US20150240273A1 - Polyhydroxyalkanoate copolymer compositions and methods of making the same - Google Patents

Polyhydroxyalkanoate copolymer compositions and methods of making the same Download PDF

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US20150240273A1
US20150240273A1 US14/434,651 US201314434651A US2015240273A1 US 20150240273 A1 US20150240273 A1 US 20150240273A1 US 201314434651 A US201314434651 A US 201314434651A US 2015240273 A1 US2015240273 A1 US 2015240273A1
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polyhydroxyalkanoate copolymer
composition
copolymer molecules
coa
hydroxybutyrate
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Thomas Martin Ramseier
Jeffrey A. Bickmeier
William R. Farmer
Catherine Morse
Himani Chinnapen
Oliver P. Peoples
Yossef Shabtai
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CJ CheilJedang Corp
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Metabolix Inc
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    • C—CHEMISTRY; METALLURGY
    • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
    • C12P—FERMENTATION OR ENZYME-USING PROCESSES TO SYNTHESISE A DESIRED CHEMICAL COMPOUND OR COMPOSITION OR TO SEPARATE OPTICAL ISOMERS FROM A RACEMIC MIXTURE
    • C12P7/00—Preparation of oxygen-containing organic compounds
    • C12P7/62—Carboxylic acid esters
    • C12P7/625—Polyesters of hydroxy carboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
    • C08G63/06—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from hydroxycarboxylic acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L67/00—Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Compositions of derivatives of such polymers
    • C08L67/04—Polyesters derived from hydroxycarboxylic acids, e.g. lactones
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2201/00—Properties
    • C08L2201/06—Biodegradable
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
    • C08L2205/025—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group containing two or more polymers of the same hierarchy C08L, and differing only in parameters such as density, comonomer content, molecular weight, structure
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2207/00—Properties characterising the ingredient of the composition
    • C08L2207/04—Thermoplastic elastomer

Definitions

  • the present disclosure relates to polyhydroxyalkanoate copolymer compositions and methods of making the same, and more particularly to polyhydroxyalkanoate copolymer compositions comprising a plurality of polyhydroxyalkanoate copolymer molecules, wherein the polyhydroxyalkanoate copolymer molecules (i) comprise 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers, (ii) have a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%, and (iii) have a biobased content of ⁇ 80%, and to methods of making the same comprising culturing an organism in the presence of one or more carbon raw materials.
  • Polyhydroxyalkanoates are biodegradable and biocompatible thermoplastic materials that can be produced from renewable resources and that have a broad range of industrial and biomedical applications.
  • Polyhydroxyalkanoates can be produced as homopolymers, such as poly-3-hydroxybutyrate (also termed “PHB”) and poly-4-hydroxybutyrate (also termed “P4HB”), or as copolymers, such as poly(3-hydroxybutyrate-co-4-hydroxybutyrate) (also termed “PHB-co-4HB”).
  • PHB poly-3-hydroxybutyrate
  • P4HB poly-4-hydroxybutyrate
  • copolymers such as poly(3-hydroxybutyrate-co-4-hydroxybutyrate) (also termed “PHB-co-4HB”).
  • Poly(3-hydroxybutyrate-co-4-hydroxybutyrate) copolymers are of interest for their potential to be produced from renewable resources and to be used for conferring rubber-like elasticity in polymer blends.
  • poly-4-hydroxybutyrate homopolymer from a genetically engineered microbial biomass metabolizing a renewable feedstock, such as glucose, has also been described, but exemplary poly-4-hydroxybutyrate homopolymer titers were less than 50% by weight of biomass titers, and in any case poly-4-hydroxybutyrate homopolymer does not have the same properties as poly(3-hydroxybutyrate-co-4-hydroxybutyrate) copolymer. Van Walsem et al., WO 2011/100601.
  • a polyhydroxyalkanoate copolymer composition comprises a plurality of polyhydroxyalkanoate copolymer molecules.
  • the polyhydroxyalkanoate copolymer molecules (i) comprise 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers, (ii) have a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%, and (iii) have a biobased content of ⁇ 80%.
  • the composition comprises a plurality of polyhydroxyalkanoate copolymer molecules.
  • the polyhydroxyalkanoate copolymer molecules (i) comprise 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers, (ii) have a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%, and (iii) have a biobased content of ⁇ 80%.
