The Influence of Residence Time Distribution on Continuous-Flow Polymerization

Continuous Polymer Synthesis and Manufacturing of Polyurethane Elastomers Enabled by Automation

Connecting polymer synthesis and processing is an important challenge for streamlining the manufacturing of polymeric materials. In this work, the automated synthesis of acrylate-capped polyurethane oligomers is integrated with vat photopolymerization 3D printing. This strategy enabled the rapid manufacturing of a library of polyurethane-based elastomeric materials with differentiated thermal and mechanical properties. The automated semicontinuous batch synthesis approach proved enabling for resins with otherwise short shelf lives because of the intimate connection between synthesis, formulation, and processing. Structure-property studies demonstrated the ability to tune properties through systematic alteration of cross-link density and chemical composition.

Controlling primary chain dispersity in network polymers: elucidating the effect of dispersity on degradation

Although dispersity has been demonstrated to be instrumental in determining many polymer properties, current synthetic strategies predominantly focus on tailoring the dispersity of linear polymers. In contrast, controlling the primary chain dispersity in network polymers is much more challenging, in part due to the complex nature of the reactions, which has limited the exploration of properties and applications. Here, a one-step method to prepare networks with precisely tuned primary chain dispersity is presented. By using an acid-switchable chain transfer agent and a degradable crosslinker in PET-RAFT polymerization, the in situ crosslinking of the propagating polymer chains was achieved in a quantitative manner. The incorporation of a degradable crosslinker, not only enables the accurate quantification of the various primary chain dispersities, post-synthesis, but also allows the investigation and comparison of their respective degradation profiles. Notably, the highest dispersity networks resulted in a 40% increase in degradation time when compared to their lower dispersity analogues, demonstrating that primary chain dispersity has a substantial impact on the network degradation rate. Our experimental findings were further supported by simulations, which emphasized the importance of higher molecular weight polymer chains, found within the high dispersity materials, in extending the lifetime of the network. This methodology presents a new and promising avenue to precisely tune primary chain dispersity within networks and demonstrates that polymer dispersity is an important parameter to consider when designing degradable materials.

Flow Optimization of Photoredox-Mediated Metal-Free Ring-Opening Metathesis Polymerization

Photoredox-mediated metal-free ring-opening metathesis polymerization (MF-ROMP) is a convenient metal-free method to produce a variety of ROMP polymers. Transitioning MF-ROMP from a batch to a continuous flow process has yet to be demonstrated and could potentially benefit the production efficiency, safety, and modularity of reaction conditions. We designed and evaluated continuous flow and droplet flow setups and compared the results for MF-ROMP across a short series of common monomers. By using the droplet flow reactor setup, we achieved flow conversions comparable to that of batch and circumvented issues with diffusion-limited mixing and air exposure.

Inverse Miniemulsion Enables the Continuous-Flow Synthesis of Controlled Ultra-High Molecular Weight Polymers

We report the controlled synthesis of ultra-high molecular weight (UHMW) polymers (Mn ≥ 106 g/mol) via continuous flow in a tubular reactor. At high monomer conversion, UHMW polymers in homogeneous batch polymerization exhibit high viscosities that pose challenges for employing continuous flow reactors. However, under heterogeneous inverse miniemulsion (IME) conditions, UHMW polymers can be produced within the dispersed phase, while the viscosity of the heterogeneous mixture remains approximately the same as the viscosity of the continuous phase. Conducting such IME polymerizations in flow results in a faster rate of polymerization compared to batch IME polymerizations while still providing excellent control over molecular weight up to 106 g/mol. Crucial emulsion parameters, such as particle size and stability under continuous flow conditions, were examined using dynamic light scattering. A range of poly(N,N-dimethylacrylamide) and poly(4-acryloylmorpholine) polymers with molecular weights of 104-106 g/mol (Đ ≤ 1.31) were produced by this method using water-soluble trithiocarbonates as photoiniferters.

