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

Aqueous Developable and CO2-Sourced Chemical Amplification Photoresist with High Performance

Seeking high-performance photoresists is an important item for semiconductor industry due to the continuous miniaturization and intelligentization of integrated circuits. Polymer resin containing carbonate group has many desirable properties, such as high transmittance, acid sensitivity and chemical formulation, thus serving as promising photoresist material. In this work, a series of aqueous developable CO2-sourced polycarbonates (CO2-PCs) were produced via alternating copolymerization of CO2 and epoxides bearing acid-cleavable cyclic acetal groups in the presence of tetranuclear organoborane catalyst. The produced CO2-PCs were investigated as chemical amplification resists in deep ultraviolet (DUV) lithography. Under the catalysis of photogenerated acid, the acetal (ketal) groups in CO2-PC were hydrolysed into two equivalents of hydroxyl groups, which change the exposed area from hydrophobicity to hydrophilicity, thus enabling the exposed area to be developed with water. Through normalized remaining thickness analysis, the optimal CO2-derived resist achieved a remarkable sensitivity of 1.9 mJ/cm2, a contrast of 7.9, a favorable resolution (750 nm, half pitch), and a good etch resistance (38 % higher than poly(tert-butyl acrylate)). Such performances outperform commercial KrF and ArF chemical amplification resists (i.e., polyhydroxystyrene-derived and polymethacrylate-based resists), which endows broad application prospects in the field of DUV (KrF and ArF) and extreme ultraviolet (EUV) lithography for nanomanufacturing.

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.

Recent Advances in Sequence-Controlled Ring-Opening Copolymerizations of Monomer Mixtures

Transforming renewable resources into functional and degradable polymers is driven by the ever-increasing demand to replace unsustainable polyolefins. However, the utility of many degradable homopolymers remains limited due to their inferior properties compared to commodity polyolefins. Therefore, the synthesis of sequence-defined copolymers from one-pot monomer mixtures is not only conceptually appealing in chemistry, but also economically attractive by maximizing materials usage and improving polymers' performances. Among many polymerization strategies, ring-opening (co)polymerization of cyclic monomers enables efficient access to degradable polymers with high control on molecular weights and molecular weight distributions. Herein, we highlight recent advances in achieving one-pot, sequence-controlled polymerizations of cyclic monomer mixtures using a single catalytic system that combines multiple catalytic cycles. The scopes of cyclic monomers, catalysts, and polymerization mechanisms are presented for this type of sequence-controlled ring-opening copolymerization.

Switchable Polymerization: A Practicable Strategy to Produce Biodegradable Block Copolymers with Diverse Properties

With the global demand for sustainable development, there has been an increasing interest in using natural biomass as raw resources to produce sustainable polymers as an alternative to petroleum-based polymers. Because monocomponent biodegradable polymers are often insufficient in performance, copolymers with well-engineered block structures are synthesized to reach wide tunability. Switchable polymerization is such a practical strategy to produce biodegradable block copolymers with diverse performance. This review focus on the performance of block copolymers bearing biodegradable polymer segments produced by diverse switchable polymerization. We highlight two main segments that are critical for biodegradable block copolymers, i. e., polyester and polycarbonate, summarize the multiple characters of materials from switchable polymerization such as antibacterial, shape memory, adhesives, etc. The state-of-the-art research on biodegradable block copolymers, as well as an outlook on the preparation and application of novel materials, are presented.

One-Pot Catalysis: A Privileged Approach for Sustainable Polymers?

