Insights into the Synthesis of Poly(ethylene 2,5-Furandicarboxylate) from 2,5-Furandicarboxylic Acid: Steps toward Environmental and Food Safety Excellence in Packaging Applications

-COOH & -OH Condensation Reaction Utilization for Biomass FDCA-based Polyesters

A green and sustainable -COOH & -OH condensation solution polymerization method was hereby reported for FDCA-based polyesters to avoid discoloration and toxic solvents. First, taking poly(ethylene 2,5-furandicarboxylate) (PEF) as the representative of FDCA-based polyester, enabling good white appearance PEF with Mn=6.51×103 g mol-1 from FDCA and ethylene glycol in green solvent γ-valerolactone (GVL), catalyzed by 4-dimethylaminopyridine (DMAP) and N-(3-dimethylaminopropyl)-N'-ethylcarbodiimide hydrochloride (EDC). Additionally, the molecular weight of PEF was rapidly improved (Mn >2.5×104 g mol-1) via remelting polycondensation within minutes, with the dispersity still kept relatively low dispersity (Đ<1.40). Importantly, the -COOH & -OH condensation solution polymerization method was successfully applied for the synthesis of various FDCA-based polyesters, including diols with varying carbon chain lengths (3 to 11 carbons) and cycloalkyl diols, especially the applicability of this method to diols containing C=C double bonds, which was found to exhibit low heat resistance. Lastly, assisting with 13C labeled 1,4-succinic acid and in-situ 13C-NMR, an in-depth study of the possible catalytic mechanism was proposed, by which, EDC activated FDCA, and then DMAP catalyzed it with diol to yield macromolecular chain of polyester. Overall, the results provided a green and sustainable strategy for the synthesis of FDCA-based polyesters.

Enzymatic Synthesis of Copolyesters with the Heteroaromatic Diol 3,4-Bis(hydroxymethyl)furan and Isomeric Dimethyl Furandicarboxylate Substitutions

Polyesters from furandicarboxylic acid derivatives, i.e., dimethyl 2,5-furandicarboxylate (2,5-DMFDCA) and 2,4-DMFDCA, show interesting properties among bio-based polymers. Another potential heteroaromatic monomer, 3,4-bis(hydroxymethyl)furan (3,4-BHMF), is often overlooked but holds promise for biopolymer synthesis. Cleaning and greening synthetic procedures, i.e., enzymatic polymerization, offer sustainable pathways. This study explores the Candida antarctica lipase B (CALB)-catalyzed copolymerization of 3,4-BHMF with furan dicarboxylate isomers and aliphatic diols. The furanic copolyesters (co-FPEs) with higher polymerization degrees are obtained using 2,4-isomer, indicating CALB's preference. Material analysis revealed semicrystalline properties in all synthesized 2,5-FDCA-based co-FPEs, with multiple melting temperatures (Tm) from 53 to 124 °C and a glass-transition temperature (Tg) of 9-10 °C. 2,4-FDCA-based co-FPEs showed multiple Tm from 43 to 61 °C and Tg of -14 to 12 °C; one of them was amorphous. In addition, all co-FPEs showed a two-step decomposition profile, indicating aliphatic and semiaromatic segments in the polymer chains.

Upcycling of Agricultural Waste Stream to High-Molecular-Weight Bio-based Poly(ethylene 2,5-furanoate)

Orange peel and sugar beet pulp contain large quantities of pectin, which can be turned via galactaric acid into furan dicarboxylic acid (FDCA) and its esters. In this work, we show the polymerisation of these FDCA esters into high-molecular-weight, 70-100 kg/mol, poly(ethylene 2,5-furanoate) (PEF). PEF is an emerging bio-based alternative for poly(ethylene terephthalate) (PET), widely used in for example packaging applications. Closing the loop, we also demonstrated and confirmed that PEF can be hydrolysed by enzymes, which are known to hydrolyse PET, back into FDCA for convenient recycling and recovery of monomers.

