Integrating Sustainability into High Performance Polyurethanes and Engineering Polymers

Engineering polymers are critical for contemporary high-performance applications where toughness, thermal stability, and density are at a premium. These materials often demand high-energy processing conditions or highly reactive monomers that hold negative impacts on human and environmental health. Thus, this work serves to remediate the negative impacts of engineering polymer synthesis by addressing toxicity and processing at the monomer level, while maintaining or exceeding previous thermomechanical and stimuli-responsive performance. Polyurethanes (PUs) represent a class of engineering polymers that possess highly modular properties due to the diverse monomer selection available for their synthesis. The efficient reaction between isocyanates and hydroxyls impart stellar properties and flexible processing modalities, however recent scrutiny regarding the toxicity of the isocyanate precursors has driven the search for non-isocyanate polyurethane (NIPU) pathways. The advancement of bis-carbonylimidazolide (BCI) monomers for the synthesis of NIPU thermoplastics and foams is thoroughly investigated in this work. Remarkably, a novel decarboxylation pathway for BCI monomers controlled by catalyst loading enabled in-situ CO2 generation during crosslinking with trifunctional amines, and resulted in a facile synthetic route for NIPU foams. Further explorations into catalyst considerations revealed Dabco® 33-LV as a suitable mechanism for controlling reaction times and careful selection of surfactant concentration provided control over pore size and geometry. This led to a library of flexible and rigid NIPU foams that displayed a wide range of thermomechanical properties. Furthermore, sequestration of the imidazole byproduct through an efficient Michael reaction identified maleimide and acrylate additives as a viable pathway to eliminate post-processing steps resulting in NIPU foam synthesis that is amenable to current industrial standards. This route held advantages over the isocyanate route, as condensate removal drove molecular weight increase and ultimately achieved the first reported phase separation behavior of a NIPU thermoplastic containing a poly(ethylene glycol) soft segment. Furthermore, sustainable considerations for engineering polymers were explored with the introduction of a novel cyclobutane bisimide monomer that readily installs into various polymeric systems. Direct installation of this monomer, CBDA-AP-I, into a polysulfone backbone enabled controlled photo-cleavage, while further hydroxy ethyl functionalization allowed for incorporation into PU systems for photo-cleavable high-performance adhesive applications.