Evolution of Copolymers of Epoxides and CO2: Catalysts, Monomers, Architectures, and Applications

The copolymerization of CO2 and epoxides presents a transformative approach to converting greenhouse gases into aliphatic polycarbonates (CO2-PCs), thereby reducing the polymer industry's dependence on fossil resources. Over the past 50 years, a wide array of metallic catalysts, both heterogeneous and homogeneous, have been developed to achieve precise control over polymer selectivity, sequence, regio-, and stereoselectivity. This review details the evolution of metal-based catalysts, with a particular focus on the emergence of organoborane catalysts, and explores how these catalysts effectively address kinetic and thermodynamic challenges in CO2/epoxides copoly2merization. Advances in the synthesis of CO2-PCs with varied sequence and chain architectures through diverse polymerization protocols are examined, alongside the applications of functional CO2-PCs produced by incorporating different epoxides. The review also underscores the contributions of computational techniques to our understanding of copolymerization mechanisms and highlights recent advances in the closed-loop chemical recycling of CO2-sourced polycarbonates. Finally, the industrialization efforts of CO2-PCs are discussed, offering readers a comprehensive understanding of the evolution and future potential of epoxide copolymerization with CO2.

Controlled synthesis of polycarbonate diols and their polylactide block copolymers using amino-bis(phenolate) chromium hydroxide complexes

A diamine-bis(phenolate) chromium(III) complex, CrOH[L] ([L] = dimethylaminoethylamino-N,N-bis(2-methylene-4,6-tert-butylphenolate)), 2, in the presence of tetrabutylammonium hydroxide effectively copolymerizes CO2 and cyclohexene oxide (CHO) into a polycarbonate diol. The resultant low molar mass (6.3 kg mol-1) diol is used to initiate ring-opening polymerization of rac-lactide with 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU) giving ABA-type block copolymers with good molar mass control through varying rac-LA-to-diol loadings and with narrow dispersities. As the degree of rac-LA incorporation increases, the glass transition temperatures (Tg) are found to decrease, whereas decomposition temperatures (Td) increase. (Diphenylphosphonimido)triphenylphosphorane (Ph2P(O)NPPh3) was used as a neutral nucleophilic cocatalyst with 2, giving phosphorus-containing polycarbonates with an Mn value of 28.5 kg mol-1, a dispersity of 1.13, a Tg value of 110 °C and a Td value of over 300 °C. A related Cr(III) complex (4) having a methoxyethyl pendent group rather than a dimethylaminoethyl group was structurally characterized as a hydroxide-bridged dimer.

Facile synthesis of telechelic poly(phenylene sulfide)s by means of electron-deficient aromatic sulfonium electrophiles

We report the facile synthesis of telechelic poly(phenylene sulfide) (PPS) derivatives bearing functional groups at both termini. α,ω-Dihalogenated dimethyl-substituted PPS were obtained in high yield with a high degree of end-functionalization by using soluble poly(2,6-dimethyl-1,4-phenylenesulfide) (PMPS) and 4,4'-dihalogenated diphenyl disulfide (X-DPS, X = Cl, Br) as a precursor and an end-capping agent, respectively. Further end-functionalization is achieved through cross-coupling reactions; particularly, the Kumada-Tamao cross-coupling reaction of bromo-terminated telechelic PMPS and a vinylated Grignard reagent afforded end-vinylated PMPS with thermosetting properties. This synthetic approach can be applied to the preparation of various aromatic telechelic polymers with the desired structures and functionalities.

One-pot terpolymerization of CHO, CO2 and L-lactide using chloride indium catalysts

Ring-opening copolymerization reactions of epoxides, carbon dioxide and cyclic esters to produce copolymers is a promising strategy to prepare CO₂-based polymeric materials. In this contribution, bimetallic chloride indium complexes have been developed as catalysts for the copolymerization processes of cyclohexene oxide, carbon dioxide and L-lactide under mild reaction conditions. The catalysts displayed good catalytic activity and excellent selectivity towards the preparation of poly(cyclohexene carbonate) (PCHC) at one bar CO₂ pressure in the absence of a co-catalyst. Additionally, polyester-polycarbonate copolymers poly(lactide-co-cyclohexene carbonate) (PLA-co-PCHC) were obtained via an one-pot one-step route without the use of a co-catalyst. The degree of incorporation of carbon dioxide can be easily modulated by changing the CO₂ pressure and the monomer feed, resulting in copolymers with different thermal properties.

