Niklas
Warlin
a,
Maria Nelly
Garcia Gonzalez
b,
Smita
Mankar
a,
Nitin G.
Valsange
a,
Mahmoud
Sayed
c,
Sang-Hyun
Pyo
c,
Nicola
Rehnberg
ad,
Stefan
Lundmark
e,
Rajni
Hatti-Kaul
*c,
Patric
Jannasch
*a and
Baozhong
Zhang
*a
aCentre for Analysis and Synthesis, Department of Chemistry, Lund University, P.O. Box 124, SE-22100 Lund, Sweden. E-mail: patric.jannasch@chem.lu.se; baozhong.zhang@chem.lu.se
bEnvironmental and Energy Systems Studies, Lund University, Lund, Sweden
cBiotechnology, Department of Chemistry, Lund University, P.O. Box 124, SE-22100, Lund, Sweden. E-mail: rajni.hatti-kaul@biotek.lu.se
dBona Sweden AB, Box 210 74, 200 21 Malmö, Sweden
ePerstorp AB, Innovation, Perstorp Industrial Park, 284 80 Perstorp, Sweden
First published on 13th November 2019
There is currently an intensive development of sugar-based building blocks toward the production of renewable high-performance plastics. In this context, we report on the synthesis of a rigid diol with a spirocyclic structure via a one-step acid-catalyzed acetalation of fructose-sourced 5-hydroxymethylfurfural and pentaerythritol. Preliminary life cycle assessment (LCA) indicated that the spiro-diol produced 46% less CO2 emission than bio-based 1,3-propanediol. Polymerizations of the spiro-diol together with another sugar-based flexible 1,6-hexanediol for the production of polyesters and poly(urethane-urea)s were investigated, and reasonably high molecular weights were achieved when up to 20 and 60 mol% spiro-diol was used for polyesters and poly(urethane-urea)s, respectively. The glass transition temperatures (Tgs) of the polyesters and poly(urethane-urea)s significantly increased upon the incorporation of the rigid spirocyclic structure. On the other hand, it was observed that the spiro-diol was heat-sensitive, which could cause coloration and partial crosslinking when >10% (with respect to dicarboxylate) was used for the polyester synthesis at high temperatures. The results indicated that the polymerization conditions have to be carefully controlled under these conditions. However, when the spiro-diol was used for the synthesis of polyurethanes at lower temperature, the side reactions were insignificant. This suggests that the new spiro-diol can be potentially suitable toward the production of sustainable rigid polyurethane materials like coatings or foams, as well as renewable polyesters after further optimization of the polymerization conditions.
Recently, the development of sugar-based (or in a broad sense any bio-based) monomers and polymers has been greatly focused on a so-called “bioadvantage” strategy,17 which means to develop high value-added monomers and high-performance plastics without the competition from the low cost fossil-based counter parts. In this direction, rigid monomers have attracted increasing attention because they can usually improve the thermal and mechanical performance of the resulting plastics. In fossil-based plastic industry, the use of rigid monomers to yield high performance polymers has been under rapid development recently. For example, fossil-based (or potentially bio-based) 1,4-cyclohexanedimethanol (CHDM)18–20 has been used as a comonomer to produce a PET-like polyester called PETG, which has higher Tg and alkaline resistance compared with PET.21 A fossil-based cyclic rigid diol, cis/trans-2,2,4,4-tetramethyl-1,3-cyclobutanediol (CBDO), has also been used to prepare polyesters with high impact resistance and superior optical clarity.22 Furthermore, the combination of both CHDM and CBDO in a polyester structure results in a high performance polyester Tritan™, commercialized by Eastman Chemical Co. Recently, a partially bio-based rigid diol with a spirocylic acetal structure has been introduced by Perstorp AB to produce a high performance polyester, Akestra™, which has Tg ≈90 to 110 °C (depending on the content of the rigid diol), and can thus be potentially used in hot-filling applications.23,24 Inspired by the industrial advances, many bio-based rigid monomers toward high-performance polymers (e.g. polyesters, polyurethanes and polycarbonates) have been reported based on a variety of biomass resources.25–31,107
Sugar-based rigid building blocks have also been intensively investigated. For example, isosorbide (a bicyclic sugar-based diol) was reported to produce diversified polymer structures with increased Tg.32–38 Sugar-based polyols like sorbitol and mannitol have been converted into rigid monomers (e.g. diols, diamines, dicarboxylates) with bicyclic structures and used in polymerizations of polyesters, polyurethanes and polyureas.39–43 Aldaric acids (sugar acids)-derived dicarboxylate monomers were prepared and used for polyester synthesis.44,45 Alditol (sugar-alcohol) was converted into cyclic acetalized tartrate monomers for the production of copolyesters with enhanced performance.46–48 Quinic acid (a sugar-based molecule in coffee beans) was reported for the production of cyclic rigid diol toward high-performance polycarbonates.49 However, none of these examples has yet reached close to industrial production and commercialization, which is probably due to various reasons like raw material scarcity, high production cost, or complicated synthesis and purification. Therefore, there is still a strong driving force to develop more suitable sugar-based rigid building blocks toward affordable high-performance biopolymers, using a simple and eco-friendly synthesis protocol.
