Synthesis and Crystallization of Waterborne Thiol–ene Polymers: Toward Innovative Oxygen Barrier Coatings

[Image: see text] The synthesis of waterborne thiol–ene polymer dispersions is challenging due to the high reactivity of thiol monomers and the premature thiol–ene polymerization that leads to high irreproducibility. By turning this challenge into an advantage, a synthesis approach of high solid content film-forming waterborne poly(thioether) prepolymers is reported based on initiator-free step growth sonopolymerization. Copolymerization of bifunctional thiol and ene monomers diallyl terephthalate, glycol dimercaptoacetate, glycol dimercaptopropionate, and 2,2-(ethylenedioxy)diethanethiol gave rise to linear poly(thioether) functional chains with molar mass ranging between 7 and 23 kDa when synthesized at 30% solid content and between 1 and 9 kDa at increased solid content of 50%. To further increase the polymers’ molar mass, an additional photopolymerization step was performed in the presence of a water-soluble photoinitiator, i.e., lithium phenyl-2,4,6-trimethylbenzoylphosphinate, leading to high molar mass chains of up to 200 kDa, the highest reported so far for step grown poly(thioethers). The polymer dispersions presented good film-forming ability at room temperature, yielding semicrystalline films with a high potential for barrier coating applications. Nevertheless, affected by the polymer chemical repeating structure, which includes an aromatic ring, these thiol–ene chains can only crystallize very slowly from the molten state. Herein, for the first time, we present the successful implementation of a self-nucleation (SN) procedure for these types of poly(thioethers), which effectively accelerates their crystallization kinetics.