Recyclable and (Bio)degradable Polyesters in a Circular Plastics Economy

Polyesters carrying polar main-chain ester linkages exhibit distinct material properties for diverse applications and thus play an important role in today's plastics economy. It is anticipated that they will play an even greater role in tomorrow's circular plastics economy that focuses on sustainability, thanks to the abundant availability of their biosourced building blocks and the presence of the main-chain ester bonds that can be chemically or biologically cleaved on demand by multiple methods and thus bring about more desired end-of-life plastic waste management options. Because of this potential and promise, there have been intense research activities directed at addressing recycling, upcycling or biodegradation of existing legacy polyesters, designing their biorenewable alternatives, and redesigning future polyesters with intrinsic chemical recyclability and tailored performance that can rival today's commodity plastics that are either petroleum based and/or hard to recycle. This review captures these exciting recent developments and outlines future challenges and opportunities. Case studies on the legacy polyesters, poly(lactic acid), poly(3-hydroxyalkanoate)s, poly(ethylene terephthalate), poly(butylene succinate), and poly(butylene-adipate terephthalate), are presented, and emerging chemically recyclable polyesters are comprehensively reviewed.

Cytotoxicity studies and antibacterial modification of poly(ethylene 2,5-furandicarboxylate) nonwoven

Novel poly(ethylene 2,5-furandicarboxylate) PEF nonwovens were produced by solution electrospinning and further modification. To improve the wettability of the hydrophobic nonwovens with water, they were treated with sodium hydroxide. Cytotoxicity tests carried out with human keratinocytes confirmed that the nonwovens did not have a toxic effect on healthy cells. The hydrophilicity of the sodium hydroxide treated nonwoven favored the adherence of the cells and their growth. In turn, the two-step modification of the nonwovens by reactions with (3-mercaptopropyl)methyldimethoxysilane and silver nitrate permitted to deposit silver particles on the fiber surfaces. The bacteria growth inhibition zones around the tested specimens were observed evidencing their antibacterial activity against Escherichia coli and Staphylococcus aureus.

Melting Behaviors of Bio-Based Poly(propylene 2,5-furan dicarboxylate)-b-poly(ethylene glycol) Co Polymers Related to Their Crystal Morphology

In this experiment, a series of poly(propylene 2,5-furan dicarboxylate)-b-poly(ethylene glycol) (PPFEG) copolymers with different ratios were synthesized using melt polycondensation of dimethylfuran-2,5-dicarboxylate (DMFD), 1,3-propanediol (PDO) and poly(ethylene glycol) (PEG). The effect of PEG content on the crystallization behavior of the poly(propylene 2,5-furan dicarboxylate) (PPF) copolymers was investigated. For PPF, the nucleation density of the β-crystals was higher than that of α-crystals. As Tc increases, the β crystals are suppressed more, but at Tc = 140 °C, the bulk of PPF has already been converted to α crystals, which crystallize faster at higher nucleation densities, resulting in a difference in polymer properties. For this case, we chose to add a soft segment material, PEG, which led to an early multi-melt crystallization behavior of the PPF. The addition of PEG led to a decrease in the crystallization temperature of PPF, as well as a decrease in the cold crystallization peak of PPF. From the crystalline morphology, it can be seen that the addition of PEG caused the transformation of the PPF crystalline form to occur earlier. From the crystalline morphology of PPF at 155 °C, it can be observed that the ring-banded spherical crystals of the PPF appear slowly with increasing time. With the addition of PEG, spherical crystals of the ring band appeared earlier, and even appeared first, and then disappeared slowly.

Effect of Monomer Type on the Synthesis and Properties of Poly(Ethylene Furanoate)

This work aimed to produce bio-based poly(ethylene furanoate) (PEF) with a high molecular weight using 2,5-furan dicarboxylic acid (FDCA) or its derivative dimethyl 2,5-furan dicarboxylate (DMFD), targeting food packaging applications. The effect of monomer type, molar ratios, catalyst, polycondensation time, and temperature on synthesized samples' intrinsic viscosities and color intensity was evaluated. It was found that FDCA is more effective than DMFD in producing PEF with higher molecular weight. A sum of complementary techniques was employed to study the structure-properties relationships of the prepared PEF samples, both in amorphous and semicrystalline states. The amorphous samples exhibited an increase in glass transition temperature of 82-87 °C, and annealed samples displayed a decrease in crystallinity with increasing intrinsic viscosity, as analyzed by differential scanning calorimetry and X-ray diffraction. Dielectric spectroscopy showed moderate local and segmental dynamics and high ionic conductivity for the 2,5-FDCA-based samples. The spherulite size and nuclei density of samples improved with increased melt crystallization and viscosity, respectively. The hydrophilicity and oxygen permeability of the samples were reduced with increased rigidity and molecular weight. The nanoindentation test showed that the hardness and elastic modulus of amorphous and annealed samples is higher at low viscosities due to high intermolecular interactions and degree of crystallinity.

