Taking dynamic covalent chemistry out of the lab and into reprocessable industrial thermosets

Dynamic covalent chemistry (DCC) allows the development of thermally (re)processable and recyclable polymer networks, which is a highly attractive feature for new generations of thermoset materials. However, despite a surge in academic interest wherein soon almost any imaginable DCC platform may have been applied in a thermoset formulation, dynamic or reversible covalent polymer networks have so far found only few industrial applications. This Review provides a perspective on the main strategies for the application of DCC in the design and development of bulk thermoset materials, and it presents some of the key hurdles for their industrial implementation. The polymer design strategies and associated chemistries are viewed from the perspective of how 'close to market' their development pathway is, thus providing a roadmap to achieve high-volume breakthrough applications.

Dynamic Mechanical Properties and Energy Absorption Capabilities of Polyureas Through Experiments and Molecular Dynamic Simulation

Polyurea (PUR) has been widely used as a protective coating in recent years. In order to complete the understanding of the relationship between PUR microstructure and its energy absorption capabilities, the mechanical and dynamic performance of PURs containing various macrodiol structural units were compared using material characterization techniques and molecular dynamic simulation. The results showed that the PUR polycarbonate diols formed as energy absorbing materials showed high tensile strength, high toughness, and excellent loss factor distribution based on the comparison of stress-strain tensile curves, glass transition temperatures, phase images, and dynamic storage loss modulus. External energy from simple shear deformation was absorbed to convert non-bond energy, in particular, based on fractional free volume, interaction energy, and total energy and hydrogen bond number change from the molecular dynamic simulation. Hydrogen bonds formed between soft segments and hard segments in the PURs have been proven to play a significant role in determining their mechanical and dynamic performance. The mechanical and dynamic properties of PURs characterized and tested using experimental techniques were quantified effectively using molecular dynamic simulation. This is believed to be an innovative theoretical guidance for the structural design of PURs at the molecular level for the optimization of energy absorption capabilities.

Synthesis and Characterization of Photocurable Difunctional Monomers for Medical Applications

Photocurable materials offer a rapid transition from a liquid to a solid state, and have recently received great interest in the medical field. However, while dental resins are very popular, only a few materials have been developed for soft tissue repair. This study aims to synthesize a difunctional methacrylate monomer using a dibutyltin dilaurate which is suitable for the photocuring of soft materials. These soft materials were compared with PhotoBioCure® (Szczecin, Poland) material with a similar molecular weight, of Mn ~7000 g/mol on average. Infrared spectroscopy was used to monitor the two-step synthesis catalyzed with dibutyltin dilaurate, while spectroscopic and chromatographic methods were used to determine the chemical structure and molecular weight of the monomers. Photopolymerization kinetics under varying light intensities were explored in a nitrogen atmosphere for representative difunctional monomers. The mechanical testing of the resulting elastomeric films confirmed tensile strength and modulus values consistent with soft tissue parameters in the range of 3-4 MPa. The 3D printability of the macromonomers was also assessed. Additionally, cytotoxicity assessments using cultured cells showed a high cell viability (97%) for all new materials. Overall, we demonstrate that difunctional methacrylate monomers converted to flexible solids during photopolymerization show great potential for biomedical applications.

Functionalization and Repurposing of Polypropylene to a Thermoset Polyurethane

Developing effective recycling pathways for polyolefin waste, enabling a move to a circular economy, is an imperative that must be met. Postuse modification has shown promising results in upcycling polyolefins, removing the limitation of inertness, and improving the final physical properties of the recycled material while extending its useful lifetime. Grafting of maleic anhydride groups to polypropylene is an established industrial process that enhances its reactivity and provides a convenient route to further functionalization and upcycling. In this work, maleic anhydride grafted polypropylene was hydroxylated and subsequently cured with a diisocyanate to form a thermoset polyurethane (PU). The crystal structure (unit cell and lamellar structure) of the polypropylene (PP) was preserved in the PU. At room temperature, the PU showed a high modulus due to the crystallization behavior of the PP; upon increasing the temperature above the melting temperature, the modulus decreased to a rubbery plateau, consistent with formation of a network. The resulting PU showed a higher glass transition temperature and lower degree of crystallinity than its PP predecessor due to the crosslinked nature of the polymer. The mechanical integrity of the PU was maintained through several reprocessing cycles due to the melt processability enabled by the presence of a urethane exchange catalyst. This functionalization and upcycling route thus offers a promising alternative to repurposing PP waste in which the creation of melt-processable thermoset polymers expands applications for the materials.

