Open Access Article
Zhiyong Liu
*ac,
Qian Chaoc,
Jinyan Zhaoc,
Ying Lin
c,
Ping Yud,
Min Chene,
Shengyu Shi*c,
Yixin Xiangc,
Jiangang Gaoc and
Youwei Ma
*b
aSchool of Chemistry & Chemical Engineering, Anhui University, Hefei, China. E-mail: liuzhiyong@ahpu.edu.cn
bInstitute of Materials, École Polytechnique Fédérale de Lausanne (EPFL), CH-1015 Lausanne, Switzerland. E-mail: youwei.ma@epfl.ch
cSchool of Chemical and Environmental Engineering, Anhui Polytechnic University, Wuhu, China. E-mail: shisy@ahpu.edu.cn
dSchool of Environmental and Chemical Engineering, Jiangsu Ocean University, Lianyungang, China
eCenter for Water and Ecology, State Key Joint Laboratory of Environment Simulation and Pollution Control, School of Environment, Tsinghua University, Beijing, China
First published on 22nd June 2026
A central challenge in designing recyclable polymers lies in the trade-off between recyclability and performance. State-of-the-art strategies leveraging supramolecular interactions or dynamic covalent bonds (DCBs), either individually or in orthogonal combination, mostly end up improving one property with the compromise of the other. Here, we present a unified molecular design strategy based on substituent engineering of DCBs to simultaneously enhance service-life performance and end-of-life recyclability. By introducing a β-ketoester substituent into dynamic oxime–urethane (OU) linkages, intermolecular hydrogen bonding is strengthened while bond thermodynamics are biased toward dissociation. We show that the engineered poly(OU)s exhibit improved mechanical and thermomechanical properties (e.g., 38 vs. 24 MPa in tensile strength; 360 vs. 169 MPa in Young's modulus; 36 vs. 20 °C in Tg) compared to the control sample lacking the β-ketoester moieties. Meanwhile, efficient depolymerization is achieved under mild conditions (140 °C), enabling recovery of the constituent components in high yields via simple vacuum distillation, particularly with an isocyanate yield of 87%, in contrast to only 14% for the depolymerization of normal poly(OU). The materials are also thermally reprocessable and enable closed-loop recycling of carbon fiber-reinforced composites. This work establishes substituent engineering of DCBs as a general strategy to decouple recyclability and performance, offering a pathway toward high-performance circular polymer materials.
State-of-the-art approaches to overcoming this dilemma consist of supramolecular engineering for thermoplastics8–13 or the incorporation of dynamic covalent bonds (DCBs) as reversible cross-links in thermosets.14–19 Supramolecular interactions (e.g., hydrogen bonding, metal–ligand coordination, and host–guest interactions) can reinforce thermoplastics through reversible noncovalent bonding, yet to an extent reduce their recyclability due to strengthened intermolecular associations.20,21 In contrast, the recently extensively investigated DCBs, including disulfide bonds,22–24 cyanurates,25–27 tri/di-ketoenamines,6,28–30 vinylogous urethanes,31–35 and dioxaborolanes,16,36–38 to name a few, enable reprocessability and chemical recycling of thermosets via bond exchange or dissociation. They sometimes compromise thermal and mechanical properties of the materials owing to the intrinsic lability of these reversible linkages.39 Although the combined use of supramolecular interactions with DCBs has emerged as a promising strategy,40–43 these elements are typically introduced in an orthogonal manner and also end up trading one property off against the other.