Mechanical and Gas Barrier Properties of Poly(Lactic Acid) Modified by Blending with Poly(Butylene 2,5-Furandicarboxylate): Based on Molecular Dynamics

Three blends of Poly(butylene 2,5-furandicarboxylate) (PBF) and Poly(lactic acid) (PLA) blends were modeled using molecular dynamics simulations, with PBF contents of 10%, 20%, and 30%, respectively. The study investigated the compatibilities of the blends, as well as the mechanical and gas barrier properties of the composite systems. The molecular dynamics simulation results show that: (1) PLA and PBF have good compatibility in the blend system; (2) the optimal toughness modification was achieved with a 20% PBF content, resulting in a 17.3% increase in toughness compared to pure PLA; (3) the barrier properties of the blend for O2, CO2, and N2 increased when increasing the PBF content. Compared to pure PLA, the diffusion coefficients of the O2, CO2, and N2 of the blends with 30% PBF decreased by 75%, 122%, and 188%, respectively. Our simulation results are in good agreement with the actual experimental results.

Polymers without Petrochemicals: Sustainable Routes to Conventional Monomers

Access to a wide range of plastic materials has been rationalized by the increased demand from growing populations and the development of high-throughput production systems. Plastic materials at low costs with reliable properties have been utilized in many everyday products. Multibillion-dollar companies are established around these plastic materials, and each polymer takes years to optimize, secure intellectual property, comply with the regulatory bodies such as the Registration, Evaluation, Authorisation and Restriction of Chemicals and the Environmental Protection Agency and develop consumer confidence. Therefore, developing a fully sustainable new plastic material with even a slightly different chemical structure is a costly and long process. Hence, the production of the common plastic materials with exactly the same chemical structures that does not require any new registration processes better reflects the reality of how to address the critical future of sustainable plastics. In this review, we have highlighted the very recent examples on the synthesis of common monomers using chemicals from sustainable feedstocks that can be used as a like-for-like substitute to prepare conventional petrochemical-free thermoplastics.

Recent advances in the development of green furan ring-containing polymeric materials based on renewable plant biomass

Fossil resources are rapidly depleting, forcing researchers in various fields of chemistry and materials science to switch to the use of renewable sources and the development of corresponding technologies. In this regard, the field of sustainable materials science is experiencing an extraordinary surge of interest in recent times due to the significant advances made in the development of new polymers with desired and controllable properties. This review summarizes important scientific reports in recent times dedicated to the synthesis, construction and computational studies of novel sustainable polymeric materials containing unchanged (pseudo)aromatic furan cores in their structure. Linear polymers for thermoplastics, branched polymers for thermosets and other crosslinked materials are emerging materials to highlight. Various polymer blends and composites based on sustainable polyfurans are also considered as pathways to achieve high-value-added products.

Recent Progress on Bio-Based Polyesters Derived from 2,5-Furandicarbonxylic Acid (FDCA)

The big challenge today is the upgrading of sustainable materials to replace miscellaneous ones from petroleum resources. Thus, a generic bio-based building block lays the foundation of the huge bio-market to green economy. 2,5-Furandicarboxylic acid (FDCA), a rigid diacid derived from lignocellulose or fructose, represents a great potential as a contender to terephthalic acid (TPA). Recently, studies on the synthesis, modification, and functionalization of bio-based polyesters based on FDCA have attracted widespread attention. To apply furanic polyesters on engineering plastics, packaging materials, electronics, etc., researchers have extended the properties of basic FDCA-based homo-polyesters by directional copolymerization and composite preparation. This review covers the synthesis and performance of polyesters and composites based on FDCA with emphasis bedded on the thermomechanical, crystallization, barrier properties, and biodegradability. Finally, a summary of what has been achieved and the issues waiting to be addressed of FDCA-based polyester materials are suggested.