Among sugar-based chemicals, 5-hydroxymethylfurfural (HMF) has recently been recognized as an important platform molecule,50,108 which can be conveniently produced by the dehydration of fructose,51 an inexpensive abundant natural resource.52–54 HMF contains an aldehyde and an alcohol in its structure, so it can be conveniently converted into many bis-functional monomers. The most notable example is the oxidation of HMF to FDCA toward PEF production.8,9 Many other HMF-derived monomers have also been reported, such as 2,5-bis(hydroxymethyl)furan, 2,5-bis(aminomethyl)furan, 5-hydroxymethyl-2-vinylfuran and 2,5-bis[(2-oxiranylmethoxy)-methyl]-furan, which can be used for the production of polyesters, polyamides, polyurethanes, vinyl polymers, and epoxy polymers.55–58 However, not many rigid diols have been prepared from HMF and investigated for polymer production. 2,5-Bis(hydroxymethyl)furan could be conveniently prepared by the reduction of HMF, but polyesters derived from this monomer usually suffer from low molecular weight and poor physical properties.59–61 Aldol condensation of HMF with acetone produced an unsaturated diol, but this was only investigated for the production of bio-fuels after hydrogenation.62 A patent issued by Stepan Company reports the reaction of HMF with glycerol to produce a rigid diol with cyclic acetal structures, which could potentially be used for the production of polyesters and polyurethanes.63 However, the preparation and physical properties of these biopolymer materials have not yet been reported. As such, the potential of HMF-based rigid diols toward high-performance bioplastics remains largely unexplored. Another important but largely ignored issue is whether or not newly developed bio-based chemicals (and the resulting biopolymers) are truly environmentally friendly. Most often, it is just taken for granted that bio-based monomers and polymers are environmentally benign without any proper assessment on their environmental impact such as greenhouse gas emissions.
Herein, we present a simple, high-yielding and eco-friendly synthesis of a novel bio-based spirocyclic diol (denoted as Monomer S) using fructose-derived HMF and bio-based pentaerythritol from Perstorp AB. The environmental impact of Monomer S has been evaluated by a cradle-to-grave life cycle assessment (LCA) of its CO2 emissions. The results show that Monomer S has a lower CO2 emission profile compared with bio-based 1,3-propanediol, which is commonly used for industrial polymer synthesis (e.g. to produce Sorona™). Step-growth polymerizations of Monomer S for the preparation of polyesters and poly(urethane-urea)s were investigated. The thermal and physical properties of the obtained copolymers showed a clear dependence on the incorporated content of the spirocylic structures. Particularly, the incorporation of Monomer S significantly increased the Tg of the resulting polymers, which showed the potential of the spiro-diol S as a green monomer for the production of high performance polyurethane or polyester materials. With the current conditions we use, polyesters containing up to 5% spiro-diol can be prepared without significant side reactions. When >10% spiro-diol was used, polyesters that were prepared under higher temperatures showed coloration and partial crosslinking, which indicated that the conditions have to be further optimized. Polyurethanes with up to 60% spirocyclic structure were synthesized at relatively low temperatures, which showed insignificant side reaction or coloration.