Development and Experimental Validation of a Dispersity Model for In Silico RAFT Polymerization

The exploitation of computational techniques to predict the outcome of chemical reactions is becoming commonplace, enabling a reduction in the number of physical experiments required to optimize a reaction. Here, we adapt and combine models for polymerization kinetics and molar mass dispersity as a function of conversion for reversible addition fragmentation chain transfer (RAFT) solution polymerization, including the introduction of a novel expression accounting for termination. A flow reactor operating under isothermal conditions was used to experimentally validate the models for the RAFT polymerization of dimethyl acrylamide with an additional term to accommodate the effect of residence time distribution. Further validation is conducted in a batch reactor, where a previously recorded in situ temperature monitoring provides the ability to model the system under more representative batch conditions, accounting for slow heat transfer and the observed exotherm. The model also shows agreement with several literature examples of the RAFT polymerization of acrylamide and acrylate monomers in batch reactors. In principle, the model not only provides a tool for polymer chemists to estimate ideal conditions for a polymerization, but it can also automatically define the initial parameter space for exploration by computationally controlled reactor platforms provided a reliable estimation of rate constants is available. The model is compiled into an easily accessible application to enable simulation of RAFT polymerization of several monomers.

A dual initiator approach for oxygen tolerant RAFT polymerization

Reversible-deactivation radical polymerizations are privileged approaches for the synthesis of functional and hybrid materials. A bottleneck for conducting these processes is the need to maintain oxygen free conditions. Herein we report a broadly applicable approach to "polymerize through" oxygen using the synergistic combination of two radical initiators having different rates of homolysis. The in situ monitoring of the concentrations of oxygen and monomer simultaneously provided insight into the function of the two initiators and enabled the identification of conditions to effectively remove dissolved oxygen and control polymerization under open-to-air conditions. By understanding how the surface area to volume ratio of reaction vessels influence open-to-air polymerizations, well-defined polymers were produced using acrylate, styrenic, and methacrylate monomers, which each represent an expansion of scope for the "polymerizing through" oxygen approach. Demonstration of this method in tubular reactors using continuous flow chemistry provided a more complete structure-reactivity understanding of how reaction headspace influences PTO RAFT polymerizations.

Materiomically Designed Polymeric Vehicles for Nucleic Acids: Quo Vadis?

Despite rapid advances in molecular biology, particularly in site-specific genome editing technologies, such as CRISPR/Cas9 and base editing, financial and logistical challenges hinder a broad population from accessing and benefiting from gene therapy. To improve the affordability and scalability of gene therapy, we need to deploy chemically defined, economical, and scalable materials, such as synthetic polymers. For polymers to deliver nucleic acids efficaciously to targeted cells, they must optimally combine design attributes, such as architecture, length, composition, spatial distribution of monomers, basicity, hydrophilic-hydrophobic phase balance, or protonation degree. Designing polymeric vectors for specific nucleic acid payloads is a multivariate optimization problem wherein even minuscule deviations from the optimum are poorly tolerated. To explore the multivariate polymer design space rapidly, efficiently, and fruitfully, we must integrate parallelized polymer synthesis, high-throughput biological screening, and statistical modeling. Although materiomics approaches promise to streamline polymeric vector development, several methodological ambiguities must be resolved. For instance, establishing a flexible polymer ontology that accommodates recent synthetic advances, enforcing uniform polymer characterization and data reporting standards, and implementing multiplexed in vitro and in vivo screening studies require considerable planning, coordination, and effort. This contribution will acquaint readers with the challenges associated with materiomics approaches to polymeric gene delivery and offers guidelines for overcoming these challenges. Here, we summarize recent developments in combinatorial polymer synthesis, high-throughput screening of polymeric vectors, omics-based approaches to polymer design, barcoding schemes for pooled in vitro and in vivo screening, and identify materiomics-inspired research directions that will realize the long-unfulfilled clinical potential of polymeric carriers in gene therapy.

The challenges of controlling polymer synthesis at the molecular and macromolecular level

In this Perspective, we outline advances and challenges in controlling the structure of polymers at various size regimes in the context of structural features such as molecular weight distribution, end groups, architecture, composition and sequence.

Autonomous polymer synthesis delivered by multi-objective closed-loop optimisation

Application of artificial intelligence and machine learning for polymer discovery offers an opportunity to meet the drastic need for the next generation high performing and sustainable polymer materials. Here, these...

Fully biobased triblock copolymers generated using an unconventional oscillatory plug flow reactor

Producing block polymers in continuous flow offers significant advantages in terms of versatility, efficiency and scalability.

