attested by industrial-scale techno-economic analysis, demonstrating sustainability and economic viability without government subsidies or tax credits.

Efficient and Selective Chemical Recycling of CO2 -Based Alicyclic Polycarbonates via Catalytic Pyrolysis

Chemical recycling of polymers to their constituent monomers is the foremost challenge in building a sustainable circular plastics economy. Here, we report a strategy for highly efficient depolymerization of various CO₂ -based alicyclic polycarbonates to epoxide monomers in solvent-free conditions by a simple Cr^III -Salen complex mediated catalytic pyrolysis process. The chemical recycling of the widely studied poly(cyclohexene carbonate) exhibits excellent reactivity (TOF up to 3000 h^-1 , 0.1 mol % catalyst loading) and high epoxide monomer selectivity (>99 %). Mechanistic investigation reveals that the process proceeds in a sequential fashion via a trans-carbonate intermediate.

Circularly Recyclable Polymers Featuring Topochemically Weakened Carbon-Carbon Bonds

Closed-loop circular utilization of plastics is of manifold significance, yet energy-intensive and poorly selective scission of the ubiquitous carbon-carbon (C-C) bonds in contemporary commercial polymers pose tremendous challenges to envisioned recycling and upcycling scenarios. Here, we demonstrate a topochemical approach for creating elongated C-C bonds with a bond length of 1.57∼1.63 Å between repeating units in the solid state with decreased bond dissociation energies. Elongated bonds were introduced between the repeating units of 12 distinct polymers from three classes. In all cases, the materials exhibit rapid depolymerization via breakage of the elongated bond within a desirable temperature range (140∼260 °C) while otherwise remaining remarkably stable under harsh conditions. Furthermore, the topochemically prepared polymers are processable and 3D-printable while maintaining a high depolymerization yield and tunable mechanical properties. These results suggest that the crystalline polymers synthesized from simple photochemistry and without expensive catalysts are promising for practical applications with complete materials' circularity.

Rapid Biodegradable Ionic Aggregates of Polyesters Constructed with Fertilizer Ingredients

Synthetic biodegradable polyesters tend to undergo slow biodegradation under ambient natural conditions and, hence, have been rejected or even banned recently in ecofriendly applications. Here, we demonstrate the preparation of polyesters exhibiting enhanced biodegradability, which were generated through a combination of old controversial macromolecules and aggregate theories. H₃PO₄-catalyzed diacid/diol polycondensation afforded polyester chains bearing chain-end -CH₂OP(O)(OH)₂ and inner-chain (-CH₂O)₂P(O)(OH) groups, which were subsequently treated with M(2-ethylhexanoate)₂ (M = Zn, Mg, Mn, and Ca) to form ionic aggregates of polyesters. The prepared ionic aggregates of polyesters, which were constructed with fertilizer ingredients (such as M²⁺ and phosphate), exhibit much faster biodegradability than that of the conventional polyesters under controlled soil conditions at 25 °C, while displaying comparable or superior rheological and mechanical properties.

Polyolefin Innovations toward Circularity and Sustainable Alternatives

The unprecedented growth and socioeconomic impacts of polyolefins clearly outline a major success story in the world of polymer science. Polyolefins revolutionizes industries such as health care, construction, and food packaging. Despite the benefits of polyolefins, there is a rising concern for the environment due to high production volume (i.e., fossil fuel consumption), often short usage time, and problems related to waste management and accumulation in the natural environment. Creating a circular economy for polyolefins through effective recycling technologies has the potential to decrease the environmental impact of these materials. This perspective discusses polyolefins and their impact, existing and emerging recycling/upcycling solutions, and recycle-by-design alternatives that are challenging the status quo.

Sustainably Recycling and Upcycling of Single-Use Plastic Wastes through Heterogeneous Catalysis

The huge amount of plastic waste has caused a series of environmental and economic problems. Depolymerization of these wastes and their conversion into desired chemicals have been regarded as a promising route for dealing with these issues, which strongly relies on catalysis for C-C and C-O bond cleavage and selective transformation. Here, we reviewed recent developments in catalysis systems for dealing with single-use plastics, such as polyethylene, polypropylene, and polyethylene glycol terephthalate. The recycling processes of depolymerization into original monomers and conversion into other economic-incentive chemicals were systemically discussed. Rational designs of catalysts for efficient conversion were particularly highlighted. Overall, improving the tolerance of catalysts to impurities in practical plastics, reducing the economic cost during the catalytic depolymerization process, and trying to obtain gaseous hydrogen from plastic wastes are suggested as the developing trends in this field.