The mother liquor and the 2-PrOH used to wash the crude product were combined and evaporated to yield a yellow oil (5.30 g), which was re-dissolved in 2-PrOH (10 mL). To this solution was then added pentaerythritol (1.43 g, 10.5 mmol) and a solution of p-TsOH (40 mg, 0.21 mmol) in 2-PrOH (5 mL), and the resulting mixture was stirred at room temperature overnight under N2. Next, the formed precipitate was collected by vacuum filtration and washed with 2-PrOH (2 × 10 mL), NaHCO3 (10 mL, 0.1 M), and distilled water (2 × 10 mL) to yield a second fraction of crude Monomer S (3.41 g, 9.66 mmol). The two fractions of the obtained crude Monomer S were then combined and recrystallized in 2-PrOH to yield a white solid as the final product Monomer S (9.09 g, 65%). Tm: 185 °C (DSC), 1H NMR (400.13 MHz, DMSO-d6, δ, ppm): 3.63 (d, 2H, J = 11.5 Hz, CH2C(CH2)3), 3.74 (dd, 2H, J = 11.5 Hz, J = 2.2 Hz, CH2C(CH2)3), 3.86 (d, 2H, J = 11.5 Hz, CH2C(CH2)3), 4.36 (d, 4H, J = 3.7 Hz, ArCH2), 4.44 (d, 2H, J = 11.5 Hz, CH2C(CH2)3), 5.24 (t, 2H, J = 5.4 Hz, J = 7.8 Hz, –OH), 5.53 (s, 2H, ArCH), 6.25 (d, 2H, J = 3.2 Hz, Ar), 6.38 (d, 2H, J = 3.2 Hz, Ar), 13C NMR (100.61 MHz, DMSO-d6, δ, ppm) 32.2, 55.6, 69.0, 69.6, 95.6, 107.3, 108.2, 149.8, 155.3, FTIR: 1469, 1398, 1337, 1201, 1156, 1075, 1045, 1033, 996, 983, 967, 943, 911, 792, 748, 701, 653, 622, 578, 534, 484, 439, 422, 401. HRMS (ESI+, m/z): exact mass calcd for C17H21O8+: 353.1231, found 353.1238. Elemental analysis: Calcd for C17H20O8 (%) C 57.95, H 5.72. Found: C 57.88, H 5.70.
PSU-18 was synthesized according to a modified procedure, because of the low solubility of Monomer S in 2-butanone. HD (2.90 g, 24.5 mmol), Monomer S (2.16 g, 6.13 mmol), IPDI (7.50 g, 33.7 mmol) and 2-butanone (15 mL) were added to a 50 mL round bottom flask with a magnetic stirrer. The reaction was heated with reflux for 5.5 h. Afterward, dibutyltin laurate (0.5 mL, 10% in 2-butanone) was added, and the reaction solution mixture immediately turned transparent. After 30 min, EDA (2 mL, 10% in 2-butanone) was added. A single droplet of the reaction mixture was taken out and measured by FTIR, showing complete disappearance of the isocyanate signal. Afterward, the reaction mixture was cooled to room temperature, diluted in THF (25 mL), and precipitated in heptane (400 mL). The precipitate was dried under vacuum overnight to give a pale yellow solid as PSU-18 (9.27 g, 73%).
PSU-43 and PSU-62 was synthesized by a further optimized procedure. A typical polymerization protocol for PSU-62 is described. HD (1.45 g, 12.3 mmol), Monomer S (6.48 g, 18.4 mmol), IPDI (7.50 g, 33.7 mmol) and 2-butanone (15 mL) were added to a 50 mL round bottom flask with a magnetic stirrer and then heated to 30 °C. As Monomer S was not fully soluble in 2-butanone, a heterogeneous slurry was formed. Afterward, dibutyltin laurate solution (0.2 mL, 10% in 2-butanone) was added dropwise into the polymerization mixture, and then the temperature was raised to 40 °C. After the reaction stirred for 10 min, a second fraction of dibutyltin laurate solution (0.2 mL, 10% in 2-butanone) was added, followed by a further increase of the reaction temperature (to 50 °C). After 10 min stirring, a third fraction of dibutyltin laurate solution (0.1 mL, 10% in 2-butanone) was added, followed by an increase of reaction temperature (to 60 °C). After 60 min stirring, 2-butanone (5 mL) was added to reduce the viscosity. After another 25 min stirring, another 5 mL 2-butanone was added to reduce the viscosity. After 10 min additional stirring, the reaction mixture turned transparent. After another 35 min stirring, 2-butanone (5 mL) was added, followed immediately by dropwise addition of EDA (0.5 mL, 10% in 2-butanone). After 15 min, the viscosity of the reaction mixture became high, so 2-butanone (5 mL) was added. After 15 min stirring, a single droplet was taken out and analyzed by FTIR to show full depletion of isocyanates. Afterward, 1.5 mL of EDA (10% in 2-butanone) was added into the reaction in order to ensure that there was no isocyanate group left. Afterward, the reaction mixture was cooled to room temperature, diluted (1:1) with THF, and precipitated into tert-butyl methyl ether. The precipitate was dried under vacuum at 50 °C overnight, followed by 8 hours at 120 °C, and finally 2 hours at 150 °C, giving a pale yellow solid as PSU-62 (11.8 g, 76%).
PSU-43 was synthesized by a similar procedure, yielding a pale yellow solid with 11.1 g (78%).
