Polymer networks that are cross-linked by dynamic covalent bonds often sacrifice the robust mechanical properties of traditional thermosets in exchange for rapid and efficient reprocessability. Polyurethanes are attractive materials for reprocessable cross-linked polymers because of their excellent mechanical properties, widespread use, and ease of synthesis, but their syntheses typically rely on harmful isocyanate precursors. Polyhydroxyurethanes (PHUs), derived from amines and cyclic carbonates, are promising alternatives to traditional polyurethanes. PHU networks are reprocessable via transcarbamoylation reactions even in the absence of external catalysts, but this process occurs over hours at temperatures above 150 °C. We have dramatically shortened the reprocessing times of PHU networks by incorporating dynamic disulfide bonds. Using cystamine as a comonomer gives materials with similar thermal stability and mechanical properties to other rigid cross-linked PHUs. Despite their excellent mechanical properties, these materials show rapid stress relaxation and have characteristic relaxation times as low as 30 s at 150 °C. This property enables reprocessing with quantitative recovery of cross-link density as measured by DMTA after only 30 min of elevated-temperature compression molding. Disulfide incorporation is a promising approach to obtain reprocessable, crosslinked PHU resins that are not derived from isocyanates.

Cross-linked polyurethane (PU) is extensively used as thermoset foam; however, methods to directly reprocess PU foam waste derived from commercial sources into similar value materials have not been developed. We demonstrate that introducing dibutyltin dilaurate (DBTDL) into cross-linked PU foams and films enables their reprocessing at elevated temperatures via dynamic carbamate exchange reactions. Both model and commercial cross-linked PU foams were continuously reprocessed using twin-screw extrusion to remove gaseous filler and produce PU filaments or films with elastomeric or rigid thermoset mechanical properties. The properties of microcompounded model PU foam were in excellent agreement with PU film synthesized using the same monomers, indicating that this process occurs efficiently. These findings will enable the bulk reprocessing of commercial thermoset PU waste and inspire the further development of reprocessing methods for other thermosets and the compatibilization of chemically distinct cross-linked materials.

Transforming how plastics are made, unmade, and remade through innovative research and diverse partnerships that together foster environmental stewardship is critically important to a sustainable future. Designing, preparing, and implementing polymers derived from renewable resources for a wide range of advanced applications that promote future economic development, energy efficiency, and environmental sustainability are all central to these efforts. In this Chemical Reviews contribution, we take a comprehensive, integrated approach to summarize important and impactful contributions to this broad research arena. The Review highlights signature accomplishments across a broad research portfolio and is organized into four wide-ranging research themes that address the topic in a comprehensive manner: Feedstocks, Polymerization Processes and Techniques, Intended Use, and End of Use. We emphasize those successes that benefitted from collaborative engagements across disciplinary lines.

The reprocessing or recycling of cross-linked polymers by incorporating dynamic covalent cross-links has the potential to increase their usable lifetimes and reduce their environmental impact. Polyurethanes (PUs) are among the largest class of cross-linked polymers, making up 31% of the thermosetting materials market in 2012; however, their direct recycling into similar value materials is not well developed. We demonstrate that several Lewis acid catalysts mediate urethane exchange, likely via a dissociative mechanism, selectively and under mild conditions. Incorporating these catalysts into cross-linked polyether and polyester PUs with structures similar to commercial PU thermosets gives cross-linked materials that can completely relax stress in 100 s at temperatures as low as 140 °C. The dynamic polymers were reprocessed via compression molding to provide materials with similar cross-linking densities to assynthesized materials. Because these systems are based on commercially available PU monomers and inexpensive Lewis acid catalysts, we anticipate that these findings will enable the recycling of traditional thermosetting PUs.

Covalent organic frameworks (COFs) generally leverage one or two monomers with specific sizes and shapes to access highly symmetric and periodic polymer networks. Almost all reported COFs employ the minimum sets of monomers needed for the polymerization (usually two, sometimes one) and crystallize in high-symmetry topologies. COFs synthesized from more than two monomers usually employ mixtures with different pendant functionalities to distribute these groups statistically throughout the structure, or monomers with different sizes in ratios targeting lower symmetry topologies. Here, we demonstrate that mixtures of monomers with different lengths generate single-phase, hexagonal two-dimensional covalent organic framework (2D COF) solid solutions at continuously variable feed ratios. X-ray diffraction measurements, Fourier-transform infrared spectroscopy, and Pawley refinement indicate that both monomers distribute randomly within the same lattice, and the lattice parameters continuously increase as more of the larger linker is incorporated. Furthermore, COF solid solutions are accessed directly by polymerizing a mixture of monomers but not via linker exchange from a preformed COF. As strain develops from the lattice accommodating monomers with different sizes, the nonlinear relationship between the monomer incorporation and the COF's lattice parameters suggests that bond-bending of the monomers plays a role in incorporating monomers of different lengths into the solid solutions. Solid solution formation represents a new strategy to design 2D COFs and increase their complexity. Specifically, varying the monomer composition of a given network enables many properties, such as the average pore size, to be continuously tuned between those of corresponding pure COFs.