Chemical recycling of polymers is critical for improving the circular economy of plastics and environmental sustainability. Traditional thermoset polymers have generally been considered permanently crosslinked materials that are difficult or impossible to recycle. Herein, we demonstrate that by activating ‘dormant’ covalent bonds, traditional polycyanurate thermosets can be recycled into the original monomers, which can be circularly reused for their original purpose. Through retrosynthetic analysis, we redirected the synthetic route from forming conventional C–N bonds via irreversible cyanate trimerization to forming the C–O bonds through reversible nucleophilic aromatic substitution of alkoxy-substituted triazine derivatives by alcohol nucleophiles. The new reversible synthetic route enabled the synthesis of previously inaccessible alkyl-polycyanurate thermosets, which exhibit excellent film properties with high chemical resistance, closed-loop recyclability and reprocessing capability. These results show that ‘apparently dormant’ dynamic linkages can be activated and utilized to construct fully recyclable thermoset polymers with a broader monomer scope and increased sustainability.
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Vitrimerization: A Novel Concept to Reprocess and Recycle Thermoset Waste via Dynamic Chemistry
A new approach for reprocessing of existing thermoset waste is presented. This work demonstrates that unrecyclable thermoset materials can be reprocessed using the concept of associative dynamic bonding, vitrimers. The developed recycling methodology relies on swelling the thermoset network into a solution of a catalyst, which enables transesterification reactions allowing dynamic bond exchange between ester and hydroxyl groups within the thermoset network. Thermal and mechanical properties for recycled polyurethane and epoxy networks are studied and a strategy to maintain the properties of recycled materials is discussed. The developed methodology promises recycling and even upcycling and reprocessing of previously thought intractable materials. Moreover, processability of vitrimerized thermosets with common thermoplastic manufacturing methods opens up the possibility of tuning recycled networks by adding nanoparticles. This flexibility keeps the application window of recycled thermosets very broad.
more » « less- NSF-PAR ID:
- 10091807
- Publisher / Repository:
- Wiley Blackwell (John Wiley & Sons)
- Date Published:
- Journal Name:
- Global Challenges
- Volume:
- 3
- Issue:
- 7
- ISSN:
- 2056-6646
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Abstract The chemically crosslinked network structures make epoxies, the most common thermosets, unable or hard to be recycled, causing environmental problems and economic losses. Epoxy‐based vitrimers, polymer networks deriving from epoxy resins, can be thermally malleable according to bond exchange reactions (BERs), opening the door to recycle epoxy thermosets. Here a series of experiments were carried out to study the effects of processing conditions (such as particle size distributions, temperature, time, and pressure) on recycling of an epoxy‐anhydride vitrimer. Polymer powders from the epoxy‐anhydride vitrimer with different size distributions were prepared and characterized, and the influence of particle size on the mechanical performance of recycled epoxy‐anhydride vitrimers was investigated by dynamic mechanical analysis and uniaxial tensile test. Experimental results demonstrated that finer polymer powders can increase the contacting surfaces of recycled materials and thus result in high quality of recycled materials. In addition, the influences of other treating parameters, such as temperature, time, and pressure, were also discussed in this study. Adjusting these treating parameters can help the design of an optimized reprocessing procedure to meet practical engineering applications.
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null (Ed.)Recycling of polyurethanes is largely infeasible due to the harsh reprocessing conditions and associated risks of side reactions and degradation whereas polymer networks incorporating dynamic covalent bonds represent an attractive approach to the design of recyclable materials. Here, we report findings on the dynamic nature of thiourethanes, and their application as a new class of recyclable analogs of urethane materials. A series of small molecule experiments was initially conducted to determine the equilibrium constant and exchange reaction kinetic constant for the thiol–isocyanate reaction. Furthermore, incorporating those thiourethane moieties into a cross-linked network resulted in thermoset materials that are readily depolymerized to liquid oligomers. The resultant oligomers can be re-crosslinked to thiourethanes without any loss of performance nor change in mechanical properties (peak stress of 25 MPa with max strain of 200%). Moreover, the recycled thiol oligomers from thiourethane network polymers could potentially be transformed into other materials with mechanical properties that exceed those of the initial, pristine thiourethane materials. Overall, the ease with which these polythiourethanes are polymerized, recycled and reformulated gives a new direction and hope in the design of sustainable polymers.more » « less
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Additive manufacturing, otherwise known as three-dimensional (3D) printing, is a rapidly growing technique that is increasingly used for the production of polymer products, resulting in an associated increase in plastic waste generation. Waste from a particular class of 3D-printing, known as vat photopolymerization, is of particular concern, as these materials are typically thermosets that cannot be recycled or reused. Here, we report a mechanical recycling process that uses cryomilling to generate a thermoset powder from photocured parts that can be recycled back into the neat liquid monomer resin. Mechanical recycling with three different materials is demonstrated: two commercial resins with characteristic brittle and elastic mechanical properties and a third model material formulated in-house. Studies using photocured films showed that up to 30 wt% of the model material could be recycled producing a toughness of 2.01 ± 0.55 MJ/m3, within error of neat analogues (1.65 ± 0.27 MJ/m3). Using dynamic mechanical analysis and atomic force microscopy-based infrared spectroscopy, it was determined that monomers diffuse into the recycled powder particles, creating interpenetrating networks upon ultraviolet (UV) exposure. This process mechanically adheres the particles to the matrix, preventing them from acting as failure sites under a tensile load. Finally, 3D-printing of the commercial brittle material with 10 wt% recycle content produced high quality parts that were visually similar. The maximum stress (46.7 ± 6.2 MPa) and strain at break (11.6 ± 2.3%) of 3D-printed parts with recycle content were within error the same as neat analogues (52.0 ± 1.7 MPa; 13.4 ± 1.8%). Overall, this work demonstrates mechanical recycling of photopolymerized thermosets and shows promise for the reuse of photopolymerized 3D-printing waste.more » « less
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Abstract Thermoset shape memory polymers (SMPs) have a series of advantages in practical applications when compared with thermoplastic SMPs. However, the reprocessing and reshaping of thermosets are difficult due to the covalent crosslinking which severely limits the reconfiguration of polymer networks even under high temperature. Here, hinered urea bond (HUB), a urea bearing a bulky substituent on its nitrogen atom that can reversibly dissociate to the corresponding bulky amine and isocyanate, is integrated into the poly(urea‐urethane) (PUU) crosslinked networks, enabling the networks to topologically reconfigure to other structures. Instead of having to cure the thermoset in a mold, the incorporation of HUBs can decouple the synthesis and shape‐forming steps, which is a huge advantage for the processing of thermoset materials compared to conventional thermosets. This new PUU thermoset shows a broad glass transition behavior and exhibits excellent triple‐shape‐memory performance. With the incorporation of this dynamic urea bonds, permanent shapes can be flexibly tuned via the network reconfiguration, which is often neglected but significant to the practical application of SMPs.