Dinuclear Nickel Complexes Using Hexadentate Benzothiazole-Based Diamine-Bisphenolate Ligands: Highly Active Catalysts for Copolymerization of Carbon Dioxide with Epoxides

We reported for the first time the utilization of hexadentate benzothiazole-based diamine-bisphenolate ligands to synthesize structurally well-characterized dinickel dicarboxylate complexes and studied their catalysis for copolymerization of carbon dioxide with epoxides. Dinickel carboxylate complexes having a 1,3-diamine-bridged backbone were demonstrated to be high-performance catalysts for alternating copolymerization of CO₂ and cyclohexene oxide (CHO) with high product selectivity. Particularly, acetate-supported nickel complex 2 enabled us to promote such CO₂-copolymerization of this kind with a maximum turnover frequency of up to 2600 h^-1 and gave good molecular weight controllability under high-pressure conditions. It is worth noting that bimetallic Ni catalyst 2 was also capable of mediating the catalytic CO₂-polymerization of alicyclic epoxides at atmospheric pressure. Kinetic investigations of CO₂/CHO copolymerization by 2 allowed us to determine the rate equation of -d[CHO]/dt = k_p[2]¹[CHO]¹, and such catalysis exhibited a first-order dependence on both dinickel complex and CHO concentrations.

Orthogonally grown polycarbonate and polyvinyl block copolymers from mechanistically distinct (co)polymerizations

Mechanistically distinct polymerization systems can afford unique block copolymers that would not be accessible by mere sequential polymerization.

Alternating Copolymerization of Carbon Dioxide with Epoxides Using Highly Active Dinuclear Nickel Complexes: Catalysis and Kinetics

A novel series of well-defined dicarboxylate dinuclear nickel complexes containing benzotriazole based 1,3-diamine-bisphenolate (1,3-DiBTP) ligands were readily synthesized through a one-pot procedure, which were highly active single-component catalysts for copolymerization of CO₂ and epoxides. X-ray structural determination of dinickel complexes 1-11 indicates that the DiBTP ligand acted as a N,O,N,N,O,N-hexadentate framework to chelate two nickel atoms, and two carboxylates are nonequivalently coordinated. The best benzoate-bonded dinickel catalyst 6 displayed the effective activity for both high-pressure and 1 atm CO₂-copolymerization of cyclohexene oxide (CHO) in a controllable manner. Noteworthily, a high turnover frequency up to 9600 h^-1 could be reached at 140 °C and a CO₂ pressure of 20.7 bar utilizing a low catalyst loading of 0.01 mol %, and the same copolymerization conditions were capable of producing narrowly dispersed poly(cyclohexene carbonate) (PCHC) having >99% polycarbonate selectivity. In addition to CO₂/CHO copolymerization, 4-vinyl-1,2-cyclohexene oxide or cyclopentene oxide was also applied to efficiently copolymerize CO₂ under conditions of 80 °C and 20.7 bar initial CO₂ pressure. Kinetic studies of CO₂/CHO copolymerization catalyzed by 6 were investigated. Such polymerization revealed first-order dependence for both catalyst 6 and CHO concentrations, and the activation energy for PCHC generation by 6 is 57.69 kJ mol^-1. A possible polymerization mechanism for CO₂-copolymerization of CHO was proposed based on kinetics and structural studies of the obtained polycarbonates.