Scheme 1 Synthesis of the HMF-based rigid diol (Monomer S, indicating its spirocyclic structure) as well as the polymerization towards copolyesters and copoly(urethane-urea)s. |
Fig. 1 Stability evaluation of HMF in various solvents. According to the CHEM21 recommendation, the 12 tested solvents were categorized as “Green” and “Non-green”.54 Neat condition (solvent-free) was categorized as “Green”. The photos were taken after the solutions of HMF had been stirred for 5 h with p-TsOH at 25, 40, and 70 °C. The solutions without significant HMF degradation (coloration) are highlighted by green dashed boxes. |
Recommendedb | Not recommendedb | ||||||
---|---|---|---|---|---|---|---|
Water | EtOH | 2-PrOH | t-BuOH | 1-PrOH | DMF | DMSO | |
a The conversion was estimated by 1H NMR spectroscopy analysis of the crude reaction mixtures. Note that the conversions given are not the isolated yields of the product (after these experiments, Monomer S was not isolated). b According to the recommendation of CHEM21 solvent guide.53 c This experiment was carried out at 30 °C instead of 25 °C in order to be above the melting point of t-BuOH (∼25–26 °C). | |||||||
25 °C | 16 | 80 | 72 | 38c | 75 | 30 | 23 |
40 °C | 15 | 60 | 62 | 44 | 65 | 40 | 30 |
70 °C | — | — | — | — | — | 23 | 20 |
In the meantime, we also synthesized Monomer S using a bio-sourced HMF prepared by the dehydration of fructose (see Experimental for synthetic details). The fructose-based HMF had slightly lower purity (88%) compared with the commercial one (95%, Fig. S3†). Nevertheless, after performing the synthesis of Monomer S using the fructose-based HMF under the optimized reaction conditions, the crude conversion was found to be just slightly lower (∼70%) than that of the reaction using commercial HMF (∼75%, Fig. S4†). The further purification and upscaling of the fructose-based HMF production is currently being investigated, and will be communicated elsewhere.
In order to verify whether the production of bio-based Monomer S was indeed eco-friendly, a life cycle assessment (LCA) was performed to identify both the positive and negative aspects in the development of Monomer S and to explore possible alternatives to enhance environmental quality.76 The evaluation of the total impact of GHG emissions by LCA for Monomer S was assessed on the basis of a cradle-to-gate approach. Fig. 2 shows the total impact of the GHG emissions for Monomer S with a very low value of 1.18 kg CO2eq per kg S, of which 0.67 kg CO2eq per kg S was derived from the HMF production and 0.41 kg CO2eq per kg S originated from the bio-based pentaerythritol production (according to Perstorp AB). The synthetic process contributed to the total emissions with a small value of 0.10 kg CO2eq per kg S (8.5% of the total). Subsequently, Monomer S was compared with bio- and fossil-based 1,3-propanediol (1,3-PD).77 As shown in Fig. 2, Monomer S showed a remarkably lower GHG emission value compared with both the bio- and fossil-based 1,3-PD. The GHG value of Monomer S equals to only 54% of the value of bio-based 1,3-PD (2.18 kg CO2eq per kg bio-1,3-PD), and even as low as 24% of the value of fossil-based 1,3-PD (5.00 kg CO2eq per kg fossil-1,3-PD). This important result suggests that Monomer S tends to be more environmentally favorable in terms of GHG emissions. Admittedly, this assessment was only intended to provide first-hand information regarding the environmental impact of Monomer S. To our knowledge, this kind of assessment during the synthetic development of new bio-based monomers or polymers is very rare.78 In order to gain a deeper insight into the environmental impacts of new building blocks and polymers, more thorough LCA investigations (e.g., estimations of other critical environmental impact categories) will be needed. It will also be highly interesting to compare the LCA results of Monomer S with other bio-based (e.g. mannitol, isosorbide, galactitol, isoidide)79 or fossil-based (e.g. CHDM, CBDO) diols, of which the LCA investigation is lacking in the literature currently. These investigations are currently being conducted and will be communicated separately.
Fig. 2 Total impact of the GHG emissions for the new Monomer S compared to bio- and fossil-based 1,3-propanediol. |
The Mn values of PHT, PHST-3, PHST-10 and PHST-16 were similar (∼9100–10900 kDa), but their Mw values increased with the increased S content, leading to increased molecular weight distribution. However, the molecular weight and polydispersity for PHST-19 were significantly higher, which was consistent with the observation that the measured hydrodynamic radius of PHST-19 (Rh ∼7 nm) was significantly larger than that of the other samples (Rh ∼5 nm). The intrinsic viscosity ([η]) values of the obtained polyesters were in the range of 0.38–0.57 dL g−1 (measured by SEC with a triple detector system) without a significant decreasing trend as the S-content increased. This result is different from a previously reported series of copolyesters with rigid-diol units, where the [η] values and molecular weights decreased as the rigid-diol content increased.41 In our case, the molecular weights and [η] values of the PHST series were not significantly reduced by the use of rigid Monomer S, which may be explained by the presence of partial branching/crosslinking that increased the molecular weight.
