Patent Application
20220340707
The present invention relates generally to polymer chemistry and particularly to the synthesis of a novel bifuran copolyester. In certain aspects, the invention also relates to food and beverage packaging materials.
Recently, there has been an increased focus on obtaining polymeric materials derived from renewable resources. This growing trend is aiming at finding replacements to fossil-based resources and materials such as poly(ethylene terephthalate), PET, a high performance plastic that is especially prevalent in packaging due to its gas barrier properties, transparency, and mechanical strength.
Biomass offers a promising renewable alternative to fossil resources, as production of chemicals and materials can be achieved in a carbon-neutral way. In particular, furans are bio-based platform-chemicals, which are easily prepared from plant-based biomasses. Moreover, furans have long been studied as potential precursors for various types of polymers such as thermosets and thermoplastics. More recently, polyesters have become a particularly prominent area of research.
As simple dehydration products of monosaccharides, furans are key bio-based aromatic chemicals with various uses. Moreover, furan-based polyesters, in particular poly(ethylene furanoate) (PEF), possess advantageous material properties. PEF is known to have low oxygen and carbon dioxide permeability, even when compared to PET, a well-known packaging polyester. Reduced permeability to various gases can lead to higher performance packaging.
2,2′-Bifuran-5,5′-dicarboxylic acid (BFDCA) has recently been described as another furan-based precursor for novel bio-based polyesters (Kainulainen et al., 2018, Miyagawa et al, 2018). As a furan “dimer”, BFDCA consists fully of bio-based carbon. It has been shown that BFDCA-based homopolyesters, e.g. poly(ethylene bifuranoate) (PEBf), have relatively high glass-transition temperatures, and that the highly conjugated molecular structure of the bifuran monomer provides inherent ultraviolet (UV) light absorption. In addition, it was shown that PEBf possesses lower O2 and water vapor permeability than PET. In the present invention, the synthesis of new random copolyesters comprising BFDCA structures is presented. Thermal and mechanical properties of the copolyesters are then compared to the pure homopolyesters.
The present invention is based on a discovery that, surprisingly, the UV light absorption property provided by BFDCA structures for the homopolyester retains in a mixed copolyester even in the case when the copolymer comprises a relatively low number of BFDCA structures. UV-protecting plastics or coatings are useful in food packages and, e.g., in photovoltaic cells, as organic solar cells can retain more of their efficiency over time when properly protected from UV radiation. Further, the novel copolyesters are also promising oxygen and water barrier materials.
Accordingly, in several embodiments, the present invention provides a copolyester comprising repeating units of (i) a 2,2′-bifuran-5,5′-dicarboxylic monomer residue, (ii) a diol monomer residue and (iii) an aliphatic or cycloaliphatic C3-C8 dicarboxylic monomer residue or an aromatic C6-C8 dicarboxylic monomer residue.
In certain aspects, the present invention provides a film or coating comprising or consisting of said copolyester.
In certain aspects, the present invention provides an article or packaging material comprising or consisting of said copolyester, preferably for use in food or beverage packaging.
In other related aspects, the present invention provides a method of preparing a bifuran copolyester, the method comprising the steps of:
a) combining at least (i) a bifuran of Formula
wherein R1 and R2 are each independently selected from the group consisting of: —H, —CH3, —CH2CH3, —(CH2)2CH3, —CH(CH3)2, —(CH2)3CH3, —(CH2)2OH, —(CH2)3OH, —(CH2)4OH, —(CH2)5OH, —(CH2)6OH, —(CH2)7OH, —(CH2)8OH, and
(ii) a diester of an aliphatic or cycloaliphatic C3-C8 dicarboxylic monomer residue or of an aromatic C6-C8 dicarboxylic monomer residue;
(iii) an aliphatic, cycloaliphatic or aromatic C1-C8 diol and (iv) a metal catalyst to form a reaction mixture;
b) subjecting the mixture combined in step a) to a temperature in the range of from about 140° C. to about 220° C. under an inert atmosphere; and
c) performing polycondensation to the mixture obtained in step b) by heating under reduced pressure to a temperature in the range of from about 210° C. to about 260° C.