Bimetallic Zinc Catalysts for Ring-Opening Copolymerization Processes

Novel bimetallic zinc acetate complexes supported by heteroscorpionate ligands have been developed for the ring-opening copolymerization of cyclohexene oxide and CO₂ and the terpolymerization of cyclohexene oxide, phthalic anhydride, and CO₂. Heteroscorpionate ligands precursors L₁-L₃ were reacted with two equivalents of zinc acetate to afford the dinuclear zinc complexes [{Zn(κ³-bpzappe)}(μ-O₂CCH₃)₃-{Zn(HO₂CCH₃)}] (1), [{Zn(κ³-bpzbdmape)}(μ-O₂CCH₃)₃-{Zn(HO₂CCH₃)}] (2), and [{Zn(κ³-bpzbdeape)}(μ-O₂CCH₃)₃{Zn(HO₂CCH₃)}] (3) in excellent yields. The molecular structure of these compounds was determined spectroscopically and confirmed by X-ray diffraction analysis. Zinc acetate complexes 1-3 were screened as catalysts for the copolymerization of cyclohexene oxide and CO₂ to produce poly(cyclohexene)carbonate, and complex 3 was found to be the most active catalyst for this process in the absence of a cocatalyst. Furthermore, the terpolymerization of cyclohexene oxide, phthalic anhydride, and CO₂ was studied using the combination of complex 3 and 4-dimethylaminopyridine as catalyst system yielding the corresponding polyester-polycarbonate materials.

Triblock polyester thermoplastic elastomers with semi-aromatic polymer end blocks by ring-opening copolymerization

Thermoplastic elastomers benefit from high elasticity and straightforward (re)processability; they are widely used across a multitude of sectors. Currently, the majority derive from oil, do not degrade or undergo chemical recycling. Here a new series of ABA triblock polyesters are synthesized and show high-performances as degradable thermoplastic elastomers; their composition is poly(cyclohexene-alt-phthalate)-b-poly(ε-decalactone)-b-poly(cyclohexene-alt-phthalate) {PE-PDL-PE}. The synthesis is accomplished using a zinc(ii)/magnesium(ii) catalyst, in a one-pot procedure where ε-decalactone ring-opening polymerization yielding dihydroxyl telechelic poly(ε-decalatone) (PDL, soft-block) occurs first and, then, addition of phthalic anhydride/cyclohexene oxide ring-opening copolymerization delivers semi-aromatic polyester (PE, hard-block) end-blocks. The block compositions are straightforward to control, from the initial monomer stoichiometry, and conversions are high (85-98%). Two series of polyesters are prepared: (1) TBPE-1 to TBPE-5 feature an equivalent hard-block volume fraction (f hard = 0.4) and variable molar masses 40-100 kg mol-1; (2) TBPE-5 to TBPE-9 feature equivalent molar masses (∼100 kg mol-1) and variable hard-block volume fractions (0.12 < f hard < 0.4). Polymers are characterized using spectroscopies, size-exclusion chromatography (SEC), thermal gravimetric analysis (TGA), differential scanning calorimetry (DSC) and dynamic mechanical thermal analysis (DMTA). They are amorphous, with two glass transition temperatures (∼-51 °C for PDL; +138 °C for PE), and block phase separation is confirmed using small angle X-ray scattering (SAXS). Tensile mechanical performances reveal thermoplastic elastomers (f hard < 0.4 and N > 1300) with linear stress-strain relationships, high ultimate tensile strengths (σ b = 1-5 MPa), very high elongations at break (ε b = 1000-1900%) and excellent elastic recoveries (98%). There is a wide operating temperature range (-51 to +138 °C), an operable processing temperature range (+100 to +200 °C) and excellent thermal stability (T d,5% ∼ 300 °C). The polymers are stable in aqueous environments, at room temperature, but are hydrolyzed upon gentle heating (60 °C) and treatment with an organic acid (para-toluene sulfonic acid) or a common lipase (Novozyme® 51032). The new block polyesters show significant potential as sustainable thermoplastic elastomers with better properties than well-known styrenic block copolymers or polylactide-derived elastomers. The straightforward synthesis allows for other commercially available and/or bio-derived lactones, epoxides and anhydrides to be developed in the future.

