Segmented Polyurethanes and Thermoplastic Elastomers from Elemental Sulfur with Enhanced Thermomechanical Properties and Flame Retardancy

Monomer centred selectivity guidelines for sulfurated ring-opening copolymerisations

Sulfur-containing polymers, such as thioesters and thiocarbonates, offer sustainability advantages, including enhanced degradability and chemical recyclability. However, their synthesis remains underdeveloped compared to that of their oxygen-containing counterparts. Although catalytic ring-opening copolymerization (ROCOP) can provide access to sulfur-containing polymers, these materials often exhibit uncontrolled microstructures and unpredictable properties. A comprehensive model that elucidates the factors determining selectivity in these catalytic reactions is still lacking, despite its central importance for advancing these polymerizations into widely applicable methodologies. In this study, we investigate the factors that lead to selectivity in sulfurated ROCOP across various monomer combinations, including thioanhydrides or carbon disulfide with epoxides, thiiranes, and oxetanes. We find that unwanted by-products primarily arise from backbiting reactions of catalyst-bound alkoxide chain ends, which can be mitigated by (i) selecting monomers that form primary alkoxide of thiolate chain ends, (ii) maximizing ring strain in the backbiting step, and (iii) timely termination of the polymerization. By applying these strategies, the selectivity of the catalytic ROCOP can be controlled and we successfully synthesized perfectly alternating poly(esters-alt-thioesters) from various oxetanes and the highly industrially relevant ethylene oxide. Our study thereby shifts the focus for achieving selectivity from catalyst to monomer choice providing valuable mechanistic insights for the development of future selective polymerizations, paving the way for sulfurated polymers as potential alternatives to current commodity materials.

Transforming Element Sulfur to High Performance Closed-Loop Recyclable Polymer via Proton Transfer Enabled Anionic Hybrid Copolymerization

The utilization of sulfur has been a global issue. Copolymerization of element sulfur (S8) with other monomers is a promising route to convert it to useful materials but is limited by the comonomers. Here, we report anionic hybrid copolymerization of S8 with acrylate and epoxide at room temperature, where S8 does not copolymerize with epoxide in the absence of acrylate. Yet, the proton transfer from the methyne in acrylate to the oxygen anion enables the ring-opening of the cyclic comonomer and hence the copolymerization. The cyclic comonomers can be expanded to lactone and cyclic carbonate. Specifically, the copolymer of S8 with bisphenl A diglycidyl ether and diacrylate displays mechanical properties comparable to those of most common plastics, namely, it has ultimate tensile strength as high as 60.8 MPa and Young's modulus up to 680 MPa. It also exhibits high UV resistance and good transparency. Particularly, it has excellent UV-induced self-healing, reprocessability and closed-loop recyclability due to the abundant dynamic S-S bonds and ester groups. This study provides an efficient strategy to turn element sulfur into closed-loop recyclable polymer with high mechanical and optical performances.

Inverse Vulcanization of Activated Norbornenyl Esters-A Versatile Platform for Functional Sulfur Polymers

Elemental sulfur has shown to be a promising alternative feedstock for development of novel polymeric materials with high sulfur content. However, the utilization of inverse vulcanized polymers is restricted by the limitation of functional comonomers suitable for an inverse vulcanization. Control over properties and structure of inverse vulcanized polymers still poses a challenge to current research due to the dynamic nature of sulfur-sulfur bonds and high temperature of inverse vulcanization reactions. In here, we report for the first time the inverse vulcanization of norbornenyl pentafluorophenyl ester (NB-PFPE), allowing for post-modification of inverse vulcanized polymers via amidation of reactive PFP esters to yield high sulfur content polymers under mild conditions. Amidation of the precursor material with three functional primary amines (α-amino-ω-methoxy polyethylene glycol, aminopropyl trimethoxy silane, allylamine) was investigated. The resulting materials were applicable as sulfur containing poly(ethylene glycol) nanoparticles in aqueous environment. Cross-linked mercury adsorbents, sulfur surface coatings, and high-sulfur content networks with predictable thermal properties were achievable using aminopropyl trimethoxy silane and allylamine for post-polymerization modification, respectively. With the broad range of different amines available and applicable for post-polymerization modification, the versatility of poly(sulfur-random-NB-PFPE) as a platform precursor polymer for novel specialized sulfur containing materials was showcased.

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.

