Toughening Biodegradable Isotactic Poly(3-hydroxybutyrate) via Stereoselective Copolymerization of a Diolide and Lactones

Innovative biomaterials for food packaging: Unlocking the potential of polyhydroxyalkanoate (PHA) biopolymers

Polyhydroxyalkanoate (PHA) biopolyesters show a good balance between sustainability and performance, making them a competitive alternative to conventional plastics for ecofriendly food packaging. With an emphasis on developments over the last decade (2014-2024), this review examines the revolutionary potential of PHAs as a sustainable food packaging material option. It also delves into the current state of commercial development, competitiveness, and the carbon footprint associated with PHA-based products. First, a critical examination of the challenges experienced by PHAs in terms of food packaging requirements is undertaken, followed by an assessment of contemporary strategies addressing permeability, mechanical properties, and processing considerations. The various PHA packaging end-of-life options, including a comprehensive overview of the environmental impact and potential solutions will also be discussed. Finally, conclusions and future perspectives are elucidated with a view of prospecting PHAs as future green materials, with a blend of performance and sustainability of food packaging solutions.

Ring Opening Polymerization of Six- and Eight-Membered Racemic Cyclic Esters for Biodegradable Materials

The low percentage of recyclability of the polymeric materials obtained by olefin transition metal (TM) polymerization catalysis has increased the interest in their substitution with more eco-friendly materials with reliable physical and mechanical properties. Among the variety of known biodegradable polymers, linear aliphatic polyesters produced by ring-opening polymerization (ROP) of cyclic esters occupy a prominent position. The polymer properties are highly dependent on the macromolecule microstructure, and the control of stereoselectivity is necessary for providing materials with precise and finely tuned properties. In this review, we aim to outline the main synthetic routes, the physical properties and also the applications of three commercially available biodegradable materials: Polylactic acid (PLA), Poly(Lactic-co-Glycolic Acid) (PLGA), and Poly(3-hydroxybutyrate) (P3HB), all of three easily accessible via ROP. In this framework, understanding the origin of enantioselectivity and the factors that determine it is then crucial for the development of materials with suitable thermal and mechanical properties.

Toward the production of block copolymers in microbial cells: achievements and perspectives

The microbial production of polyhydroxyalkanoate (PHA) block copolymers has attracted research interests because they can be expected to exhibit excellent physical properties. Although post-polymerization conjugation and/or extension have been used for PHA block copolymer synthesis, the discovery of the first sequence-regulating PHA synthase, PhaCAR, enabled the direct synthesis of PHA-PHA type block copolymers in microbial cells. PhaCAR spontaneously synthesizes block copolymers from a mixture of substrates. To date, Escherichia coli and Ralstonia eutropha have been used as host strains, and therefore, sequence regulation is not a host-specific phenomenon. The monomer sequence greatly influences the physical properties of the polymer. For example, a random copolymer of 3-hydroxybutyrate and 2-hydroxybutyrate deforms plastically, while a block copolymer of approximately the same composition exhibits elastic deformation. The structure of the PHA block copolymer can be expanded by in vitro evolution of the sequence-regulating PHA synthase. An engineered variant of PhaCAR can synthesize poly(D-lactate) as a block copolymer component, which allows for greater flexibility in the molecular design of block copolymers. Therefore, creating sequence-regulating PHA synthases with a further broadened substrate range will expand the variety of properties of PHA materials. This review summarizes and discusses the sequence-regulating PHA synthase, analytical methods for verifying block sequence, properties of block copolymers, and mechanisms of sequence regulation. KEY POINTS: • Spontaneous monomer sequence regulation generates block copolymers • Poly(D-lactate) segment can be synthesized using a block copolymerization system • Block copolymers exhibit characteristic properties.

Atactic, Isotactic, and Syndiotactic Methylated Polyhydroxybutyrates: An Unexpected Series of Isomorphic Polymers

Polyhydroxyalkanoates (PHAs), such as poly[(R)-3-hydroxybutyrates] [(R)-P3HB], are produced by bacteria and are promising alternatives to nondegradable polyolefin plastics, but their semicrystallinity and high melting points are only maintained at high tacticity, which are commonly seen in other semicrystalline polymers like isotactic polypropylene (iPP). We herein report a class of synthetic PHAs, cis-poly(3-hydroxy-2-methylbutyrate)s (cis-PHMBs), that exhibit tacticity-independent semicrystallinity. The syndiotactic, isotactic, and even atactic PHMBs all share high melting points (Tm > 170 °C) and nearly identical crystal structures. The isomorphism of these polymers across three different tacticities has allowed access to iPP-like, high-performance PHMB without the requirement of high tacticity.

