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Conventional polyurethanes involve the use of isocyanates, which require hazardous and toxic phosgene for
their manufacture. These monomers cannot be manufactured without elaborate safety devices and huge
investment. Isocyanates are also considerably toxic and moisture sensitive. Growing global awareness of the
need to protect our environment and continually strive to ensure the safety, health and well-being of those in
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the industry and consumers has created a demand for environment-friendly products. The cyclic carbonate–
primary amine addition reaction which results in hydroxyurethanes is a unique reaction and has been
extensively studied over the last few years. This chemistry is now attracting research interest due to its potential
application in the preparation of ‘‘green’’, non-porous, moisture-insensitive, isocyanate free polyurethanes. This
review focuses on catalysis, the mechanism involved in the formation of Non-Isocyanate Polyurethanes (NIPU)
Received 24th August 2012,
from five-membered cyclic carbonates and the reaction kinetics for their synthesis. The higher homologues of
Accepted 28th November 2012
the cyclic carbonate family, the six-membered cyclic carbonates, are similar to, but more reactive than, the five-
DOI: 10.1039/c2ra21938g
membered cyclic carbonates and can also serve as a source for production of isocyanate free polyurethanes. This
www.rsc.org/advances review also summarizes various application of NIPU in coatings, composites, construction and biochemical fields.
Toxicity of isocyanates nate and primary diamines, tend to lose ethylene glycol when
Isocyanates are synthesized from an even more toxic pre- subjected to vacuum distillation with an alcohol at 150 uC in
decessor, phosgene, which causes environmental hazards. the presence of barium oxide or zinc borate as catalysts
Exposure to isocyanates4 can result in health effects, such as (Scheme 3). Here, the alcohol group might be part of the bis(2-
skin irritation and long-term asthma.5 hydroxyethyl carbamate) or part of a diol. They also obtained
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prepare diols that could be cured with conventional technol- The intramolecular hydrogen bond blocks the carbonyl
ogies, since in most curing reactions the isocyanates are used carbon resulting in low susceptibility of the whole urethane
as chain extenders and produce urethane or biureate linkages group to hydrolysis and hence improved hydrolytic stability,
in the backbone. Mandlecha attempted the synthesis of diols well above that of conventional PURs, could be achieved.
from ethanolamine, ethylene glycol and urea. He observed that Moreover, materials containing intramolecular hydrogen
carbon dioxide is the first dicarboxylic acid. Its diester is bonds display chemical resistance 1.5–2 times greater than
dimethyl carbonate; its half ester half amide is urethane. Since materials having similar chemical structure without such
it is a diacid, its products do appear as polycarbonate and half bonds.2 NIPUs exhibit improved thermal stability because
ester and half amides appear as PURs. He synthesized a series there are no thermally labile biuret and allophanate groups
of diols by the reaction of urea and monoethanolamine and incorporated in the PUR backbone. Further, NIPU synthesis is
urea and ethylene glycol, producing high viscosity diols that not sensitive to moisture and hence application of the coating
could be crosslinked with melamine formaldehyde or diiso- is not as tedious as that of conventional PUR.20 With
cyanates, producing hard and flexible coatings (Scheme 4(a)). increasingly strict regulations and the need for more envir-
Thus, coatings with urethane like properties could be onmentally-friendly technology for polymer synthesis,
researchers all over the world are now exploring the utilization
of cyclic carbonate–amine chemistry to prepare high perfor-
mance polymers for coatings, adhesives, foams etc. Use of
cyclic carbonates for coatings which serve the dual purposes of
carbon dioxide capture and environmental advantages should,
therefore, be an important area of research. The purpose of
this review is to provide researchers engaged in this field with
comprehensive information in one place. In this review, we
discuss various routes for PUR synthesis from cyclic carbo-
nates, catalysis for this reaction, kinetics of this reaction and
its applications in various fields.
