Vitrimerization: Converting Thermoset Polymers into Vitrimers

Recyclable Covalent Adaptable Polystyrene Networks Using Boronates and TetraAzaADamantanes

With an ever-increasing annual production of polymers and the accumulation of polymer waste leading to progressively adverse environmental consequences, it has become important that all polymers can be efficiently recycled at the end of their life cycle. Especially thermosets are intrinsically difficult to recycle because of their permanent covalent cross-links. A possible solution is to switch from using thermosets to covalent adaptable networks, sparking the rapid development of novel dynamic covalent chemistries and derived polymer materials. Next to development of these innovative polymer materials, there is also an evident advantage of merging the virtues of covalent adaptable networks with the proven material properties of widely used commodity plastics, by introducing dynamic covalent bonds in these original thermoplastic materials to obtain recyclable thermosets. Here we report the synthesis and characterization of a polystyrene polymer, functionalized with TetraAzaADamantanes and cross-linked with dynamic covalent boronic esters. The material properties were characterized for different degrees of cross-linking. The materials showed good solvent resistance with a high remaining insoluble fraction. In line with the typical behavior of traditional covalent adaptable networks, the prepared polystyrene-based boronate-TetraAzaADamantane materials were able to undergo stress relaxation. The material relaxation was also shown to be tunable by mixing with an acid catalyst. Lastly, the materials could be recycled at least 2 times.

New Advances in Covalent Network Polymers via Dynamic Covalent Chemistry

Covalent network polymers, as materials composed of atoms interconnected by covalent bonds in a continuous network, are known for their thermal and chemical stability. Over the past two decades, these materials have undergone significant transformations, gaining properties such as malleability, environmental responsiveness, recyclability, crystallinity, and customizable porosity, enabled by the development and integration of dynamic covalent chemistry (DCvC). In this review, we explore the innovative realm of covalent network polymers by focusing on the recent advances achieved through the application of DCvC. We start by examining the history and fundamental principles of DCvC, detailing its inception and core concepts and noting its key role in reversible covalent bond formation. Then the reprocessability of covalent network polymers enabled by DCvC is thoroughly discussed, starting from the significant milestones that marked the evolution of these polymers and progressing to their current trends and applications. The influence of DCvC on the crystallinity of covalent network polymers is then reviewed, covering their bond diversity, synthesis techniques, and functionalities. In the concluding section, we address the current challenges faced in the field of covalent network polymers and speculates on potential future directions.

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.

Plastic bio-mitigation by Pseudomonas mendocina ABF786 and simultaneous conversion of its CO2 byproduct to microalgal biodiesel

Bio-mitigation of plastics by microorganisms generates carbon dioxide (CO2) that can be utilized for algal biomass generation. Pseudomonas mendocina ABF786, reportedly the most efficient plastic-degrading bacteria, was screened using the modified most probable number technique. This study highlights the use of an integrative prototype for the production of microalgal biomass (Chlorella vulgaris) in combination with bio-mitigation of plastics, which serves a dual purpose: (i) increased plastic-degradation capability by microorganisms (53%-85% increase in plastic weight loss) due to removal of CO2 feedback inhibition and (ii) increased algal biomass generation (200%-237%) due to supply of extra CO2 from plastic degradation to the algal cultivation flask. Whole-genome sequencing and functional annotation confirmed that all the genes involved in the mineralization of plastic to CO2 are present within the genome of P. mendocina ABF786. Using two or more microbial cultures for remediation may increase the process efficiency.

