Versatile Phosphate Diester-Based Flame Retardant Vitrimers via Catalyst-Free Mixed Transesterification

Bio-derived Schiff base vitrimer with outstanding flame retardancy, toughness, antibacterial, dielectric and recycling properties

Thermosetting resins are widely used in high-tech applications for excellent mechanical robustness and chemical resistance. With increasing attention to the environmental and usage safety issues, it is necessary to develop bio-derived, recyclable, tough, and fire-retardant thermosetting resins. Herein, a high-performance, vanillin-based vitrimer (CIP1.0) was prepared. The CIP1.0 with 1.0 wt% phosphorus passes vertical burning (UL-94) V-0 rating with a limiting oxygen index (LOI) of 27.2%. The phosphorus-containing and Schiff base groups act synergistically in gas and condensed phases during combustion, endowing CIP1.0 with outstanding fire retardancy. The CIP1.0 shows excellent toughness with high elongation at break of 45.0% due to the π-π stacking of numerous rigid aromatic groups and appropriate cross-linking density. The highly symmetrical structure and low polarizability of CIP1.0 result in a low dielectric constant. The CIP1.0 exhibits superior antimicrobial properties. The CIP1.0 can be reprocessed by hot-pressing at 140 °C for 10 min. The non-destructive, closed-loop recycling of carbon fibers in the carbon fiber-reinforced CIP1.0 composite can be achieved under mild conditions due to the degradable Schiff base groups of CIP1.0. In this work, a bio-derived, tough, fire-retardant, low dielectric, and antimicrobial vitrimer is prepared to provide a rational strategy for the design of advanced environmentally friendly thermosetting resins.

Towards Sustainable and Fire-Safe Thermosets Using Phosphorus-Containing Covalent Adaptable Networks

Dynamic covalent chemistry is a promising strategy for developing recyclable thermosets and their carbon fiber reinforced composites, in line with the goal of green and sustainable development. However, a significant challenge lies in balancing the dynamic reversibility and the desired service performances, such as thermal, mechanical properties, and flame retardancy. It has hindered the broader application of dynamic materials beyond the initial proof of concept. This concept provides an overview of the current state of research on phosphorus-containing covalent adaptable networks (CANs), highlighting key designing and regulating principles for tailoring comprehensive properties including flame retardancy, mechanical and thermal properties, as well as dynamic behaviours such as malleability, reprocessability and degradability. Finally, new frontiers and opportunities in developing high-performance sustainable CANs-based thermosets and their carbon fiber composites for structural engineering applications are prospected.