Circularity in mixed-plastic chemical recycling enabled by variable rates of polydiketoenamine hydrolysis

Footwear, carpet, automotive interiors, and multilayer packaging are examples of products manufactured from several types of polymers whose inextricability poses substantial challenges for recycling at the end of life. Here, we show that chemical circularity in mixed-polymer recycling becomes possible by controlling the rates of depolymerization of polydiketoenamines (PDK) over several orders of magnitude through molecular engineering. Stepwise deconstruction of mixed-PDK composites, laminates, and assemblies is chemospecific, allowing a prescribed subset of monomers, fillers, and additives to be recovered under pristine condition at each stage of the recycling process. We provide a theoretical framework to understand PDK depolymerization via acid-catalyzed hydrolysis and experimentally validate trends predicted for the rate-limiting step. The control achieved by PDK resins in managing chemical and material entropy points to wide-ranging opportunities for pairing circular design with sustainable manufacturing.

Chemically Recyclable Ester-Linked Polypropylene

Polyolefins represent the largest class of commodity materials due to their excellent material properties; however, they have limited pathways to chemical recycling and are often difficult to mechanically recycle. Here we demonstrate a new catalyst for the isoselective copolymerization of propylene and butadiene capable of favoring 1,4-insertion over 1,2-insertion while maintaining good molecular weights and turnover frequencies. This isotactic propylene copolymer with main-chain unsaturation was depolymerized to a telechelic macromonomer using an olefin metathesis catalyst and 2-hydroxyethyl acrylate. After hydrogenation, the telechelic macromonomer was repolymerized to form an ester-linked polypropylene material. This polymer shows thermal and mechanical properties comparable to linear low-density polyethylene. Finally, the telechelic macromonomer could be regenerated through the depolymerization of the ester-linked polypropylene material, which allows for the chemical recycling to macromonomer. This process provides a route to transform partially unsaturated polyolefins to chemically recyclable materials with similar properties to their parent polymers.

Chemical Recycling of Poly(Cyclohexene Carbonate) Using a Di-MgII Catalyst

Chemical recycling of polymers to true monomers is pivotal for a circular plastics economy. Here, the first catalyzed chemical recycling of the widely investigated carbon dioxide derived polymer, poly(cyclohexene carbonate), to cyclohexene oxide and carbon dioxide is reported. The reaction requires dinuclear catalysis, with the di-Mg^II catalyst showing both high monomer selectivity (>98 %) and activity (TOF=150 h^-1 , 0.33 mol %, 120 °C). The depolymerization occurs via a chain-end catalyzed depolymerization mechanism and DFT calculations indicate the high selectivity arises from Mg-alkoxide catalyzed epoxide extrusion being kinetically favorable compared to cyclic carbonate formation.

Sustainable polyesters via direct functionalization of lignocellulosic sugars

The development of sustainable plastics from abundant renewable feedstocks has been limited by the complexity and efficiency of their production, as well as their lack of competitive material properties. Here we demonstrate the direct transformation of the hemicellulosic fraction of non-edible biomass into a tricyclic diester plastic precursor at 83% yield (95% from commercial xylose) during integrated plant fractionation with glyoxylic acid. Melt polycondensation of the resulting diester with a range of aliphatic diols led to amorphous polyesters (M_n = 30-60 kDa) with high glass transition temperatures (72-100 °C), tough mechanical properties (ultimate tensile strengths of 63-77 MPa, tensile moduli of 2,000-2,500 MPa and elongations at break of 50-80%) and strong gas barriers (oxygen transmission rates (100 µm) of 11-24 cc m^-2 day^-1 bar^-1 and water vapour transmission rates (100 µm) of 25-36 g m^-2 day^-1) that could be processed by injection moulding, thermoforming, twin-screw extrusion and three-dimensional printing. Although standardized biodegradation studies still need to be performed, the inherently degradable nature of these materials facilitated their chemical recycling via methanolysis at 64 °C, and eventual depolymerization in room-temperature water.