The Mark–Houwink–Sakurada parameters for the polyesters were given directly by SEC analysis. As shown in Table 2, the a parameter showed a general decreasing trend with the increased S-content. For PHT, a = 0.75, indicating that this polymer formed a random coil conformation in chloroform. For copolyester PHST-3, the a value decreased to 0.67, indicating that chloroform was a less favorable solvent for this polymer. For the polyesters with higher S-content (PHST-10, PHST-16 and PHST-19), the a parameter was slightly below 0.5 (0.44–0.48), indicating that these polymers attained compact spherical conformations in chloroform.82 This observation was consistent with the presence of branching in these polymers. Compared with hyperbranched polymers with a ∼0.16–0.40,83 the PHST samples had a values closer to 0.5, which qualitatively suggested that they had a lower degree of branching compared with hyperbranched polymers.84–86
Feed S (%) | Incorporated S (%) | M n (kDa) | M w (kDa) | Đ | [η] (dL g−1) | R h (nm) | −logK | a | |
---|---|---|---|---|---|---|---|---|---|
a Feed S is the is the mol% of Monomer S in the monomer mixture. Incorporated S is the mol% of Monomer S in the polymer as estimated by NMR. Mn, Mw, Đ, intrinsic viscosity [η], hydrodynamic radius Rh, and Mark–Houwink–Sakurada parameters K and a were determined by SEC. | |||||||||
PHT | — | — | 9.4 | 18.1 | 1.93 | 0.57 | 5.3 | 3.4 | 0.75 |
PHST-3 | 3.7 | 3 | 9.1 | 18.5 | 2.03 | 0.52 | 5.1 | 3.1 | 0.67 |
PHST-10 | 14.7 | 10 | 10.9 | 27.5 | 2.57 | 0.38 | 5.0 | 2.4 | 0.47 |
PHST-16 | 18.3 | 16 | 9.8 | 37.2 | 3.80 | 0.40 | 5.1 | 2.4 | 0.48 |
PHST-19 | 21.8 | 19 | 15.4 | 113.0 | 7.37 | 0.47 | 7.4 | 2.3 | 0.44 |
The presence of partial branching/crosslinking in PHST-10, PHST-16 and PHST-19 might be attributed to a ring-opening process of the spirocyclic acetal structures (Fig. S7, ESI†), as well as furfural alcohol condensation and subsequent branching reactions.87 In order to gain some insight into ring-opening possibility, we analyzed the condensed yellow solid in the vacuum outlet of the reaction flask (Fig. S8†). According to the 1H NMR spectrum, the condensed yellow solid from the polymerization mixture contained HD and dimethyl terephthalate monomers, as well as HMF (Fig. S9†). Because HMF was not present in the starting polymerization mixture, we assumed that it was formed through the degradation of Monomer S, possibly giving HMF and a polyol (Fig. S7†). These polyols can participate in the condensation polymerization to form branched or cross-linked structures. In addition, the possible side reaction caused by furfural alcohol condensation was checked by the 1H NMR spectra. As shown in Fig. S10 (ESI†), a small signal at ∼3.94 ppm was observed, which could potentially correspond to the methylene bridge between two furan rings, as a product formed by furfural condensation.88
The molecular structure of the polyesters was investigated by 1H NMR spectroscopy. First, all the signals in the spectrum of Monomer S were unambiguously assigned (Fig. 3A), including the two doublets at 6.25 (c) and 6.38 ppm (d) (the aromatic protons of furan), the singlet at 5.53 ppm (e, acetal proton), the triplet at 5.24 ppm (a, the OH proton), and the doublet at 4.44 ppm (b, the CH2 groups α to the furan rings). Interestingly, the CH2 protons on the spiroacetal units showed four discernable peaks, which was due to the different axial and equatorial C–H orientation on the rigid spirocyclic structure. With the help of 2D NMR investigations (i.e. COSY, HMQC, HMBC and NOESY, see Fig. S11–S26†), we assigned the two doublets at 3.63 (i) and 3.86 ppm (f) to the axial protons, and the other two doublets at 3.74 (g) and 4.36 ppm (h) to the equatorial protons. Such an assignment was consistent with other similar reported compounds with spirocyclic acetal structures.71,89 After the polymerizations, the resulting polyesters (Fig. 3B–F) showed broadened 1H NMR signals, indicating the formation of the polymers. In all these spectra, a CH2 signal (α to the ester bond) at 4.38 ppm (1), two broad aliphatic signals at 1.85 ppm (2) and 1.56 ppm (3), and an aromatic singlet at 8.10 ppm (4) were observed, which confirmed the PHT structures in all polyesters. The incorporation of Monomer S residues in the copolyesters was confirmed by the observation of the corresponding signals (b′–i′ in Fig. 3C–F). Furthermore, the OH signal of Monomer S (a) disappeared in the spectra of copolyesters, and the signal of the CH2 attached to the furan ring significantly shifted toward lower field (from 4.44 to 5.55 ppm). These observations also confirmed that Monomer S residues were incorporated by the formation of ester bonds. In addition, the furan signals (c′, d′) moved slightly downfield, which was consistent with the formation of electron withdrawing ester bonds. The intensity of the signals indicated that the spirocyclic units consistently increased as the Monomer S content increased. It was noted that there were small shifts for the spirocyclic CH2 signals (i.e. f′, g′, h′ and i′) compared with the corresponding signals of the monomer (i.e. f, g, h and i), which could be attributed to the different NMR solvents used for the monomer and the polymers. Unfortunately, Monomer S was only soluble in DMSO-d6 (among commonly used NMR-solvents), while the polyesters were only soluble in chloroform-d. Hence, the NMR spectra of monomer and polymers were recorded in different solvents.
