Controlled Radical Polymerization: Industrial Stakes, Obstacles and Achievements

Highly efficient dual photoredox/copper catalyzed atom transfer radical polymerization achieved through mechanism-driven photocatalyst design

Atom transfer radical polymerization (ATRP) with dual photoredox/copper catalysis combines the advantages of photo-ATRP and photoredox-mediated ATRP, utilizing visible light and ensuring broad monomer scope and solvent compatibility while minimizing side reactions. Despite its popularity, challenges include high photocatalyst (PC) loadings (10 to 1000 ppm), requiring additional purification and increasing costs. In this study, we discover a PC that functions at the sub-ppm level for ATRP through mechanism-driven PC design. Through studying polymerization mechanisms, we find that the efficient polymerizations are driven by PCs whose ground state oxidation potential-responsible for PC regeneration-play a more important role than their excited state reducing power, responsible for initiation. This is verified by screening PCs with varying redox potentials and triplet excited state generation capabilities. Based on these findings, we identify a highly efficient PC, 4DCDP-IPN, featuring moderate excited state reducing power and a maximized ground state oxidation potential. Employing this PC at 50 ppb, we synthesize poly(methyl methacrylate) with high conversion, narrow molecular weight distribution, and high chain-end fidelity. This system exhibits oxygen tolerance and supports large-scale reactions under ambient conditions. Our findings, driven by the systematic PC design, offer meaningful insights for controlled radical polymerizations and metallaphotoredox-mediated syntheses beyond ATRP.

Near-infrared Light-Induced Polymerizations: Mechanisms and Applications

Photopolymerizations have garnered significant attention in polymer science due to their low polymerization temperature, high production efficiency, environmental friendliness, and spatial controllability. Despite these merits, the poor penetration and severe chemical damage from ultraviolet/visible (UV/Vis) light resources pose significant barriers to their success in conventional photopolymerizations. A recent breakthrough involving the utilization of near-infrared (NIR) laser with long wavelength has been exploited for diverse applications. With the combination of a NIR photosensitizer (PS), NIR-induced photopolymerizations have been successfully developed to alleviate the challenges in conventional methods. The enhancement of penetration depth and safety of NIR-induced photopolymerizations can contribute significantly to improving the efficiency of polymerization for production of intricate structures across various scales. In this concept, the typical types of PSs and polymerization mechanisms (PMs) within the NIR-induced photopolymerization systems have been classified in detail. Additionally, the applications of various polymers achieved by NIR-induced photopolymerizations are summarized. Furthermore, research directions and future challenges of this field are also discussed comprehensively.

Robust Miniemulsion PhotoATRP Driven by Red and Near-Infrared Light

Photoinduced polymerization techniques have gathered significant attention due to their mild conditions, spatiotemporal control, and simple setup. In addition to homogeneous media, efforts have been made to implement photopolymerization in emulsions as a practical and greener process. However, previous photoinduced reversible deactivation radical polymerization (RDRP) in heterogeneous media has relied on short-wavelength lights, which have limited penetration depth, resulting in slow polymerization and relatively poor control. In this study, we demonstrate the first example of a highly efficient photoinduced miniemulsion ATRP in the open air driven by red or near-infrared (NIR) light. This was facilitated by the utilization of a water-soluble photocatalyst, methylene blue (MB+). Irradiation by red/NIR light allowed for efficient excitation of MB+ and subsequent photoreduction of the ATRP deactivator in the presence of water-soluble electron donors to initiate and mediate the polymerization process. The NIR light-driven miniemulsion photoATRP provided a successful synthesis of polymers with low dispersity (1.09 ≤ Đ ≤ 1.29) and quantitative conversion within an hour. This study further explored the impact of light penetration on polymerization kinetics in reactors of varying sizes and a large-scale reaction (250 mL), highlighting the advantages of longer-wavelength light, particularly NIR light, for large-scale polymerization in dispersed media owing to its superior penetration. This work opens new avenues for robust emulsion photopolymerization techniques, offering a greener and more practical approach with improved control and efficiency.

Effect of Radical Polymerization Method on Pharmaceutical Properties of Π Electron-Stabilized HPMA-Based Polymeric Micelles

Polymeric micelles are among the most extensively used drug delivery systems. Key properties of micelles, such as size, size distribution, drug loading, and drug release kinetics, are crucial for proper therapeutic performance. Whether polymers from more controlled polymerization methods produce micelles with more favorable properties remains elusive. To address this question, we synthesized methoxy poly(ethylene glycol)-b-(N-(2-benzoyloxypropyl)methacrylamide) (mPEG-b-p(HPMAm-Bz)) block copolymers of three different comparable molecular weights (∼9, 13, and 20 kDa), via both conventional free radical (FR) and reversible addition-fragmentation chain transfer (RAFT) polymerization. The polymers were subsequently employed to prepare empty and paclitaxel-loaded micelles. While FR polymers had relatively high dispersities (Đ ∼ 1.5-1.7) compared to their RAFT counterparts (Đ ∼ 1.1-1.3), they formed micelles with similar pharmaceutical properties (e.g., size, size distribution, critical micelle concentration, cytotoxicity, and drug loading and retention). Our findings suggest that pharmaceutical properties of mPEG-b-p(HPMAm-Bz) micelles do not depend on the synthesis route of their constituent polymers.