Switchable Catalysis Improves the Properties of CO2-Derived Polymers: Poly(cyclohexene carbonate-b-ε-decalactone-b-cyclohexene carbonate) Adhesives, Elastomers, and Toughened Plastics

Carbon dioxide/epoxide copolymerization is an efficient way to add value to waste CO2 and to reduce pollution in polymer manufacturing. Using this process to make low molar mass polycarbonate polyols is a commercially relevant route to new thermosets and polyurethanes. In contrast, high molar mass polycarbonates, produced from CO2, generally under-deliver in terms of properties, and one of the most widely investigated, poly(cyclohexene carbonate), is limited by its low elongation at break and high brittleness. Here, a new catalytic polymerization process is reported that selectively and efficiently yields degradable ABA-block polymers, incorporating 6-23 wt % CO2. The polymers are synthesized using a new, highly active organometallic heterodinuclear Zn(II)/Mg(II) catalyst applied in a one-pot procedure together with biobased ε-decalactone, cyclohexene oxide, and carbon dioxide to make a series of poly(cyclohexene carbonate-b-decalactone-b-cyclohexene carbonate) [PCHC-PDL-PCHC]. The process is highly selective (CO2 selectivity >99% of theoretical value), allows for high monomer conversions (>90%), and yields polymers with predictable compositions, molar mass (from 38-71 kg mol-1), and forms dihydroxyl telechelic chains. These new materials improve upon the properties of poly(cyclohexene carbonate) and, specifically, they show good thermal stability (Td,5 ∼ 280 °C), high toughness (112 MJ m-3), and very high elongation at break (>900%). Materials properties are improved by precisely controlling both the quantity and location of carbon dioxide in the polymer chain. Preliminary studies show that polymers are stable in aqueous environments at room temperature over months, but they are rapidly degraded upon gentle heating in an acidic environment (60 °C, toluene, p-toluene sulfonic acid). The process is likely generally applicable to many other lactones, lactides, anhydrides, epoxides, and heterocumulenes and sets the scene for a host of new applications for CO2-derived polymers.

Update and Challenges in Carbon Dioxide-Based Polycarbonate Synthesis

The utilization of carbon dioxide as a comonomer to produce polycarbonates has attracted a great deal of attention from both industrial and academic communities because it promises to replace petroleum-derived plastics and supports a sustainable environment. Significant progress in the copolymerization of cyclic ethers (e.g., epoxide, oxetane) and carbon dioxide has been made in recent decades, owing to the rapid development of catalysts. In this Review, the focus is to summarize and discuss recent advances in the development of homogeneous catalysts, including metal- and organo-based complexes, as well as the preparation of carbon dioxide-based block copolymer and functional polycarbonates.

Highly active bimetallic nickel catalysts for alternating copolymerization of carbon dioxide with epoxides

Catalyst 1 was reported for the first time to be effective for nickel-catalyzed CO₂/CHO copolymerization at 1 atm CO₂ pressure.

Synthesis and characterization of di-nuclear bis(benzotriazole iminophenolate) cobalt complexes: catalysis for the copolymerization of carbon dioxide with epoxides

A family of di-nuclear bis(benzotriazole iminophenolate) (BiIBTP) cobalt complexes containing diverse ancillary carboxylate derivatives have been synthesized and structurally characterized. The one-pot synthesis of the BiIBTP ligand precursor with cobalt perchlorate salt (2.0 equiv.) and carboxylic acid derivatives (2.0 or 5.0 equiv.) in the presence of triethylamine (5.0 equiv.) under refluxing methanolic solution generated bimetallic di-carboxylate Co(ii)/Co(ii) complexes [(^C83CBiIBTP)Co₂(O₂CR)₂] (R = C₆H₅ (1), C₆F₅ (2), 4-CF₃-C₆H₄ (3), 4-OMe-C₆H₄ (4), CF₃ (5)) in ≧65% yields. Interestingly, the Co(ii)/Co(iii) mixed-valence complex 6 resulted from the treatment of 1 with silver perchlorate (1.0 equiv.) as the oxidizing agent under an O₂-atmosphere in 50% yield. The crystal structure of 6 reveals an ionic and di-nuclear benzoate species composed of a cationic moiety formulated as [(^C83CBiIBTP)Co₂(O₂CC₆H₅)₂]⁺ and a counterbalanced perchlorate anion, and both metal atoms are attributed to hexa-coordinated cobalt ions with varied coordination environments. Catalysis results of CO₂/epoxide copolymerization indicated that complex 1 was more efficient than 2-6 where compound 6 was shown to be the least active. Co complex 1 incorporating benzoate coligands was demonstrated to effectively catalyze the CO₂-copolymerization of cyclohexene oxide (CHO), 4-vinyl-1,2-cyclohexene oxide or cyclopentene oxide, producing the associated CO₂-based polycarbonates with >99% carbonate repeated units under optimal conditions. Not only the controllable character of complex 1 for CO₂/CHO copolymerization is enabled, but also 1 has been shown to catalyze such a copolymerization in the "immortal" manner. Using the same di-cobalt catalyst in combination with excess ratios of neopentyl glycol (up to 150 equiv.) as the chain transfer agent could give low molecular weight poly(cyclohexene carbonate) polyols with monomodal molecular weight distributions. This work offers the facilely prepared di-nuclear cobalt complexes as catalysts for the efficient catalysis of CO₂-copolymerization.