Polyimides from 2,5-bis[4-(4-aminophenoxy)benzoyl]furan and their thermal crosslinking reaction

Several polyimides were prepared via two-step polycondensation from novel 2,5-furandicarboxylic acid–based diamine, 2,5-bis[4-(4-aminophenoxy)benzoyl]furan, with commercial dianhydrides. The chemical structures of the monomers and polymers were characterized by FT-IR and NMR in detail, respectively. The polyimides exhibited high performances with 5 wt% weight loss temperatures of over 410 oC, glass transition temperatures of over 214 oC, and tensile strengths and Young’s moduli of up to 130 MPa and 3.2 GPa, respectively. The thermal crosslinking mechanism was studied by FT-IR, Raman spectroscopy, and model reaction analysis, which showed the Diels–Alder reaction between the furan group and diphenylethylene group was the main reaction. The crosslinked polyimide films showed improved solvent resistance, and thermal and mechanical properties.

Effectiveness of Esterification Catalysts in the Synthesis of Poly(Ethylene Vanillate)

Over the last few decades, bio-based polymers have attracted considerable attention from both academic and industrial fields regarding the minimization of the environmental impact arising from the excessive use of petrochemically-based polymeric materials. In this context, poly(ethylene vanillate) (PEV), an alipharomatic polyester prepared from 4-(2-hydroxyethoxy)-3-methoxybenzoic acid, a monomer originating from lignin-derived vanillic acid, has shown promising thermal and mechanical properties. Herein, the effects of three different catalysts, namely titanium butoxide (TBT), titanium isopropoxide (TIS), and antimony trioxide (Sb2O3), on the synthesis of PEV via a two-stage melt polycondensation method are investigated. The progress of the reaction is assessed using various complementary techniques, such as intrinsic viscosity measurement (IV), end group analysis (AV), nuclear magnetic resonance spectroscopy (NMR), Fourier-transformed infrared spectroscopy (FTIR), and differential scanning calorimetry (DSC). The thermal stability of the produced polyesters is studied by evolved gas analysis mass spectrometry (EGA-MS). Moreover, as the discoloration in polymers affects their applications, color measurement is performed here. Finally, theoretical kinetic studies are carried out to rationalize the experimental observations.

Synthesis of 2,5-furandicarboxylic acid-enriched-chitosan for anti-inflammatory and metal ion uptake

The main aim of the present study is to synthesize a hitherto unreported polymer of chitosan (CS) and 2,5-furandicarboxylic acid (FDCA) derived from renewable biomass resources. For this purpose, CS was chosen which had -NH₂ groups as abundant active sites. Synthesis of 2,5-furandicarboxylic acid-enriched-chitosan polymer (CS-FDCA) was carried out by reaction involving EDC-NHS coupling reagents. The structure of CS-FDCA polymer was confirmed by various characterization techniques such as Fourier-transform infrared spectroscopy (FTIR), proton nuclear magnetic resonance (¹H NMR), X-ray powder diffraction (XRD), high resolution-field emission scanning electron microscope (HR-FESEM), and thermogravimetric analysis (TGA). Moreover, CS and CS-FDCA were scrutinized to examine their efficacies towards ameliorate inflammation via detection of lipopolysaccharide (LPS) induced nitric oxide (NO) production. As compared to CS, CS-FDCA with low concentration (1.0 μM) exhibited the better efficacy to reduce the NO production. Furthermore, CS-FDCA polymer showed high as 12.6% of Cu²⁺ ion uptake while CS showed 9.2% of Cu²⁺ ion uptake. Overall, it can be inferred that CS-FDCA polymer is expected to be used for biomedical application and for the removal of metal contaminants from industrial wastewater.

Poly(Ethylene Furanoate) along Its Life-Cycle from a Polycondensation Approach to High-Performance Yarn and Its Recyclate

We report on the pilot scale synthesis and melt spinning of poly(ethylene furanoate) (PEF), a promising bio-based fiber polymer that can heave mechanical properties in the range of commercial poly(ethylene terephthalate) (PET) fibers. Catalyst optimization and solid state polycondensation (SSP) allowed for intrinsic viscosities of PEF of up to 0.85 dL·g-1. Melt-spun multifilament yarns reached a tensile strength of up to 65 cN·tex-1 with an elongation of 6% and a modulus of 1370 cN·tex-1. The crystallization behavior of PEF was investigated by differential scanning calorimetry (DSC) and XRD after each process step, i.e., after polymerization, SSP, melt spinning, drawing, and recycling. After SSP, the previously amorphous polymer showed a crystallinity of 47%, which was in accordance with literature. The corresponding XRD diffractograms showed signals attributable to α-PEF. Additional, clearly assignable signals at 2θ > 30° are discussed. A completely amorphous structure was observed by XRD for as-spun yarns, while a crystalline phase was detected on drawn yarns; however, it was less pronounced than for the granules and independent of the winding speed.