Digital Light Processing 3D Printing of Isosorbide- and Vanillin-Based Ester and Ester-Imine Thermosets: Structure-Property Recyclability Relationships

Four isosorbide-based photocurable resins were designed to reveal correlations between the composition and chemical structure, digital light processing (DLP) three-dimensional (3D) printability, thermoset properties, and recyclability. Especially, the role of functional groups, i.e., the concentration of ester groups vs the combination of ester and imine functionalities, in the recyclability of the resins was investigated. The resins consisted of methacrylated isosorbide alone or in combination with methacrylated vanillin or a flexible methacrylated vanillin Schiff-base. The composition of the resins significantly affected their 3D printability as well as the physical and chemical properties of the resulting thermosets. The results indicated the potential of methacrylated isosorbide to confer rigidity to thermosets with some negative effects on the printing quality and solvent-resistance properties. An increase in the methacrylated vanillin concentration in the resin enabled us to overcome these drawbacks, leading, however, to thermosets with lower thermal stability. The replacement of methacrylated vanillin with the methacrylated Schiff-base resin decreased the rigidity of the networks, ensuring, on the other hand, improved solvent-resistance properties. The results highlighted an almost complete preservation of the elastic modulus after the reprocessing or chemical recycling of the ester-imine thermosets, thanks to the presence of two distinct dynamic covalent bonds in the network; however, the concentration of the ester functions in the ester thermosets played a significant role in the success of the chemical recycling procedure.

Influence of Catalyst Content and Epoxy/Carboxylate Ratio on Isothermal Creep of Epoxy Vitrimers

In the present work, a commercial epoxy based on epoxy anhydride and tertiary amine was modified by a metallic catalyst (Zn2+) to induce vitrimeric behavior by promoting the transesterification reaction. The effect of two different epoxy/acid ratios (1 and 0.6) at two different zinc acetate amounts (Zn(Ac)2) on the thermomechanical and viscoelastic performances of the epoxy vitrimers were investigated. Creep experiments showed an increase in molecular mobility above the critical "Vitrimeric" temperature (Tv) of 170 °C proportionally to the amount of Zn(Ac)2. A procedure based on Burger's model was set up to investigate the effect of catalyst content on the vitrimer ability to flow as the effect of the dynamic exchange reaction. The analysis showed that in the case of a balanced epoxy/acid formulation, the amount of catalyst needed for promoting molecular mobility is 5%. This system showed a value of elastic modulus and dynamic viscosity at 170 °C of 9.50 MPa and 2.23 GPas, respectively. The material was easily thermoformed in compression molding, paving the way for the recyclability and weldability of the thermoset system.

Second-Generation Soft Actuators Driven by NIR Light Based on Croconaine Dye-Doped Vitrimers

Soft actuators with photo-response can be selectively driven by the light source, but it is challenging to achieve a selective response of multiple components under a uniform light field, which is actually of great importance for the development of soft robots. In this work, a series of near-infrared light (NIR)-responsive vitrimers (CR-vitrimers) are synthesized by carboxylate transesterification using carboxyl-bearing croconaine dye (CR-800) as a photothermal agent (PTA). NIR-responsive liquid crystalline elastomers (CR-vitrimer-LCEs) under NIR laser (λmax = 808 nm) without the template can be further prepared. More importantly, the dynamic covalent bonding properties of vitrimer allow for the fabrication of a hand-shaped actuator by hot pressing, consisting of "fingers" with different NIR-response threshold values. After programming as needed, the hand-shaped actuator successfully achieves local and sequential control under a uniform NIR light field.

An Investigation of the Healing Efficiency of Epoxy Vitrimer Composites Based on Zn2+ Catalyst

The need to recycle carbon-fibre-reinforced composite polymers (CFRP) has grown significantly to reduce the environmental impact generated by their production. To meet this need, thermoreversible epoxy matrices have been developed in recent years. This study investigates the performance of an epoxy vitrimer made by introducing a metal catalyst (Zn2+) and its carbon fibre composites, focusing on the healing capability of the system. The dynamic crosslinking networks endow vitrimers with interesting rheological behaviour; the capability of the formulated resin (AV-5) has been assessed by creep tests. The analysis showed increased molecular mobility above a topology freezing temperature (Tv). However, the reinforcement phase inhibits the flow capability, reducing the flow. The fracture behaviour of CFRP made with the vitrimeric resin has been investigated by Mode I and Mode II tests and compared with the conventional system. The repairability of the vitrimeric CFRP has been investigated by attempting to recover the delaminated samples, which yielded unsatisfactory results. Moreover, the healing efficiency of the modified epoxy composites has been assessed using the vitrimer as an adhesive layer. The joints were able to recover about 84% of the lap shear strength of the pristine system.