Toughening Brittle Bio-P3HB with Synthetic P3HB of Engineered Stereomicrostructures

Poly(3-hydroxybutyrate) (P3HB), a biologically produced, biodegradable natural polyester, exhibits excellent thermal and barrier properties but suffers from mechanical brittleness, largely limiting its applications. Here we report a mono-material product design strategy to toughen stereoperfect, brittle bio or synthetic P3HB by blending it with stereomicrostructurally engineered P3HB. Through tacticity ([mm] from 0 to 100 %) and molecular weight (Mn to 788 kDa) tuning, high-performance synthetic P3HB materials with tensile strength to ≈30 MPa, fracture strain to ≈800 %, and toughness to 126 MJ m-3 (>110× tougher than bio-P3HB) have been produced. Physical blending of the brittle P3HB with such P3HB in 10 to 90 wt % dramatically enhances its ductility from ≈5 % to 95-450 % and optical clarity from 19 % to 85 % visible light transmittance while maintaining desirably high elastic modulus (>1 GPa), tensile strength (>35 MPa), and melting temperature (160-170 °C). This P3HB-toughening-P3HB methodology departs from the traditional approach of incorporating chemically distinct components to toughen P3HB, which hinders chemical or mechanical recycling, highlighting the potential of the mono-material product design solely based on biodegradable P3HB to deliver P3HB materials with diverse performance properties.

Tailoring the Nucleation and Crystallization Rate of Polyhydroxybutyrate by Copolymerization

In the polyester family, the biopolymer with the greatest industrial potential could be poly(3-hydroxybutyrate) (PHB), which can be produced nowadays biologically or chemically. The scarce commercial use of PHB derives from its poor mechanical properties, which can be improved by incorporating a flexible aliphatic polyester with good mechanical performance, such as poly(ε-caprolactone) (PCL), while retaining its biodegradability. This work studies the structural, thermal, and morphological properties of block and random copolymers of PHB and PCL. The presence of a comonomer influences the thermal parameters following nonisothermal crystallization and the kinetics of isothermal crystallization. Specifically, the copolymers exhibit lower melting and crystallization temperatures and present lower overall crystallization kinetics than neat homopolymers. The nucleation rates of the PHB components are greatly enhanced in the copolymers, reducing spherulitic sizes and promoting transparency with respect to neat PHB. However, their spherulitic growth rates are depressed so much that superstructural growth becomes the dominating factor that reduces the overall crystallization kinetics of the PHB component in the copolymers. The block and random copolymers analyzed here also display important differences in the structure, morphology, and crystallization that were examined in detail. Our results show that copolymerization can tailor the thermal properties, morphology (spherulitic size), and crystallization kinetics of PHB, potentially improving the processing, optical, and mechanical properties of PHB.

All-Polyhydroxyalkanoate Triblock Copolymers via a Stereoselective-Chemocatalytic Route

Biodegradable polyhydroxyalkanoate (PHA) homopolymers and statistical copolymers are ubiquitous in microbially produced PHAs, but the step-growth polycondensation mechanism the biosynthesis operates on presents a challenge to access well-defined block copolymers (BCPs), especially higher-order tri-BCP PHAs. Here we report a stereoselective-chemocatalytic route to produce discrete hard-soft-hard ABA all-PHA tri-BCPs based on the living chain-growth ring-opening polymerization of racemic (rac) 8-membered diolides (rac-8DL^R; R denotes the two substituents on the ring). Depending on the composition of the soft B block, originated from rac-8DL^R (R = Et, ⁿBu), and its ratio to the semicrystalline, high-melting hard A block, derived from rac-8DL^Me, the resulting all-PHA tri-BCPs with high molar mass (M_n up to 238 kg mol^-1) and low dispersity (Đ = 1.07) exhibit tunable mechanical properties characteristic of a strong and tough thermoplastic, elastomer, or a semicrystalline thermoplastic elastomer.

Nature-inspired methylated polyhydroxybutyrates from C1 and C4 feedstocks

Polyolefin plastics are widely used due to their low cost and outstanding properties, but their environmental persistence presents a major societal challenge. Polyhydroxyalkanoates (PHA) are biodegradable substitutes for polyolefins, but their high cost and thermal instability are impediments to their widespread application. Here we report a series of methylated polyhydroxybutyrates, poly(3-hydroxy-2-methylbutyrate)s, which are structurally inspired by natural PHAs. The cis homopolymers exhibit tacticity-independent crystallinity, which allows for the discovery of high-melting, thermally stable and mechanically tough copolymers, and a full range of polyolefin-like properties can be further achieved by tailoring the cis/trans ratio of the repeating units. Moreover, these materials can be synthesized from inexpensive carbon monoxide and 2-butene feedstocks, and they can be chemically recycled or upcycled at their end of life. The versatile properties, abundant feedstocks and end-of-life utility of this family of polyesters will enable a powerful platform for the discovery of sustainable alternatives to polyolefin plastics.