Towards High Molecular Weight Furan-Based Polyesters: Solid State Polymerization Study of Bio-Based Poly(Propylene Furanoate) and Poly(Butylene Furanoate)

In the era of polymers from renewable resources, polyesters derived from 2,5 furan dicarboxylic acid (FDCA) have received increasing attention due to their outstanding features. To commercialize them, it is necessary to synthesize high molecular weight polymers through efficient and simple methods. In this study, two furan-based polyesters, namely poly (propylene furanoate) (PPF) and poly(butylene furanoate) (PBF), were synthesized with the conventional two-step melt polycondensation, followed by solid-state polycondensation (SSP) conducted at different temperatures and reaction times. Molecular weight, structure and thermal properties were measured for all resultant polyesters. As expected, increasing SSP time and temperature results in polymers with increased intrinsic viscosity (IV), increased molecular weight and reduced carboxyl end-group content. Finally, those results were used to generate a simple mathematical model that prognosticates the time evolution of the materials' IV and end groups concentration during SSP.

A Perspective on PEF Synthesis, Properties, and End-Life

This critical review considers the extensive research and development dedicated, in the last years, to a single polymer, the poly(ethylene 2,5-furandicarboxylate), usually simply referred to as PEF. PEF importance stems from the fact that it is based on renewable resources, typically prepared from C6 sugars present in biomass feedstocks, for its resemblance to the high-performance poly(ethylene terephthalate) (PET) and in terms of barrier properties even outperforming PET. For the first time synthesis, properties, and end-life targeting—a more sustainable PEF—are critically reviewed. The emphasis is placed on how synthetic roots to PEF evolved toward the development of greener processes based on ring open polymerization, enzymatic synthesis, or the use of ionic liquids; together with a broader perspective on PEF end-life, highlighting recycling and (bio)degradation solutions.

Polymorphism and Multiple Melting Behavior of Bio-Based Poly(propylene 2,5-furandicarboxylate)

Furandicarboxylate-based polyesters are considered an interesting class of bio-based polymers due to their improved properties with respect to the petrol-based terephthalate homologs. An in-depth analysis of the crystal structure of poly(propylene 2,5-furandicarboxylate) (PPF), after maximum possible removal of the catalyst, was carried out. The study disclosed that purified PPF presents two different crystalline phases after crystallization from the melt. Crystallizations at temperatures lower than 120 °C lead to growth of a single crystal form (β-form), whereas two different crystal forms (α and β) were found to coexist at higher T_cs. This behavior is opposite to that previously observed for unpurified PPF. The possibility that the catalyst nucleates the α-phase, which therefore becomes the kinetically favored modification at low crystallization temperatures in the presence of a higher amount of catalyst residue, has been considered as a feasible explanation. Two concomitantly different spherulitic morphologies were observed and connected to the β- and α-phase, respectively. The association between polymorphism and melting behavior was studied. The origin of the peaks that compose the multiple melting endotherm recorded at conventional heating rates was determined by combined wide-angle X-ray scattering, differential scanning calorimetry, fast scanning chip calorimetry, and polarized light optical microscopy measurements. The higher thermal stability of the α-crystals in comparison with the β-form was thus demonstrated.

Synthesis, Thermal Properties, and Rheological Characteristics of Indole-Based Aromatic Polyesters

Currently, there is an intensive development of bio-based aromatic building blocks to replace fossil-based terephthalates used for poly(ethylene terephthalate) production. Indole is a ubiquitous aromatic unit in nature, which has great potential as a bio-based feedstock for polymers or plastics. In this study, we describe the synthesis and characterization of new indole-based dicarboxylate monomers with only aromatic ester bonds, which can improve the thermal stability and glass-transition temperature (T _g) of the resulting polyesters. The new dicarboxylate monomers were polymerized with five aliphatic diols to yield 10 new polyesters with tunable chemical structures and physical properties. Particularly, the T _g values of the obtained polyesters can be as high as 113 °C, as indicated by differential scanning calorimetry and dynamic mechanical analysis. The polyesters showed decent thermal stability and distinct flow transitions as revealed by thermogravimetric analysis and rheology measurements.