Almost all aspects of daily life involve polymers in some form or the other. However, polymer production is largely based on finite feedstocks. These limitations combined with environmental concerns force us to rethink the strategies for the synthesis of these materials. As an abundant and renewable resource, biomass is composed of a very diverse range of molecules that deserve to be valorized. The development of new methods for transforming biomass into resources suitable for polymer production remains a crucial hurdle on the road to a more sustainable chemical economy. The main challenge is to design efficient and selective transformations of abundant and inexpensive raw materials into innovative polymers. For the chemical industry to meet these challenges, process intensification must play an important role in developing cleaner and more energy-efficient technologies while aiming for safer and more sustainable processes. Catalysis is an important tool to support more sustainable plastics production by being ideally efficient, practical, and versatile. In this regard, the creation of sustainable polymers through one-pot catalysis represents an exciting frontier in materials science.In this Account, we describe some of the published advances for achieving one-pot synthesis of biobased monomers and the resulting (co)polymers. These studies demonstrate that one-pot reactions can produce sustainable materials for a wide range of applications. We show that these new multistep "one-pot" approaches are very promising from an academic and industrial point of view. These synthetic schemes have indeed allowed us to investigate the formation of new polyesters, polypeptides, and poly(meth)acrylates by different polymerization mechanisms. We discuss their efficiency by highlighting their ability to perform multiple (quantitative) synthetic transformations and bond formation steps while bypassing multiple purification procedures at the same time. While enabling the development of novel polymeric structures, we demonstrate that these one-pot procedures can also contribute to reducing the environmental footprint.In light of the growing concerns for sustainable development, these procedures may therefore allow, in the near future, one to prepare sustainable polymeric materials with advanced properties through extremely simplified routes from renewable feedstocks. Among these materials, block and alternating copolymers are unique structures that can exhibit a wide range of properties. While their multistep synthesis remains a demanding process, the one-pot synthesis of these polymers is much more scalable and can create multiblock or alternating copolymers with a wide range of potential sequences. These approaches then give access to materials whose structure and functionality can be designed to suit the need.

Switchable Polymerization Organocatalysis: From Monomer Mixtures to Block Copolymers

One-pot production of sequence-controlled block copolymer from mixed monomers is a crucial but rarely reached goal. Using a switchable Lewis-pair organocatalyst, we have accomplished sequence-selective polymerization from a mixture of O-carboxyanhydride (OCA) and epoxide. Polymerization of the OCA monomer occurs first and exclusively because of its exceedingly high polymerizability. When OCA is fully consumed, alternating copolymerization of epoxide and CO₂ liberated in OCA polymerization is triggered from the termini of the first block. The two polymerizations thus occur in tandem, both in chemoselective fashion, so that a sequence-controlled block polymer with up to 99 % CO₂ conversion is furnished in this one-pot protocol. Calculations and experimental results demonstrate a chemoselective and cooperative mechanism, where the high polymerizability of the OCA monomers guarantees exquisite sequence selectivity and the cooperative decarboxylation partly arose from the stabilization effect by triethylborane, which facilitates the smooth transformation of the chain end from carbonate to alkoxide.

Diblock dialternating terpolymers by one-step/one-pot highly selective organocatalytic multimonomer polymerization

The synthesis of well-defined block copolymers from a mixture of monomers without additional actions ("one-pot/one-step") is an ideal and industrially valuable method. In addition, the presence of controlled alternating sequences in one or both blocks increases the structural diversity of polymeric materials, but, at the same time, the synthetic difficulty. Here we show that the "one-pot/one-step" ring-opening terpolymerization of a mixture of three monomers (N-sulfonyl aziridines; cyclic anhydrides and epoxides), with tert-butylimino-tris(dimethylamino)phosphorene (t-BuP1) as a catalyst, results in perfect diblock dialternating terpolymers having a sharp junction between the two blocks, with highly-controllable molecular weights and narrow molecular weight distributions (Ð < 1.08). The organocatalyst switches between two distinct polymerization cycles without any external stimulus, showing high monomer selectivity and kinetic control. The proposed mechanism is based on NMR, in-situ FTIR, SEC, MALDI-ToF, reactivity ratios, and kinetics studies.

Mg(ii) heterodinuclear catalysts delivering carbon dioxide derived multi-block polymers