Tuning Reprocessing Temperature of Aliphatic Polyurethane Networks by Alkoxyamine Selection

Recent studies have shown that the largest employed thermoset family, polyurethanes (PUs), has great potential to be reprocessed due to the dynamic behavior of carbamate linkage. However, it requires high temperatures, especially in the case of aliphatic PUs, which causes side reactions besides the desired exchange reaction. To facilitate the reprocessing of aliphatic PUs, in this work, we have explored the dynamic potential of alkoxyamine bonds in PU networks to facilitate the reprocessing under mild conditions considering their fast recombination ability. Taking advantage of the structural effect of the nitroxide and alkyl radicals on the dissociation energy, two different alkoxyamine-based diols have been designed and synthesized to generate PU networks. Our study shows that replacing 50 mol % of a nondynamic diol chain extender with these dynamic blocks boosts the relaxation times of the networks, enabling reprocessing at temperatures as low as 80 °C.

Oxime metathesis: tuneable and versatile chemistry for dynamic networks

Oxime chemistry has emerged as a versatile tool for use in a wide range of applications. In particular, the combination of oximes with esters and urethanes has enabled the realisation of Covalent Adaptable Networks (CANs) with improved and tunable dynamic properties. Nevertheless, an exclusively oxime-based chemistry has not yet been explored in the fabrication of CANs. In this work, we investigate the mechanism of the acid-catalysed dynamic exchange of oximes. We propose a metathesis mechanism that is well supported by both experimental and computational studies, which highlight the importance of the substituent effect on the exchange reaction kinetics. Then, as a proof of concept, we incorporate oxime groups into a cross-linked polymeric material and demonstrate the ability of oxime-based polymers to be reprocessed under acid catalysis while maintaining their structural integrity.

Biomass- and Carbon Dioxide-Derived Polyurethane Networks for Thermal Interface Material Applications

Recent environmental concerns have increased demand for renewable polymers and sustainable green resource usage, such as biomass-derived components and carbon dioxide (CO2). Herein, we present crosslinked polyurethanes (CPUs) fabricated from CO2- and biomass-derived monomers via a facile solvent-free ball milling process. Furan-containing bis(cyclic carbonate)s were synthesized through CO2 fixation and further transformed to tetraols, denoted FCTs, by aminolysis and utilized in CPU synthesis. Highly dispersed polyurethane-based hybrid composites (CPU-Ag) were also manufactured using a similar ball milling process. Due to the malleability of the CPU matrix, enabled by transcarbamoylation (dynamic covalent chemistry), CPU-based composites are expected to present very low interfacial thermal resistance between the heat sink and heat source. The characteristics of the dynamic covalent bond (i.e., urethane exchange reaction) were confirmed by the results of dynamic mechanical thermal analysis and stress relaxation analysis. Importantly, the high thermal conductivity of the CPU-based hybrid material was confirmed using laser flash analysis (up to 51.1 W/m·K). Our mechanochemical approach enables the facile preparation of sustainable polymers and hybrid composites for functional application.

Reprocessable Polyurethane Foams Using Acetoacetyl-Formed Amides

Like any other thermosetting material, polyurethane foams (PUFs) contain permanent cross-links that hinder their reprocessability and make their recyclability a tedious and environmentally unfriendly process. Herein, we introduce acetoacetyl-formed amides, formed by the reaction of isocyanates with acetoacetate groups, as dynamic units in the backbone of PUFs. By extensive variation of the foam composition, optimum parameters have been found to produce malleable foams above temperatures of 130 °C, without the requirement of any solvent during the foaming process. The PU cross-linked material can be compression-molded at least three times, giving rise to PU elastomers and thus maintaining a cross-linked network structure. Characterization of the original foams shows comparable properties to standard PUFs, for example, having a density of 32 kg/m3, while they show similar chemical and thermal properties upon reprocessing to strong PU elastomers, exhibiting Tg ranging from -42 to -48 °C. This research provides a straightforward method to produce thermally reprocessable PUFs as a promising pathway to address the recycling issues of end-of-life foams.

Magnetic Nanoparticles Improve Flow Rate and Enable Self-Healing in Covalent Adaptable Networks

Covalent adaptable networks (CANs) combine the mechanical and chemical stability of thermosets with the reprocessability of thermoplastics through the incorporation of stimuli-responsive dynamic crosslinks. To allow for processing through induction heating, we have created associative CANs that include fillers in the polymer matrix for efficient heat transfer. While the inclusion of inorganic fillers often decreases flow rate in CANs and complicates reprocessing of the material, the presence of Fe₃O₄ nanoparticles had no detrimental effect on flow behavior in a vinylogous urethane vitrimer, an observation we attribute to the catalytic nature of nanoparticles on the dynamic exchange chemistry. We employed two methods of nanoparticle incorporation: blending bare nanoparticles and crosslinking chemically modified nanoparticles. The vitrimers with covalently crosslinked nanoparticles exhibited a decreased relaxation time compared to those with blended nanoparticles. The magnetic character of the Fe₃O₄ nanoparticles enabled self-healing of the vitrimer composite materials upon exposure to an alternating electromagnetic field during induction heating.