The integration of the 1H NMR signals provided valuable information regarding the chemical composition of the resulting polyesters. By comparing the integrals of the furan signals (c′ and d′) with that of the terephthalate aromatic signals (4), we calculated the S content (taking terephthalate as 100%) for each copolyester (Table 2). Compared with the monomer feed, the S content of the copolyester was lower in percentage (68–87% of the fed Monomer S). This may be attributed to a lower reactivity of the sterically hindered Monomer S compared with that of HD. Another explanation may be that the degradation of Monomer S (or incorporated S units in the polyesters) during the polymerization (Fig. S7†) could lower the observed S-content in the resulting polymers. The latter was consistent with the observation of HMF in the vacuum outlet of the reaction vessel (Fig. S8 and 9†).
The chemical structures of the polyesters were also confirmed by FTIR analyses (Fig. 4). All the polyesters’ spectra showed characteristic ester signals, including CO stretching at 1714 cm−1 and C–O stretching at 1269 cm−1. The signal at 728 cm−1 originated from the out of plane C–H bending.90 The aromatic and aliphatic C–H stretching was also observed at 2800–3000 cm−1,91 which was consistent with the presence of PHT residues in all polymers. Furthermore, the characteristic spiroacetal signals at 1201 and 1156 cm−1 (shown in the spectrum of Monomer S) were also observed in the spectra of all polyesters with increasing intensity along with the increasing S content.71,92 This confirmed the incorporation of the spiroacetal S residues in the copolyesters.
The thermal stability of Monomer S and the different polyesters was evaluated by TGA (Fig. 5 and Table 3). For the homopolymer PHT, a single decomposition rate maximum was observed at 400 °C (Td). All copolymers showed three decomposition rate maxima (Td ∼320 °C, 400 °C, and 450 °C). The first decomposition rate maximum at ∼320 °C was attributed to the degradation of the spirocyclic acetal units in the PHST backbone, which was similar as the thermal decomposition profile of Monomer S (Td ∼320 °C). The second decomposition rate maximum at ∼400 °C was attributed to the degradation of PHT units in the copolymers, presumably through a 6-membered cyclic β-hydrogen transfer mechanism.93 The third decomposition rate maximum at 450 °C was more prominent for PHST samples with higher Monomer S content. This may be explained by the formation of degradation-induced crosslinking (Fig. S7†) during the TGA measurements. To further verify this explanation, a PHST-19 sample was purposely prepared by extending the reaction time to 4 days, which resulted in the formation of completely insoluble polymer gel (designated PHST-19gel). Comparing the TGA profile of this sample with that of the original PHST-19 (Fig. S27†), a much more pronounced decomposition rate maximum was observed for PHST-19gel at 450 °C. This supported that the decomposition rate maximum at 450 °C was due to crosslinking. Among the polyester series, the T5 and Td values showed a general decreasing trend as more Monomer S units were incorporated. The char yields (CY) increased with the Monomer S contents, which was consistent with the results for polyesters with rigid building blocks.54
TGA | DSC | DMA | ||||||
---|---|---|---|---|---|---|---|---|
T 5 (°C) | T d (°C) | CY (%) | T g (°C) | T m (°C) | T c (°C) | T g (°C) | E′ (MPa) | |
a T 5 is the temperature at 5% weight loss. Td is the temperature with the maximal degradation rate. T5, Td, and char yield (CY) were all obtained by TGA. Tg and Tm were measured from the second heating DSC curves, and Tc was measured from the second cooling DSC curves. Note that there were three decomposition rate maxima in the TGA curves (Fig. 5), but only the highest rate maxima were listed in the table as the Td values. | ||||||||
PHT | 368 | 401 | 4 | 17 | 140, 146 | 116 | 29 | 1279 |
PHST-3 | 349 | 402 | 6 | 25 | 133, 141 | 106, 122 | 42 | 1453 |
PHST-10 | 312 | 302, 389, 432 | 12 | 34 | 123 | — | 32 | 1143 |
PHST-16 | 324 | 317, 402, 446 | 15 | 42 | — | — | 42 | 1615 |
PHST-19 | 304 | 305, 388, 435 | 15 | 47 | — | — | 43 | 1488 |
Monomer S | 267 | 323 | 20 | — | 185 | — | — | — |