In a further aspect, the present invention is directed to a use of a diester of 2,2′-bifuran-5,5′-dicarboxylate in preparing copolyesters having ultraviolet light (UV) blocking properties.
The term “polyester” as used herein is inclusive of polymers prepared from multiple monomers that are referred to herein as copolyesters. Terms such as “polymer” and “polyester” are used herein in a broad sense to refer to materials characterized by repeating moieties or units. The polyesters as described herein may have desirable physical and thermal properties and can be used to partially or wholly replace polyesters derived from fossil resources, such as poly(ethylene terephthalate), PET.
In the context of the present specification, ester monomers preferably comprise the general formula R′OOCRCOOR″, where R may be an alkyl group, or an aryl group, and R′ and R″ may be an alkyl group or an aryl group. Dashed lines in the structure formulas presented herein represent the linkage between a C atom and an 0 atom or between a C atom and another C atom (such as linkages selected from the group consisting of C—R, R—C, R′—O and —O—R″ in the formula R′OOCRCOOR″).
In various aspects described herein, polyesters can be prepared from biomass by utilizing monomers which are obtained from biomass. Furfural and hydroxymethylfurfural (HMF) may be obtained from pentoses and hexoses, respectively. HMF can also be oxidized or reduced to obtain 2,5-furandicarboxylic acid (FDCA). The preparation of dimethyl 2,5-furandicarboxylate and dimethyl 2,2′-bifuran-5,5′-dicarboxylate are described in the Experimental Section below.
In general, polyesters are prepared by reacting a dicarboxylic monomer containing furan and/or other aromatic functionality, and at least one diol. Suitable diols include aliphatic or cycloaliphatic C3-C10 diols, non-limiting examples of which include 1,3-propanediol, 1,4-butanediol, and 1,2-ethanediol.
Unless otherwise clear from context, percentages referred to herein are expressed as percent by weight based on the total composition weight.
The present invention is directed to a copolyester comprising repeating units of (i) a 2,2′-bifuran-5,5′-dicarboxylic monomer residue, (ii) a diol monomer residue and (iii) an aliphatic or cycloaliphatic C3-C8 dicarboxylic monomer residue or an aromatic C6-C8 dicarboxylic monomer residue. Preferably, the molar ratio of (i) the 2,2′-bifuran-5,5′-dicarboxylic residues and (iii) the aliphatic or cycloaliphatic C3-C8 dicarboxylic residues or the aromatic C6-C8 dicarboxylic residues is between 2000:1 and 1:2000 in said copolyester. More preferably, said ratio is 90:10, 75:25, 50:50, 25:75, 10:90, 5:95, 1:100, 1:200, 1:500, 1:1000, 1:2000 or any range between the listed ratios. Most preferably, said range is between 50:50 and 1:2000, between 50:50 and 1:200, between 10:90 and 1:100, 1:200 or 1:2000.
