Non-isocyanate polyurethane: from the monomer synthesis to foamed materials

Polyurethane (PU) is one of the most important polymers in our everyday life with numerous applications such as thermosets, thermoplastics, elastomers, adhesives, sealants, coatings, rigid and flexible foams... Classically, PUs are produced by a step-growth polymerization between diols and diisocyanates. However, isocyanates are harmful upon prolonged exposure to vapours which can lead to health issues such as asthma and skin irritation. In addition, isocyanates are produced from even more toxic and explosive phosgene. Due to these problems in combination with increasing regulatory scrutiny, there is today a need to develop isocyanate- and phosgene free- PU synthesis, also called non-isocyanate polyurethane or NIPUs. One of the most promising alternatives to the conventional synthesis of PU relies on the step-growth polymerization between bicyclic carbonate monomers and diamines, but until now, obtaining high molar mass NIPUs in a short time still remains a challenge. This study will be focused on three objectives:
1) The synthesis of CO2-sourced biscyclic carbonates by CO2/epoxide coupling using new highly efficient bicomponent organocatalysts allowing the fast conversion of epoxides into the corresponding cyclic carbonates under mild and solvent-free conditions.
2) The synthesis of high molar mass NIPUs from CO2-sourced monomers and diamines thanks to the use of efficient organocatalysts. A series of organic compounds interacting with cyclic carbonates by hydrogen bonding were first identified and their catalytic activity was highlighted by a model reaction between ethylene carbonate and a primary amine before extrapolation to NIPU synthesis.
3) The scCO2-assisted foaming of CO2-sourced NIPUs with production of potential carbon zero-emission materials with low thermal conductivity