Installing Controlled Stereo-Defects Yields Semicrystalline and Biodegradable Poly(3-Hydroxybutyrate) with High Toughness and Optical Clarity

Stereo-defects present in stereo-regular polymers often diminish thermal and mechanical properties, and hence suppressing or eliminating them is a major aspirational goal for achieving polymers with optimal or enhanced properties. Here, we accomplish the opposite by introducing controlled stereo-defects to semicrystalline biodegradable poly(3-hydroxybutyrate) (P3HB), which offers an attractive biodegradable alternative to semicrystalline isotactic polypropylene but is brittle and opaque. We enhance the specific properties and mechanical performance of P3HB by drastically toughening it and also rendering it with the desired optical clarity while maintaining its biodegradability and crystallinity. This toughening strategy of stereo-microstructural engineering without changing the chemical compositions also departs from the conventional approach of toughening P3HB through copolymerization that increases chemical complexity, suppresses crystallization in the resulting copolymers, and is thus undesirable in the context of polymer recycling and performance. More specifically, syndio-rich P3HB (sr-P3HB), readily synthesized from the eight-membered meso-dimethyl diolide, has a unique set of stereo-microstructures comprising enriched syndiotactic [rr] and no isotactic [mm] triads but abundant stereo-defects randomly distributed along the chain. This sr-P3HB material is characterized by high toughness (U_T = 96 MJ/m³) as a result of its high elongation at break (>400%) and tensile strength (34 MPa), crystallinity (T_m = 114 °C), optical clarity (due to its submicron spherulites), and good barrier properties, while it still biodegrades in freshwater and soil.

Alternating Isotactic Polyhydroxyalkanoates via Site- and Stereoselective Polymerization of Unsymmetrical Diolides

Naturally produced, biodegradable polyhydroxyalkanoates (PHAs) promise more sustainable alternatives to nonrenewable/degradable plastics, but biological PHA's stereomicrostructures are strictly confined to isotactic (R)-polymers or copolymers of random sequences. Chemical synthesis via catalyzed ring-opening polymerization (ROP) of cyclic (di)esters offers expedient access to diverse PHA microstructures, including those with defined comonomer sequences and tacticities. However, the synthesis of alternating isotactic PHAs has not been achieved by the existing methodologies. Here, we report the design of unsymmetrically disubstituted eight-membered diolides (rac-8DL^R1-R2) and their site- and stereoselective ROP with discrete chiral catalysts, enabling the synthesis of alternating isotactic PHAs, poly(3-hydroxybutyrate-alt-3-hydroxyvalerate) (alt-P3HBV) and poly(3-hydroxybutyrate-alt-3-hydroxyheptanoate) (alt-P3HBHp), with high to quantitative (>99%) alternation and isotacticity and M_n up to 113 kDa and Đ = 1.01. Physical properties of such PHAs are substantially determined by the degree of backbone sequence alternation and tacticity, ranging from amorphous to semi-crystalline materials. The alt-P3HBV shows significantly improved mechanical performance relative to the constituent homopolymers. Intriguingly, enantiomeric (R)-alt-P3HBV and (S)-alt-P3HBV, synthesized by kinetically resolved ROP of rac-8DL^Me-Et, form a stereocomplex with a significantly enhanced T_m (by 53 °C), while the enantiomeric homopolymers do not form a stereocomplex.

Simple and Rapid Access toward AB, BAB and ABAB Block Copolyesters from One-Pot Monomer Mixtures Using an Indium Catalyst

The synthesis of well-defined block copolymers from one-pot monomer mixtures is particularly challenging when monomers are from the same class and show similar reactivity. Herein, an indium-based catalyst that shows comparable rates in the ring-opening homopolymerization of β-butyrolactone (β-BL) and ε-decalactone (ε-DL), demonstrates monomer-selective behavior in one-pot copolymerizations of β-BL and ε-DL. This provides simple and rapid access to well-defined di-, tri-, or tetra-block copolyesters from monomer mixtures. The sequence-controlled nature of these polymers was confirmed by kinetic analysis, ¹³C{¹H} NMR spectroscopy, DSC, and TGA measurements.

Crystallization of microbial polyhydroxyalkanoates: A review

Polyhydroxyalkanoates (PHAs), produced by the microbial fermentation, is a promising green polymer and has attracted much attention due to its excellent biocompatibility, complete biodegradability, and non-cytotoxicity. The physical properties of PHAs are closely related to their chemical and crystalline structure. Therefore, deep understanding and regulating the structure and crystallization of PHAs are the key factors to improve the performance of PHAs. This review first provides a brief overview of the development history, chemical structure, and basic properties of PHAs. Then, the crystal structure, crystal morphology, kinetics theories and crystallization behavior of nucleation-induced PHAs are systematically summarized to provide a theoretical foundation for improving PHAs crystallization rate and physical properties. In the end, the outlook on the crystallization and application prospects of PHAs is also addressed.

Ring opening copolymerization of δ-valerolactone with 2-methyl-1,3-dioxane-4-one towards poly(3-hydroxypropionate-co-5-hydroxyvalerate) copolyesters

A straightforward strategy of ring-opening copolymerization (ROCOP) toward the synthetic copolyesters is gaining increasing interest. In present work, a novel series of poly(3-hydroxypropionate-co-5-hydroxyvalerate) P(3HP-co-5HV) copolyesters are obtained through ROCOP of...