Polyhydroxyurethanes (PHUs) Derived from Diphenolic Acid and Carbon Dioxide and Their Application in Solvent- and Water-Borne PHU Coatings

Challenges and Opportunities in the Catalytic Synthesis of Diphenolic Acid and Evaluation of Its Application Potential

Diphenolic acid, or 4,4-bis(4-hydroxyphenyl)pentanoic acid, represents one of the potentially most interesting bio-products obtainable from the levulinic acid supply-chain. It represents a valuable candidate for the replacement of bisphenol A, which is strongly questioned for its toxicological issues. Diphenolic acid synthesis involves the condensation reaction between phenol and levulinic acid and requires the presence of a Brønsted acid as a catalyst. In this review, the state of the art related to the catalytic issues of its synthesis have been critically discussed, with particular attention to the heterogeneous systems, the reference benchmark being represented by the homogeneous acids. The main opportunities in the field of heterogeneous catalysis are deeply discussed, as well as the bottlenecks to be overcome to facilitate diphenolic acid production on an industrial scale. The regioselectivity of the reaction is a critical point because only the p,p'-isomer is of industrial interest; thus, several strategies aiming at the improvement of the selectivity towards this isomer are considered. The future potential of adopting alkyl levulinates, instead of levulinic acid, as starting materials for the synthesis of new classes of biopolymers, such as new epoxy and phenolic resins and polycarbonates, is also briefly considered.

Accelerating the Curing of Hybrid Poly(Hydroxy Urethane)-Epoxy Adhesives by the Thiol-Epoxy Chemistry

The polyaddition between dicyclic carbonates and diamines leading to poly(hydroxy urethane)s (PHUs) has emerged as the preferred method for the synthesis of green, non-isocyanate polyurethanes. However, when proposed for use as structural adhesives, the long times for completion of aminolysis of the 5-membered cyclic carbonates under ambient conditions force the use of complementary chemistries to accelerate the curing process. In this work, a system that combines an amino-terminated PHU (NH₂-PHU-NH₂), an epoxy resin, and a thiol compound was employed to develop high-shear strength PHU-epoxy hybrid adhesives able to cure at room temperature in short times. A NH₂-PHU-NH₂ prepolymer synthesized by using a sub-stoichiometric quantity of dicyclic carbonates was mixed with a bisphenol A-based epoxy resin for the preparation of the structural adhesive. While this adhesive showed good lap-shear strength and shear resistance under static load and temperature, the curing process was slow. In order to speed up the curing process, a thiol (trimethylolpropane tris(3-mercapto propionate)) was added and its impact on the curing process as well as on the adhesive properties was evaluated. The trifunctional thiol additive allowed for faster curing in the presence of the 1,1,3,3-tetramethylguanidine basic catalyst. Moreover, a combination of NH₂-PHU-NH₂ and the thiol as curing agents for the epoxy resin resulted in adhesives with superior toughness, without any deterioration of the ultimate lap-shear strength or shear resistance under load and temperature, making these adhesives suitable for high-demand applications in the automotive industry.

Nanocomposites of Polyhydroxyurethane with POSS Microdomains: Synthesis via Non-Isocyanate Approach, Morphologies and Reprocessing Properties

In this contribution, we reported the synthesis of a novel trifunctional POSS cyclic carbonate [POSS-3(5CC)]. With a difunctional five-member cyclic carbonate and a trifunctional polyetheramine as the precursor, the nanocomposites of polyhydroxyurethane (PHU) with POSS were synthesized. Transmission electron microscopy (TEM) showed that the nanocomposites of PHUs with POSS were microphase-separated; the spherical POSS microdomains via POSS-POSS interactions were generated with the size of 20~40 nm in diameter. After the introduction of POSS microdomains, the nanocomposites displayed improved thermal and mechanical properties. More importantly, the nanocomposites still displayed the reprocessing properties of vitrimers.

Poly(hydroxyurethane) Adhesives and Coatings: State-of-the-Art and Future Directions

Polyurethane (PU) adhesives and coatings are widely used to fabricate high-quality materials due to their excellent properties and their versatile nature, which stems from the wide range of commercially available polyisocyanate and polyol precursors. This polymer family has traditionally been used in a wide range of adhesive applications including the bonding of footwear soles, bonding of wood (flooring) to concrete (subflooring), in the automotive industry for adhering different car parts, and in rotor blades, in which large surfaces are required to be adhered. Moreover, PUs are also frequently applied as coatings/paints for automotive finishes and can be applied over a wide range of substrates such as wood, metal, plastic, and textiles. One of the major drawbacks of this polymer family lies in the use of toxic isocyanate-based starting materials. In the context of the REACH regulation, which places restrictions on the use of substances containing free isocyanates, it is now urgent to find greener routes to PUs. While non-isocyanate polyurethanes (NIPUs) based on the polyaddition of poly(cyclic carbonate)s to polyamines have emerged in the past decade as greener alternatives to conventional PUs, their industrial implementation is at an early stage of development. In this review article, recent advances in the application of NIPUs in the field of adhesives and coatings are summarized. The article also draws attention to the opportunities and challenges of implementing NIPUs at the industrial scale.