The dicarboxylic monomer residues of the copolyester are preferably derived or obtained from the diesters of said monomers. An example of an diester of the aromatic C6 dicarboxylic monomer residue is dimethyl 2,5-furandicarboxylate, FDCA (see Experimental Section below). An example of an diester of the aromatic Cs dicarboxylic monomer residue is dimethyl terephthalate (DMT):
In a preferred embodiment, said 2,2′-bifuran-5,5′-dicarboxylic monomer residue corresponds to or is derived from the compound of Formula
wherein R1 and R2 are each independently selected from the group consisting of: —H, —CH3, —CH2CH3, —(CH2)2CH3, —CH(CH3)2, —(CH2)3CH3, —(CH2)2OH, —(CH2)3OH, —(CH2)4OH, —(CH2)5OH, —(CH2)6OH, —(CH2)7OH, —(CH2)8OH, and
In preferred embodiments, said aliphatic or cycloaliphatic C3-C8 dicarboxylic monomer residue or said aromatic C6-C8 dicarboxylic monomer residue corresponds to or is derived from the compound of Formula
wherein R1 and R2 are each independently as defined above and R3 is selected from the group consisting of —CH2—, —(CH2)2—, —(CH2)3—, —(CH2)4—, —(CH2)5—, and -(CH2)6—, and the following cyclic ring structures
In another preferred embodiment, the present invention is directed to a bifuran copolyester comprising the structure of Formula
wherein R3 is selected from the group consisting of —CH2—, —(CH2)2—, —(CH2)3—, —(CH2)4—, —(CH2)5—, and —(CH2)6—, and the following cyclic ring structures
wherein each R4 is independently selected from the group consisting of —CH2—, —(CH2)2—, —(CH2)3—, —(CH2)4—, —(CH2)5—, —(CH2)6—, —(CH2)7—, —(CH2)8—, and
wherein the two structures in parenthesis represent randomly repeating units or residues of the copolyester, and wherein x is independently an integer of 1 or more, preferably 1-30, and y is independently an integer of 1 or more, preferably 1-30. Preferably, the ratio of x:y is between 2000:1 and 1:2000. More preferably, said ratio is 90:10, 75:25, 50:50, 25:75, 10:90, 5:95, 1:100, 1:200, 1:500, 1:1000, 1:2000 or any range between the listed ratios. Most preferably, said range is between 50:50 and 1:2000, between 50:50 and 1:200, between 10:90 and 1:100, 1:200 or 1:2000.
In a more preferred embodiment, R3 is selected from the group consisting of:
In another more preferred embodiment, R3 is
In another preferred embodiment, R3 is selected from the group consisting of:
In a more preferred embodiment, R3 is
In another preferred embodiment, R3 is selected from the group consisting of:
In another preferred embodiment, each R4 is —(CH2)4—.
In another preferred embodiment, said copolyester comprises the structure
wherein x is independently an integer of 1 or more and y is independently an integer of 1 or more, and wherein the ratio of x:y is preferably between 2000:1 and 1:2000.
Having similar or better properties compared to PET (see Experimental Section below), a person skilled in the art would understand that the above described copolyester can be applied to beverage bottles, food package films, shopping bags and other food package containers.
The present invention is thus also directed to an article or packaging material comprising the bifuran copolyester as defined above. Preferably, said article is a food package or a beverage container.
The present invention is also directed to a film or coating comprising or consisting of the bifuran copolyester as defined above.
The present invention is further directed to a method of preparing a bifuran copolyester, the method comprising the steps of:
a) combining at least (i) a bifuran of Formula
wherein R1 and R2 are each independently selected from the group consisting of: —H, —CH3, —CH2CH3, —(CH2)2CH3, —CH(CH3)2, —(CH2)3CH3, —(CH2)2OH, —(CH2)3OH, —(CH2)4OH, —(CH2)5OH, —(CH2)6OH, —(CH2)7OH, —(CH2)8OH, and
(ii) a diester of an aliphatic or cycloaliphatic C3-C8 dicarboxylic monomer residue or of an aromatic C6-C8 dicarboxylic monomer residue, preferably a diester compound of Formula
wherein R1 and R2 are each independently as defined above for Formula (I) and R3 is selected from the group consisting of —CH2—, —(CH2)2—, —(CH2)3—, —(CH2)4—, —(CH2)5—, and —(CH2)6—, and the following cyclic ring structures
(iii) an aliphatic or cycloaliphatic C1-C8 diol, preferably 1,3-propanediol, 1,4-butanediol or 1,2-ethanediol, and (iv) a metal catalyst to form a reaction mixture;
b) subjecting the mixture combined in step a) to a temperature in the range of from about 140° C. to about 220° C. under an inert atmosphere, such as nitrogen or argon atmosphere; and
c) performing polycondensation to the mixture obtained in step b) by heating under reduced pressure to a temperature in the range of from about 210° C. to about 260° C.