Polymerized and Colloidal Ionic Liquids─Syntheses and Applications

The breadth and importance of polymerized ionic liquids (PILs) are steadily expanding, and this review updates advances and trends in syntheses, properties, and applications over the past five to six years. We begin with an historical overview of the genesis and growth of the PIL field as a subset of materials science. The genesis of ionic liquids (ILs) over nano to meso length-scales exhibiting 0D, 1D, 2D, and 3D topologies defines colloidal ionic liquids, CILs, which compose a subclass of PILs and provide a synthetic bridge between IL monomers (ILMs) and micro to macro-scale PIL materials. The second focus of this review addresses design and syntheses of ILMs and their polymerization reactions to yield PILs and PIL-based materials. A burgeoning diversity of ILMs reflects increasing use of nonimidazolium nuclei and an expanding use of step-growth chemistries in synthesizing PIL materials. Radical chain polymerization remains a primary method of making PILs and reflects an increasing use of controlled polymerization methods. Step-growth chemistries used in creating some CILs utilize extensive cross-linking. This cross-linking is enabled by incorporating reactive functionalities in CILs and PILs, and some of these CILs and PILs may be viewed as exotic cross-linking agents. The third part of this update focuses upon some advances in key properties, including molecular weight, thermal properties, rheology, ion transport, self-healing, and stimuli-responsiveness. Glass transitions, critical solution temperatures, and liquidity are key thermal properties that tie to PIL rheology and viscoelasticity. These properties in turn modulate mechanical properties and ion transport, which are foundational in increasing applications of PILs. Cross-linking in gelation and ionogels and reversible step-growth chemistries are essential for self-healing PILs. Stimuli-responsiveness distinguishes PILs from many other classes of polymers, and it emphasizes the importance of segmentally controlling and tuning solvation in CILs and PILs. The fourth part of this review addresses development of applications, and the diverse scope of such applications supports the increasing importance of PILs in materials science. Adhesion applications are supported by ionogel properties, especially cross-linking and solvation tunable interactions with adjacent phases. Antimicrobial and antifouling applications are consequences of the cationic nature of PILs. Similarly, emulsion and dispersion applications rely on tunable solvation of functional groups and on how such groups interact with continuous phases and substrates. Catalysis is another significant application, and this is an historical tie between ILs and PILs. This component also provides a connection to diverse and porous carbon phases templated by PILs that are catalysts or serve as supports for catalysts. Devices, including sensors and actuators, also rely on solvation tuning and stimuli-responsiveness that include photo and electrochemical stimuli. We conclude our view of applications with 3D printing. The largest components of these applications are energy related and include developments for supercapacitors, batteries, fuel cells, and solar cells. We conclude with our vision of how PIL development will evolve over the next decade.

On Lightweight Shape Memory Vitrimer Composites

Lightweight materials are highly desired in many engineering applications. A popular approach to obtain lightweight polymers is to prepare polymeric syntactic foams by dispersing hollow particles, such as hollow glass microbubbles (HGMs), in a polymer matrix. Integrating shape memory vitrimers (SMVs) in fabricating these syntactic foams enhances their appeal due to the multifunctionality of SMVs. The SMV-based syntactic foams have many potential applications, including actuators, insulators, and sandwich cores. However, there is a knowledge gap in understanding the effect of the HGM volume fraction on different material properties and behaviors. In this study, we prepared an SMV-based syntactic foam to investigate the influence of the HGM volume fractions on a broad set of properties. Four sample groups, containing 40, 50, 60, and 70% HGMs by volume, were tested and compared to a control pure SMV group. A series of analyses and various chemical, physical, mechanical, thermal, rheological, and functional experiments were conducted to explore the feasibility of ultralight foams. Notably, the effect of HGM volume fractions on the rheological properties was methodically evaluated. The self-healing capability of the syntactic foam was also assessed for healing at low and high temperatures. This study proves the viability of manufacturing multifunctional ultralightweight SMV-based syntactic foams, which are instrumental for designing ultralightweight engineering structures and devices.

Overcoming the barrier: designing novel thermally robust shape memory vitrimers by establishing a new machine learning framework

Shape memory vitrimers (SMVs) are an emerging class of advanced materials that have garnered significant interest from researchers in the past five to six years. These materials can return to their original shape when exposed to a stimulus, while also healing damage they have sustained. However, achieving both high healing/recycling efficiency and a high glass transition temperature (Tg) in SMVs has been challenging, due to the conflicting requirements between molecular chain mobility and the formation and reaction of dynamic covalent bond exchange. Based on the understanding of chemo-physical properties, this study first leverages machine learning (ML), involving supervised and unsupervised learning approaches, to navigate this complex design space of SMVs. Furthermore, we elaborated the basic mathematical frameworks of ML approaches and comprehensively compared their performances. Based on the best performing model, we designed four types of thermally robust shape memory vitrimers (TRSMVs), which boast high recycling efficiency, elevated Tg, and exemplary shape memory effects, overcoming conventional barriers. One of the discovered samples exhibited outstanding performance with a Tg of 233.5 °C, a recycling efficiency of 84.1%, and a recovery stress of 33 MPa in experiments. It aligns well with ML predictions, showcasing the potential of our ML framework in driving innovative materials design and advancing the field of smart polymers.