Controlling dispersity in aqueous atom transfer radical polymerization: rapid and quantitative synthesis of one-pot block copolymers

The dispersity (Đ) of a polymer is a key parameter in material design, and variations in Đ can have a strong influence on fundamental polymer properties. Despite its importance, current polymerization strategies to control Đ operate exclusively in organic media and are limited by slow polymerization rates, moderate conversions, significant loss of initiator efficiency and lack of dispersity control in block copolymers. Here, we demonstrate a rapid and quantitative method to tailor Đ of both homo and block copolymers in aqueous atom transfer radical polymerization. By using excess ligand to regulate the dissociation of bromide ions from the copper deactivator complexes, a wide range of monomodal molecular weight distributions (1.08 < Đ < 1.60) can be obtained within 10 min while achieving very high monomer conversions (∼99%). Despite the high conversions and the broad molecular weight distributions, very high end-group fidelity is maintained as exemplified by the ability to synthesize in situ diblock copolymers with absolute control over the dispersity of either block (e.g. low Đ → high Đ, high Đ → high Đ, high Đ → low Đ). The potential of our approach is further highlighted by the synthesis of complex pentablock and decablock copolymers without any need for purification between the iterative block formation steps. Other benefits of our methodology include the possibility to control Đ without affecting the M n, the interesting mechanistic concept that sheds light onto aqueous polymerizations and the capability to operate in the presence of air.

Machine-Learning-Guided Discovery of 19F MRI Agents Enabled by Automated Copolymer Synthesis

Modern polymer science suffers from the curse of multidimensionality. The large chemical space imposed by including combinations of monomers into a statistical copolymer overwhelms polymer synthesis and characterization technology and limits the ability to systematically study structure-property relationships. To tackle this challenge in the context of 19F magnetic resonance imaging (MRI) agents, we pursued a computer-guided materials discovery approach that combines synergistic innovations in automated flow synthesis and machine learning (ML) method development. A software-controlled, continuous polymer synthesis platform was developed to enable iterative experimental-computational cycles that resulted in the synthesis of 397 unique copolymer compositions within a six-variable compositional space. The nonintuitive design criteria identified by ML, which were accomplished by exploring <0.9% of the overall compositional space, lead to the identification of >10 copolymer compositions that outperformed state-of-the-art materials.

Tuning Ligand Concentration in Cu(0)-RDRP: A Simple Approach to Control Polymer Dispersity

Cu(0)-reversible deactivation radical polymerization (RDRP) is a versatile polymerization tool, providing rapid access to well-defined polymers while utilizing mild reaction conditions and low catalyst loadings. However, thus far, this method has not been applied to tailor dispersity, a key parameter that determines the physical properties and applications of polymeric materials. Here, we report a simple to perform method, whereby Cu(0)-RDRP can systematically control polymer dispersity (Đ = 1.07-1.72), while maintaining monomodal molecular weight distributions. By varying the ligand concentration, we could effectively regulate the rates of initiation and deactivation, resulting in polymers of various dispersities. Importantly, both low and high dispersity PMA possess high end-group fidelity, as evidenced by MALDI-ToF-MS, allowing for a range of block copolymers to be prepared with different dispersity configurations. The scope of our method can also be extended to include inexpensive ligands (i.e., PMDETA), which also facilitated the polymerization of lower propagation rate constant monomers (i.e., styrene) and the in situ synthesis of block copolymers. This work significantly expands the toolbox of RDRP methods for tailoring dispersity in polymeric materials.

Sampling and Analysis in Flow: The Keys to Smarter, More Controllable, and Sustainable Fine-Chemical Manufacturing

Process analytical technology (PAT) is a system designed to help chemists better understand and control manufacturing processes. PAT systems operate through the combination of analytical devices, reactor control elements, and mathematical models to ensure the quality of the final product through a quality by design (QbD) approach. The expansion of continuous manufacturing in the pharmaceutical and fine-chemical industry requires the development of PAT tools suitable for continuous operation in the environment of flow reactors. This requires innovative approaches to sampling and analysis from flowing media to maintain the integrity of the reactor content and the analyte of interest. The following Review discusses examples of PAT tools implemented in flow chemistry for the preparation of small organic molecules, and applications of self-optimization tools.