Ultrarobust, Self-Healing Poly(urethane-urea) Elastomer with Superior Tensile Strength and Intrinsic Flame Retardancy Enabled by Coordination Cross-Linking

Poly(urethane-urea) elastomers (PUUEs) have gained significant attention recently due to their growing demand in electronic skin, wearable electronic devices, and aerospace applications. The practical implementation of these elastomers necessitates many exceptional properties to ensure robust and safe utilization. However, achieving an optimal balance between high mechanical strength, good self-healing at moderate temperatures, and efficient flame retardancy for poly(urethane-urea) elastomers remains a formidable challenge. In this study, we incorporated metal coordination bonds and flame-retarding phosphinate groups into the design of poly(urethane-urea) simultaneously, resulting in a high-strength, self-healing, and flame-retardant elastomer, termed PNPU-2%Zn. Additional supramolecular cross-links and plasticizing effects of phosphinate-endowed PUUEs with relatively remarkable tensile strength (20.9 MPa), high elastic modulus (10.8 MPa), and exceptional self-healing efficiency (above 97%). Besides, PNPU-2%Zn possessed self-extinguishing characteristics with a limiting oxygen index (LOI) of 26.5%. Such an elastomer with superior properties can resist both mechanical fracture and fire hazards, providing insights into the development of robust and high-performance components for applications in wearable electronic devices.

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.

Dithiophosphoric Acids for Polymer Functionalization

Dithiophosphoric acids (DTPAs) are an intriguing class of compounds that are sourced from elemental sulfur and white phosphorus and are prepared from the reaction of phosphorus pentasulfide with alcohols. The electrophilic addition of DTPAs to alkenes and unsaturated olefinic substrates is a known reaction, but has not been applied to polymer synthesis and polymer functionalization. We report on the synthesis and application of DTPAs for the functionalization of challenging poly-enes, namely polyisoprene (PI) and polynorbornene (pNB) prepared by ring-opening metathesis polymerization (ROMP). The high heteroatom content within DTPA moieties impart intriguing bulk properties to poly-ene materials after direct electrophilic addition reactions to the polymer backbone introducing DTPAs as side chain groups. The resulting materials possess both enhanced optical and flame retardant properties vs the poly-ene starting materials. Finally, we demonstrate the ability to prepare crosslinked polydiene films with di-functional DTPAs, where the crosslinking density and thermomechanical properties can be directly tuned by DTPA feed ratios.

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.

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

Organosulfur polymers, such as those derived from elemental sulfur, are an important new class of macromolecules that have recently emerged via the inverse vulcanization process. Since the launching of this new field in 2013, the development of new monomers and organopolysulfide materials based on the inverse vulcanization process is now an active area in polymer chemistry. While numerous advances have been made over the last decade concerning this polymerization process, insights into the mechanism of inverse vulcanization and structural characterization of the high-sulfur-content copolymers that are produced remain challenging due to the increasing insolubility of the materials with a higher sulfur content. Furthermore, the high temperatures used in this process can result in side reactions and complex microstructures of the copolymer backbone, complicating detailed characterization. The most widely studied case of inverse vulcanization to date remains the reaction between S₈ and 1,3-diisopropenylbenzene (DIB) to form poly(sulfur-random-1,3-diisopropenylbenzene)(poly(S-r-DIB)). Here, to determine the correct microstructure of poly(S-r-DIB), we performed comprehensive structural characterizations of poly(S-r-DIB) using nuclear magnetic resonance spectroscopy (solid state and solution) and analysis of sulfurated DIB units using designer S-S cleavage polymer degradation approaches, along with complementary de novo synthesis of the sulfurated DIB fragments. These studies reveal that the previously proposed repeating units for poly(S-r-DIB) were incorrect and that the polymerization mechanism of this process is significantly more complex than initially proposed. Density functional theory calculations were also conducted to provide mechanistic insights into the formation of the derived nonintuitive microstructure of poly(S-r-DIB).