Strategy for Constructing Phosphorus-Based Flame-Retarded Polyurethane Elastomers for Advanced Performance in Long-Term

Polyurethane elastomer (PUE), which is widely used in coatings for construction, transportation, electronics, aerospace, and other fields, has excellent physical properties. However, polyurethane elastomers are flammable, which limits their daily use, so the flame retardancy of polyurethane elastomers is very important. Reactive flame retardants have the advantages of little influence on the physical properties of polymers and low tendency to migrate out. Due to the remarkable needs of non-halogenated flame retardants, phosphorus flame retardant has gradually stood out as the main alternative. In this review, we focus on the fire safety of PUE and provide a detailed overview of the current molecular design and mechanisms of reactive phosphorus-containing, as well as P-N synergistic, flame retardants in PUE. From the structural characteristics, several basic aspects of PUE are overviewed, including thermal performance, combustion performance, and mechanical properties. In addition, the perspectives on the future advancement of phosphorus-containing flame-retarded polyurethane elastomers (PUE) are also discussed. Based on the past research, this study provides prospects for the application of flame-retarded PUE in the fields of self-healing materials, bio-based materials, wearable electronic devices, and solid-state electrolytes.

Exploration of the Fire-Retardant Potential of Microencapsulated Ammonium Polyphosphate in Epoxy Vitrimer Containing Dynamic Disulfide Bonds

Epoxy vitrimers appear as a promising alternative to common epoxy thermoset composites. Nevertheless, the possibilities of applying these materials are limited due to their high flammability which may cause high fire risks. To date, the flame-retardant epoxy vitrimer systems reported in the literature almost all rely on intrinsic flame retardancy to achieve high fire safety; however, the complex and expensive synthesis process hinders their large-scale application. In this work, disulfide-based epoxy vitrimer (EPV) was fabricated with 4, 4'-dithiodianiline as the curing agent, and microencapsulated ammonium polyphosphate (MFAPP) was employed as a potential additive flame retardant to improve their fire retardancy. As a comparative study, common epoxy (EP) composites were also prepared using 4,4'-diaminodiphenylmethane as the curing agent. The results showed that the introduction of dynamic disulfide bonds led to a reduction in the initial thermal decomposition temperature of EPV by around 70 °C compared to EP. Moreover, the addition of 7.5 wt.% of MFAPP endowed EP with excellent fire performance: the LOI value was as high as 29.9% and the V-0 rating was achieved in the UL-94 test (3.2 mm). However, under the same loading, although EPV/MFAPP7.5% showed obvious anti-dripping performance, it did not reach any rating in the UL-94 test. The flame-retardant mechanisms in the condensed phase were evaluated using SEM-EDS, XPS, and Raman spectroscopy. The results showed that the residue of EPV/MFAPP7.5% presented numerous holes during burning, which failed to form a continuous and dense char layer as a physical barrier resulting in relatively poor flame retardancy compared to EP/MFAPP7.5%.

Flame-Retardant and Recyclable Soybean Oil-Based Thermosets Enabled by the Dynamic Phosphate Ester and Tannic Acid

The demands of safety and sustainability have driven the development of intrinsic flame-retardant biobased polymers from renewable materials. Herein, a mechanically robust, good flame-retardant, and recyclable thermoset was developed from renewable epoxidized soybean oil (ESO) by using 2-hydroxyethyl methacrylate phosphate (HEMAP) as the reactive flame retardant and tannic acid (TA) as the charring agent. The flame resistance of the obtained ESO-based thermoset achieved the highest UL-94 of V-0 rating and a limited oxygen index value of 26.7% due to the synergistic flame-retardant effect of phosphate and TA. The flame-retardant mechanisms of the gaseous phase and condensed phase were fully investigated by thermogravimetric infrared, scanning electron microscopy-energy-dispersive spectrometry, X-ray photoelectron spectroscopy, and Raman spectra. It is confirmed that the incorporation of phosphate and TA could effectively promote the formation of dense carbon layers and delay the pyrolysis of long aliphatic chains. The ternary crosslinking of ESO, HEMAP, and TA via free-radical polymerization and epoxy-ring opening reaction resulted in a rigid network with a high crosslink density, bestowing the thermoset with superior tensile strength (20.0 MPa), flexural strength (36.3 MPa), and bonding strength (16.7 MPa on steel). Moreover, the ESO-based thermoset exhibited a fast stress relaxation behavior due to the transesterification of dynamic β-hydroxyl phosphate esters, which enables the network with thermal-healing ability and recyclability. This study explores a feasible method to prepare an intrinsic flame-retardant polymer from commercially available and renewable vegetable oils and natural polyphenols.