This dilemma is particularly evident in polyurethane and polyurea fields. Incorporation of supramolecular interactions into linear or branched polyurethanes and polyureas can significantly enhance mechanical strength, thermal stability, and chemical resistance;13,44,45 however, the resulting materials often require harsher conditions for recycling or reprocessing, such as elevated temperatures, the presence of (more) catalysts, or excess depolymerization agents. In parallel, replacing conventional urethane or urea linkages with isocyanate-derived DCBs such as hindered urea,46 pyrazole–urea,47 and oxime–urethane linkages48 confers intrinsic recyclability and reprocessability to cross-linked networks, but sometimes at the expense of thermal and mechanical performance. Subsequent efforts to incorporate supramolecular interactions into these dynamic covalent networks (with no chemical alteration to DCBs) can improve material performance,49,50 yet typically lead to more demanding recycling conditions. Moreover, despite nearly a century of development in isocyanate-based polymer chemistry, direct recycling of isocyanates from their derived polymers remains exceedingly rare due to their high reactivity and propensity for side reactions.51
To challenge the status quo, here we propose a general molecular design strategy based on substituent engineering of DCBs. Unlike the orthogonal use of DCBs and supramolecular bonds, this strategy involves simultaneous modulation of intermolecular interactions and bond thermodynamics at the same reactive site. Specifically, we selected the well-established oxime–urethane (OU) bonds as the model system.48,52–56 They are functionalized with a β-ketoester motif, an essential synthon that was introduced by the Du Prez lab to the realm of recyclable polymer synthesis,31,33,34,57 and subsequently attracted extensive investigations, including research by some of our authors.35,58–61 The functionalization serves a dual and cooperative role (Scheme 1): the additional carbonyl groups enhance intermolecular hydrogen bonding,58,62 thereby improving thermal and mechanical properties, while the electron-withdrawing nature of the β-ketoester lowers the thermodynamic stability of the OU linkage, shifting the equilibrium toward dissociation.63,64 This dual-function design enables the resulting poly(acetoacetated oxime–urethane)s (PAOUs) to achieve both enhanced service-life performance and efficient end-of-life recyclability. The PAOUs exhibit improved mechanical and thermomechanical properties compared to the poly(OU) lacking the β-ketoester moiety (Scheme 1b). Small-molecule model studies and mechanistic investigations demonstrate that the acetoacetated oxime–urethane (AOU) bonds exhibit a significantly reduced equilibrium constant, favoring dissociation into isocyanates and acetoacetated oximes at equilibrium (Scheme 1a). Consequently, PAOUs can be depolymerized under mild conditions (140 °C), enabling high-yield recovery of monomers via simple vacuum distillation. Notably, isocyanates are recovered in up to 87% yield—a rarely reported achievement due to the high reactivity of isocyanates—whereas the poly(OU) control exhibits minimal recovery (<14%).
O) stretching vibration from 1747 to 1761 cm−1, supports the successful formation of AOU linkages (Fig. 1b). The materials exhibit excellent chemical resistance, as reflected by non-dissolution of the PAOU-HDI films when immersed in various organic solvents including 1,4-dioxane, THF, toluene, and CHCl3 for 7 days (Fig. 1c). Moreover, the three PAOU networks display swelling ratios of 40–170% (Fig. S1), and regardless of the solvent type, their gel fractions are comparable, all around 90% (Fig. 1d), indicating the same level of cross-link densities present in them.
Differential Scanning Calorimetry (DSC) analysis reveals that all PAOU networks exhibit a glass transition temperature (Tg) ranging between 22 °C to 44 °C (Fig. 1e). Among them, PAOU-HMDI possesses the highest Tg, which primarily arises from the rigid 4,4-methylenedicyclohexyl skeleton provided by HMDI. Dynamic Mechanical Analysis (DMA) traces show a sharp drop in storage modulus E′, along with the emergence of a peak in the tan
δ plots at temperatures of 31–57 °C (Fig. 1f), which marks their Tg. The Tg thus measured follows the same trend as those obtained from DSC (Fig. 1e), but differ by ca. 10 °C in the specific value. This discrepancy is primarily attributed to the 1 Hz oscillating force employed in the DMA measurement, consistent with previous reports.65,66 Following the thermal transition, a rubbery regime appears in all PAOU films, and the E′ values of the rubbery plateau converge to approximately 4.5 MPa for all samples (Fig. 1f), reaffirming their comparable cross-link densities.
The stress–strain curves of all three PAOUs display plastic-like tensile behavior, with stress at break values of 32–64 MPa and strain at break values of 7–63% (Fig. 1g). Among them, PAOU-TMDI and PAOU-HMDI outperform their counterparts in terms of extensibility and rigidity, respectively. More specifically, varying the diisocyanate cross-linker from TMDI to HDI and HMDI leads to a progressive increase in stress at break and a decrease in strain at break (Fig. 1g). This is mainly because of the increased Tg that restricts polymer chain mobility and thereby enhances stiffness at the expense of extensibility (Fig. 1e).
Systematic comparisons of PAOU-HDI and a poly(OU) sample (lacking the β-ketoester substituent; synthesis details are provided in the SI) in thermal, thermomechanical, and mechanical properties were made. As shown in Fig. 1e–g, they demonstrate that PAOU-HDI shows higher stress at break (38 vs. 24 MPa), Young's modulus (360 vs. 169 MPa), and toughness (6.6 vs. 5.3 MJ m−3), and higher Tg determined by both DSC (36 vs. 20 °C) and DMA (41 vs. 37 °C) than those of the poly(OU) control. The performance enhancement is partially due to the presence of two carbonyl groups in AOU, which serves as hydrogen-bonding acceptors for urethane amine protons.58,62 We then employed Density Functional Theory (DFT) calculations (M06-2X/def2-TZVP) to investigate the hydrogen bonding interactions. It shows that the hydrogen bond between two AOUs exhibits a higher calculated intensity of 2.2 kcal mol−1 as compared to only 1.8 kcal mol−1 present in two normal OUs (Fig. S2). Thus, the increased number and intensity of hydrogen bonds jointly strengthen the polymer networks.