Lignin-Based Polyurethane: Recent Advances and Future Perspectives

Polyurethane (PU), as a polymer material with versatile product forms and excellent performance, is used in coatings, elastomers, adhesives, and foams widely. However, the raw materials (polyols and isocyanates) of PU are usually made using petroleum-derived chemicals. With the concern for depletion of petroleum resources and the associated negative impact on the environment, developing technologies that can use renewable raw materials as feedstock has become a research hotspot. Lignin, as an abundant, natural, and renewable organic carbon resource, has been explored as raw material for making polyurethanes because it possesses rich hydroxyl groups on its surface. Meanwhile, compared to vegetable oils, lignin does not compete with food supply and performance of the resulting products is superior. Lignin or modified lignin has been shown to impart the polyurethane material with additional functionalities, such as UV-blocking ability, hydrophobicity, and flame retardancy. However, the utilization of lignin has encountered some challenges, such as product isolation, heterogeneity, aggregation, steric hindrance, and low activity. This paper summarizes recent research progress on utilizing lignin and modified lignin for bio-based polyurethane synthesis with a focus on elastomers and foams. Opportunities and challenges for application of the lignin-based polyurethanes in various fields are also discussed.

Surface Properties of Poly(Hydroxyurethane)s Based on Five-Membered Bis-Cyclic Carbonate of Diglycidyl Ether of Bisphenol A

Poly(hydroxyurethane)s (PHU) are alternatives for conventional polyurethanes due to the use of bis-cyclic dicarbonates and diamines instead of harmful and toxic isocyanates. However, the surface properties of poly(hydroxyurethane)s are not well known. In this work, we focus on the analysis of the surface properties of poly(hydroxyurethane) coatings. Poly(hydroxyurethane)s were obtained by a catalyst-free method from commercially available carbonated diglycidyl ether of bisphenol A (Epidian 6 epoxy resins) and various diamines: ethylenediamine, trimethylenediamine, putrescine, hexamethylenediamine, 2,2,4(2,4,4)-trimethyl-1,6-hexanediamine, m-xylylenediamine, 1,8-diamino-3,6-dioxaoctane, 4,7,10-trioxa-1,13-tridecanediamine, and isophorone diamine, using a non-isocyanate route. The structures of the obtained polymers were confirmed by FT-IR, ¹H NMR and ¹³C NMR spectroscopy, and thermogravimetric (TGA) and differential scanning calorimetry (DSC) analyses were performed. The rheological characteristic of the obtained polymers is presented. The static contact angles of water, diidomethane, and formamide, deposited on PHU coatings, were measured. From the measured contact angles, the surface free energy was calculated using two different approaches: Owens-Wendt and van Oss-Chaudhury-Good. Moreover, the wetting envelopes of PHU coatings were plotted, which enables the prediction of the wetting effect of various solvents. The results show that in the investigated coatings, a mainly dispersive interaction occurs.

Water-based non-isocyanate polyurethane-ureas (NIPUUs)

This review aims at discussing the achievements and the remaining challenges in the development of water-soluble NIPUUs, NIPUUs-based hydrogels and water-borne NIPUU dispersions.

Green Synthesis of Novel Polyesterurethane Materials from Epoxides and Carbon Dioxide by New Set of One-Dimensional Coordination Polymer Catalyst