One-Pot Synthesis of Depolymerizable δ-Lactone Based Vitrimers

A depolymerizable vitrimer that allows both reprocessability and monomer recovery by a simple and scalable one-pot two-step synthesis of vitrimers from cyclic lactones is reported. Biobased δ-valerolactone with alkyl substituents (δ-lactone) has low ceiling temperature; thus, their ring-opening-polymerized aliphatic polyesters are capable of depolymerizing back to monomers. In this work, the amorphous poly(δ-lactone) is solidified into an elastomer (i.e., δ-lactone vitrimer) by a vinyl ether cross-linker with dynamic acetal linkages, giving the merits of reprocessing and healing. Thermolysis of the bulk δ-lactone vitrimer at 200 °C can recover 85-90 wt% of the material, allowing reuse without losing value and achieving a successful closed-loop life cycle. It further demonstrates that the new vitrimer has excellent properties, with the potential to serve as a biobased and sustainable replacement of conventional soft elastomers for various applications such as lenses, mold materials, soft robots, and microfluidic devices.

Analysis of Poly(thiourethane) Covalent Adaptable Network through Broadband Dielectric Spectroscopy

The dielectric spectra of the poly(thiourethane) network, HDI-S3, have been analyzed to know the nature and the cooperativity of each of the six dielectric processes observed. At low temperatures, γ₁, γ₂, and β dielectric relaxations were attributed to noncooperative local motions in the glassy state, in which apparent activation energies are 30, 36, and 60 kJ·mol^-1, respectively. At higher temperatures, three dielectric relaxations are observed (α_Tg, α*, ρ). The α_Tg relaxation is attributed to the glass transition, and it is overlapped with the α* relaxation. The molecular origin of α* relaxation is associated with the bond exchange reaction. Finally, the ρ relaxation is ascribed to the heterogeneity of the sample although its origin is uncertain. The DC conductivity (σ_DC) is found to be an appropriate variable to analyze the bond exchange reaction. Accordingly, the HDI-S3 has a molecular exchange mechanism of dissociative nature.

Healable Ionoelastomer Designed from Polymeric Ionic Liquid and Vitrimer Chemistry

The growing demand for all-solid flexible, stretchable, and wearable devices has boosted the need for liquid-free and stretchable ionoelastomers. These ionic conducting materials are subjected to repeated deformations during functioning, making them susceptible to damage. Thus, imparting cross-linked materials with healing ability seems particularly promising to improve their durability. Here, a polymeric ionic liquid (PIL) bearing allyl functional groups was synthesized based on the quaternization of N-allylimidazole with a copolymer rubber of poly(epichlorohydrin) and poly(ethylene oxide) (PEO). The resulting PIL was then cross-linked with dynamic boronic ester cross-linkers 2,2'-(1,4-Phenylene)-bis[4-mercaptan-1,3,2-dioxaborolane] (BDB) through thiol-ene "click" photoaddition. PEO dangling chains were additionally introduced for acting as free volume enhancers. The properties of the resulting all-solid PIL networks were investigated by tuning dynamic cross-linkers and dangling chain contents. Adjusting the cross-linker and dangling chain quantities yielded soft (0.2 MPa), stretchable (300%), and highly conducting ionoelastomers (1.6 × 10^-5 S·cm^-1 at 30 °C). The associative exchange reaction between BDB endowed these materials with vitrimer properties such as healing and recyclability. The recycled materials were able to retain their original mechanical properties and ionic conductivity. These healable PIL networks display a great potential for applications requiring solid electrolytes with high ionic conductivity, healing ability, and reprocessability.

