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Given their ubiquity in modern society, the development of biodegradable and renewably sourced plastics is essential for the creation of an environmentally sustainable society. One of the drawbacks for currently available biodegradable plastics such as poly(l-lactic acid) (PLLA) and polyhydroxyalkanoates (PHAs) is that it is difficult to simultaneously achieve mechanical flexibility and certain crystallization behavior in these materials, which limits their use as replacements for established petroleum-based plastics such as isotactic polypropylene (iPP). Here, we report the synthesis and characterization of a new biodegradable plastic, poly(3-hydroxy-2-methylbutyrate) [P(3H2MB)], which is a member of the bacterial PHA family whose members include an α-methylated monomer unit. Biosynthesis of P(3H2MB) was achieved using recombinant Escherichiacoli expressing an engineered pathway. Biosynthesized P(3H2MB) exhibited the highest melting temperature (197 °C) among the biosynthesized PHAs and improved thermal resistance. It also exhibited improved crystallization behavior and mechanical flexibility nearly equal to those of iPP. The primary nucleation rate of P(3H2MB) was faster than that of P(3HB), and the spherulite morphology of P(3H2MB) was much finer than that of P(3HB). This crystal morphology may result in more rapid crystallization behavior, increased transparency, and enhanced mechanical properties. The superior physical properties of P(3H2MB) have the potential to open new avenues for the production of high-performance biodegradable plastics for replacing petroleum-based bulk commodity plastics.

3-Hydroxy-2-methylbutyrate (3H2MB) has been identified as a minor component of polyhydroxyalkanoates (PHAs) synthesized by bacteria living in activated sludge. In this study, we found that PHA synthase derived from Aeromonas caviae (PhaC Ac ) polymerizes 3H2MB. By expressing PhaC Ac in recombinant Escherichia coli LS5218 and growing cells in the presence of tiglic acid, a PHA copolymer [P(3HB-co-3H2MB)], mainly consisting of 3-hydroxybutyrate (3HB) and up to 37 mol% 3H2MB, was obtained. Analysis of the thermal properties of this novel copolymer indicates that incorporation of 3H2MB into P(3HB) sequence reduced the glass transition temperature (T g ), melting temperature (T m ), and melting enthalpy (DH m ). The cold crystallization temperature (T cc ) was also lowered by incorporating 7 or 23 mol% 3H2MB, in contrast to the findings for other PHA copolymers. This result suggests that P(3HB-co-3H2MB) copolymers are easier to crystallize than P(3HB) and other PHAs. Thus, 3H2MB provides promising new opportunities to generate 3HB-based polymers with novel thermal properties.

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