Thermogravimetric Analysis on a Resonant Microcantilever

Thermogravimetric analysis (TGA) is a widely applied classic method for material characterization. However, the existing TGA method has reached its technical ceiling in regard to its sensitivity, efficiency, application scope, and extensibility. With temperature-programming and a picogram (10^-12 g) mass resoluble measurement function, an integrated resonant microcantilever is proposed and developed into micro-electromechanical system-based TGA (MEMS TGA) technology to satisfy the significantly higher TGA requirements. With only a nanogram (10^-9 g) level of a loaded sample, the microcantilever can conduct ultrasensitive mass-loss analysis along with ultrafast and controllable heating up to 1200 °C. Experiments have verified that MEMS TGA can improve heating efficiency by at least one order of magnitude compared to conventional TGA while maintaining measurement accuracy. The trace sample requirement also enables MEMS TGA to directly test explosive substances in an air atmosphere, while conventional TGA with a larger amount of sample has difficulty in avoiding explosion-induced equipment damage during heating. The silicon MEMS TGA microchip also exhibits functional combination (even integration) with other analytical techniques such as Raman spectroscopy to realize operando characterization.

Determination of the Influence of Multiple Closed Recycling Loops on the Property Profile of Different Polyolefins

In a circular economy, polymeric materials are used in multiple loops to manufacture products. Therefore, closed-loops are also envisaged for the mechanical recycling of plastics, in which plastic is used for products that are in turn collected and reprocessed again and again to make further products. However, this reprocessing involves degradation processes within the plastics, which become apparent through changes in the property profile of the material. In the present paper, the influence of multiple recycling loops on the material properties of four different polyolefins was analyzed. Two different closed-loop cycles with industrially sized processing machines were defined, and each polyolefin was processed and reprocessed within the predefined cycles. For the investigation of the effect of the respective loops, samples were taken after each loop. The samples were characterized by high-pressure liquid chromatography coupled to a quadru-pole time-of-flight MS, high-temperature gel permeation chromatography, melt flow rate measurements, infrared spectroscopy, differential thermal analysis, and tensile tests. With increasing number of processing loops, the tested polyolefins showed continuous material degradation, which resulted in significant changes in the property profiles.

Kelly A, Bai S. Using Asphalt as an Additive for Waste Cross-Linked Polyethylene Recycled Materials to Improve Thermoplastic Processing

With good insulation, cross-linked polyethylene (XLPE) cables are widely used as an important basic material for power transportation. Due to being insoluble and infused, the cross-linked network structure caused a challenge in the recycling of waste XLPE, which is usually treated by incineration and landfilling. In this research, XLPE was part-de-cross-linked via solid-state shear milling (S³M) technology, but the resulting powder was difficult to process. In order to improve the re-processability of XLPE, asphalt with a similar structure was added during the thermoplastic processing. To deeply understand the influence of asphalt on the matrix, the compatibility, dispersion, and rheological properties of the composites were characterized. Due to the good compatibility between de-cross-linked XLPE and asphalt, the viscosity of the composites decreased significantly. Some sea-island structures also formed in composites, which increased the toughness of the composites, so the elongation at break reached as high as 322%. The use of asphalt to achieve the processing performance of part-de-cross-linked XLPE powder was highly effective. Furthermore, the prepared composites showed potential application in the field of waterproofing, which could recycle waste XLPE cables on a large scale.

Closed-loop additive manufacturing of upcycled commodity plastic through dynamic cross-linking

A sustainable closed-loop manufacturing would become reality if commodity plastics can be upcycled into higher-performance materials with facile processability. Such circularity will be realized when the upcycled plastics can be (re)processed into custom-designed structures through energy/resource-efficient additive manufacturing methods, especially by approachable and scalable fused filament fabrication (FFF). Here, we introduce a circular model epitomized by upcycling a prominent thermoplastic, acrylonitrile butadiene styrene (ABS) into a recyclable, robust adaptive dynamic covalent network (ABS-vitrimer) (re)printable via FFF. The full FFF processing of ABS-vitrimer overcomes the major challenge of (re)printing cross-linked materials and produces stronger, tougher, solvent-resistant three-dimensional objects directly reprintable and separable from unsorted plastic waste. This study thus offers an imminently adoptable approach for advanced manufacturing toward the circular plastics economy.