Upcycling of thermosetting polymers into high-value materials

Thermosetting polymers, a large class of polymers featuring excellent properties, have been widely used and play an irreplaceable role in our life. Nevertheless, they are arduous to be recycled or reused on account of their permanently cross-linked networks, and the main recycling approaches used currently include energy recovery through incineration, utilization as fillers after mechanical grinding, and pyrolysis, which only reclaim a small fraction or partial value of thermosetting polymers and their downstream materials. In this minireview, we provide an overview of the efforts undertaken towards upcycling thermosetting polymers in recent years. The research progress on physical upcycling, carbonization, solvolysis and vitrimerization of thermoset waste to high-value materials, including oil-water separation materials, 3D printable materials, functional carbon materials (supercapacitors, photothermal conversion materials, and catalytic materials), additives, emulsifiers, biolubricants, and vitrimers, are summarized and discussed. Perspectives on the future development of the art of upcycling thermosets are also provided.

Characterising different molecular landscapes in dynamic covalent networks

Dynamic covalent networks present a unique opportunity to exert molecular-level control on macroscopic material properties, by linking their thermal behaviour to the thermodynamics and kinetics of the underlying chemistry. Yet, existing methods do not allow for the extraction and analysis of the influence of local differences in chemical reactivity caused by available reactants, catalysts, or additives. In this context, we present a rheological paradigm that allows us to correlate the composition of a reactive polymer segment to a faster or slower rate of network rearrangement. We discovered that a generalised Maxwell model could separate and quantify the dynamic behaviour of each type of reactive segment individually, which was crucial to fully comprehend the mechanics of the final material. More specifically, Eyring and Van 't Hoff analysis were used to relate possible bond catalysis and dissociation to structural changes by combining statistical modelling with rheology measurements. As a result, precise viscosity changes could be measured, allowing for accurate comparison of various dynamic covalent network materials, including vitrimers and dissociative networks. The herein reported method therefore facilitated the successful analysis of virtually any type of rate-enhancing effect and will allow for the design of functional and fast (re)processable materials, as well as improve our ability to predict and engineer their properties for future applications.

Recycling of plastic wastes generated from COVID-19: A comprehensive illustration of type and properties of plastics with remedial options

Plastic has contributed enormously to the healthcare sector and towards public health safety during the COVID-19 pandemic. With the frequent usage of plastic-based personal protective equipment (PPEs) (including face masks, gloves, protective body suits, aprons, gowns, face shields, surgical masks, and goggles), by frontline health workers, there has been a tremendous increase in their manufacture and distribution. Different types of plastic polymers are used in the manufacture of this equipment, depending upon their usage. However, since a majority of these plastics are still single-use plastics (SUP), they are not at all eco-friendly and end up generating large quantities of plastic waste. The overview presents the various available and practiced methods in vogue for disposal cum treatment of these highly contaminated plastic wastes. Among the current methods of plastic waste disposal, incineration and land filling are the most common ones, but both these methods have their negative impacts on the environment. Alongside, numerous methods that can be used to sterilize them before any treatment have been discussed. There are several new sorting technologies, to help produce purer polymers that can be made to undergo thermal or chemical treatments. Microbial degradation is one such novel method that is under the spotlight currently and being studied extensively, because of its ecological advantages, cost-effectiveness, ease of use, and maintenance. In addition to the deliberations on the methods, strategies have been enumerated for combination of different methods, vis-à-vis studying the life cycle assessment towards a more circular economy in handling this menace to protect mankind.

Vitrimerization of Crosslinked Unsaturated Polyester Resins: A Mechanochemical Approach to Recycle and Reprocess Thermosets

Unsaturated polyester resins (UPRs) are expansively used in different applications and recycling the significant amounts of UPR waste is still a universal problem. Vitrimerization is a feasible, environmental-friendly, cost effective, and operative method, which can be used for recycling the crosslinked UPRs. In this method, the thermoset permanent network is changed into a dynamic network similar to the vitrimer-type polymers. The results show that the existence of a transesterification catalyst in the system significantly enhances the efficiency of vitrimerization. The vitrimerized UPR thermosets can be reprocessed three times with mechanical properties comparable to the initial UPR. The results show that the excess of external hydroxyl groups in the system can prevent the formation of zinc ligand complexes in the network and consequently reduce the crosslinked density and mechanical properties of vitrimerized samples. The vitrimerized thermoset powder can be reprocessed through injection molding, extrusion, and compression molding which are conventional thermoplastic processing techniques. The unrecyclable UPR thermoset wastes can be recycled and reused through vitrimerization with the least loss in mechanical properties.