Precise Control of Both Dispersity and Molecular Weight Distribution Shape by Polymer Blending

The breadth and the shape of molecular weight distributions can significantly influence fundamental polymer properties that are critical for various applications. However, current approaches require the extensive synthesis of multiple polymers, are limited in dispersity precision and are typically incapable of simultaneously controlling both the dispersity and the shape of molecular weight distributions. Here we report a simplified approach, whereby on mixing two polymers (one of high Đ and one of low Đ), any intermediate dispersity value can be obtained (e.g. from 1.08 to 1.84). Unrivalled precision is achieved, with dispersity values obtained to even the nearest 0.01 (e.g. 1.37→1.38→1.39→1.40→1.41→1.42→1.43→1.44→1.45), while maintaining fairly monomodal molecular weight distributions. This approach was also employed to control the shape of molecular weight distributions and to obtain diblock copolymers with high dispersity accuracy. The straightforward nature of our methodology alongside its compatibility with a wide range of polymerisation protocols (e.g. ATRP, RAFT), significantly expands the toolbox of tailored polymeric materials and makes them accessible to all researchers.

High-Throughput Routes to Biomaterials Discovery

Many existing clinical treatments are limited in their ability to completely restore decreased or lost tissue and organ function, an unenviable situation only further exacerbated by a globally aging population. As a result, the demand for new medical interventions has increased substantially over the past 20 years, with the burgeoning fields of gene therapy, tissue engineering, and regenerative medicine showing promise to offer solutions for full repair or replacement of damaged or aging tissues. Success in these fields, however, inherently relies on biomaterials that are engendered with the ability to provide the necessary biological cues mimicking native extracellular matrixes that support cell fate. Accelerating the development of such "directive" biomaterials requires a shift in current design practices toward those that enable rapid synthesis and characterization of polymeric materials and the coupling of these processes with techniques that enable similarly rapid quantification and optimization of the interactions between these new material systems and target cells and tissues. This manuscript reviews recent advances in combinatorial and high-throughput (HT) technologies applied to polymeric biomaterial synthesis, fabrication, and chemical, physical, and biological screening with targeted end-point applications in the fields of gene therapy, tissue engineering, and regenerative medicine. Limitations of, and future opportunities for, the further application of these research tools and methodologies are also discussed.

One Reagent with Two Functions: Simultaneous Living Radical Polymerization and Chain-End Substitution for Tailoring Polymer Dispersity

The molecular weight distribution of polymer, termed dispersity (Đ), is a fundamental parameter that determines polymer properties. Sodium azide (NaN₃) functions as a catalyst in organocatalyzed living radical polymerization when the reaction medium is nonpolar. In contrast, NaN₃ can act as a nucleophile when the reaction medium is polar. In this paper, we report an efficient approach to dispersity control by exploiting the dual functions of NaN₃ under the varied solvent polarity. Simultaneous polymerization and chain-end substitution allowed us to tune the Đ values of various polymethacrylates and poly(butyl acrylate). Notably, the Đ value could be tuned to a wide range approximately from 1.2 to 2.0 for polymethacrylates and to 3.8 for poly(butyl acrylate). This approach afforded polymer brushes on surfaces with tailored Đ values. An interesting finding was that the polymer brushes exhibited a unique interaction with external molecules, depending on the Đ value.

Residence time distribution (RTD) revisited

Residence Time Distribution (RTD) theory is revisited and tracer technology discussed. The background of RTD following Danckwerts ideas is presented by introducing "distribution" functions for residence time, internal age and intensity function and how to experimentally obtain them with tracer techniques (curves C and F of Danckwerts). Compartment models to describe fluid flow in real reactors are reviewed and progressive modeling of chromatographic processes discussed in some detail. The shortcomings of Standard Dispersion Model (SDM) are addressed, the Taylor-Aris model discussed and the Wave Model of Westerterp's group introduced. The contribution of Computational Fluid Dynamics (CFD) is highlighted to calculate RTD from momentum and mass transport equations and to access spatial age distribution and degree of mixing. Finally smart RTD and future challenges are discussed.

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.

Tailoring polymer dispersity by mixing ATRP initiators

Herein we present a simple batch method to control polymer dispersity using a mixture of two ATRP initiators with different reactivities.