Mussel-Inspired, Underwater Self-Healing Ionoelastomers Based on α-Lipoic Acid for Iontronics

Weak adhesion and lack of underwater self-healability hinder advancing soft iontronics particularly in wet environments like sweaty skin and biological fluids. Mussel-inspired, liquid-free ionoelastomers are reported based on seminal thermal ring-opening polymerization of a biomass molecule of α-lipoic acid (LA), followed by sequentially incorporating dopamine methacrylamide as a chain extender, N,N'-bis(acryloyl) cystamine, and lithium bis(trifluoromethanesulphonyl) imide (LiTFSI). The ionoelastomers exhibit universal adhesion to 12 substrates in both dry and wet states, superfast self-healing underwater, sensing capability for monitoring human motion, and flame retardancy. The underwater self-repairabilitiy prolongs over three months without deterioration, and sustains even when mechanical properties greatly increase. The unprecedented underwater self-mendability benefits synergistically from the maximized availability of dynamic disulfide bonds and diverse reversible noncovalent interactions endowed by carboxylic groups, catechols, and LiTFSI, along with the prevented depolymerization by LiTFSI and tunability in mechanical strength. The ionic conductivity reaches 1.4 × 10^-6 -2.7 × 10^-5 S m^-1 because of partial dissociation of LiTFSI. The design rationale offers a new route for creating a wide range of LA- and sulfur-derived supramolecular (bio)polymers with superior adhesion, healability, and other functionalities, and thus has technological implications for coatings, adhesives, binders and sealants, biomedical engineering and drug delivery, wearable and flexible electronics, and human-machine interfaces.

Highly Ordered Thermoplastic Polyurethane/Aramid Nanofiber Conductive Foams Modulated by Kevlar Polyanion for Piezoresistive Sensing and Electromagnetic Interference Shielding

Highly ordered and uniformly porous structure of conductive foams is a vital issue for various functional purposes such as piezoresistive sensing and electromagnetic interference (EMI) shielding. With the aids of Kevlar polyanionic chains, thermoplastic polyurethane (TPU) foams reinforced by aramid nanofibers (ANF) with adjustable pore-size distribution were successfully obtained via a non-solvent-induced phase separation. In this regard, the most outstanding result is the in situ formation of ANF in TPU foams after protonation of Kevlar polyanion during the NIPS process. Furthermore, in situ growth of copper nanoparticles (Cu NPs) on TPU/ANF foams was performed according to the electroless deposition by using the tiny amount of pre-blended Ti3C2Tx MXene as reducing agents. Particularly, the existence of Cu NPs layers significantly promoted the storage modulus in 2,932% increments, and the well-designed TPU/ANF/Ti3C2Tx MXene (PAM-Cu) composite foams showed distinguished compressive cycle stability. Taking virtues of the highly ordered and elastic porous architectures, the PAM-Cu foams were utilized as piezoresistive sensor exhibiting board compressive interval of 0-344.5 kPa (50% strain) with good sensitivity at 0.46 kPa-1. Meanwhile, the PAM-Cu foams displayed remarkable EMI shielding effectiveness at 79.09 dB in X band. This work provides an ideal strategy to fabricate highly ordered TPU foams with outstanding elastic recovery and excellent EMI shielding performance, which can be used as a promising candidate in integration of satisfactory piezoresistive sensor and EMI shielding applications for human-machine interfaces.

Stretchable, Ultratough, and Intrinsically Self-Extinguishing Elastomers with Desirable Recyclability

Advanced elastomers are increasingly used in emerging areas, for example, flexible electronics and devices, and these real-world applications often require elastomers to be stretchable, tough and fire safe. However, to date there are few successes in achieving such a performance portfolio due to their different governing mechanisms. Herein, a stretchable, supertough, and self-extinguishing polyurethane elastomers by introducing dynamic π-π stacking motifs and phosphorus-containing moieties are reported. The resultant elastomer shows a large break strain of ≈2260% and a record-high toughness (ca. 460 MJ m-3 ), which arises from its dynamic microphase-separated microstructure resulting in increased entropic elasticity, and strain-hardening at large strains. The elastomer also exhibits a self-extinguishing ability thanks to the presence of both phosphorus-containing units and π-π stacking interactions. Its promising applications as a reliable yet recyclable substrate for strain sensors are demonstrated. The work will help to expedite next-generation sustainable advanced elastomers for flexible electronics and devices applications.