Dynamic covalent exchange induced cyclization in poly(methacrylic anhydride)

Anhydride dynamic covalent exchange crosslinked poly(methacrylic anhydride) allows recycling at elevated temperatures and pressures and also produces cyclic anhydrides.

Catalyst-Free Mechanochemical Recycling of Biobased Epoxy with Cellulose Nanocrystals

Mechanochemical vitrimerization, as a method to recycle cross-linked thermosets by converting the permanent network into a recyclable and reprocessable vitrimer network, inevitably requires a catalyst to accelerate the bond exchange reactions. Here, we demonstrate a catalyst-free approach to achieve the recycling of a cross-linked biobased epoxy into high-performance nanocomposites with cellulose nanocrystals (CNCs). CNCs provide abundant free hydroxyl groups to promote the transesterification exchange reactions while also acting as reinforcing fillers for the resultant nanocomposites. This technique introduces an effective way to fabricate high-performance thermoset nanocomposites based on recycled polymers in an ecofriendly way, promoting the recycle and reuse of thermosets as sustainable nanocomposites for different applications.

Cellulose Nanocrystals: Accelerator and Reinforcing Filler for Epoxy Vitrimerization

The novel vitrimerization concept of converting permanently cross-linked networks of thermoset polymers into dynamic exchangeable networks often relies on transesterification reactions. Transesterification exchange reactions, for example, in epoxy vitrimers, are usually contingent on equivalent ratios of hydroxyl to ester groups and large amounts of catalysts to achieve proper dynamic exchange capability. In general, postconsumer epoxy cured with anhydrides contains very few hydroxyl groups in the network, and it is challenging to convert it into efficient dynamic networks by vitrimerization. Here, we demonstrate that introducing cellulose nanocrystals as feedstock of external hydroxyl groups in the mechanochemical vitrimerization process could improve the exchange reaction rate as well as the thermomechanical properties of the vitrimerized epoxy. This work offers an effective way to recycle and reprocess postconsumer epoxy/anhydride waste with inherent low ratios of hydroxyl to ester groups into higher value-added vitrimer nanocomposites.

Recyclable High-Performance Epoxy-Anhydride Resins with DMP-30 as the Catalyst of Transesterification Reactions

Epoxy-anhydride resins are widely used in engineering fields due to their excellent performance. However, the insolubility and infusibility make the recycling of epoxy resins challenging. The development of degradable epoxy resins with stable covalent networks provides an efficient solution to the recycling of thermosets. In this paper, 2,4,6-tris(dimethylaminomethyl)phenol (DMP-30) is incorporated into the epoxy-glutaric anhydride (GA) system to prepare high-performance epoxy resins that can be recycled below 200 °C at ordinary pressure via ethylene glycol (EG) participated transesterification. The tertiary amine groups in DMP-30 can catalyze the curing reaction of epoxy and anhydride, as well as the transesterification between ester bonds and alcoholic hydroxyl groups. Compared with early recyclable anhydride-cured epoxy resins, the preparation and recycling of diglycidyl ether of bisphenol A (DGEBA)/GA/DMP-30 systems do not need any special catalysts such as TBD, Zn(Ac)2, etc., which are usually expensive, toxic, and have poor compatibility with other compounds. The resulting resins have glass transition temperatures and strengths similar to those of conventional epoxy resins. The influences of GA content, DMP-30 content, and temperature on the dissolution rate were studied. The decomposed epoxy oligomer (DEO) is further used as a reaction ingredient to prepare new resins. It is found that the DEO can improve the toughness of epoxy resins significantly. This work provides a simple method to prepare readily recyclable epoxy resins, which is of low-cost and easy to implement.