Carbon dioxide derived polymers are emerging as useful materials for applications spanning packaging, construction, house-hold goods and automotive components. To accelerate and broaden their uptake requires both more active and selective catalysts and greater structural diversity for the carbon dioxide derived polymers. Here, highly active catalysts show controllable selectivity for the enchainment of mixtures of epoxide, anhydride, carbon dioxide and lactone. Firstly, metal dependent selectivity differences are uncovered using a series of dinuclear catalysts, Mg(ii)Mg(ii), Zn(ii)Zn(ii), Mg(ii)Zn(ii), and Mg(ii)Co(ii), each exposed to mixtures of bio-derived tricyclic anhydride, cyclohexene oxide and carbon dioxide (1 bar). Depending upon the metal combinations, different block structures are possible with Zn(ii)Zn(ii) yielding poly(ester-b-carbonate); Mg(ii)Mg(ii) or Mg(ii)Co(ii) catalysts delivering poly(carbonate-b-ester); and Mg(ii)Zn(ii) furnishing a random copolymer. These results indicate that carbon dioxide insertion reactions follow the order Co(ii) > Mg(ii) > Zn(ii). Using the most active and selective catalyst, Mg(ii)Co(ii), and exploiting reversible on/off switches between carbon dioxide/nitrogen at 1 bar delivers precision triblock (ABA), pentablock (BABAB) and heptablock (ABABABA) polymers (where A = poly(cyclohexylene oxide-alt-tricyclic anhydride), PE; B = poly(cyclohexene carbonate), PCHC). The Mg(ii)Co(ii) catalyst also selectively polymerizes a mixture of anhydride, carbon dioxide, cyclohexene oxide and ε-caprolactone to deliver a CBABC pentablock copolymer (A = PE, B = PCHC C = poly(caprolactone), PCL). The catalysts combine high activity and selectivity to deliver new polymers featuring regularly placed carbon dioxide and biomass derived linkages.

Sequence Control from Mixtures: Switchable Polymerization Catalysis and Future Materials Applications

There is an ever-increasing demand for higher-performing polymeric materials counterbalanced by the need for sustainability throughout the life cycle. Copolymers comprising ester, carbonate, or ether linkages could fulfill some of this demand as their monomer-polymer chemistry is closer to equilibrium, facilitating (bio)degradation and recycling; many monomers are or could be sourced from renewables or waste. Here, an efficient and broadly applicable route to make such copolymers is discussed, a form of switchable polymerization catalysis which exploits a single catalyst, switched between different catalytic cycles, to prepare block sequence selective copolymers from monomer mixtures. This perspective presents the principles of this catalysis, catalyst design criteria, the selectivity and structural copolymer characterization tools, and the properties of the resulting copolymers. Uses as thermoplastic elastomers, toughened plastics, adhesives, and self-assembled nanostructures, and for programmed degradation, among others, are discussed. The state-of-the-art research into both catalysis and products, as well as future challenges and directions, are presented.

Recent Developments in Ring-Opening Copolymerization of Epoxides With CO2 and Cyclic Anhydrides for Biomedical Applications

The biomedical applications of polyesters and polycarbonates are of interest due to their potential biocompatibility and biodegradability. Confined by the narrow scope of monomers and the lack of controlled polymerization routes, the biomedical-related applications of polyesters and polycarbonates remain challenging. To address this challenge, ring-opening copolymerization (ROCOP) has been exploited to prepare new alternating polyesters and polycarbonates, which would be hard to synthesize using other controlled polymerization methods. This review highlights recent advances in catalyst development, including the emerging dinuclear organometallic complexes and metal-free Lewis pair systems. The post-polymerization modification methods involved in tailoring the biomedical functions of resultant polyesters and polycarbonates are summarized. Pioneering attempts for the biomedical applications of ROCOP polyesters and polycarbonates are presented, and the future opportunities and challenges are also highlighted.

Monomer Controlled Switchable Copolymerization: A Feasible Route for the Functionalization of Poly(lactide)

Switchable polymerization is an attractive strategy to enable the sequential selectivity of multi-block polyesters. Besides, these well-defined multi-block polyesters could enable further modification for wider applications. Herein, based on the reversible insertion of CO₂ by Salen-Mn^III , a new monomer controlled self-switchable polymerization route was developed. Chemoselective ring opening copolymerization of O-carboxyanhydrides (OCAs) and lactide (LA) was explored without cocatalyst. The sequential conversion of OCAs and LA into the polymer chain could form multi-block polyesters. Based on this strategy, a series of multi-block polyesters with different pendant groups were synthesized. Furthermore, by modifying the propargyl-containing copolymers with quaternary ammonium groups, we have realized antibacterial functionalization of PLA. These results imply the potential application of this strategy for the fabrication of functional polymers for biomedical applications.