A typically useful procedure is thus a conventional two-step melt-polymerization method, such as generally also used in the production of PET. Thereby a mixture of the diol and dicarboxylic monomers are subjected to heating, in two stages. Thus, e.g., the mixture is first exposed to a temperature in the range of 140° C. — 220° C., and thereafter to a temperature of 210° C. — 260° C. Vacuum may be applied gradually, to obtain high molecular weight polyesters. Typically, the pressure applied during step c) is subatmospheric, for example 0.1 to 900 mBar, for example about 1 to 100 mBar.
In a preferred embodiment, said metal catalyst in step a) comprises at least one titanium, bismuth, zirconium, tin, antimony, germanium, aluminium, cobalt, magnesium, or manganese compound. More preferably said metal catalyst is tetrabutyl titanate (titanium (IV) butoxide).
Accordingly, in embodiments of the invention, at least one metal catalyst is present in steps a) and b). The amount of metal in the metal catalyst is in the range of from 20 parts per million (ppm) to 400 ppm by weight, based on a theoretical yield of 100% of the polymer produced. In one embodiment, the metal catalyst is present in the mixture in a concentration in the range of from about 20 ppm to about 300 ppm, based on the total weight of the polymer. Suitable metal catalysts can include, for example, titanium compounds, bismuth compounds such as bismuth oxide, germanium compounds such as germanium dioxide, zirconium compounds such as tetraalkyl zirconates, tin compounds such as butyl stannoic acid, tin oxides and alkyl tins, antimony compounds such as antimony trioxide and antimony triacetate, aluminum compounds such as aluminum carboxylates and alkoxides, inorganic acid salts of aluminum, cobalt compounds such as cobalt acetate, manganese compounds such as manganese acetate, or a combination thereof. Alternatively, the catalyst can be a tetraalkyl titanate Ti(OR)4, for example tetraisopropyl titanate, tetrabutyl titanate (tetra-n-butyl titanate), tetrakis(2-ethylhexyl) titanate, titanium chelates such as, acetylacetonate titanate, ethyl acetoacetate titanate, triethanolamine titanate, lactic acid titanate, or a combination thereof. In one embodiment, the metal catalyst comprises at least one titanium, bismuth, zirconium, tin, antimony, germanium, aluminum, cobalt, magnesium, or manganese compound. In one embodiment, the metal catalyst comprises at least one titanium compound. Suitable metal catalysts can be obtained commercially or prepared by known methods.
In preferred embodiments, said bifuran of Formula (I) in step a) is dimethyl 2,2′-bifuran-5,5′-dicarboxylate having the structure
In other preferred embodiments, said diester compound in step a) is dimethyl 2,5-furandicarboxylate having the structure
In other preferred embodiments, said aliphatic C1-C8 diol is 1,4-butanediol having the structure
In particularly preferred embodiments, the molar ratio of compounds (i) and (ii) in step a) is between 2000:1 and 1:2000. More preferably, said ratio is 90:10, 75:25, 50:50, 25:75, 10:90, 5:95, 1:100, 1:200, 1:500, 1:1000, 1:2000 or any range between the listed ratios. Most preferably, said range is between 50:50 and 1:2000, between 50:50 and 1:200, between 10:90 and 1:100, 1:200 or 1:2000.
In one embodiment, in step b) of the process a mixture comprising a bifuran of Formula (I), a diester compound of Formula (II), a diol selected from the group consisting of ethylene glycol, 1,3-propanediol, 1,4-butanediol, 1,4-cyclohexanedimethanol, or mixtures thereof, and a metal catalyst is contacted at a temperature in the range of from 140° C. to 220° C. to form a prepolymer.
In the methods disclosed herein, the step b) is preferably performed at a temperature in the range of from 140° C. to 220° C., for example in the range of from 150° C. to 215° C. or from 170° C. to 215° C. or from 180° C. to 210° C. or from 190° C. to 210° C. The time is typically from one hour to several hours, for example 2, 3, 4, or 5 hours or any time in between 1 hour and 5 hours.