Synthesis of NIPUs
Most of the published work on NIPU preparation is based on
cyclic carbonate oligomers/polymers. The general method for
preparation of NIPU comprises the synthesis of cyclic
carbonates, followed by their reaction with amines or
polyamine compounds.
modified with the addition of CO2 over the epoxide ring at of these two types of polymer are different due to different
elevated temperature and in the presence of a catalyst backbone structures.18–20 The amine functional hydroxyur-
(Scheme 6). The cyclic carbonate moiety thus prepared opens ethanes can be prepared using excess amine or diamine, in
up in favorable reaction conditions and can be utilized to which two amine groups have different reactivities, and can be
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synthesize linear or cross-linked NIPU networks depending on employed as crosslinkers or diluent for adhesives and
the cyclic carbonate functionality of the oligomer.21 Oxirane to paints.26,27 Preparation of carbonate functional oligomers
cyclic carbonate conversion also utilizes CO2 as a sustainable from excess of a bis-carbonate of a bis-glycidyl ether of
solvent which is non-flammable, has low toxicity, is an neopentyl glycol and 1,4-cyclohexanediamethanol with poly-
inexpensive by-product of most industries and is abundant. oxyalkylene diamines has also been studied in the past.28
It also acts as an aprotic solvent in the reaction system.22
low to medium conversions,4,41 but in the presence of a crown anion.48 In general, the silica supported ammonium salts have
ether, such as 18-crown-6, KI acts as very efficient catalyst.42 Of higher catalytic activities than low molecular weight catalysts
various other catalysts investigated for the reaction, the most under the same reaction conditions, probably due to the
commonly used catalyst is tetraalkylammonium halide. synergistic effect between silica gel and quaternary ammo-
Tetrabutylammonium bromide (TBAB) at 5% molar concen- nium salts for the activation of CO2. The other advantage of
tration with respect to epoxy content has been reported to give using silica-supported quaternary ammonium salts is that
maximum conversion to cyclic carbonates. It is also observed these act as heterogeneous catalysts and can be easily
that the catalytic activity of such quaternary ammonium salts recovered by a simple filtration and reused more than four
increases when the nucleophilicity of the halide anion and times with slight loss of their catalytic activity.21 Recently, a
Lewis acidity of the cation increases. The proposed mechan- catalytic system of tetranuclear zinc cluster and tetrabutylam-
ism for cyclic carbonate formation is shown in Scheme 7. monium iodide for the synthesis of cyclic carbonates by
Here, the rate determining step is the nucleophilic attack of solvent free CO2 coupling under atmospheric pressure and
Published on 04 December 2012 on http://pubs.rsc.org | doi:10.1039/C2RA21938G
the halide anion on the oxirane ring. The reactivity of oxiranes temperature was investigated, with the particular advantage
is also dependent on the type of substituents (R) attached to that the zinc cluster catalytic system showed high catalytic
the oxirane ring. As the bulkiness of substituents (R) on the activity and tolerance to impurities, including water and
oxirane ring decreases or the electron withdrawing ability of R oxygen.49
increases, the reactivity of the oxirane increases. The oxiranes To overcome the problem of catalyst separation, various
and the cyclic carbonates are also observed to show the same solid catalysts, such as basic metal oxide,50,51 calcined
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stereochemistry, as the SN2 type of inversion occurs during the hydrotalcites52 and ion-exchange resins,53–55 have been devel-
conversion.43 Kinetic analysis of the reaction shows that the oped. However, these heterogeneous systems are restricted
reaction rate can be expressed by the empirical equation eqn due to the formation of side products, as well as co-solvent or
(1): co-catalyst requirements, low activity and high cost. However,
lanthanide oxychloride, especially SmOCl, is reported to show
{d½epoxide
~k½epoxide½catalystm (1) excellent activity and selectivity for the reaction of supercritical
dt CO2 and propylene oxide.56
where ‘‘m’’ depends on the Lewis acidity of the catalyst and In recent years, ionic liquid (IL) based heterogeneous
molecular weight of the epoxide polymer.44 catalysts have attracted significant attention for the synthesis
Homogeneous TBAB catalyst gives good conversion to cyclic of cyclic carbonates, as they give the advantages of both
carbonates, but requires tedious process of extraction of the homogeneous ILs and heterogeneous catalysts. Previously,
catalyst.45,46 The silica supported quaternary ammonium salt quaternary ammonium salts, alkali halides and imidazolium
is reported to give more efficient cyclic carbonate synthesis alkyl halides immobilized on silica 55 or polymer supports 57,58
under supercritical carbon dioxide conditions, where CO2 acts have been extensively explored for IL-based heterogeneous
both as a reagent and a solvent.21 Higher carbonate yield and catalysts with respect to the cycloaddition reaction. Carboxylic
faster epoxy conversion with respect to those of homogenous acid functionalized imidazolium based ILs,59 modified amino
catalysts at atmospheric CO2 pressure could also be achieved acid IL,60 silica-supported IL,61 chitosan supported ILs,
with silica supported catalysts.47 The Si–OH on the silica carboxymethyl cellulose supported ILs 62 etc. have been
surface acts as a weak acid to activate the epoxide, which studied effectively for cyclic carbonate synthesis. Recently, a
undergoes simultaneous nucleophilic attack by the halide highly efficient catalytic synthesis of cyclic carbonates using
polymer supported diol functionalized ionic liquid was
reported. 63 The presence of a vicinal hydroxyl group on an
ionic liquid cation moiety has been observed to accelerate the
reaction in the forward direction, due to its strong chelating
ability, through hydrogen bonding with the oxygen atom of
epoxide, enabling the ring opening even more effectively than
ILs containing monohydroxyl groups.
