Continuous Flow Synthesis of Functional Isocyanate-Free Poly(oxazolidone)s by Step-Growth Polymerization

Flow chemistry presents many advantages over batch processes for the fast and continuous production of polymers under more robust, safer, and easily scalable conditions. Although largely exploited for chain-growth polymerizations, it has rarely been applied to step-growth polymerizations (SGP) due to their inherent limitations. Here, we report the facile and fast preparation of an emerging class of nonisocyanate polyurethanes, i.e., CO2-based poly(oxazolidone)s, by SGP in continuous flow reactors. Importantly, we also demonstrate that functional poly(oxazolidone)s are easily prepared by telescoping a flow module where SGP occurs with reagents able to simultaneously promote two polymer derivatizations in a second module, i.e., dehydration followed by cationic thiol-ene to yield poly(N,S-acetal oxazolidone)s. The functional polymer is produced at a high rate and functionalization degree, without requiring the isolation of any intermediates. This work demonstrates the enormous potential of flow technology for the facile and fast continuous production of functional polymers by SGP.

Covalent Adaptable Networks through Dynamic N,S-Acetal Chemistry: Toward Recyclable CO2-Based Thermosets

Finding new chemistry platforms for easily recyclable polymers has become a key challenge to face environmental concerns and the growing plastics demand. Here, we report a dynamic chemistry between CO2-sourced alkylidene oxazolidones and thiols, delivering circular non-isocyanate polyurethane networks embedding N,S-acetal bonds. The production of oxazolidone monomers from CO2 is facile and scalable starting from cheap reagents. Their copolymerization with a polythiol occurs under mild conditions in the presence of a catalytic amount of acid to furnish polymer networks. The polymer structure is easily tuned by virtue of monomer design, translating into a wide panel of mechanical properties similar to commodity plastics, ranging from PDMS-like elastomers [with Young's modulus (E) of 2.9 MPa and elongation at break (εbreak) of 159%] to polystyrene-like rigid plastics (with E = 2400 MPa, εbreak = 3%). The highly dissociative nature of the N,S-acetal bonds is demonstrated and exploited to offer three different recycling scenarios to the thermosets: (1) mechanical recycling by compression molding, extrusion, or injection molding─with multiple recycling (at least 10 times) without any material property deterioration, (2) chemical recycling through depolymerization, followed by repolymerization, also applicable to composites, and (3) upcycling of two different oxazolidone-based thermosets into a single one with distinct properties. This work highlights a new facile and scalable chemical platform for designing highly dynamic polymer networks containing elusive oxazolidone motifs. The versatility of this chemistry shows great potential for the preparation of materials (including composites) of tuneable structures and properties, with multiple end-of-life scenarios.