The thermal transitions of the polymers were investigated by DSC (Fig. 6 and Table 3). First, it was noted that the incorporation of rigid S units into PHT significantly increased the Tg of the polyesters (from 17 °C for PHT to 47 °C for PHST-19). This was consistent with the previous reports on polyesters containing bicyclic diacetalized glucitol units.54 It should be noted that the increase in Tg may be partially ascribed to crosslinking.94 Furthermore, the incorporation of S units also affected the melting/crystallization behavior, similar to the incorporation of other rigid structures in polyesters.54,80,95 The DSC results showed that PHT and PHST-3 were semicrystalline, which was indicated by the presence of melting endotherms during heating (Fig. 6A) and crystallization exotherms during cooling (Fig. 6B). The existence of two melting peaks was consistent with the multiple crystalline forms reported for PHT.96,97 The melting (Tm) and crystallization temperature (Tc) both decreased with the incorporation of S units (3 mol%). When more than 10% S units were incorporated, the copolyesters became fully amorphous. PHST-10 showed a minor melting endotherm during the heating cycle most likely caused by cold crystallization, since no visible crystallization peak was observed during the cooling cycle. PHST-16 and PHST-19 did not show any melting or crystallization peaks.
Finally, the obtained polyesters were characterized by DMA, and results were compared with that of commercially available Akestra90 (ESI Fig. S28†). The Tg values were measured as the temperature for the peak loss modulus of each sample (Fig. S28B, ESI†), which showed consistent growing trend for PHST-10, PHST-16 and PHST-19. The other two polymers PHT and PHST-3 showed some deviation in their Tg values compared with the DSC results, which could be attributed to the broad peaks on the E′′ curves. It was also noted that the storage modulus at the glassy plateau (20 °C) for the obtained polyesters was in the range of ∼1143 to 1615 MPa, which is close to the value of Akestra (∼1428 MPa, under the same measurement conditions).
Feed S (%) | Incorporated S (%) | M n (kDa) | M w (kDa) | Đ | T g (°C) | T d (°C) | T 5 (°C) | CY (%) | |
---|---|---|---|---|---|---|---|---|---|
a Feed S is the mol% of Monomer S in the monomer mixture. Incorporated S is the mol% of Monomer S in the polymer as estimated by NMR. Mn, Mw and Đ were determined by SEC in DMF. T5 is the temperature at 5% weight loss. Td is the temperature with the maximal degradation rate. T5, Td, and the char yield (CY) were obtained by TGA. Tg was measured from the second heating DSC curves. | |||||||||
PU | — | — | 12 | 22.8 | 1.9 | 79 | 323 | 276 | 2 |
PSU-5 | 5.0 | 5.4 | 16 | 43.8 | 2.7 | 90 | 321 | 279 | 5 |
PSU-10 | 10 | 10 | 17 | 78.5 | 4.6 | 97 | 315 | 270 | 9 |
PSU-18 | 20 | 18 | 21 | 75.0 | 3.5 | 104 | 306 | 266 | 8 |
PSU-43 | 40 | 43 | 53 | 137 | 2.6 | 120 | — | 283 | 14 |
PSU-62 | 60 | 62 | 37 | 125 | 3.4 | 131 | — | 284 | 19 |
The molecular structure of the poly(urethane-urea)s was analyzed using 1H NMR spectroscopy. As shown in Fig. 7B–E, the signals for the polymers were broadened compared to that of Monomer S, which indicated the formation of polymers. Furthermore, two new signals at 6.8–7.1 ppm (signals 12 and 4, in Fig. 7B–E) were observed after the polymerizations, which corresponded to the N–H protons in urethane bonds formed between IPDI and HD. Furthermore, two new signals at 7.16 (14) and 7.30 ppm (15) were observed with increasing intensity from PSU-10 and PSU-62, which corresponded to the N–H protons in urethane bonds formed between IPDI and Monomer S. In addition, the S content was determined by comparing the integral of the signal corresponding to the α-protons of the primary isocyanate on IPDI (11) with that of the signal corresponding to the aromatic protons on the furan units (c′ and d′). As a result, the S content in the copolymers was consistent with the initial monomer feed ratio (Table 4). It was also noted that in the 1H NMR spectra of PSU-43 and PSU-62, signals corresponded to the S structure at the chain ends were clearly visible (designated as aend, bend, cend and dend in Fig. 7G). By comparing the integrals of these chain end groups with that of the backbone signals (e.g. the methylene signal 11), the molecular weights of PSU-43 and PSU-62 were estimated