Compared to heating by thermal energy, such as in an oil
bath, microwave irradiation is an effective heating mode
which affords a marked decrease in activation energy due to its
non-thermal effect. The rapid and solvent free synthesis of
cyclic carbonates from CO2 and epoxides under microwave
irradiation with controlled temperature and pressure has also
been reported.64 Pseudo-first order kinetics of the reaction
also suggested that the observed reaction acceleration under
microwave irradiation was mainly due to the non-thermal
effects of microwave, which lead to a decrease in activation
energy.
Scheme 7 Typical mechanism of cyclic carbonate formation using quaternary
ammonium salts.
Stage II: Synthesis of NIPU and HNIPU polymer ring opening reaction of cyclic carbonates by amines may also
be accelerated by activating either the monomers, that is, by
During the process of formation of NIPU, simultaneous
additions of weakly Lewis acidic and oxophilic additives to
nucleophilic attack of amine over cyclocarbonate takes places
increase the electrophilicity of the cyclic carbonate group or
and is followed by a deprotonation reaction. In the first stage,
basic additives to increase nucleophilicity of amines. In 1958,
amine attacks the carboxyl group in cyclic carbonates,
NaH and N-acetyl-e-caprolactam were first reported to lead to
resulting in the formation of a tetrahedral intermediate. The
formation of hydroxyurethanes.74 Meanwhile, many authors
reactions are observed to be slow at room temperature due to
have worked on catalysis of this particular reaction. Lewis
the relatively stable nature of cyclic carbonates compared to
acids, such as LiCl, activate the carbonyl group without
their oxirane counterparts.4 In the second stage, deprotona-
deactivation of the amine, that is, the increased electrophili-
tion of the intermediate occurs through attack of another
city of the activated cyclic carbonate by the appropriate Lewis
amine, resulting in the removal of hydrogen ions. The carbon-
acids is hence the most plausible factor for the enhanced
oxygen bond is then broken, which is favored by the strong
yields of high molecular weight polyhydroxyurethanes.75 The
Published on 04 December 2012 on http://pubs.rsc.org | doi:10.1039/C2RA21938G
electron-withdrawing effect of nitrogen atoms. reaction can also be effectively catalyzed by use of triethyla-
Simultaneously, the newly generated alkyl-oxygen ion com- mine which reduces the activation energy of the reaction by up
bines with hydrogen ions, resulting in rapid formation of the to 20% compared to that of the non-catalyzed system. Various
product.65 Such polyaddition reactions of cyclic carbonate and other catalysts, including piperazine, TBAB, glacial acetic acid,
amine generally give two isomers of hydroxyurethanes methane sulfonic acid etc., can also be used effectively.76
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Table 1 (Continued)
1,3-dioxolan-4-yl)methyl] benzene-1,4-dicarboxylate was pre- requires neither solvent nor photoinitiator and is quantitative
pared by esterification of the carboxylic acid groups of in stoichiometric conditions. Various bis-cyclic carbonates
benzene-1,4-dicarboxylic acid with alcohol functionality of 4- prepared from 4-(3-butenyl)-1,3-dioxolan-2-one,94 4-ethenyl-
(hydroxymethyl)-1,3-dioxolan-2-one. However, the presence of 1,3-dioxolan-2-one95 and 4-[(prop-2-en-1-yloxy)methyl]-1,3-
an ester linkage in the backbone makes them more sensitive to dioxolan-2-one (Scheme 12) have been prepared.
