Hierarchical fractal-structured allophanate-derived network formation in bulk polyurethane synthesis

Single-Step Synthesis and Characterization of Non-Linear Tough and Strong Segmented Polyurethane Elastomer Consisting of Very Short Hard and Soft Segments and Hierarchical Side-Reacted Networks and Single-Step Synthesis of Hierarchical Hyper-Branched Polyurethane

Polyurethane elastomers are among the most versatile classes of industrial polymers-typically achieved through a two-step synthesis of segmented block copolymers, comprising very long and soft segments that provide elasticity and significantly long and hard segments that provide strength. The present research focused on the design of a single-step synthesis of a new segmented polyurethane consisting of very short soft and hard segments, crosslinked by preferentially side-reacted hierarchical tertiary oligo-uret network structures, thus exhibiting significant strength, elasticity, and toughness. Despite the theoretically linear structure, both FTIR and solid-state 13C NMR spectroscopy analyses indicated the quasi-equal presence of urethane groups and tertiary oligo-uret structures in the resulting polymer, indicating a preferential consecutive side reaction mechanism. Thermal analysis indicated the significant crystallization of soft segments consisting of only four ethylene oxide units, which was, hereby, demonstrated to occur via an extended chain mechanism. Tensile mechanical properties included significant strength, elasticity, and toughness. Increasing the soft segment length led to a decreased tertiary oligo-uret secondary crosslinking efficacy. The preferential hierarchical side reaction mechanism was, hereby, further confirmed through the synthesis of a completely new type of hyper-branched polymer via diisocyanate and a mono-hydroxy-terminated reagent. The structure-property relations and reaction mechanisms demonstrated in the present research can facilitate the design of new polyurethanes of enhanced performance and processing efficacy for a variety of novel applications.

Chemical Structure and Side Reactions in Polyurea Synthesized via the Water-Diisocyanate Synthesis Pathway

Industrial polyureas are typically synthesized using diisocyanates via two possible alternative pathways: the extremely quick and highly exothermal diamine-diisocyanate pathway and the relatively slow and mild water-diisocyanate pathway. Although polyurea synthesis via the water-diisocyanate pathway is known and has been industrially applied for many decades, there is surprisingly very little analytical information in the literature in relation to the type and extent of the occurring side reactions and the resulting chemical structures following this synthesis pathway. The synthesis of polyureas exhibiting very high concentrations of carbonyl-containing groups resulted in strong and accurate diagnostic analytical signals of combined FTIR and solid-state 13C NMR analysis. Despite the strictly linear theoretical chemical structure designed, the syntheses resulted in highly nonlinear and crosslinked polymers. It was analytically found that the water-diisocyanate pathway preferentially produced highly dominant and almost equal contents of both biuret structures and tertiary oligo-uret structures, with a very small occurrence of urea groups. This is in strong contrast with the chemical structures previously obtained via the diamine-diisocyanate polyurea synthesis pathway, which almost exclusively resulted in biuret structures. The much slower reaction and crosslinking rate of the water-diisocyanate synthesis pathway enabled the further access of isocyanate groups to the already-formed secondary nitrogens, thus facilitating the formation of complex hierarchical tertiary oligo-uret structures.

Synthesis and Characterisation of Poly(3-hydroxybutyrate-co-3-hydroxyvalerate)-b-poly(3-hydroxybutyrate-co-3-hydroxyvalerate) Multi-Block Copolymers Produced Using Diisocyanate Chemistry

Bacterially derived polyhydroxyalkanoates (PHAs) are attractive alternatives to commodity petroleum-derived plastics. The most common forms of the short chain length (scl-) PHAs, including poly(3-hydroxybutyrate) (P3HB) and poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV), are currently limited in application because they are relatively stiff and brittle. The synthesis of PHA-b-PHA block copolymers could enhance the physical properties of PHAs. Therefore, this work explores the synthesis of PHBV-b-PHBV using relatively high molecular weight hydroxy-functionalised PHBV starting materials, coupled using facile diisocyanate chemistry, delivering industrially relevant high-molecular-weight block copolymeric products. A two-step synthesis approach was compared with a one-step approach, both of which resulted in successful block copolymer production. However, the two-step synthesis was shown to be less effective in building molecular weight. Both synthetic approaches were affected by additional isocyanate reactions resulting in the formation of by-products such as allophanate and likely biuret groups, which delivered partial cross-linking and higher molecular weights in the resulting multi-block products, identified for the first time as likely and significant by-products in such reactions, affecting the product performance.

Preparation of hetero-armed POSS-cored star-shaped PCL-PLA/PLA composites and effect of different diisocyanates as compatibilizer

Eight-armed A₄B₄-type hetero-arm star-shaped PCL-PLA polymers ((PCL)₄-POSS-(PLA)₄, SPLA30) with POSS core were successfully prepared via combination of the "arm-first" approach utilizing ring-opening polymerization (ROP) and click chemistry techniques. Firstly, alkyne-functional PLA and PCL polymers having arms with 30 repeating units were synthesized via ROP with utilizing propargyl alcohol as initiator and stannous octoate (Sn(Oct)₂) as catalyst. Then, the obtained hetero-armed star-shaped polymers were prepared by Cu(I)-catalyzed alkyne-azide cycloaddition (CuAAC) click reaction between alkyne functional polymers (1:1 PCL:PLA) and azido functional polyhedral oligomeric silsesquoxane (POSS-(N₃)₈) molecules. Finally, these obtained star-shaped SPLA30 was blended with neat PLA at different PLA/SPLA30 ratios (95/5 and 90/10 wt%) via melt blending by utilizing micro-compounder (a lab-scale) to enhance thermal, morphological, and mechanical properties of neat PLA. Also, different diisocyanates (1,4-phenylene diisocyanate (PDI), isophorone diisocyanate (IPDI), methylene diphenyl diisocyanate (MDI), and toluene 2,4-diisocyanate (TDI)) at constant ratio (1 wt%) were used as a chain extender bonding terminal group of polymers. It was found that addition of SPLA30 and SPLA30+ diisocyanates provided improvements in mechanical properties (especially in elongation at break and impact strength) of neat PLA. When the thermal properties were examined, it was seen that the decomposition temperatures of the blends decreased significantly compared to neat PLA and that there was a significant increment in the T_g and T_m values. In addition, it has been found that especially the diisocyanates added to provide good interfacial adhesion with polymer blends and show a homogeneous distribution on the surface.

Urethane Formation with an Excess of Isocyanate or Alcohol: Experimental and Ab Initio Study

A kinetic and mechanistic investigation of the alcoholysis of phenyl isocyanate using 1-propanol as the alcohol was undertaken. A molecular mechanism of urethane formation in both alcohol and isocyanate excess is explored using a combination of an accurate fourth generation Gaussian thermochemistry (G4MP2) with the Solvent Model Density (SMD) implicit solvent model. These mechanisms were analyzed from an energetic point of view. According to the newly proposed two-step mechanism for isocyanate excess, allophanate is an intermediate towards urethane formation via six-centered transition state (TS) with a reaction barrier of 62.6 kJ/mol in the THF model. In the next step, synchronous 1,3-H shift between the nitrogens of allophanate and the cleavage of the C–N bond resulted in the release of the isocyanate and the formation of a urethane bond via a low-lying TS with 49.0 kJ/mol energy relative to the reactants. Arrhenius activation energies of the stoichiometric, alcohol excess and the isocyanate excess reactions were experimentally determined by means of HPLC technique. The activation energies for both the alcohol (measured in our recent work) and the isocyanate excess reactions were lower compared to that of the stoichiometric ratio, in agreement with the theoretical calculations.