Efficient Synthesis of Cyclic Carbonates from Unsaturated Acids and Carbon Dioxide and their Application in the Synthesis of Biobased Polyurethanes

Bio-derived furan- and diacid-derived cyclic carbonates have been synthesized in high yields from terminal epoxides and CO₂ . Furthermore, four highly substituted terpene-derived cyclic carbonates were isolated in good yields with excellent diastereoselectivity in some cases. Eleven new cyclic carbonates derived from 10-undecenoic acid under mild reaction conditions were prepared, providing the corresponding carbonate products in excellent yields. The catalyst system also performed the conversion of an epoxidized fatty acid n-pentyl ester into a cyclic carbonate under relatively mild reaction conditions (80 °C, 20 bar, 24 h). This bis(cyclic carbonate) was obtained in high yields and with different cis/trans ratios depending on the co-catalyst used. An allyl alcohol by-product was only observed as a minor product when bis(triphenylphosphine)iminium chloride was used as co-catalyst. Finally, two cyclic carbonates were used as building blocks for the preparation of non-isocyanate poly(hydroxy)urethanes by reaction with 1,4-diaminobutane.

Advances, Challenges, and Opportunities of Poly(γ-butyrolactone)-Based Recyclable Polymers

The discovery and prosperous growth of synthetic polymers have presented both significant advantages and daunting challenges in the last century. To address the issues of environmental pollution and fossil consumption, recyclable, degradable, and/or biobased polymers have been given much attention in the polymer science community. This viewpoint focuses on the emerging fully chemical recyclable poly(γ-butyrolactone)-based polymers. The breakthrough from nonpolymerizable to efficient polymerization is highlighted by the benefits of the development of a series of catalysis for ring-opening polymerization of γ-butyrolactone. Subsequently, the design of γ-butyrolactone derivatives and synthesis of more recyclable polymers are summarized together with the discussions about the structure and property relationship. Finally, the remaining challenges and promising opportunities are suggested in order to provide insights into the further direction for sustainable polymers.

Ortho-vanillin derived Al(iii) and Co(iii) catalyst systems for switchable catalysis using ε-decalactone, phthalic anhydride and cyclohexene oxide

Switchable catalysis is a useful one-pot method to prepare block polyesters utilising a single catalyst exposed to a mixture of monomers.

A One-Pot Strategy to Synthesize Block Copolyesters from Monomer Mixtures Using a Hydroxy-Functionized Ionic Liquid

One-pot transformation of monomer mixtures into block copolymers remains a key challenge. Herein, a metal-free route to prepare block copolymers from monomer mixtures by a hydroxyl functionalized ionic liquid of 3-(2-hydroxyl-ethyl)-1-methylimidazolium bromide (HEMIMB) is described. HEMIMB can bridge two catalytic cycles including ring-opening alternating copolymerization (ROAC) of phthalic anhydride (PA) with epoxides and ring-opening polymerization (ROP) of L-lactide (LA), and enable a selective copolymerization from PA, LA, and epoxides. The selective copolymerization depends on the presence of PA in mixed feedstocks, exhibits the first ROAC of PA with epoxides and then ROP of LA to the formation of block polyesters in one-pot strategy. This work is beneficial to the development of metal-free catalysts for sequence-controlled polymerization that enable block architectures from mixtures of monomers.

Recent Advances in Photocatalytic CO2 Utilisation Over Multifunctional Metal–Organic Frameworks

The efficient conversion of carbon dioxide (CO2) to high-value chemicals using renewable solar energy is a highly attractive but very challenging process that is used to address ever-growing energy demands and environmental issues. In recent years, metal–organic frameworks (MOFs) have received significant research attention owing to their tuneability in terms of their composition, structure, and multifunctional characteristics. The functionalisation of MOFs by metal nanoparticles (NPs) is a promising approach used to enhance their light absorption and photocatalytic activity. The efficient charge separation and strong CO2 binding affinity of hybrid MOF-based photocatalysts facilitate the CO2 conversion process. This review summarises the latest advancements involving noble metal, non-noble-metal, and miscellaneous species functionalised MOF-based hybrid photocatalysts for the reduction of CO2 to carbon monoxide (CO) and other value-added chemicals. The novel synthetic strategies and their corresponding structure–property relationships have also been discussed for solar-to-chemical energy conversion. Furthermore, the current challenges and prospects in practical applications are also highlighted for sustainable energy production.

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.