A healable, re-cyclable and thermochromic epoxy resin for thermal-responsive smart windows

Traditional thermoset polymers such as epoxy resin have strong mechanical strength, but are difficult to recycle, reshape and reprocess after being cured. When these materials are damaged, they can only...

From Drug Molecules to Thermoset Shape Memory Polymers: A Machine Learning Approach

Ultraviolet (UV)-curable thermoset shape memory polymers (TSMPs) with high recovery stress but mild glass transition temperature (T_g) are highly desired for 3D/4D printing lightweight load-bearing structures and devices. However, a bottleneck is that high recovery stress usually means high T_g. For a few TSMPs with high recovery stress, their T_g values are close to the decomposition temperature, and thus, the shape memory effect cannot be triggered safely and effectively. While machine learning (ML) has served as a useful tool to discover new materials and drugs, the grand challenge of using ML to discover new TSMPs persists in the very limited data available. Here, we report an enhanced ML approach by combining the transfer learning-variational autoencoder with a weighted-vector combination method. By learning a large data set with drug molecules in a pretraining process, we were able to effectively map the TSMPs to a hidden space that is much closer to a Gaussian distribution. Through this approach, we created a large compositional space and were able to discover five new types of UV-curable TSMPs with desired properties, one of which was validated by the experiments. Our contribution includes (1) representing the features of TSMPs by drug molecules to overcome the barrier of a limited training data set and (2) developing a ML framework that is able to overcome the barrier of mapping the molar ratio information. It is shown that this approach can effectively learn TSMP features by utilizing the relatedness between the data-scarce (and biased) TSMP target and data-abundant drug source, and the result is much more accurate and more robust than the benchmark set by the support vector machine method using direct label encoding and Morgan encoding. Therefore, it is believed that this framework is a state-of-the-art study in the TSMP field. This study opens new opportunities for discovering not only new TSMPs but also other thermoset polymers.

Room-Temperature Self-Healable and Mechanically Robust Thermoset Polymers for Healing Delamination and Recycling Carbon Fibers

The advocacy of carbon neutrality and circular economy encourages people to pursue self-healing and recycling of glassy thermoset polymers in a more realistic and energy-saving manner, the best being intrinsic healing under room temperature. However, the high mechanical robustness and healing ability are mutually exclusive because of their completely opposite requirements for the mobility of the polymer networks. Here, we report a dual-cross-linked network by slightly coupling the low-molecular-weight branched polyethylenimine with an ester-containing epoxy monomer in a nonstoichiometric proportion. The highly mobile and dense noncovalent hydrogen bonds at the chain branches and ends can not only complement the mechanical robustness (tensile strength of 61.6 MPa, elastic modulus of 1.6 GPa, and toughness of 19.2 MJ/m3) but also endow the glassy thermoset polymer (Tg > 40 °C) with intrinsic self-healing ability (healing efficiency > 84%) at 20 °C. Moreover, the resultant covalent adaptive network makes the thermoset polymer stable to high temperatures and solvents, yet it is readily dissolved in ethylene glycol through internal catalyzed transesterification. The application to room temperature delamination healing and carbon fiber recycling was demonstrated as a proof-of-concept.