  • the method comprises culturing an organism in the presence of one or more carbon raw materials under conditions under which (a) the one or more carbon raw materials are converted to 3-hydroxybutyryl-CoA and 4-hydroxybutyryl-CoA and (b) the 3-hydroxybutyryl-CoA and the 4-hydroxybutyryl-CoA are polymerized to form the polyhydroxyalkanoate copolymer molecules, thereby forming the composition.
  • the organism has been genetically engineered to comprise enzymatic activities of a polyhydroxyalkanoate synthase, an acetyl-CoA acetyltransferase, an acetoacetyl-CoA reductase, a succinate semialdehyde dehydrogenase, a succinic semialdehyde reductase, and a CoA transferase, and to not comprise enzymatic activities of either an NAD+-dependent succinate-semialdehyde dehydrogenase or an NADP+-dependent succinate-semialdehyde dehydrogenase or both.
  • the one or more carbon raw materials, taken together, have a biobased content of ⁇ 80%.
  • FIG. 1 is a schematic diagram of exemplary E. coli central metabolic pathways showing reactions that were modified or introduced in the Examples or that could be modified in the future. Reactions that were eliminated by deleting the corresponding genes in certain Examples are marked with an “X”.
  • PEP phosphoenolpyruvate
  • PYR pyruvate
  • Ac-CoA acetyl-CoA
  • AcAc-CoA acetoacetyl-CoA
  • 3HB-CoA 3-hydroxybutyryl-CoA
  • CIT citrate
  • ICT isocitrate
  • SUC-CoA succinyl-CoA; “SUC”, succinate; “Fum”, fumarate; “MAL”, L-malate
  • OAA oxaloacetate
  • SSA succinic semialdehyde
  • 4HB 4-hydroxybutyrate
  • 4HB-P 4-hydroxybutyrate
  • a polyhydroxyalkanoate copolymer composition comprises a plurality of polyhydroxyalkanoate copolymer molecules.
  • the composition can be, for example, a biomass composition, e.g. an organism that has produced, and comprises therein, the plurality of polyhydroxyalkanoate copolymer molecules, a composition free of non-polyhydroxyalkanoate biomass, e.g. a composition comprising polyhydroxyalkanoate copolymer molecules that have been isolated and/or purified from an organism that has produced the polyhydroxyalkanoate copolymer molecules, or a bioplastic composition, e.g. a homogeneous or blended composition comprising the polyhydroxyalkanoate copolymer molecules and suitable for use as a bioplastic.
  • the polyhydroxyalkanoate copolymer molecules comprise 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers. Accordingly, each polyhydroxyalkanoate copolymer molecule comprises both 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers.
  • Such molecules can be synthesized, for example, by PHA-synthase mediated copolymerization of 3-hydroxybutyryl-CoA and 4-hydroxybutyryl-CoA to yield molecules of the copolymer, e.g. poly(3-hydroxybutyrate-co-4-hydroxybutyrate) copolymer. Exemplary suitable PHA synthases are described in the Examples below.
  • Each polyhydroxyalkanoate copolymer molecule also optionally can comprise further additional monomers, e.g.
  • 5-hydroxyvalerate monomers for example based on the further presence of polymerizable precursors of the additional monomers during PHA-synthase mediated copolymerization of 3-hydroxybutyryl-CoA and 4-hydroxybutyryl-CoA.
  • the polyhydroxyalkanoate copolymer molecules have a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%. Accordingly, 23.5 to 75% of the monomeric units of the polyhydroxyalkanoate copolymer molecules, taken together, are 4-hydroxybutyrate monomers, with the remaining 25 to 76.5% of the monomeric units of the polyhydroxyalkanoate copolymer molecules corresponding to 3-hydroxybutyrate monomers and optionally further additional monomers. In some embodiments, substantially all, e.g. ⁇ 95% or ⁇ 99%, of the remaining 25 to 76.5% of the monomeric units correspond to 3-hydroxybutyrate monomers, with the rest corresponding to further additional monomers.
  • all of the remaining 25 to 76.5% of the monomeric units correspond to 3-hydroxybutyrate monomers, such that the polyhydroxyalkanoate copolymer molecules include no further additional monomers.
  • the remaining 25 to 76.5% of the monomeric units of the polyhydroxyalkanoate copolymer molecules correspond to 3-hydroxybutyrate monomers.
  • Exemplary suitable methods for determining the monomeric molar percentage of 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers of polyhydroxyalkanoate copolymer molecules are described in the Examples below.