Hydrogen-Bonding Affords Sustainable Plastics with Ultrahigh Robustness and Water-Assisted Arbitrarily Shape Engineering

Herein, the supramolecular plastic-like hydrogel (SPH) is introduced as a platform to fabricate sustainable plastics with ultrahigh stiffness and strength as well as water-assisted arbitrarily shapeable capability. The transparent plastics are constructed from SPHs of cellulose ether/polycarboxylic acid complexes and demonstrate mechanical robustness with Young's modulus up to 3.4 GPa and tensile strength up to 124.0 MPa, superior or comparable to most common plastics. Meanwhile, the shape of the plastics can be reversibly engineered by air drying of the SPHs with diverse 2D/3D shapes and structures, which are generated conveniently via origami, kirigami, embossing, etc., in virtue of plastic deformation and shape memory effect of SPHs. On the basis of multi-dimensional infrared-spectral analysis, it is revealed that the dense acid-acid and acid-ether hydrogen (H)-bonding network in the plastic is responsible for the mechanical robustness while the evolution of water-polymer H-bonds into polymer-polymer H-bonds during air drying contributes to the shape fixing. This work provides a novel method of manufacturing sustainable plastics with simultaneous strong mechanical performance and convenient processibility from hydrogels with plastic-like mechanical behavior.

Thionolactone as a Resin Additive to Prepare (Bio)degradable 3D Objects via VAT Photopolymerization

Three-dimensional (3D) printing and especially VAT photopolymerization leads to cross-linked materials with high thermal, chemical, and mechanical stability. Nevertheless, these properties are incompatible with requirements of degradability and re/upcyclability. We show here that thionolactone and in particular dibenzo[c,e]-oxepane-5-thione (DOT) can be used as an additive (2 wt %) to acrylate-based resins to introduce weak bonds into the network via a radical ring-opening polymerization process. The low amount of additive makes it possible to modify the printability of the resin only slightly, keep its resolution intact, and maintain the mechanical properties of the 3D object. The resin with additive was used in UV microfabrication and two-photon stereolithography setups and commercial 3D printers. The fabricated objects were shown to degrade in basic solvent as well in a homemade compost. The rate of degradation is nonetheless dependent on the size of the object. This feature was used to prepare 3D objects with support structures that could be easily solubilized.

Zr(IV) Catalyst for the Ring-Opening Copolymerization of Anhydrides (A) with Epoxides (B), Oxetane (B), and Tetrahydrofurans (C) to Make ABB- and/or ABC-Poly(ester-alt-ethers)

Poly(ester-alt-ethers) can combine beneficial ether linkage flexibility and polarity with ester linkage hydrolysability, furnishing fully degradable polymers. Despite their promising properties, this class of polymers remains underexplored, in part due to difficulties in polymer synthesis. Here, a catalyzed copolymerization using commercially available monomers, butylene oxide (BO)/oxetane (OX), tetrahydrofuran (THF), and phthalic anhydride (PA), accesses a series of well-defined poly(ester-alt-ethers). A Zr(IV) catalyst is reported that yields polymer repeat units comprising a ring-opened PA (A), followed by two ring-opened cyclic ethers (B/C) (-ABB- or -ABC-). It operates with high polymerization control, good rate, and successfully enchains epoxides, oxetane, and/or tetrahydrofurans, providing a straightforward means to moderate the distance between ester linkages. Kinetic analysis of PA/BO copolymerization, with/without THF, reveals an overall second-order rate law: first order in both catalyst and butylene oxide concentrations but zero order in phthalic anhydride and, where it is present, zero order in THF. Poly(ester-alt-ethers) have lower glass-transition temperatures (-16 °C < T_g < 12 °C) than the analogous alternating polyesters, consistent with the greater backbone flexibility. They also show faster ester hydrolysis rates compared with the analogous AB polymers. The Zr(IV) catalyst furnishes poly(ester-alt-ethers) from a range of commercially available epoxides and anhydride; it presents a straightforward method to moderate degradable polymers' properties.

One-Step Synthesis of Degradable Vinylic Polymer-Based Latexes via Aqueous Radical Emulsion Polymerization

Aqueous emulsion copolymerizations of dibenzo[c,e]oxepane-5-thione (DOT) were performed with n-butyl acrylate (BA), styrene (S) and a combination of both. In all cases, stable latexes were obtained in less than two hours under conventional conditions; that is in the presence of sodium dodecyl sulfate (SDS) used as surfactant and potassium persulfate (KPS) as initiator. A limited solubility of DOT in BA was observed compared to S, yielding to a more homogeneous integration of DOT units in the PS latex. In both cases, the copolymer could be easily degraded under basic conditions. Emulsion terpolymerization between DOT, BA and S allowed us to produce stable latexes not only composed of degradable chains but also featuring a broad range of glass transition temperatures.