Block copolymer synthesis by controlled/living radical polymerisation in heterogeneous systems

Nanostructured soft materials open up new opportunities in material design and application, and block copolymer self-assembly is one particularly powerful phenomenon that can be exploited for their synthesis. The advent of controlled/living radical polymerisation (CLRP) has greatly simplified block copolymer synthesis, and versatility towards monomer types and polymer architectures across the different forms of CLRP has vastly expanded the range of functional materials accessible. CLRP-controlled synthesis of block copolymers has been applied in heterogeneous systems, motivated by the numerous process advantages and the position of emulsion polymerisation at the forefront of industrial latex synthesis. In addition to the inherent environmental advantages of heterogeneous routes, the incidence of block copolymer self-assembly within dispersed particles during polymerisation leads to novel nanostructured materials that offer enticing prospects for entirely new applications of block copolymers. Here, we review the range of block copolymers prepared by heterogeneous CLRP techniques, evaluate the methods applied to maximise purity of the products, and summarise the unique nanoscale morphologies resulting from in situ self-assembly, before discussing future opportunities within the field

Sustainable synthesis and precise characterisation of bio-based star polycaprolactone synthesised with a metal catalyst and with lipase

Bio-based building blocks and sustainable synthesis pathways were used to synthesise star-shaped polymers composed of a D-sorbitol core and polycaprolactone arms by ring opening polymerisation (ROP). The use of volatile organic solvents was avoided and less energy intense reaction conditions were achieved by performing the ROP in the bulk or in a green solvent, supercritical CO2 (scCO2). Two catalysts were tested: conventional tin(II) 2-ethylhexanoate (Sn(Oct)2) which is a Food and Drug Administration (FDA) approved metal catalyst and an enzyme, Novozym 435 (Lipase B from Candida Antarctica immobilised on a solid support). The influence of the reaction medium and of the nature of the catalyst on the molecular weight, the dispersity and the architecture of the PCL stars was investigated. The star polymers were characterised by 1H and 31P nuclear magnetic resonance (1H and 31P NMR) spectroscopy, size exclusion chromatography – multi-angle light scattering (SEC-MALS) and matrix-assisted laser desorption and ionisation-time of flight (MALDI-TOF) mass spectrometry. The use of scCO2 enabled the reduction of the reaction temperature of Sn(Oct)2 catalysed star D-sorbitol-polycaprolactone polymerisations from 140 to 95 °C. In addition, star polymers were successfully synthesised by enzyme catalysis in the bulk or in scCO2 at 60 °C; lower temperatures that could provide significant energy savings on a commercial scale. Thecatalyst was shown to have a pronounced influence on the architecture of the PCL stars. Regular star polymers were obtained in the presence of Sn(Oct)2 whereas Novozym 435 gave access to miktoarmtype star PCL. Finally, the influence of the number and length of the arms on the thermal properties of the star polymers was investigated by differential scanning calorimetry (DSC)

Supercritical carbon dioxide: putting the fizz into biomaterials

This paper describes recent progress made in the use of high pressure or supercritical fluids to process polymers into three-dimensional tissue engineering scaffolds. Three current examples are highlighted: foaming of acrylates for use in cartilage tissue engineering; plasticization and encapsulation of bioactive species into biodegradable polyesters for bone tissue engineering; and a novel laser sintering process used to fabricate three-dimensional biodegradable polyester structures from particles prepared via a supercritical route