In the preferred methods disclosed herein, polycondensation in step c) is performed by heating the prepolymer obtained in step b) under reduced pressure to a temperature in the range of from 210° C. to 260° C. to form the bifuran copolyester. A different catalyst, or more of the same catalyst as used in step b), can be added in step c). The temperature in step c) is typically in the range of from 220° C. to 260° C., for example from 225° C. to 255° C. or from 230° C. to 250° C. The pressure can be from less than about one atmosphere to 0.0001 atmospheres. In this step, the prepolymer undergoes polycondensation reactions, increasing the molecular weight of the polymer, and the diol is distilled off. The polycondensation step can be continued at a temperature in the range of from 210° C. to 260° C. for such a time as the intrinsic viscosity of the polymer reaches at least about 0.60 dL/g. The time is typically from 1 hour to several hours, for example 2, 3, 4, 5, 6, 7, 8, 9 or 10 hours or any time in between 1 hour and 10 hours. In one embodiment, the polymer obtained from step c) has an intrinsic viscosity of at least 0.60 dL/g. Once the desired intrinsic viscosity of the polymer is reached, the reactor and its contents can be cooled, for example to room temperature, to obtain the bifuran copolyester.
The present invention is also directed to use of a 2,2′-bifuran-5,5′-dicarboxylic monomer in preparing copolyesters having ultraviolet light (UV) blocking properties. Preferably, said 2,2′-bifuran-5,5′-dicarboxylic monomer is a diester of the 2,2′-bifuran-5,5′-dicarboxylic monomer, such as dimethyl 2,2′-bifuran-5,5′-dicarboxylate. Preferably, the prepared copolyester contains 0.5-6% of 2,2′-bifuran-5,5′-dicarboxylic monomer residues.
It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.
Materials and Methods
Commercial grade solvents and reagents were used as received unless otherwise noted.
Dimethyl 2,5-furandicarboxylate, FDCA (1): 2,5-Furandicarboxylic acid (4.00 g) was mixed with dry methanol (120 mL), and 98% sulfuric acid (2 equiv) was added into the mixture.
After refluxing overnight, the cooled mixture was evaporated to about ½ volume. After dilution with deionized water, the precipitated diester was filtered onto paper. After drying in air, the raw product was dissolved in ethyl acetate and filtered through silica gel. After evaporation, dimethyl 2,5-furandicarboxylate was afforded (4.25 g, 93%). 1H NMR (400 MHz, CDCl3, ppm): δ 7.23 (s, 2H), 3.94 (s, 6H).
Dimethyl 2,2′-bifuran-5,5′-dicarboxylate, BFDCA (2): The synthesis method reported previously was followed to afford dimethyl 2,2′-bifuran-5,5′-dicarboxylate (4.53 g, 91%) as small white needles (Kainulainen et al., 2018). 1H NMR (400 MHz, CDCl3, ppm): 6 7.26 (d, 2H, J=3.7 Hz), 6.90 (d, 2H, J=3.7 Hz), 3.93 (s, 6H).
Polyester synthesis: The polyesters were synthesized by weighing the diester(s) 1 and 2 in an appropriate ratio into a round-bottom flask equipped with a magnetic stirring bar. Dry 1,4-butanediol was added, together with tetrabutyl titanate (0.1 mol % relative to the total diester amount). The flask was heated to 180° C. under argon to initiate the reaction. After 3 h reaction, the pressure was gradually lowered to 2 mbar over the period of 1 h. After increasing the temperature to 250° C., the reaction was allowed to continue for 1 h. The cooled, solid polyester was allowed to dissolve in a mixture of CF3COOH and CHCl3. The polyester was precipitated into methanol, affording a fibrous solid. The polyester was dried under vacuum at 60° C. For NMR measurements, a polyester sample was dissolved in CF3COOD.
Dilute solution viscometry: Intrinsic viscosities were evaluated using flow-times measured with a micro-Ubbelohde viscometer 30.0° C. Polyester samples were dissolved in CF3COOH, and the solution filtered to prepare 0.5 g/dL solutions for measurements.