  • the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules can be 25 to 70%.
  • the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules can be, for example, 30 to 40%, 40 to 50%, 50 to 60%, or 60 to 70%.
  • the monomeric molar percentages of 4-hydroxybutyrate monomers of polyhydroxyalkanoate copolymer molecules affect properties of compositions thereof, for example with respect to melting temperatures, elongation to break, glass transition temperatures, and the like.
  • the monomeric molar percentages of 4-hydroxybutyrate monomers of poly(3-hydroxybutyrate-co-4-hydroxybutyrate) copolymer molecules increase above 10%, the melting temperature decreases below 130° C. and the elongation to break increases above 400%. Saito Y. et al., 39 Polym. Int. 169 (1996).
  • polyhydroxyalkanoate copolymer molecules having monomeric molar percentages of 4-hydroxybutyrate monomers in each of the various ranges disclosed above can be used to engineer compositions to have particular desired properties.
  • the polyhydroxyalkanoate copolymer molecules have a biobased content of ⁇ 80%.
  • Biobased content means the amount of biobased carbon in a material or product as a percent of the weight (mass) of the total organic carbon of the material or product, as defined in ASTM D6866-12, Standard Test Methods for Determining the Biobased Content of Solid, Liquid, and Gaseous Samples Using Radiocarbon Analysis (ASTM International, U.S., 2012), which is incorporated by reference herein.
  • total organic carbon can include both biobased carbon and fossil carbon.
  • Biobased carbon corresponds to organic carbon that includes radiocarbon, i.e.
  • biobased content means the amount of biobased carbon in the polyhydroxyalkanoate copolymer molecules as a percent of the weight (mass) of the total organic carbon of the polyhydroxyalkanoate copolymer molecules.
  • the biobased content of the polyhydroxyalkanoate copolymer molecules can be measured, for example, in accordance with ASTM D6866-12, based on determining the contents of 14 C and 12 C in CO 2 derived by combustion of the polyhydroxyalkanoate, and correcting for post 1950 bomb 14 C injection into the atmosphere, among other methods.
  • the polyhydroxyalkanoate copolymer molecules can have a biobased content of ⁇ 80% as measured in accordance with ASTM D6866-12.
  • Other suitable approaches for measuring biobased content as are known in the art, also can be used. Differences in biobased contents between different polyhydroxyalkanoate copolymer molecules are indicative of structural differences, i.e. differences in the ratios of 14 C to 12 C thereof, between the different polyhydroxyalkanoate copolymer molecules.
  • the biobased content of the polyhydroxyalkanoate copolymer molecules is ⁇ 95%. In some embodiments, the biobased content of the polyhydroxyalkanoate copolymer molecules is ⁇ 99%. In some embodiments, the biobased content of the polyhydroxyalkanoate copolymer molecules is 100%. Thus, for example, the biobased content of the polyhydroxyalkanoate copolymer molecules can be ⁇ 95%, or ⁇ 99%, or 100%, in each case again as measured in accordance with ASTM D6866-12.
  • Polyhydroxyalkanoate copolymer molecules having the above-noted biobased contents can be used for the manufacture of biobased plastics in which most or all fossil carbon has been replaced by renewable biobased carbon, with accompanying environmental benefits. Moreover, polyhydroxyalkanoate copolymer molecules having the above-noted biobased contents can be distinguished readily from polyhydroxyalkanoate copolymer molecules and other polymers and compounds not having the above-noted biobased contents, based on the above-noted structural differences associated with differences in biobased contents, with accompanying regulatory benefits.
  • the polyhydroxyalkanoate copolymer molecules can have a weight average molecular weight of 250 kilodalton (“kDa”) to 2.0 megadalton (“MDa”).
  • the polyhydroxyalkanoate copolymer molecules can occur in a distribution with respect to their molecular weights, and the physical properties and rheological properties of compositions of the polyhydroxyalkanoate copolymer molecules can depend on the distribution.
  • Molecular weights of polymers can be calculated various ways. Weight average molecular weight, also termed M w , is the sum of the weights of the various chain lengths, times the molecular weight of the chain, divided by the total weight of all of the chains ( ⁇ N i M i 2 / ⁇ N i M i ).
  • Number average molecular weight also termed M n , is the sum of the number of chains of a given length, times the molecular weight of the chain, divided by the total number of chains ( ⁇ N i M i / ⁇ N i ).