Heterodinuclear zinc and magnesium catalysts for epoxide/CO2 ring opening copolymerizations

The ring-opening copolymerization of carbon dioxide and epoxides is a useful means to make aliphatic polycarbonates and to add-value to CO2. Recently, the first heterodinuclear Zn(ii)/Mg(ii) catalyst showed greater activity than either homodinuclear analogue (J. Am. Chem. Soc. 2015, 137, 15078-15081). Building from this preliminary finding, here, eight new Zn(ii)/Mg(ii) heterodinuclear catalysts featuring carboxylate co-ligands are prepared and characterized. The best catalysts show very high activities for copolymerization using cyclohexene oxide (TOF = 8880 h-1, 20 bar CO2, 120 °C, 0.01 mol% catalyst loading) or cyclopentene oxide. All the catalysts are highly active in the low pressure regime and specifically at 1 bar pressure CO2. The polymerization kinetics are analysed using in situ spectroscopy and aliquot techniques: the rate law is overall second order with a first order dependence in both catalyst and epoxide concentrations and a zero order in carbon dioxide pressure. The pseudo first order rate coefficient values are compared for the catalyst series and differences are primarily attributed to effects on initiation rates. The data are consistent with a chain shuttling mechanistic hypothesis with heterodinuclear complexes showing particular rate enhancements by optimizing distinct roles in the catalytic cycles. The mechanistic hypothesis should underpin future heterodinuclear catalyst design for use both in other (co)polymerization and carbon dioxide utilization reactions.

Nonionic Aliphatic Polycarbonate Diblock Copolymers Based on CO2, 1,2-Butylene Oxide, and mPEG: Synthesis, Micellization, and Solubilization

Carbon dioxide (CO₂) is a renewable carbon source that is easily available in high purity and is utilized as a co-monomer in the direct ring-opening polymerization of epoxides to obtain aliphatic polycarbonates. In this work, degradable aliphatic polycarbonate diblock copolymers (mPEG- b-PBC) are synthesized via catalytic copolymerization of CO₂ and 1,2-butylene oxide, starting from monomethoxy poly(ethylene glycol) (mPEG) as a chain transfer reagent. The polymerization proceeds at low temperatures and high CO₂ pressure, utilizing the established binary catalytic system ( R, R)-Co(salen)Cl/[PPN]Cl. Amphiphilic nonionic diblock copolymers with varying PBC block lengths and hydrophilic-lipophilic balance values between 9 and 16 are synthesized. The polymers are characterized via NMR and Fourier transform infrared spectroscopies as well as size exclusion chromatography, exhibiting molecular weights ranging from 2400 to 4100 g mol^-1 with narrow dispersities ( Đ = M_w/ M_n) from 1.07 to 1.18. Furthermore, the thermal properties, i.e., T_g, T_m, and T_d, are determined. Surface tension measurements prove that the amphiphilic polymers form micelles above the critical micelle concentration, whereas small-angle neutron scattering shows that they are of nearly spherical shape. Adding small amounts of the synthesized mPEG- b-PBC polymers to different microemulsion systems, we found that the polymers were able to strongly increase the efficiency of medium-chain surfactants to solubilize polar oils.

Waste not, want not: CO2 (re)cycling into block polymers

A new way to combine two different polymerisation reactions, using a single catalyst, results in efficient block polymer synthesis. The selective polymerisation of mixtures of l-lactide-O-carboxyanhydride and cyclohexene oxide, using a di-zinc catalyst in a one-pot procedure, allows the preparation of poly(l-lactide-b-cyclohexene carbonate). The catalysis near quantitatively recycles the carbon dioxide released during polyester formation into the subsequent polycarbonate block, with an atom economy of up to of 91%.