hydrolysis reaction.93 Polyhydroxyurethanes synthesized by step growth poly addi-
Thioethers with bis-cyclic carbonates prepared by a one step tion reaction of these bis-cyclocarbonate oligomers contain
reaction by thiol-ene coupling of dithiol and glycerol carbonate neither hydrolysis sensitive ester bonds nor UV sensitive
derivatives are also reported in the literature. This ‘‘click-
chemistry’’ reaction is particularly advantageous, since it
Scheme 9 Phosgenation reaction for cyclocarbonate synthesis. Scheme 10 Cyclocarbonate synthesis using dimethyl carbonate.
amines, like ethylenediamine, hexamethylenediamine etc., to successfully to catalyze this carbon dioxide conversion reac-
give the corresponding NIPU networks (Fig. 3). NIPU can be tion and to enable facile catalyst recovery by filtration, thus
prepared with high tensile strength and other mechanical eliminating solvent extraction. In comparison to soya-based
properties which could be varied by the type of amine and (CSBO), the carbonate content of carbonated linseed oil
cyclocarbonate oligomer used.104 (CLSO) is substantially higher. Mixing together CSBO and
The latest study by Javani et al. revealed that aromatic CLSO enabled variation of carbonate content in order to
amines/diamines could be employed as hardeners for NIPU explore the influence of curing agents and the carbonate
systems. They used m-xylylenediamine, p-xylylenediamine and content on the thermal and mechanical properties of NIPU.
aliphatic/cycloaliphatic diamines for curing reactions of cyclic With increasing crosslink density, stiffness and Tg increased
carbonated soyabean oil. The aromatic nature of the xylylene- significantly. Tg can be increased by using a cycloaliphatic
diamine reagent resulted in increased tensile strength with curing agent, isophorone diamine, for curing purpose.106 In
inferior elongation compared to the aliphatic diamine.23 this case, Tg increased from 20 to 60 uC, while stiffness
Recently, catalytic conversion of epoxide groups with carbon increased by three orders of magnitude at the expense of
dioxide was used to prepare carbonated linseed oil.105 In elongation at break. While most conventional CSBO-based
addition to the homogeneous TBAB catalyst, the silica- systems are rather soft and flexible, this approach indicates
supported alkylpyridinium iodide SiO2–(I) was employed that NIPU can be developed to meet the demands of
engineering applications with higher dimensional stability
and stiffness.
A disadvantage of these oil based NIPUs is that the cure
reaction is sometimes accompanied by cleavage of the ester
Scheme 15 Synthesis of Si-CPS particles and CBGPPO. Fig. 3 General structure of CSBO.
4) NIPU in nanotechnology
Nanostructured systems could be employed with NIPU
NIPU from six-membered cyclic carbonates
technology for superior performance. NIPU-SiO2 nanocompo- Six-membered cyclic carbonates (6CC) are very similar to five-
sites are reported to give significant improvements in rigidity, membered cyclic carbonates and can be used efficiently for
toughness and transparence. Cyclic carbonate functional SiO2 polymer synthesis by various methods. These can be synthe-
nanoparticles (Fig. 4) can be prepared from tetraethylorthosi- sized through several different routes. Synthesis of 6CC such
licate and cyclic carbonated glycidoxy silanes via sol–gel as trimethylene carbonate is traditionally achieved by reacting
1,3-propanediol with phosgene or its derivatives. Although
cyclic carbonates can also be obtained by direct coupling of
CO2 with oxetanes at elevated temperature and pressure using
organometallic catalyst, the synthesis route of transesterifica-
tion of 1,3-diols with dialkyl carbonates is preferred, due to its
environmentally benign procedure.112 In this two-step synth-
esis, oligomers are generally formed. As the temperature is
increased, depolymerization of linear polycarbonates produces
the cyclic monomer which can be easily distilled off under
vacuum. Metallic base catalysts, stannous 2-ethylhexanoate,
chlorides, oxides and carbonates113 have been successfully
used for such reactions in the past.114 Trimethylol propane can
also be converted to 6CC with pendant functional groups via a
lipase mediated reaction between DMC without any cata-
Fig. 4 Cyclic carbonate functional silica particles. lyst.115 The 6CC derivative prepared from trimethylol propane
Table 2 Structures of 6CC containing compounds can be further modified to incorporate a desired structural
moiety (Table 2, entry 1–8) for specific applications. Table 2
Fig. No. Structure Ref. summarizes some such products reported in the literature.