  • Polydispersity index provides a measure of the broadness of a molecular weight distribution of a polymer and is calculated as the weight average molecular weight divided by the number average molecular weight.
  • molecular weight refers to weight average molecular weight unless context indicates otherwise.
  • Weight average molecular weight of polyhydroxyalkanoate copolymer molecules can be determined, for example, by use of light scattering and gel permeation chromatography with polystyrene standards. Chloroform can be used as both the eluent for the gel permeation chromatography and as the diluent for the polyhydroxyalkanoates. Calibration curves for determining molecular weights can be generated by using linear polystyrenes as molecular weight standards and a calibration method based on log molecular weight as a function of elution volume.
  • the weight average molecular weight of the polyhydroxyalkanoate copolymer molecules is 1.5 MDa to 2.0 MDa, e.g. as determined by use of light scattering and gel permeation chromatography with polystyrene standards. In some embodiments the weight average molecular weight of the polyhydroxyalkanoate copolymer molecules is 1.7 MDa to 2.0 MDa, e.g. again as determined by use of light scattering and gel permeation chromatography with polystyrene standards.
  • polyhydroxyalkanoate copolymer molecules having a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%, e.g. 25 to 70%, 30 to 40%, 40 to 50%, 50 to 60%, or 60 to 70% can be obtained in polyhydroxyalkanoate titers ⁇ 50% by weight of biomass titers in accordance with the methods described below, e.g. culturing an organism in the presence of one or more carbon raw materials, as discussed below, wherein the organism has been genetically engineered, as also discussed below.
  • polyhydroxyalkanoate copolymer molecules can be obtained in polyhydroxyalkanoate titers exceeding 50% by weight of biomass titers by culturing the organism in the presence of glucose as a sole carbon source and thus in the absence of compounds that are immediate precursors of 4-hydroxybutyryl-CoA and/or compounds that are typically manufactured from nonrenewable resources.
  • polyhydroxyalkanoate titers ⁇ 50% by weight of biomass titers of the polyhydroxyalkanoate copolymer molecules that can be obtained by the methods described below are indicative of unexpectedly higher molecular weights associated with the polyhydroxyalkanoate copolymer molecules.
  • Polyhydroxyalkanoate copolymer molecules having weight average molecular weights in the above-noted ranges can be used to prepare polyhydroxyalkanoate copolymer compositions having desired physical properties and rheological properties.
  • the composition can have a glass transition temperature of ⁇ 60° C. to ⁇ 5° C.
  • Glass transition temperature is the temperature above which polymer molecules begin coordinated molecular motions. Physically, the polymer modulus begins to drop several orders of magnitude until the polymer finally reaches a rubbery state.
  • the glass transition temperature of the composition is, for example, ⁇ 50° C. to ⁇ 15° C., ⁇ 50° C. to ⁇ 20° C., or ⁇ 45° C. to ⁇ 15° C.
  • Compositions having glass transition temperatures in the above-noted ranges can be used to ensure that the compositions are in a rubbery state at desired temperatures of use.
  • the composition can be one wherein the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules does not decrease with increasing molecular weight of the polyhydroxyalkanoate copolymer molecules.
  • the polyhydroxyalkanoate copolymer molecules can occur in a distribution with respect to their molecular weights.
  • Monomeric molar percentages of 4-hydroxybutyrate monomers may vary between individual polyhydroxyalkanoate copolymer molecules.
  • a composition wherein the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules does not decrease with increasing molecular weight of the polyhydroxyalkanoate copolymer molecules can be, for example, a composition wherein the monomeric molar percentage of 4-hydroxybutyrate monomers of polyhydroxyalkanoate copolymer molecules at the high end of the molecular weight distribution is not lower than the monomeric molar percentage of 4-hydroxybutyrate monomers of polyhydroxyalkanoate copolymer molecules at the low end of the molecular weight distribution.
  • the composition can be one wherein the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules does not vary substantially, e.g. at all, with increasing molecular weight of the polyhydroxyalkanoate copolymer molecules, e.g. the monomeric molar percentage of 4-hydroxybutyrate monomers of polyhydroxyalkanoate copolymer molecules at the high end of the molecular weight distribution is essentially the same, e.g. identical, to that of polyhydroxyalkanoate copolymer molecules at the low end of the molecular weight distribution.