From circular synthesis to material manufacturing: advances, challenges, and future steps for using flow chemistry in novel application area

We review the emerging use of flow technologies for circular chemistry and material manufacturing, highlighting advances, challenges, and future directions.

Progress and Perspectives Beyond Traditional RAFT Polymerization

The development of advanced materials based on well-defined polymeric architectures is proving to be a highly prosperous research direction across both industry and academia. Controlled radical polymerization techniques are receiving unprecedented attention, with reversible-deactivation chain growth procedures now routinely leveraged to prepare exquisitely precise polymer products. Reversible addition-fragmentation chain transfer (RAFT) polymerization is a powerful protocol within this domain, where the unique chemistry of thiocarbonylthio (TCT) compounds can be harnessed to control radical chain growth of vinyl polymers. With the intense recent focus on RAFT, new strategies for initiation and external control have emerged that are paving the way for preparing well-defined polymers for demanding applications. In this work, the cutting-edge innovations in RAFT that are opening up this technique to a broader suite of materials researchers are explored. Emerging strategies for activating TCTs are surveyed, which are providing access into traditionally challenging environments for reversible-deactivation radical polymerization. The latest advances and future perspectives in applying RAFT-derived polymers are also shared, with the goal to convey the rich potential of RAFT for an ever-expanding range of high-performance applications.

General route to design polymer molecular weight distributions through flow chemistry

The properties of a polymer are known to be intrinsically related to its molecular weight distribution (MWD); however, previous methodologies of MWD control do not use a design and result in arbitrary shaped MWDs. Here we report a precise design to synthesis protocol for producing a targeted MWD design with a simple to use, and chemistry agnostic computer-controlled tubular flow reactor. To support the development of this protocol, we constructed general reactor design rules by combining fluid mechanical principles, polymerization kinetics, and experiments. The ring opening polymerization of lactide, the anionic polymerization of styrene, and the ring opening metathesis polymerization are used as model polymerizations to develop the reactor design rules and synthesize MWD profiles. The derivation of a mathematical model enables the quantitative prediction of the experimental results, and this model provides a tool to explore the limits of any MWD design protocol.

Tailoring Polymer Dispersity in Photoinduced Iron-Catalyzed ATRP

Although dispersity (Đ) plays an important role in controlling polymer properties, there are very few chemical methods that can sufficiently tune it. Here we report a simple, batch, and environmentally benign photoinduced iron-catalyzed ATRP methodology that enables the efficient control of Đ for both homopolymers and block copolymers. We show that by judiciously varying the concentration of the FeBr₃/TBABr catalyst, a range of dispersities can be obtained (1.18 < Đ < 1.80) while maintaining monomodal molecular weight distributions. High end-group fidelity was confirmed by MALDI-ToF-MS and was further supported by the efficient synthesis of in situ block copolymers where the dispersity of the second block could be controlled upon demand. Importantly, through the use of low ppm amounts of the catalyst, perfect temporal control could be attained during intermittent "on/off" cycles. This work considerably expands the chemical toolbox for tuning Đ of homo- and block copolymers.

Polymerizations in Continuous Flow: Recent Advances in the Synthesis of Diverse Polymeric Materials

The number of reports using continuous flow technology in tubular reactors to perform precision polymerizations has grown enormously in recent years. Flow polymerizations allow highly efficient preparation of polymers exhibiting well-defined molecular characteristics, and has been applied to a slew of monomers and various polymerization mechanisms, including anionic, cationic, radical, and ring-opening. Polymerization conducted in continuous flow offers several distinct advantages, including improved efficiency, reproducibility, and enhanced safety for exothermic polymerizations using highly toxic components, high pressures, and high temperatures. The further development of this technology is thus of relevance for many industrial polymerization processes. While much progress has been demonstrated in recent years, opportunities remain for increasing the compositional and architectural complexity of polymeric materials synthesized in a continuous fashion. Extending the reactor processing principles that have heretofore been focused on optimizing homopolymerization to include multisegment block copolymers, particularly from monomers that propagate via incompatible mechanisms, represents a major challenge and coveted target for continuous flow polymerization. Likewise, the spatial and temporal control of reactivity afforded by flow chemistry has and will continue to enable the production of complex polymeric architectures. This Viewpoint offers a brief background of continuous flow polymerization focused primarily on tubular (micro)reactors and includes selected examples that are relevant to these specific developments.