Effective Interaction between Homo- and Heteropolymer Block of Poly(n-butyl acrylate)-b-poly(methyl methacrylate-r-styrene) Diblock Copolymers

We investigated the segregation behavior of a molten diblock copolymer, poly(n-butyl acrylate)-b-poly(methyl methacrylate-r-styrene) (PBA-b-P(MMA-r-S)), wherein styrene (S) is incorporated as a comonomer in the second block to modulate the effective interaction between homopolymer and a random copolymer block. The temperature dependence of the effective interaction parameter χeff between n-butyl acrylate (BA) and the average monomer of the MMA-r-S random block was evaluated from small-angle X-ray scattering (SAXS) analysis using the random phase approximation (RPA) approach. The calculated χeff, as a function of the styrene fraction in the random copolymer block, shows a good agreement with the mean-field binary interaction model. This consistency indicates that the effective interaction between component BA and the average monomer of the random copolymer block is smaller than the interactions between pure components (χBA,MMA,χBA,S). The present study suggests that the introduction of a random copolymer block to a block copolymer can effectively reduce the degree of incompatibility of the block copolymer system without altering the constituent species, which may serve as a viable methodology in designing novel thermoplastic elastomers based on triblock or multiblock copolymers.

Reversed Controlled Polymerization (RCP): Depolymerization from Well-Defined Polymers to Monomers

Controlled polymerization methods are well-established synthetic protocols for the design and preparation of polymeric materials with a high degree of precision over molar mass and architecture. Exciting recent work has shown that the high end-group fidelity and/or functionality inherent in these techniques can enable new routes to depolymerization under relatively mild conditions. Converting polymers back to pure monomers by depolymerization is a potential solution to the environmental and ecological concerns associated with the ultimate fate of polymers. This perspective focuses on the emerging field of depolymerization from polymers synthesized by controlled polymerizations including radical, ionic, and metathesis polymerizations. We provide a critical review of current literature categorized according to polymerization technique and explore numerous concepts and ideas which could be implemented to further enhance depolymerization including lower temperature systems, catalytic depolymerization, increasing polymer scope, and controlled depolymerization.

Small-Angle X-ray Scattering Analysis on the Estimation of Interaction Parameter of Poly(n-butyl acrylate)-b-poly(methyl methacrylate)

The temperature dependence of the Flory-Huggins interaction parameter χ for poly(n-butyl acrylate)-b-poly(methyl methacrylate) (PBA-b-PMMA) was quantified from small-angle X-ray scattering (SAXS) analysis using random phase approximation (RPA) theory. It was found from the χ estimation (χ=0.0103+14.76/T) that the enthalpic contribution, χH, a measure for temperature susceptibility of χ, is 1.7-4.5 folds smaller for PBA-b-PMMA than for the conventional styrene-diene-based block copolymers, which have been widely used for thermoplastic elastomers. This finding suggests that these fully acrylic components can be a desirable chemical pair for constituting terpolymers applied for thermally stable and mechanically resilient elastomers.

Glycopolymer-Based Materials: Synthesis, Properties, and Biosensing Applications

Glycopolymer materials have emerged as a significant biopolymer class that has piqued the scientific community's attention due to their potential applications. Recently, they have been found to be a unique synthetic biomaterial; glycopolymer materials have also been used for various applications, including direct therapeutic methods, medical adhesives, drug/gene delivery systems, and biosensor applications. Therefore, for the next stage of biomaterial research, it is essential to understand current breakthroughs in glycopolymer-based materials research. This review discusses the most widely utilized synthetic methodologies for glycopolymer-based materials, their properties based on structure–function interactions, and the significance of these materials in biosensing applications, among other topics. When creating glycopolymer materials, contemporary polymerization methods allow precise control over molecular weight, molecular weight distribution, chemical activity, and polymer architecture. This review concludes with a discussion of the challenges and complexities of glycopolymer-based biosensors, in addition to their potential applications in the future.