Sequence controlled copolymerization of lactide and a functional cyclic carbonate using stereoselective aluminum catalysts

Stereoselective aluminum complexes were applied for the ROP of LA and MAC producing functional copolyesters with quasi-diblock, tapered, gradient and random sequence distributions.

Advances in the use of CO2 as a renewable feedstock for the synthesis of polymers

Carbon dioxide offers an accessible, cheap and renewable carbon feedstock for synthesis. Current interest in the area of carbon dioxide valorisation aims at new, emerging technologies that are able to provide new opportunities to turn a waste into value. Polymers are among the most widely produced chemicals in the world greatly affecting the quality of life. However, there are growing concerns about the lack of reuse of the majority of the consumer plastics and their after-life disposal resulting in an increasing demand for sustainable alternatives. New monomers and polymers that can address these issues are therefore warranted, and merging polymer synthesis with the recycling of carbon dioxide offers a tangible route to transition towards a circular economy. Here, an overview of the most relevant and recent approaches to CO2-based monomers and polymers are highlighted with particular emphasis on the transformation routes used and their involved manifolds.

Indium Catalysts for Low-Pressure CO2/Epoxide Ring-Opening Copolymerization: Evidence for a Mononuclear Mechanism?

The alternating copolymerization of CO₂/epoxides is a useful means to incorporate high levels of carbon dioxide into polymers. The reaction is generally proposed to occur by bimetallic or bicomponent pathways. Here, the first indium catalysts are presented, which are proposed to operate by a distinct mononuclear pathway. The most active and selective catalysts are phosphasalen complexes, which feature ligands comprising two iminophosphoranes linked to sterically hindered ortho-phenolates. The catalysts are active at 1 bar pressure of carbon dioxide and are most effective without any cocatalyst. They show low-pressure activity (1 bar pressure) and yield polymer with high carbonate linkage selectivity (>99%) and isoselectivity ( P_m > 70%). Using these complexes, it is also possible to isolate and characterize key catalytic intermediates, including the propagating indium alkoxide and carbonate complexes that are rarely studied. The catalysts are mononuclear under polymerization conditions, and the key intermediates show different coordination geometries: the alkoxide complex is pentacoordinate, while the carbonate is hexacoordinate. Kinetic analyses reveal a first-order dependence on catalyst concentration and are zero-order in carbon dioxide pressure; these findings together with in situ spectroscopic studies underpin the mononuclear pathway. More generally, this research highlights the future opportunity for other homogeneous catalysts, featuring larger ionic radius metals and new ligands, to operate by mononuclear mechanisms.

Bimetallic Chromium Catalysts with Chain Transfer Agents: A Route to Isotactic Poly(propylene oxide)s with Narrow Dispersities

Bimetallic chromium catalysts are investigated for the enantioselective polymerization of propylene oxide. The catalyst is composed of two salen chromium species linked by an alkyl chain, the length of which significantly impacts the rate of polymerization. While the use of a chloride initiator on the catalyst resulted in bimodal molecular weight distributions, switching to a trifluoroacetate initiating group and adding a diol chain transfer agent afforded polymers of controllable molecular weight with low, unimodal dispersities.

A One-Step Route to CO2 -Based Block Copolymers by Simultaneous ROCOP of CO2 /Epoxides and RAFT Polymerization of Vinyl Monomers

The one-step synthesis of well-defined CO₂ -based diblock copolymers was achieved by simultaneous ring-opening copolymerization (ROCOP) of CO₂ /epoxides and RAFT polymerization of vinyl monomers using a trithiocarbonate compound bearing a carboxylic group (TTC-COOH) as the bifunctional chain transfer agent (CTA). The double chain-transfer effect allows for independent and precise control over the molecular weight of the two blocks and ensures narrow polydispersities of the resultant block copolymers (1.09-1.14). Notably, an unusual axial group exchange reaction between the aluminum porphyrin catalyst and TTC-COOH impedes the formation of homopolycarbonates. By taking advantage of the RAFT technique, it is able to meet the stringent demand for functionality control to well expand the application scopes of CO₂ -based polycarbonates.