Two novel polyesterurethane materials, PEU1 and PEU2, were synthesized via nontoxic and isocyanate-free route by simple conversion of two epoxides 1,2-epoxy-3-phenoxy propane (2) and styrene epoxide (3) utilizing CO₂. Epoxides 2 and 3 were converted to the respective cyclic carbonates 4 and 5 by a new set of cobalt-based catalyst 1a in the presence of 10 bar of CO₂ and 80 °C temperature without using cocatalyst tetrabutylammonium bromide (TBAB). The mechanistic pathway of the catalysis reaction for the cycloaddition of epoxides with CO₂ to generate the cyclic carbonates was investigated by several spectroscopic techniques and utilizing analogous zinc-based 1D coordination polymer 1b, which does not act as an efficient catalyst in the absence of TBAB. Cyclic carbonates 4 and 5 were converted to the respective polyesterurethanes PEU1 and PEU2 sequentially by first synthesizing the ring-opened diols 6 and 7 reacting with ethylenediamine and subsequently annealing the respective diols 6 and 7 at 120 °C in the presence of terepthalyl chloride and triethylamine. The polyesterurethanes PEU1 and PEU2 were characterized by multinuclear NMR and FTIR. PEU1 was also characterized by MALDI-TOF mass spectrometry. The thermal studies of PEU1 and PEU2 showed the stability up to 200-270 °C. The number-average and weight-average molecular weights were determined for PEU1 and PEU2 by GPC analysis. The weight-average molecular weight for PEU1 was found to be 5948 with a polydispersity of 1.1, and PEU2 showed the weight-average molecular weight as 4224 with a polydispersity of 1.06.

Hybrid Poly(hydroxy urethane)s: Folded-Sheet Morphology and Thermoreversible Adhesion

Hybrid poly(hydroxy urethane)s (PHUs) are synthesized by copolymerizing aromatic/alicyclic cyclic carbonates with a polyether amine via addition polymerization. They result into polymers with an average molecular weight of 10 kDa and exhibit solubility in common organic solvents. The hybrid PHUs display T g up to 18 °C. PHUs are enriched with multiple H-bonded interactions and they are assessed using temperature-dependent 1H NMR and Fourier-transform infrared studies. PHUs possess folded-sheet morphology with nanogap between folds and nanowidth between chains. The secondary interactions bestow thermoreversible property to PHUs, and they display good adhesion to both polar (Al-Al) and nonpolar (HDPE-HDPE) substrates. Hybrid PHUs show improved optical transparency compared to homo PHUs. The PHUs are thermally stable up to 250 °C.

Polymers Based on Cyclic Carbonates as Trait d'Union Between Polymer Chemistry and Sustainable CO2 Utilization

Given the large amount of anthropogenic CO₂ emissions, it is advantageous to use CO₂ as feedstock for the fabrication of everyday products, such as fuels and materials. An attractive way to use CO₂ in the synthesis of polymers is by the formation of five-membered cyclic organic carbonate monomers (5CCs). The sustainability of this synthetic approach is increased by using scaffolds prepared from renewable resources. Indeed, recent years have seen the rise of various types of carbonate syntheses and applications. 5CC monomers are often polymerized with diamines to yield polyhydroxyurethanes (PHU). Foams are developed from this type of polymers; moreover, the additional hydroxyl groups in PHU, absent in classical polyurethanes, lead to coatings with excellent adhesive properties. Furthermore, carbonate groups in polymers offer the possibility of post-functionalization, such as curing reactions under mild conditions. Finally, the polarity of carbonate groups is remarkably high, so polymers with carbonates side-chains can be used as polymer electrolytes in batteries or as conductive membranes. The target of this Review is to highlight the multiple opportunities offered by polymers prepared from and/or containing 5CCs. Firstly, the preparation of several classes of 5CCs is discussed with special focus on the sustainability of the synthetic routes. Thereafter, specific classes of polymers are discussed for which the use and/or presence of carbonate moieties is crucial to impart the targeted properties (foams, adhesives, polymers for energy applications, and other functional materials).

Rapidly Reprocessable Cross-Linked Polyhydroxyurethanes Based on Disulfide Exchange

Polymer networks that are cross-linked by dynamic covalent bonds often sacrifice the robust mechanical properties of traditional thermosets in exchange for rapid and efficient reprocessability. Polyurethanes are attractive materials for reprocessable cross-linked polymers because of their excellent mechanical properties, widespread use, and ease of synthesis, but their syntheses typically rely on harmful isocyanate precursors. Polyhydroxyurethanes (PHUs), derived from amines and cyclic carbonates, are promising alternatives to traditional polyurethanes. PHU networks are reprocessable via transcarbamoylation reactions even in the absence of external catalysts, but this process occurs over hours at temperatures above 150 °C. We have dramatically shortened the reprocessing times of PHU networks by incorporating dynamic disulfide bonds. Using cystamine as a comonomer gives materials with similar thermal stability and mechanical properties to other rigid cross-linked PHUs. Despite their excellent mechanical properties, these materials show rapid stress relaxation and have characteristic relaxation times as low as 30 s at 150 °C. This property enables reprocessing with quantitative recovery of cross-link density as measured by DMTA after only 30 min of elevated-temperature compression molding. Disulfide incorporation is a promising approach to obtain reprocessable, cross-linked PHU resins that are not derived from isocyanates.