Atom Transfer Radical Polymerization: A Mechanistic Perspective

Since its inception, atom transfer radical polymerization (ATRP) has seen continuous evolution in terms of the design of the catalyst and reaction conditions; today, it is one of the most useful techniques to prepare well-defined polymers as well as one of the most notable examples of catalysis in polymer chemistry. This Perspective highlights fundamental advances in the design of ATRP reactions and catalysts, focusing on the crucial role that mechanistic studies play in understanding, rationalizing, and predicting polymerization outcomes. A critical summary of traditional ATRP systems is provided first; we then focus on the most recent developments to improve catalyst selectivity, control polymerizations via external stimuli, and employ new photochemical or dual catalytic systems with an outlook to future research directions and open challenges.

Design of biointerfaces composed of soft materials using controlled radical polymerizations

Soft interface materials have an immense potential for the improvement of biointerfaces, which are the interface of biological and artificially designed materials. Controlling the chemical and physical structures of the interfaces at the nanometer level plays an important role in understanding the mechanism of the functioning and its applications. Controlled radical polymerization (CRP) techniques, including atom transfer radical polymerization (ATRP) and reversible addition-fragmentation chain-transfer (RAFT) polymerization, have been developed in the field of precision polymer chemistry. It allows the formation of well-defined surfaces such as densely packed polymer brushes and self-assembled nanostructures of block copolymers. More recently, a novel technique to prepare polymers containing biomolecules, called biohybrids, has also been developed, which is a consequence of the advancement of CRP so as to proceed in an aqueous media with oxygen. This review article summarizes recent advances in CRP for the design of biointerfaces.

Block Copolymers Based on Ethylene and Methacrylates Using a Combination of Catalytic Chain Transfer Polymerisation (CCTP) and Radical Polymerisation

Two scalable polymerisation methods are used in combination for the synthesis of ethylene and methacrylate block copolymers. ω-Unsaturated methacrylic oligomers (MMA_n ) produced by catalytic chain transfer (co)polymerisation (CCTP) of methyl methacrylate (MMA) and methacrylic acid (MAA) are used as reagents in the radical polymerisation of ethylene (E) in dimethyl carbonate solvent under relatively mild conditions (80 bar, 70 °C). Kinetic measurements and analyses of the produced copolymers by size exclusion chromatography (SEC) and a combination of nuclear magnetic resonance (NMR) techniques indicate that MMA_n is involved in a degradative chain transfer process resulting in the formation of (MMA)_n -b-PE block copolymers. Molecular modelling performed by DFT supports the overall reactivity scheme and observed selectivities. The effect of MMA_n molar mass and composition is also studied. The block copolymers were characterised by differential scanning calorimetry (DSC) and their bulk behaviour studied by SAXS/WAXS analysis.

Tuning dispersity of linear polymers and polymeric brushes grown from nanoparticles by atom transfer radical polymerization

Molecular weight distribution imposes considerable influence on the properties of polymers, making it an important parameter, impacting morphology and structural behavior of polymeric materials.

Achieving molecular weight distribution shape control and broad dispersities using RAFT polymerizations

Metered additions of chain transfer agents are used to control molecular weight distribution (MWD) features in reversible addition-fragmentation chain-transfer polymerizations, giving polymers with tailored MWD shapes and dispersities as high as 6.2.

Novel tetraphenylethylene (TPE)-functionalized nitroxide/alkoxyamine for nitroxide-mediated homogeneous and heterogeneous polymerizations

Tetraphenylethylene (TPE)-functionalized nitroxide/alkoxyamine realized the “in situ observation” of the NMP process for both homogeneous and heterogeneous polymerization systems.

Iodine-Transfer Polymerization (ITP) of Ethylene and Copolymerization with Vinyl Acetate

Controlled radical polymerization of ethylene using different commercially available, cheap, and non-toxic iodo alkyls is performed by iodine transfer polymerization (ITP) under mild conditions (≤100 °C and ≤200 bar). The formed well-defined iodo end-capped polyethylene (PE-I) species is very stable upon storage. Narrow molar-mass distributions (dispersities around 1.6) were obtained up to number average molar masses of 7300 g mol^-1 . The ethylene copolymerization by ITP (ITcoP) with vinyl acetate allowed to form a broad range of poly(ethylene-co-vinyl acetate) (EVA) containing from 0 to 85 mol % of VAc unit. In addition, EVA-b-PE block copolymers or EVA-b-EVA gradient block copolymers with different content of VAc in the blocks were obtained for the first time using ITP. Finally, reactivity trends were explored by a theoretical mechanistic study. This highly versatile synthetic platform provides a straightforward access to a diverse range of well-defined PE based polymer materials.