  • the composition can be one wherein the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules increases with increasing molecular weight of the polyhydroxyalkanoate copolymer molecules, e.g. the monomeric molar percentage of 4-hydroxybutyrate monomers of polyhydroxyalkanoate copolymer molecules at the high end of the molecular weight distribution is higher than that of polyhydroxyalkanoate copolymer molecules at the low end of the molecular weight distribution.
  • the polyhydroxyalkanoate copolymer molecules having a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%, and more particularly about 50 to 60% can be obtained in forms in which the monomeric molar percentages of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules of a culture of an organism do not decrease during later stages of culturing of the organism, e.g. during stationary phase, in accordance with the methods described below, e.g. culturing an organism in the presence of one or more carbon raw materials, such as glucose as a sole carbon source, as discussed below, wherein the organism has been genetically engineered, as also discussed below.
  • one or more carbon raw materials such as glucose as a sole carbon source
  • Polyhydroxyalkanoate copolymer molecules wherein the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules does not decrease with increasing molecular weight of the polyhydroxyalkanoate copolymer molecules can be used to ensure consistent structural and physical properties of compositions thereof.
  • the composition can be one wherein the polyhydroxyalkanoate copolymer molecules are produced in a fermentation process using one or more carbon raw materials that, taken together, have a biobased content of ⁇ 80%; the one or more carbon raw materials comprise a carbon source selected from the group consisting of glucose, levoglucosan, sucrose, lactose, fructose, xylose, maltose, arabinose, and mixtures thereof; and the yield is greater than 0.25 g of the polyhydroxyalkanoate copolymer molecules per gram of the carbon source. For example, in some embodiments the yield is greater than 0.30 g, or greater than 0.35 g, or greater than 0.40 g, of the polyhydroxyalkanoate copolymer molecules per gram of the carbon source.
  • a polymer blend composition is also provided.
  • the polymer blend composition comprises a polyhydroxyalkanoate composition and a plurality of molecules of a second polymer.
  • the polyhydroxyalkanoate composition can be any of the polyhydroxyalkanoate compositions as described above, for example a polyhydroxyalkanoate copolymer composition comprising a plurality of polyhydroxyalkanoate copolymer molecules, wherein the polyhydroxyalkanoate copolymer molecules (i) comprise 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers, (ii) have a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%, and (iii) have a biobased content of ⁇ 80%.
  • the polyhydroxyalkanoate composition can be one, for example, wherein (a) the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules is 25 to 70%, 30 to 40%, 40 to 50%, 50 to 60%, or 60 to 70%, (b) the biobased content of the polyhydroxyalkanoate copolymer molecules is ⁇ 95%, ⁇ 99%, or 100% (c) the polyhydroxyalkanoate copolymer molecules have a weight average molecular weight of 250 kDa to 2.0 MDa, 1.5 MDa to 2.0 MDa, or 1.7 MDa to 2.0 MDa, (d) the composition has a glass transition temperature of ⁇ 60° C. to ⁇ 5° C., ⁇ 50° C.
  • the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules does not decrease with increasing molecular weight of the polyhydroxyalkanoate copolymer molecules, and/or (f) the polyhydroxyalkanoate copolymer molecules are produced in a fermentation process using one or more carbon raw materials that, taken together, have a biobased content of ⁇ 80%, as described above.
  • the second polymer can be, for example, a biobased polymer or a non-biobased polymer.
  • Suitable biobased polymers include, for example, polylactic acid, polybutylene succinate, polybutylene succinate adipate, polybutylene adipate terephthalate, and/or polypropylene carbonate, wherein the polymers of the biobased plastics are derived from biobased succinic acid, biobased adipic acid, biobased 1,4-butanediol, biobased polypropylene oxide, and/or carbon dioxide.
  • Suitable biobased polymers also include, for example, additional polyhydroxyalkanoates other than poly(3-hydroxybutyrate-co-4-hydroxybutyrate) copolymer, such as, for example, homopolymers such as poly-3-hydroxybutyrate homopolymer and poly-4-hydroxybutyrate homopolymer, other copolymers, such as poly-3-hydroxybutyrate-co-hydroxyvalerate and poly-3-hydroxybutyrate-co-3-hydroxyhexanoate, and blends of these and other polyhydroxyalkanoates.
  • Suitable non-biobased polymers include, for example, polyvinylchloride.
  • the polymer blend composition can be used for a wide variety of applications, e.g. packaging film, based on optimization of mechanical properties (e.g. tensile strength, puncture resistance, and elongation), thermal properties (e.g. heat distortion temperature), and/or optical properties (e.g. clarity).