Catalyst-Free Vitrimer Cross-Linked by Biomass-Derived Compounds with Mechanical Robustness, Reprocessability, and Multishape Memory Effects

Vitrimerization of thermoset polymers plays an important role in addressing resource recovery and reuse. Vitrimer elastomers with good mechanical properties often require well-designed crosslinking agents or fillers, but this increases processing complexity or reduces vitrimer dynamic properties. In this report, a simple green strategy to build a strong vitrimer elastomer is designed. Commercially available epoxidized natural rubber (ENR) is cross-linked with biomass-derived D-Fructose 1,6-bisphosphoric acid to get a vitrimer elastomer cross-linked by β-hydroxy phosphate ester bonds and has abundant hydrogen bonds. Hydrogen bonds can preferentially break and dissipate energy under external forces, which makes the sample robust. The topological network can be reformed at high temperatures through the dynamic exchange of β-hydroxy phosphate ester bonds, which gives the material malleability and recyclability. In addition, through the strategy of combining reprocessing and welding, multiple shape memory effects can be achieved in one postprocessing step. Considering that a variety of commercially available epoxy polymers are easily available, it is believed that this strategy can be a simple and versatile way to enable commercial epoxy polymers to achieve green crosslinking through biomass crosslink agents, which results in robust and recyclable vitrimers based on β-hydroxy phosphate bonds.

Efficient Exchange in a Bioinspired Dynamic Covalent Polymer Network via a Cyclic Phosphate Triester Intermediate

Bond exchange via neighboring group-assisted reactions in dynamic covalent networks results in efficient mechanical relaxation. In Nature, the high reactivity of RNA toward nucleophilic substitution is largely attributed to the formation of a cyclic phosphate ester intermediate via neighboring group participation. We took inspiration from RNA to develop a dynamic covalent network based on β-hydroxyl-mediated transesterifications of hydroxyethyl phosphate triesters. A simple one-step synthetic strategy provided a network containing phosphate triesters with a pendant hydroxyethyl group. 31P solid-state NMR demonstrated that a cyclic phosphate triester is an intermediate in transesterification, leading to dissociative network rearrangement. Significant viscous flow at 60-100 °C makes the material suitable for fast processing via extrusion and compression molding.

DOPO-Decorated Two-Dimensional MXene Nanosheets for Flame-Retardant, Ultraviolet-Protective, and Reinforced Polylactide Composites

This study presents a novel and facile strategy for fabricating fire-resistant, ultraviolet (UV)-shielding, and tensile-enhanced polylactide (PLA) composites using two-dimensional (2D) MXene (Ti₃C₂) flakes chemically modified with 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO). The thermal and burning performances of PLA composites were demonstrated by the limiting oxygen index, UL-94 test, and cone calorimetry. The UV-shielding and tensile performances were also examined. The results revealed that PLA/Ti₃C₂-DOPO (3 wt %) displayed a V-0 rating in the UL-94 test. The enhancement against fire hazard was reflected by the significant reduction in the peak heat release rate (33.7%), total heat release (47%), peak CO production (58.8%), and total smoke production (41.7%). The improved fire-safety performance of the composites is attributed to the interplay of catalytic, barrier, and condensed effects of the Ti₃C₂-DOPO nanosheets in the PLA matrix. PLA/Ti₃C₂-DOPO also showed an increase (∼9%) in tensile strength and an "Excellent" level (UPF 50+) in the UV-protection assessment. In all, this study introduces a novel chemical modification strategy for 2D MXene flakes to fabricate multifunctional PLA composites, which are promising candidates for next-generation sustainable and protective plastic products.

Shape memory-assisted self-healing of dynamic thiol-acrylate networks

By following shape-memory assisted self-healing (SMASH), we used the shape-memory properties of thiol-acrylate photopolymers to physically close a scratch, whilst chemical healing was obtained via thermo-activated dynamic exchange reactions.