Exploiting the Use of the Decarboxylative S-Alkylation Reaction to Produce Self-Blowing, Recyclable Polycarbonate Foams

Polymeric foams are widely used in many industrial applications due to their light weight and superior thermal, mechanical, and optical properties. Currently, increasing research efforts is being directed towards the development of greener foam formulations that circumvent the use of isocyanates/blowing agents that are commonly used in the production of foam materials. Here, a straightforward, one-pot method is presented to prepare self-blown polycarbonate (PC) foams by exploiting the (decarboxylative) S-alkylation reaction for in situ generation of the blowing agent (CO2). The concomitant formation of a reactive alcohol intermediate promotes a cascade ring-opening polymerization of the cyclic carbonates to yield a cross-linked polymer network. It is shown that these hydroxyl-functionalized polycarbonate-based foams can be easily recycled into films through thermal compression molding. Furthermore, it is demonstrated that complete hydrolytic degradation of the foams is possible, thus offering the potential for zero-waste materials. This straightforward and versatile process broadens the scope of isocyanate-free, self-foaming materials, opening a new pathway for next-generation environmentally friendly foams.

Automated summary

Polymeric foams are widely used in industries due to their light weight and superior properties. This study presents a one-pot method to prepare self-blown polycarbonate foams using a reaction that generates blowing agent in situ. These foams can be easily recycled and degraded, offering a potential for zero-waste materials. This versatile process opens a pathway for environmentally friendly foams.