Synthesis of two-phase polymer particles in supercritical carbon dioxide

The synthesis of particles with discrete phases using traditional emulsion polymerisation is a well-established process. Phase-separated particles have a wide range of applications, such as in coatings, drug delivery, impact modification and as supports in catalysis. However, as a dry powder is often desired for the end application, post-polymerisation, energy intensive drying steps are usually required for the removal of water. Alternatively, dispersion polymerisation utilising supercritical carbon dioxide (scCO2) as a reaction medium allows for the production of dry, free-flowing powders upon release of the CO2. Here, we present the innovative use of scCO2 to provide a novel and environmentally acceptable route for creating phase-separated particles. Particles containing a high Tg poly(methyl methacrylate) (PMMA) phase, combined with a low Tg polymer phase of either poly(benzyl acrylate) (PBzA) or poly(butyl acrylate) (PBA), were investigated. Both monomers were added to the reaction after the formation of PMMA seed particles. Benzyl acrylate (BzA) was chosen as a model low Tg monomer, with well-defined and detectable functionality when mixed with PMMA. Butyl acrylate (BA) was also used as an alternative, more industrially relevant monomer. The loading of the low Tg monomer was varied and full characterisation of the particles produced was performed to elucidate their internal morphologies and compositions

In situ Crosslinking of Nanostructured Block Copolymer Microparticles in Supercritical Carbon Dioxide

We report a novel and facile approach to “fix” the internal nanostructure of block copolymer (BCP) microparticles via in situ crosslinking copolymerisation in dispersion in supercritical CO2 (scCO2). By delaying the addition of the crosslinker and a portion of the second monomer, polymerisation induced microphase separation (PIMS) within the microparticles is well preserved, while the growing chains of precursor poly(methyl methacrylate)-block-poly(4-vinyl pyridine) (PMMA-b-P4VP) or poly(methyl methacrylate)-block-poly(benzyl methacrylate) (PMMA-b-PBzMA) microparticles are crosslinked. The unique structure of the as-synthesised crosslinked microparticles were fully characterised using transmission electron microscopy (TEM), scanning electron microscopy (SEM) and atomic force microscopy (AFM). Moreover, the swelling and solubility behaviour of the crosslinked PMMA-b-P4VP microparticles was investigated. Notably, the porosity generated by swelling in ethanol can be well controlled by the quantity of crosslinker incorporated. Macropores > 100 nm – ~20 nm, sub-10 nm mesopores, and non-porous microparticles were all achieved by varying the crosslinker incorporation from 0, 0.5, 1, to 4 wt%, respectively. In situ AFM nanomapping of the crosslinked P4VP domains in 80% humidity revealed that microparticles with a high degree of crosslinking (8 wt% divinylbenzene) are highly resistant to swelling in humidity, by contrast to their non-crosslinked counterparts. This versatile approach further expands the available repertoire for fabricating porous BCP microparticles with tunable physico-chemical properties, morphologies and pore sizes, greatly broadening their application potential to more diverse fields

New renewably-sourced polyesters from limonene-derived monomers

The functionalisation of limonene has enabled the synthesis of two renewably-sourced monomers for the formation of terpene-derived polyesters. Three methods for the synthesis of the novel hydroxy-acid 6 are reported and their green-credentials scrutinised through comparison of their sustainability-metrics. Step-growth homo-polymerisation of 6 is demonstrated to yield a low molecular weight (2.6 kDa) novel polyester with 100% of its carbon content originating from the terpene starting material. The corresponding diol 2 is shown to act as a co-monomer with a renewable diacid. The resultant polyesters display impressive Mns of up to 30 kDa with Tgs between −6 and 24 °C. These materials have been shown to depolymerise under basic conditions for reclamation of the diol monomer 2

Versatile routes to functional RAFT chain transfer agents through the Passerini multicomponent reaction

The widespread adoption of RAFT polymerization stems partly from the ease and utility of installing a functional chain transfer agent onto the ends of the generated polymer chains. In parallel, the Passerini multicomponent reaction offers great versatility in converting a wide range of easily accessible building blocks to functional materials. In this work, we have combined the two approaches such that a single, commonly available, RAFT agent is used in Passerini reactions to generate a variety of multifunctional RAFT chain transfer agents containing ester linkages. Reactions to generate the multifunctional RAFT agents took place under mild conditions and in good yields. The resulting Passerini-RAFT agents were able to exert control over radical polymerization to generate materials of well-defined molecular weights and dispersity. Furthermore, the presence in these polymer cores of ester and amide functionality through the Passerini chemistries, provided regions in the materials which are inherently biodegradable, facilitating any subsequent biomedical applications. The work overall thus demonstrates a versatile and facile synthetic route to multi functional RAFT chain transfer agents and biodegradable polymers