The challenge of doing so arises from the high reactivity of isocyanates that can recombine with nucleophiles or undergo side reactions such as hydrolysis, biuret formation, and trimerization during depolymerization.51 Here, we drew inspiration from reactive distillation strategies used for recovering reactive cyclic monomers via ring-closing depolymerization,65,74 and adopted a vacuum distillation set-up to continuously separate the dissociated species. The depolymerization of PAOU-HDI was then carried out at a moderate temperature (140 °C) for 3 h under a reduced pressure of 0.01 Pa (Fig. 2a and S3). Under these conditions, recovery of both TAO and HDI in high yields of 82% and 87%, respectively, was enabled, with high chemical purity as confirmed by 1H NMR spectroscopy (Fig. 2b and c). The high quality of the recovered materials was further supported by their repolymerization under the same conditions for the preparation of the parent PAOU-HDI, which refurnished the polymer networks with thermomechanical and mechanical properties comparable to those of the initial ones (Fig. 2d and e). However, the same depolymerization treatment for the normal poly(OU) results in substantially lower recovery yields of oximes (11%) and HDI (14%). This marked difference highlights the significance of the β-ketoester substituent in improving the recycling efficiency of PAOU.
The good performance and closed-loop recyclability of PAOUs potentially position them as attractive polymeric substrates for the fabrication of recyclable thermosetting composites. To confirm this, we endeavored to use PAOUs to prepare engineering materials through compositing with carbon fibers (CFs), which were subsequently subjected to chemical recycling analysis. The composite was fabricated by first impregnating CFs with the reaction mixture of TAO and HDI, followed by post-curing of the prepreg in a drying oven at 40 °C for 48 h. The resulting material exhibits significant improvement in tensile strength to 607 MPa in comparison to 38 MPa for neat PAOU-HDI and 428 MPa for CFs (Fig. 2f). Noteworthily, when we applied the vacuum distillation treatment on the composite, both TAO and HDI were afforded in high yields of 76% and 83%, respectively, and in high quality (Fig. S4 and S5). Effective recovery of the valuable CFs is also achieved; SEM (Fig. 2g) and EDX (Fig. 2h, S6 and S7) analyses on the original and recycled CFs show that no distinguishable difference is noted, suggesting good retention of their morphology and chemical structure after the recycling.
Although chemical recycling is particularly advantageous for reusing CF-reinforced composites due to their non-flowable nature, thermal reprocessing remains a more energy- and resource-efficient approach.75,76 Thus, we subsequently explored the reprocessability of PAOU networks. Their flowability, an essential parameter for assessing polymer reprocessability and determining feasible reprocessing conditions, was initially examined by stress relaxation experiments.31,57 The results demonstrate that all three samples are capable of relaxing their stress in the temperature tested between 90 and 120 °C, with the stress dissipated at a faster rate at higher temperature (Fig. S8a–c). The increased stress relaxation rate primarily originates from the accelerated exchange reactions between AOUs at higher temperatures (Fig. S9a), which enable the polymer networks to rearrange themselves more easily. Arrhenius analysis of the relaxation times yields Ea for stress relaxation that is comparable across all three PAOU networks, ranging from 36.8 to 38.5 kcal mol−1 (Fig. S8d). This is a result of the same dynamic AOU bonds that serve as their network cross-links.
The stress-relaxation behavior guided us to reprocess the polymers by compression-molding at 100 °C under a pressure of 10 MPa for 0.5 h. The treatment refurnished homogeneous films even after being repeated three times, with the demonstration of the reprocessing of PAOU-HDI shown in Fig. S9(b). FTIR analysis, DSC and tensile testing measurements were conducted on the reprocessed PAOUs, with the results compared with those of the original materials (Fig. S9c–k). Gratifyingly, no discernible differences were observed before and after the reprocessing, confirming the excellent recovery of the chemical structures and thermal and mechanical properties, which demonstrates the good reprocessability of the materials.