Upgrading Polyurethanes into Functional Ureas through the Asymmetric Chemical Deconstruction of Carbamates

The importance of systematic and efficient recycling of all forms of plastic is no longer a matter for debate. Constituting the sixth most produced polymer family worldwide, polyurethanes, which are used in a broad variety of applications (buildings, electronics, adhesives, sealants, etc.), are particularly important to recycle. In this study, polyurethanes are selectively recycled to obtain high value-added molecules. It is demonstrated that depolymerization reactions performed with secondary amines selectively cleave the C-O bond of the urethane group, while primary amines unselectively break C-O and C-N bonds. The selective cleavage of C-O bonds, catalyzed by an acid:base mixture, led to the initial polyol and a functional diurea in several hours to a few minutes for both model polyurethanes and commercial polyurethane foams. Different secondary amines were employed as nucleophiles to synthesize a small library of diureas obtained in good to excellent yields. This study not only targets the recovery of the initial polyol but also aims to form new diureas which are useful building blocks for the polymerization of innovative materials.

Sustainable cycloaliphatic polyurethanes: from synthesis to applications

Polyurethanes (PUs) are a versatile and major polymer family, mainly produced via polyaddition between polyols and polyisocyanates. A large variety of fossil-based building blocks is commonly used to develop a wide range of macromolecular architectures with specific properties. Due to environmental concerns, legislation, rarefaction of some petrol fractions and price fluctuation, sustainable feedstocks are attracting significant attention, e.g., plastic waste and biobased resources from biomass. Consequently, various sustainable building blocks are available to develop new renewable macromolecular architectures such as aromatics, linear aliphatics and cycloaliphatics. Meanwhile, the relationship between the chemical structures of these building blocks and properties of the final PUs can be determined. For instance, aromatic building blocks are remarkable to endow materials with rigidity, hydrophobicity, fire resistance, chemical and thermal stability, whereas acyclic aliphatics endow them with oxidation and UV light resistance, flexibility and transparency. Cycloaliphatics are very interesting as they combine most of the advantages of linear aliphatic and aromatic compounds. This original and unique review presents a comprehensive overview of the synthesis of sustainable cycloaliphatic PUs using various renewable products such as biobased terpenes, carbohydrates, fatty acids and cholesterol and/or plastic waste. Herein, we summarize the chemical modification of the main sustainable cycloaliphatic feedstocks, synthesis of PUs using these building blocks and their corresponding properties and subsequently present their major applications in hot-topic fields, including building, transportation, packaging and biomedicine.

Self-Reporting Joule Heating Modulated Stiffness of Polymeric Nanocomposites for Shape Reconfiguration

Shape reconfigurable devices, e.g., foldable phones, have emerged with the development of flexible electronics. But their rigid frames limit the feasible shapes for the devices. To achieve freely changeable shapes yet keep the rigidity of devices for user-friendly operations, stiffness-tunable materials are desired, especially under electrical control. However, current such systems are multilayer with at least a heater layer and a structural layer, leading to complex fabrication, high cost, and loss of reprocessability. Herein, we fabricate covalent adaptable networks-carbon nanotubes (CAN-CNT) composites to realize Joule heating controlled stiffness. The nanocomposites function as stiffness-tunable matrices, electric heaters, and softening sensors all by themselves. The self-reporting of softening is used to regulate the power control, and the sensing mechanism is investigated by simulating the CNT-polymer chain interactions at the nanoscale during the softening process. The nanocomposites not only have adjustable mechanical and thermodynamic properties but also are easy to fabricate at low cost and exhibit reprocessability and recyclability benefiting from the dynamic exchange reactions of CANs. Shape and stiffness control of flexible display systems are demonstrated with the nanocomposites as framing material, where freely reconfigurable shapes are realized to achieve convenient operation, wearing, or storage, fully exploiting their flexible potential.