Controlled Disassembly of Elemental Sulfur: An Approach to the Precise Synthesis of Polydisulfides

The usage of elemental sulfur (S₈ ) for constructing sulfur-containing polymers is of great significance in terms of sulfur resource utilization or fabrication of high-performance polymers. Currently, the random disassembly of S₈ hinders its direct use in the precise synthesis of sulfur-containing polymers. Herein, we provide an effective strategy for controlling the dismantlement of S₈ to synthesize polydisulfides, a promising category of dynamic bonds containing polymers. In this strategy, the completely alternating copolymerization of one sulfur atom, which is orderly derived from S₈ , with episulfides is achieved with MTBD (7-methyl-1,5,7-triazabicyclo[4.4.0]dec-5-ene) as catalyst and [PPN]SbF₆ ([PPN]⁺ is bis(triphenylphosphine)iminium) as cocatalyst. Delightedly, the living- polymerization feature, and the good monomer compatibility allows for the access to diverse polydisulfides. Furthermore, the density functional theory (DFT) was employed to elaborate the copolymerization process.

Inverse Vulcanization of Norbornenylsilanes: Soluble Polymers with Controllable Molecular Properties via Siloxane Bonds

The inverse vulcanization produces high sulfur content polymers from alkenes and elemental sulfur. Control over properties such as the molar mass or the solubility of polymers is not well established, and existing strategies lack predictability or require large variations of the composition. Systematic design principles are sought to allow for a targeted design of materials. Herein, we report on the inverse vulcanization of norbornenylsilanes (NBS), with a different number of hydrolysable groups at the silicon atom. Inverse vulcanization of mixtures of NBS followed by polycondensation yielded soluble high sulfur content copolymers (50 wt % S) with controllable weight average molar mass (MW ), polydispersity (Đ), glass transition temperature (TG ), or zero-shear viscosity (η0 ). Polycondensation was conducted in the melt with HCl as a catalyst, abolishing the need for a solvent. Purification by precipitation afforded polymers with a greatly reduced amount of low molar mass species.

High strength, epoxy cross-linked high sulfur content polymers from one-step reactive compatibilization inverse vulcanization

Inverse vulcanization provides a simple, solvent-free method for the preparation of high sulfur content polymers using elemental sulfur, a byproduct of refining processes, as feedstock. Despite the successful demonstration of sulfur polymers from inverse vulcanization in optical, electrochemical, and self-healing applications, the mechanical properties of these materials have remained limited. We herein report a one-step inverse vulcanization using allyl glycidyl ether, a heterobifunctional comonomer. The copolymerization, which proceeds via reactive compatibilization, gives an epoxy cross-linked sulfur polymer in a single step, as demonstrated through isothermal kinetic experiments and solid-state 13C NMR spectroscopy. The resulting high sulfur content (≥50 wt%) polymers exhibited tensile strength at break in the range of 10-60 MPa (70-50 wt% sulfur), which represents an unprecedentedly high strength for high sulfur content polymers from vulcanization. The resulting high sulfur content copolymer also exhibited extraordinary shape memory behavior along with shape reprogrammability attributed to facile polysulfide bond rearrangement.

A comparison of adhesive polysulfides initiated by garlic essential oil and elemental sulfur to create recyclable adhesives

Sulfur and garlic essential oil can initiate polymerization with a variety of natural monomers to form sustainable adhesives. The sulfur source has a substantial impact on the adhesion strength and material properties.

Tributylphosphine-catalyzed aziridine-based cycloaddition polymerization toward thiacyclic polymers

Cycloaddition polymerization of bis(N-sulfonyl aziridine)s with diisocyanates in the presence of tributylphosphine allows the facile synthesis of poly(thiazolidin-2-imine)s.

Tracking side reactions of the inverse vulcanization process and developing monomer selection guidelines

Various olefin monomers were inverse-vulcanized. The structural analysis and evaluation of the thermal stability of the products revealed that aliphatic internal olefins are suitable monomers for suppressing side reactions.

Sulfur-Dipentene polysulfides: from industrial waste to sustainable, low-cost materials

The synthesis of poly(S-dipentene) with a sulfur content greater than 50 wt % by catalytic inverse vulcanization in the presence of zinc-based accelerators was investigated at 140 °C for the...

Polymerizations with Elemental Sulfur: From Petroleum Refining to Polymeric Materials

The production of elemental sulfur from petroleum refining has created a technological opportunity to increase the valorization of elemental sulfur by the synthesis of high-performance sulfur-based plastics with improved optical, electrochemical, and mechanical properties aimed at applications in thermal imaging, energy storage, self-healable materials, and separation science. In this Perspective, we discuss efforts in the past decade that have revived this area of organosulfur and polymer chemistry to afford a new class of high-sulfur-content polymers prepared from the polymerization of liquid sulfur with unsaturated monomers, termed inverse vulcanization.