Circular Reprocessing of Thermoset Polyurethane Foams.

Thermoset polyurethane (PU) foams are widely used in industrial applications, but they cannot be recycled by conventional melt reprocessing because of their cross-linked structures. The introduction of carbamate exchange catalysts converts thermoset PU into covalent adaptable networks (CANs), which are amenable to reprocessing at elevated temperatures. However, this approach has produced solid PU films, which have fewer uses and lower commercial demand. In this work, simultaneous reprocessing and refoaming of thermoset PU foams is demonstrated by leveraging the melt-processability of PU CANs and allowing cell growth by gas generation in a twin-screw extruder. The optimal operating temperature of the refoaming process is determined through chemical, thermal, and structural analysis of PU foam extrudates. The foam-to-foam extrusion process produces controllable, continuous, and uniform foam structures, as characterized by cell diameter and cell number density. Low-density PU foams are obtained through a process simulating injection molding. The compression properties of reprocessed PU foam are compared with as-synthesized PU foam to demonstrate efficacy of the refoaming processes. These results demonstrate that PU foams can be prepared through recycling while maintaining microstructural and chemical integrity. In the future, this strategy may be applied to thermoset PU foams of various chemical compositions and shows promise for scalability.

Mechanistic Study of Stress Relaxation in Urethane-Containing Polymer Networks.

Cross-linked polymers are used in many commercial products and are traditionally incapable of recycling via melt reprocessing. Recently, tough and reprocessable cross-linked polymers have been realized by incorporating cross-links that undergo associative exchange reactions, such as transesterification, at elevated temperatures. Here we investigate how cross-linked polymers containing urethane linkages relax stress under similar conditions, which enables their reprocessing. Materials based on hydroxyl-terminated star-shaped poly(ethylene oxide) and poly((±)-lactide) were cross-linked with methylene diphenyldiisocyanate in the presence of stannous octoate catalyst. Polymers with lower plateau moduli exhibit faster rates of relaxation. Reactions of model urethanes suggest that exchange occurs through the tin-mediated exchange of the urethanes that does not require free hydroxyl groups. Furthermore, samples were incapable of elevated-temperature dissolution in a low-polarity solvent (1,2,4-trichlorobenzene) but readily dissolved in a high-polarity aprotic solvent (DMSO, 24 to 48 h). These findings indicate that urethane linkages, which are straightforward to incorporate, impart dynamic character to polymer networks of diverse chemical composition, likely through a urethane reversion mechanism.

Sustainable Polyester Elastomers from Lactones: Synthesis, Properties, and Enzymatic Hydrolyzability.

Chemically cross-linked elastomers are an important class of polymeric materials with excellent temperature and solvent resistance. However, nearly all elastomers are petroleum-derived and persist in the environment or in landfills long after they are discarded; this work strives to address these issues by demonstrating the synthesis of renewable, enzymatically hydrolyzable, and mechanically competitive polyester elastomers. The elastomers described were synthesized using a novel bis(ß-lactone) cross-linker and star-shaped, hydroxyl-terminated poly(γ-methyl-ε-caprolactone). Using model compounds, we determined that the bis(ß-lactone) cross-linker undergoes acyl bond cleavage to afford ß-hydroxyesters at the junctions. The mechanical properties of the cross-linked materials were tunable and competitive with a commodity rubber band. Furthermore, the elastomers demonstrated high thermal stability and a low glass transition (-50 °C), indicating a wide range of use temperatures. The polyester networks were also subjected to enzymatic hydrolysis experiments to investigate the potential for these materials to biodegrade in natural environments. We found that they readily hydrolyzed at neutral pH and environmentally relevant temperatures (2-40 °C); complete hydrolysis was achieved in all cases at temperature-dependent rates. The results presented in this work exemplify the development of high performance yet sustainable alternatives to conventional elastomers.

Mechanically activated, catalyst-free polyhydroxyurethane vitrimers.

Vitrimers are polymer networks whose cross-links undergo associative exchange processes at elevated temperature, usually in the presence of an embedded catalyst. This design feature enables the reshaping of materials with mechanical properties similar to thermoset resins. Here we report a new class of vitrimers consisting of polyhydroxyurethanes (PHUs) derived from six-membered cyclic carbonates and amines. PHU networks relax stress and may be reprocessed at elevated temperature and pressure in the absence of an external catalyst. The as-synthesized networks exhibit tensile properties comparable to those of leading thermosets and recover ca. 75% of their as-synthesized values following reprocessing. Stress relaxation occurs through an associative process involving nucleophilic addition of free hydroxyl groups to the carbamate linkages and exhibits an Arrhenius activation energy of 111 ± 10 kJ/mol, which is lower than that observed for molecular model compounds (148 ± 7 kJ/mol). These findings suggest that transcarbamoylation is activated by mechanical stress, which we attribute, on the basis of DFT calculations, to the twisting of N lone pairs out of conjugation with the carbonyl π orbitals. PHU vitrimers are a promising new class of repairable networks because of their outstanding mechanical properties, avoidance of toxic isocyanate monomers, and catalyst-free repair processes.

Polylactide Vitrimers.

While much research has been aimed at new approaches to the healing of cross-linked polymers, there is a dearth of effort in the healing of renewable cross-linked polymers. In this study, the healing ability of renewable polylactide-based vitrimers containing Sn(Oct)2 was investigated. The vitrimers were prepared from hydroxyl-terminated star-shaped poly((±)-lactide) samples that were cross-linked with methylenediphenyl diisocyanate. Cross-linked samples were prepared with isocyanate:hydroxyl (IC:OH) ratios of 0.6:1 to 1.1:1 and initial catalyst:hydroxyl (Sn(Oct)2:OH) ratios ranging from 0.013:1 to 0.050:1. The plateau modulus and Tg values for the cross-linked samples decreased with decreasing IC:OH ratio. The materials were subjected to stress relaxation analyses, which confirmed that the materials not only were vitrimeric in nature but also exhibited remarkably short characteristic relaxation times of less than 50 s at 140 °C. Finally, vitrimers fractured in uniaxial tensile testing were healed by compression molding and exhibited up to 67% recovery of ultimate elongation, up to 102% recovery of tensile strength, and up to 133% recovery of tensile modulus values.