One-pot synthesis of Mannich polyols from bisphenol A polycarbonate for polyurethane foam applications

To address the escalating plastic waste crisis, chemical upcycling has emerged as a promising strategy for converting waste into valuable materials. In this study, we present a one-pot upcycling method to transform bisphenol A polycarbonate (BPA-PC) into Mannich polyols, which are subsequently used to produce polyurethane foams. The process involves two consecutive reactions, BPA-PC depolymerization via methanolysis followed by Mannich polyol synthesis, performed efficiently within a single vessel without intermediate purification steps. The resulting Mannich polyol is used to prepare a rigid polyurethane foam, which exhibits low density, a closed-cell morphology, and excellent thermal conductivity (23.3 mW·m ⁻¹·K ⁻¹), making it highly suitable for thermal insulation applications. This work offers a practical strategy for creating new-generation materials that incorporate recycled content, contributes to potential carbon reduction, and addresses critical environmental challenges posed by plastic waste.