as 22 and 13 kDa, which were significantly lower than the results from SEC in DMAc. This discrepancy could be related to the relatively large error range of the NMR integrals of small end groups and the assumption that every polymer has two end groups (neglecting branching, crosslinking and cyclic structures), as well as the reported overestimation tendency for SEC for rigid polymers using flexible PS standards.99–102 Finally, the 1H NMR spectrum of PSU-62 was examined in order to evaluate whether there were furfural condensation side reactions (Fig. S60, ESI†). Unfortunately, the area where the peak for the methylene CH2 group (in connection with two furan rings) is severely overlapped with the backbone peaks, which prevented this assessment.
The molecular structures of the obtained poly(urethane-urea)s were further confirmed by FTIR spectra. As shown in Fig. 8, the absorption band at 3495 cm−1 for Monomer S was attributed to the –OH stretching vibrations.103 This band was not observed in the spectra of any of the poly(urethane-urea)s. Furthermore, a broad absorption band at 3320 cm−1 was observed in the spectra of all the obtained polymers, which was attributed to the N–H stretching band in the urethane units. These observations indicated that the reaction between the isocyanate and the diols was complete.103 Finally, the complete disappearance of the isocyanate absorption bands (2250–2270 cm−1) and the appearance of characteristic carbonyl absorption band at 1692 cm−1 also confirmed the formation of the target poly(urethane-urea)s.103,104
The thermal stability of the poly(urethane-urea)s was evaluated using TGA. As shown in Fig. 9 and Table 4, all these polymers showed good thermal stability (T5 > 270 °C). A single decomposition rate maximum was observed for polymers with relatively low S content (<10%), which was in agreement with other reported IPDI-based polyurethanes.105 However, the copolymers with higher S content (≥18%) showed a complex decomposition pattern in their derivative weight loss curves (Fig. 9B). For PSU-18, a small shoulder was observed at ∼350 °C on the derivative weight loss curve. For PSU-43 and PSU-62, the corresponding curves look even more complicated. For PSU-43, there was a local peak at ∼300 °C, followed by a broad peak at 320–380 °C. For PSU-62, there was a shoulder at ∼300 °C, and a broad peak at higher temperature. Therefore, no Td value could be meaningfully given (Table 4). This complicated thermal decomposition behavior when higher S content was incorporated in PSUs may be related to the thermal decomposition of the spirocyclic acetal or furan structures in PSU, which can cause subsequent crosslinking during TGA measurements. The exact mechanism remains to be unraveled. The char yield (CY) increased with the increased S content in the polymers, which was consistent with the observed trend in the PHST polyesters discussed above. This may be attributed to the increased aromatic content in the polymers, which has been reported to increase the char yields under nitrogen.106 The thermal behavior of the poly(urethane-urea)s was further investigated using DSC. As shown in Fig. 10 and Table 4, all the obtained polymers were completely amorphous without any melting endotherm, which was expected due the asymmetric structure of IPDI. The Tg values increased significantly with the increased S content (from 79 °C for PU to 131 °C for PSU-62).
Fig. 9 TGA (A) thermograms and (B) first derivative curves of Monomer S and the poly(urethane-urea)s. |
Finally, the obtained poly(urethane-urea) samples were dissolved in THF (50 mg mL−1) for film-casting. The homogeneous polymer solution was spread evenly across a glass slide, followed by evaporation at room temperature under a glass conical funnel overnight. The use of glass conical funnel enabled the production of smooth polymer films without significant wrinkles, cracks and bubbles. Afterward, the glass slides were placed under vacuum for 24 h to completely remove the solvent THF, yielding almost colorless transparent films (Fig. 11). The water contact angle (θ) on the films was seemingly unaffected by the S content (74–79°, Fig. S61, ESI†).
Footnote |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/c9gc03055g |
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