Progress Toward Sustainable Reversible Deactivation Radical Polymerization

The recent focus of media and governments on renewability, green chemistry, and circular economy has led to a surge in the synthesis of renewable monomers and polymers. In this review, focussing on renewable monomers for reversible deactivation radical polymerizations (RDRP), it is highlighted that for the majority of the monomers and polymers reported, the claim to renewability is not always accurate. By closely examining the sustainability of synthetic routes and the renewability of starting materials, fully renewable monomers are identified and discussed in terms of sustainability, polymerization behavior, and properties obtained after polymerization. The holistic discussion considering the overall preparation process of polymers, that is, monomer syntheses, origin of starting materials, solvents used, the type of RDRP technique utilized, and the purification method, allows to highlight certain topics which need to be addressed in order to progress toward not only (partially) renewable, but sustainable monomers and polymers using RDRPs.

Fundamentals of Emulsion Polymerization

A comprehensive overview of the fundamentals of emulsion polymerization and related processes is presented with the object of providing theoretical and practical understanding to researchers considering use of these methods for synthesis of polymer colloids across a wide range of applications. Hence, the overview has been written for a general scientific audience with no prior knowledge assumed. Succinct introductions are given to key topics of background science to assist the reader. Importance is placed on ensuring mechanistic understanding of these complex polymerizations and how the processes can be used to create polymer colloids that have particles with well-defined properties and morphology. Mathematical equations and associated theory are given where they enhance understanding and learning and where they are particularly useful for practical application. Practical guidance also is given for new researchers so that they can begin using the various processes effectively and in ways that avoid common mistakes.

New Variants of Nitroxide Mediated Polymerization

Nitroxide-mediated polymerization is now a mature technique, at 35 years of age. During this time, several variants have been developed: enhanced spin capture polymerization (ESCP), photoNMP (NMP2), chemically initiated NMP (CI-NMP), spin label NMP (SL-NMP), and plasmon-initiated NMP (PI-NMP). This mini-review is devoted to the features and applications of these variants.

On the nitroxide mediated polymerization of methacrylates derived from bio-sourced terpenes in miniemulsion, a step towards sustainable products

The typical use of toxic solvents, expensive control agents and the need of intermediate purification steps hinders the introduction of bio-sourced monomers into industrially viable block copolymers. This study aims at overcoming these limitations.

An enzymatic acetal/hemiacetal conversion for the physiological temperature activation of the alkoxyamine C–ON bond homolysis

Enzymatic trigger. Upon enzymatic hydrolysis by Subtilisin A, highly stable alkoxyamines are transformed into highly labile alkoxyamines able to homolyze spontaneously in less than 500 seconds, at 37 °C.

A Novel Strategy for the Synthesis of Amphiphilic and Thermoresponsive Poly(N-isopropylacrylamide)-b-Polystyrene Block Copolymers via ATRP

A new synthetic approach is presented for the preparation of Poly(N-isopropylacrylamide-block-styrene) PNIPAM-b-PS via an Atom Transfer Radical Polymerization (ATRP) technique. The proposed method is based on application of 2-chloro-N-(2-hydroxyethyl)propanamide (NCPAE) as a bifunctional initiator, which enables ATRP of two monomers, differing in activity and polarity, into two stages. The synthesized copolymer molecules contain two well-defined polymer chains connected by a linker, which is a derivative of the proposed initiator. Using NCPAE led to PNIPAMs with well-planned molecular weight, low polydispersities (PDI=1.1÷1.3) and hydroxyl functionality. Activation of such blocks for initiation of styrene polymerization was performed using α-bromoisobutyryl bromide. After such a modification, the synthesized homopolymers acted as macroinitiators in ARGET ATRP and a well-defined polystyrene block, as the next one in the polymer chain was successfully formed. Both of the synthesized macromolecules, PNIPAM and PNIPAM-b-PS, exhibit a thermoresponsive behavior with explicit lower critical solution temperatures (LCST) in their aqueous solutions. The synthesized homopolymers and subsequently derived block copolymers were characterized using Size-Exclusion Chromatography, Differential Scanning Calorimetry, Dynamic Light Scattering, and NMR spectroscopy.

Synthesis and Viscosimetric Behavior of Poly(acrylamide-co-2-acrylamido-2-methylpropanesulfonate) Obtained by Conventional and Adiabatic Gel Process via RAFT/MADIX Polymerization

High molar masses homopolymers of both acrylamide (AM) and 2-acrylamido-2-methylpropanesulfonate (AMPS) as well as poly(AM-stat-AMPS) exhibiting a large range copolymer composition has been obtained via the optimization of a purely adiabatic gel process. Monomer concentrations ranging from 2.0 to 3.47 M have been successfully tested while keeping the control of the molar masses up to 5 × 10⁶ g mol^-1. The products have been characterized in terms of molecular mass and viscosimetric properties.