The impact of β-ketoester on thermodynamic equilibrium of the reactions was next investigated by reacting 1 with either an acetoacetated oxime (AO) or a normal oxime, namely 2-butanone oxime (BO), at room temperature for 48 h (Fig. S12 and S13). After the reaction, BO was converted to OU nearly quantitatively, whereas the conversion of AO to AOU reached ca. 82%, independent of the initial stoichiometry (Fig. S12 and Tables S2–S3). Calculation of the reaction equilibrium constants, Keq, shows that varying the amount of 1 relative to AO from 0.9 to 1.1 equiv. leads to a gradual decrease in Keq from 111 to 51 M−1 (Fig. 3d), probably due to competing side reactions involving isocyanates. Under stoichiometric conditions, the Keq for AOU formation is nearly two orders of magnitude lower than that for the OU-forming reaction (69 vs. 4944 M−1). This reduced Keq indicates that incorporation of the β-ketoester substituent shifts the equilibrium toward the dissociated state, thereby favoring the formation of free AOs and isocyanates.
We next explored the mechanism underlying the reversibility of AOU bonds. Given their structural similarity to normal OU bonds and Knoevenagel adducts, both of which are known to undergo thermally induced metathesis,48,77–81 we anticipated that AOUs would exhibit similar associative exchange behavior (Fig. 3e). To validate this, two AOU compounds were mixed in an equimolar ratio and heated at 90–110 °C. Reaction progress was monitored by High-Performance Liquid Chromatography (HPLC), which confirmed successful exchange between the two species, affording two additional AOU compounds (Fig. S15). The reaction rate increases with temperature, indicating thermally accelerated exchange kinetics (Fig. 3e). In parallel, the dissociative capability of AOU was assessed by temperature-variable FTIR spectroscopy. Upon heating from 70 °C to 120 °C, the characteristic C
N stretching band at 1644 cm−1 progressively decreases and shifts to 1630 cm−1, while the isocyanate absorption at 2240 cm−1 becomes increasingly pronounced (Fig. 3f). These spectral changes provide clear evidence for thermal dissociation of AOU bonds into isocyanate and AO groups (Fig. 3f). Taken together, these results demonstrate that AOU linkages can undergo reversible reactions through both associative and dissociative mechanisms (Fig. 3e and f).
To further gain mechanistic insight, we then carried out DFT calculations (M06-2X/def2-TZVP) on the reactions of isocyanate 1 with AO, and also with BO as a control (Fig. 4). Prior to nucleophilic addition to 1, both AO and BO undergo isomerization to their corresponding nitrone tautomers (AO1 and BO1). For AO, this transformation proceeds via a unimolecular pathway facilitated by conjugation between the β-ketoester and oxime functionalities, which promotes intramolecular proton transfer (Fig. S18). In contrast, such a pathway is energetically unfavorable for BO due to the absence of the β-ketoester substituent, as evidenced by the high calculated Gibbs free energy (ΔG0) of 51.5 kcal mol−1 for the corresponding transition state BO-TS1 (Fig. S19). Inspired by previous studies,48,82 a bimolecular pathway was adopted, involving an initial association of two BO molecules to form a six-membered cyclic complex through intermolecular hydrogen bonding, followed by proton transfer within the complex and subsequent dissociation into two BO1 species (Fig. S20). This bimolecular isomerization route is chemically sound, with calculated ΔG0 not exceeding 16.6 kcal mol−1 along the reaction coordinate.
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| Fig. 4 Gibbs free energies (ΔG0) of the stationary points for the reaction of isocyanate 1 with AO (top) or BO (bottom) to form AOU1 or OU1, respectively. | ||
The nitrone intermediates AO1 and BO1 subsequently undergo nucleophilic addition to the isocyanate functionality and afford the corresponding transition states AOU-TS2 and OU-TS2, with calculated ΔG0 values of 26.5 and 22.8 kcal mol−1, respectively (Fig. 4). These values correspond to the Ea for AOU and OU formation, indicating slightly lower kinetics for accessing AOU. This trend is consistent with experimental observations, where the reaction rate constant for affording OU is 6.3 × 10−5 s−1, triple that (2.1 × 10−5 s−1) for AOU formation (Fig. S21). The calculated Ea values for the reverse reactions are comparable for AOU and OU (30.9 vs. 30.6 kcal mol−1), suggesting similar kinetic accessibility for bond cleavage. However, AOU exhibits a ΔG0 of −4.4 kcal mol−1, which is less negative than −7.8 kcal mol−1 of OU, substantiating its reduced thermodynamic stability and a greater propensity for dissociation.
Altogether, the combined experimental and computational results demonstrate that the β-ketoester substituent primarily modulates the thermodynamic landscape of the reversible reaction, favoring bond dissociation without significantly altering the kinetic barrier for cleavage. This shift in equilibrium increases the concentration of free AOs and isocyanates under reaction conditions. When coupled with vacuum-assisted distillation, this thermodynamic bias facilitates efficient separation and recovery of the dissociated species, thereby accounting for the enhanced recycling efficiency observed in PAOU networks.
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