Differential scanning calorimetry (DSC): Differential scanning calorimeter (Mettler Toledo DSC 821e) with heating and cooling rates of 10° C./min and nitrogen gas flow of 60 cm3/min was used. 5 mg samples placed in sealed 40 μL A1 pans were used for the measurements.
Thermogravimetric analysis: Thermogravimetric analyzer (Mettler-Toledo TGA851e) with nitrogen flow of 95 cm3/min was run from 30 to 700° C. at a heating rate of 10° C./min.
Melt pressing: Dry polyester was melted at the appropriate temperature inside a closed heat-press, and the melt was then pressed into a film between two polyimide-coated aluminium plates. After cooling, a transparent film was obtained.
Tensile testing: Rectangular tensile test specimens were cut from the films, and the specimens were allowed to stand for 1-2 weeks prior to the tensile tests conducted at 23° C. Tensile tester (Instron 5544, USA) with a gage length of 30 mm and crosshead speed of 5 mm/min was used to characterize the tensile modulus, tensile strength and elongation at break.
UV-Vis: Spectrophotometer (Shimadzu UV-1800) was used to characterize the absorption and transmittance of the melt-pressed films.
Results and Discussion
Dimethyl esters of FDCA (1), BFDCA (2) and 1,4-butanediol were polymerized in accordance with Table 1.
aCalculated from 1H NMR integrals in CF3COOD.
bIntrinsic viscosity according to the Billmeyer relationi.
cVia 13C NMR using Equations 1 and 2, randomness index Ri calculated from Equation 3.
iBillmeyer, F. Methods for estimating intrinsic viscosity. J. Polym. Sci., 1949, 4, 83-86.
Using the appropriate feed ratio of 1 and 2, the desired polyesters were prepared in the presence of catalytic tetrabutyl titanate (TBT). The purity and structure of the polyesters were confirmed with 1H NMR analysis (
1H and 13C NMR analysis also confirms the random distribution of furan and bifuran units in the polyester chains. Specifically, assignment of the chain structure was obtained (
The thermal properties were characterized using DSC. Slow 10° C./min scanning rate reveals that PBF and PBBf are typical semi-crystalline materials, having clear cold-crystallization and melting peaks (
Thermogravimetric analysis shows that the thermal stabilities (Table 4 and
All copolyesters had excellent mechanical properties, most notably exceeding the performance of PBF, with tensile strengths of ≥65 MPa. The tensile moduli were practically unchanged across the series.
aFive amorphous specimens were evaluated for each composition.
The most notable effect provided by the bifuran moieties is their inherent UV absorbance. The copolyesters functioned as effective UV light filters up to 400 nm wavelengths (
PBF and PBBf are bio-based semi-crystalline polyesters, while their random copolyesters become more amorphous when more of the minor comonomer is incorporated. The copolyesters were characterized by good mechanical strengths and glass-transition temperatures of 42-60° C. Incorporating more of the minor comonomer, a degree of control over the crystallization can be achieved. Most notably, incorporating a low level of the minor comonomer allows tailored properties. In particular, surprisingly low bifuran content provides a copolyester with very low UV transmittance, lower melting point and higher glass-transition temperature, depending on the exact monomer ratio. Very high bifuran content allows the preparation of materials with higher glass-transition temperature.
Billmeyer, F. Methods for estimating intrinsic viscosity. J. Polym. Sci., 1949, 4, 83-86.
Kainulainen, T. P., Sirviö, J. A., Sethi, J., Hukka, T. I., Heiskanen, J. P. UV-Blocking Synthetic Biopolymer from Biomass-Based Bifuran Diester and Ethylene Glycol., Macromolecules, 2018, 51, 1822-1829.
Miyagawa, N., Suzuki, T., Okano, K., Matsumoto, T., Nishino, T., Mori, A., Synthesis of Furan Dimer-Based Polyamides with a High Melting Point, J. Polym. Sci., Part A: Polym. Chem., 2018, 56, 1516-1519.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/FI2019/050487 | 6/20/2019 | WO |