Thia-Michael Reaction: The Route to Promising Covalent Adaptable Networks

While the Michael addition has been employed for more than 130 years for the synthesis of a vast diversity of compounds, the reversibility of this reaction when heteronucleophiles are involved has been generally less considered. First applied to medicinal chemistry, the reversible character of the hetero-Michael reactions has recently been explored for the synthesis of Covalent Adaptable Networks (CANs), in particular the thia-Michael reaction and more recently the aza-Michael reaction. In these cross-linked networks, exchange reactions take place between two Michael adducts by successive dissociation and association steps. In order to understand and precisely control the exchange in these CANs, it is necessary to get an insight into the critical parameters influencing the Michael addition and the dissociation rates of Michael adducts by reconsidering previous studies on these matters. This review presents the progress in the understanding of the thia-Michael reaction over the years as well as the latest developments and plausible future directions to prepare CANs based on this reaction. The potential of aza-Michael reaction for CANs application is highlighted in a specific section with comparison with thia-Michael-based CANs.

Fast Dynamic Siloxane Exchange Mechanism for Reshapable Vitrimer Composites

To develop siloxane-containing vitrimers with fast dynamic characteristics, different mechanistic pathways have been investigated using a range of catalysts. In particular, one siloxane exchange pathway has been found to show a fast dynamic behavior in a useful temperature range (180-220 °C) for its application in vitrimers. The mechanism is found to involve 1,5,7-triazabicyclo [4.4.0] dec-5-ene (TBD) as an organic catalyst in the presence of hydroxyl groups. Using this new mechanistic approach, vitrimers with ultrafast stress-relaxation characteristics (relaxation times below 10 s) have been prepared with a readily available epoxy resin and siloxane-amine hardener. Subsequently, the low viscosity siloxane-containing vitrimer resin enabled the preparation of glass fiber-reinforced vitrimer composites using an industrially relevant vacuum-assisted resin infusion technique. The resulting composite was successfully thermoformed into a new shape, which makes it possible to envision a second life for such highly engineered materials.

Arbitrarily Reconfigurable and Thermadapt Reversible Two-Way Shape Memory Poly(thiourethane) Accomplished by Multiple Dynamic Covalent Bonds

The fabrication of a single polymer network that exhibits a good reversible two-way shape memory effect (2W-SME), can be formed into arbitrarily complex three-dimensional (3D) shapes, and is recyclable remains a challenge. Herein, we design and fabricate poly(thiourethane) (PTU) networks with an excellent thermadapt reversible 2W-SME, arbitrary reconfigurability, and good recyclability via the synergistic effects of multiple dynamic covalent bonds (i.e., ester, urethane, and thiourethane bonds). The PTU samples with good mechanical performance simultaneously demonstrate a maximum tensile stress of 29.7 ± 1.1 MPa and a high strain of 474.8 ± 7.5%. In addition, the fraction of reversible strain of the PTU with 20 wt % hard segment reaches 22.4% during the reversible 2W-SME, where the fraction of reversible strain is enhanced by self-nucleated crystallization of the PTU. A sample with arbitrarily complex permanent 3D shapes can be realized via the solid-state plasticity, and that sample also exhibits excellent reversible 2W-SME. A smart light-responsive actuator with a double control switch is fabricated using a reversible two-way shape memory PTU/MXene film. In addition, the PTU networks are de-cross-linked by alcohol solvolysis, enabling the recovery of monomers and the realization of recyclability. Therefore, the present study involving the design and fabrication of a PTU network for potential applications in intelligent actuators and multifunctional shape-shifting devices provides a new strategy for the development of thermadapt reversible two-way shape memory polymers.

Dynamic Covalent Polyurethane Network Materials: Synthesis and Self-Healability

Polyurethane (PU) has not only been widely used in the daily lives, but also extensively explored as an important class of the essential polymers for various applications. In recent years, significant efforts have been made on the development of self-healable PU materials that possess high performance, extended lifetime, great reliability, and recyclability. A promising approach is the incorporation of covalent dynamic bonds into the design of PU covalently crosslinked polymers and thermoplastic elastomers that can dissociate and reform indefinitely in response to external stimuli or autonomously. This review summarizes various strategies to synthesize self-healable, reprocessable, and recyclable PU materials integrated with dynamic (reversible) Diels-Alder cycloadduct, disulfide, diselenide, imine, boronic ester, and hindered urea bond. Furthermore, various approaches utilizing the combination of dynamic covalent chemistries with nanofiller surface chemistries are described for the fabrication of dynamic heterogeneous PU composites.

Long-chain polyamide covalent adaptable networks based on renewable ethylene brassylate and disulfide exchange

Long-chain polyamide covalent adaptable networks with high strength and short relaxation times were prepared based on a renewable ethylene brassylate and disulfide exchange.