Highly coloured and electrophoretically active polymer microparticles via staggered dispersion polymerisation in supercritical carbon dioxide and dodecane

Devices featuring electrophoretic displays (EPD) have become extremely popular in recent years because of their low power consumption, high readability and thin display designs, but a product with a full colour gamut comparable with liquid crystal displays (LCDs) has not yet been commercialised. In this article, we demonstrate that staggering the addition of methyl methacrylate (MMA) monomer and low quantities of a coloured dye crosslinker is an effective route to producing well-defined and covalently-linked, strongly coloured PMMA microparticles in one-pot, via dispersion polymerisation in supercritical carbon dioxide (scCO2). This novel methodology is synthetically simple, readily scalable and has the added cachet of being cost effective because the functional molecules can be confined on the microparticle surface such that even at low concentrations, the resulting materials are brightly coloured. We then demonstrate the applicability of this approach to another functional comonomer/crosslinker system in 2-dimethylaminoethyl methacrylate (DMAEMA)/ethyleneglycol dimethacrylate (EGDMA), in this case allowing hierarchically structured ‘pomegranate-like’ microparticles with polarisable charge to be produced over a range of DMAEMA loadings as high as 44 wt%. Finally, the performance of these materials in out-of-plane EPD test cells is compared against analogues synthesised in dodecane. These tests revealed that the coloured microparticles fabricated in scCO2 performed as well as or better than their dodecane synthesised counterparts, consistently producing the cleanest white state and achieving effective colour switching over ten cycles

One-pot synthesis of micron-sized polybetaine particles: innovative use of supercritical carbon dioxide

Polybetaines exhibit unique properties combining anti-polyelectrolyte and low protein fouling behaviour, as well as biocompatibility. To date, the synthesis of polybetaine particles >50 nm has proved to be extremely challenging with standard emulsion and dispersion techniques being unsuccessful. Here we present the first reported synthesis of micron-sized, discrete cross-linked polybetaine particles, using polymerisation in scCO2 with methanol as a co-solvent. Discrete particles are produced only when the methanol is efficiently removed in situ using scCO2 extraction. A relatively high crosslinking agent initial concentration (10 wt%) was found to result in the most well defined particles, and particle integrity reduced as the crosslinking agent initial concentration was decreased. A monomer loading of between 3.0 × 10−2 mol L−1 and 1.8 × 10−1 mol L−1 resulted in discrete micron sized particles, with significant agglomoration occuring as the monomer loading was increased further. A spherical morphology and extremely low size dispersity was observed by SEM analysis for the optimised particles. The particles were readily re-dispersed in aqueous solution and light scattering measurements confirmed their low size dispersity

Enzymatic One-Pot Synthesis of Renewable and Biodegradable Surfactants in Supercritical Carbon Dioxide (scCO2)

We seek to expand the opportunities to exploit glycerol, a largely untapped renewable feedstock, by exploiting enzymatic catalysis in supercritical carbon dioxide (scCO2). This work highlights a promising and clean approach to bio-renewable amphiphilic polyester-based biodegradable surfactants. We have developed a low temperature (40, 50 and 60 °C), low energy melt processing route to biodegradable, renewable poly(glycerol succinate) (PGLSA) polymers that importantly have a low degree of branching (3% 85%) or insoluble crosslinked materials. We have exploited these linear PGLSA materials to create a library of ‘green’ surfactants by end-capping with lauric acid or poly(ethylene glycol). Our approach avoids pre-modification of the monomers and fewer synthetic steps are required. Finally, we evaluate the performance of these new surfactants, focussing upon surface tension, critical aggregation concentration (CAC) and water contact angle