1 116 6CCs undergo ring-opening polymerization (ROP) to give
the corresponding linear polycarbonates without side reac-
tions and volume shrinkage, especially under anionic condi-
tions. These are preferred for ROP to five-membered
carbonates, as they are less thermodynamically stable than
their ring-opened polymers and thus retain CO2 during the
2 116 polymerization process.122,123 Under cationic conditions,
however, the polymerization is accompanied by partial/no
elimination of carbon dioxide to afford polycarbonates with an
Published on 04 December 2012 on http://pubs.rsc.org | doi:10.1039/C2RA21938G
7 120
8 121
Fig. 5 Structures of 6BCC and 5BCC. Scheme 20 Preparation of ionic, hydrophobic and hydrophilic coupler.
Applications of NIPU
As PUR has manifold applications in the coatings industry,
non-isocyanate based polyurethanes can also find various
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conventionally filled polymers and composites. Due to their ing the performance of NIPUs. Recent developments in
nanometer phase dimensions, the nanocomposites exhibit preparation of cyclic carbonates and their polymers hold
new and improved properties without sacrificing impact promise. Six-membered cyclic carbonates will provide great
resistance. A very interesting way of introducing nanoparticles opportunities in production of isocyanate-free polyurethanes.
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is to use compounds that can form nano-particles "in situ". A variety of cyclic carbonates bearing various functional
The use of organosilanes makes the possible. For example, groups can be prepared and polymerized with tailor-made
after hardening by cross-linking, NIPU network may be used as properties for use in large volume industrial applications, as
a matrix of composite materials to serve as structural well as in general and high-end materials. Reaction of
components.154 unsaturated components of polymer material with hydrogen
NIPU network can be used as matrix for enzyme immobi- peroxide and subsequently with carbon dioxide is a very
lization. Low density polyethylene films co-grafted with promising green solution to the various problems of isocya-
vinylene carbonate and N-vinyl-N-methylacetamide and matrix nate and amine synthesis. This would lead to green coatings
for the immobilization of enzyme alkaline phosphates that do not use hazardous phosgene and isocyanates, but rely
prepared and immobilized either by direct fixation or by on simple, harmless molecules such as carbon dioxide and
inserting spacers is reported. When water soluble alkyldia- hydrogen peroxide. The range of possible applications of these
mine such as ethylene diamine, diaminobutane, diethylene- monomers from renewable resources is likely to be expanded
triamine, and hexamethylene diamine are used as the spacers as a result of the increasing interest of both industry and
between matrix and enzyme, the surface concentration of academia.
active enzyme coupled on the matrix is increased. Using this
technique enzyme immobilization can be performed success-
fully.158 Opportunities for research
Opportunities for research in this subject are enormous.
Catalysts for curing at room temperature are a challenge that
Conclusion appears attainable. Nature produces several polyols and
The chemical industry is facing increasing demand for hydroxylated monomers and polymers such as sugar, xylitol,
environmentally benign and safe processes and products. manitol, glucose, starch, cellulose and lignin. A starch
Ways are being investigated to reduce carbon dioxide derivative abundantly manufactured is sorbitol. Possibilities
accumulation to avoid global warming. Production of iso- exist to convert part of the hydroxyl groups into carbonates to
cyanate-free polymers attracts increasing attention and has generate sites for cross-linking. This could lead to a new
great potential to avoid the use of toxic and environmentally dimension of green chemistry. Researchers all around the
hazardous materials such as isocyanates and phosgene, world may conduct extensive research in this area to find the
manufacturing of which is a capital intensive process. NIPU commercial applications of these systems for actual imple-
materials open a window for the developing world by simple mentation.
reaction of epoxides with carbon dioxide. It also leaves the
option of using a large number of aromatic diamines as
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