  • the polymer blend composition wherein the second polymer is a biobased polymer in particular can be used for optimizing performance properties and to achieve high biobased contents.
  • the polymer blend composition wherein the second polymer is polyvinylchloride has improved properties including improved processing in comparison to polyvinylchloride alone.
  • the polymer blend composition can be blended by suitable methods that are known in the art.
  • the polymer blend composition can be one, for example, wherein the polyhydroxyalkanoate copolymer molecules are present at 5 to 95 weight percent of the polymer blend composition.
  • the polymer blend composition can be one wherein the polyhydroxyalkanoate copolymer molecules are present at 20 to 40 weight percent, 25 to 35 weight percent, or 28 to 33 weight percent, of the polymer blend composition.
  • the polymer blend composition also can be, for example, continuous or co-continuous.
  • the polymer blend composition also can be one, for example, wherein the polyhydroxyalkanoate copolymer molecules and the molecules of the second polymer form a single phase, e.g. wherein the second polymer is polyvinyl chloride.
  • the polymer blend composition also can be one, for example, wherein the polyhydroxyalkanoate copolymer molecules and the molecules of the second polymer form more than a single phase, e.g. wherein the second polymer is polylactic acid.
  • the polymer blend composition also can have, for example, a lower crystallizability, i.e. maximum theoretical crystallinity, than a corresponding composition that lacks the polyhydroxyalkanoate copolymer molecules.
  • a biomass composition comprises a polyhydroxyalkanoate composition, e.g. any of the polyhydroxyalkanoate compositions as described above, wherein the polyhydroxyalkanoate copolymer molecules are present at ⁇ 50 weight percent of the biomass composition.
  • the polyhydroxyalkanoate copolymer composition can be one, for example, comprising a plurality of polyhydroxyalkanoate copolymer molecules, wherein the polyhydroxyalkanoate copolymer molecules (i) comprise 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers, (ii) have a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%, and (iii) have a biobased content of ⁇ 80%.
  • the polyhydroxyalkanoate composition can be one, for example, wherein (a) the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules is 25 to 70%, 30 to 40%, 40 to 50%, 50 to 60%, or 60 to 70%, (b) the biobased content of the polyhydroxyalkanoate copolymer molecules is ⁇ 95%, ⁇ 99%, or 100%, (c) the polyhydroxyalkanoate copolymer molecules have a weight average molecular weight of 250 kDa to 2.0 MDa, 1.5 MDa to 2.0 MDa, or 1.7 MDa to 2.0 MDa, (d) the composition has a glass transition temperature of ⁇ 60° C. to ⁇ 5° C., ⁇ 50° C.
  • the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules does not decrease with increasing molecular weight of the polyhydroxyalkanoate copolymer molecules, and/or (f) the polyhydroxyalkanoate copolymer molecules are produced in a fermentation process using one or more carbon raw materials that, taken together, have a biobased content of ⁇ 80%, as described above.
  • the polyhydroxyalkanoate copolymer molecules are present at ⁇ 50 weight percent of the biomass composition.
  • weight percent of the biomass composition refers to dry weight of the biomass composition, e.g. cell dry weight.
  • the polyhydroxyalkanoate copolymer molecules can be present, for example, at ⁇ 60, ⁇ 70, ⁇ 80, ⁇ 85, or ⁇ 90 weight percent of the biomass composition.
  • polyhydroxyalkanoate copolymer composition can be any of the polyhydroxyalkanoate compositions as described above, for example a polyhydroxyalkanoate copolymer composition comprising a plurality of polyhydroxyalkanoate copolymer molecules, wherein the polyhydroxyalkanoate copolymer molecules (i) comprise 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers, (ii) have a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%, and (iii) have a biobased content of ⁇ 80%.
  • the polyhydroxyalkanoate composition can be one, for example, wherein (a) the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules is 25 to 70%, 30 to 40%, 40 to 50%, 50 to 60%, or 60 to 70%, (b) the biobased content of the polyhydroxyalkanoate copolymer molecules is ⁇ 95%, ⁇ 99%, or 100%, (c) the polyhydroxyalkanoate copolymer molecules have a weight average molecular weight of 250 kDa to 2.0 MDa, 1.5 MDa to 2.0 MDa, or 1.7 MDa to 2.0 MDa, (d) the composition has a glass transition temperature of ⁇ 60° C. to ⁇ 5° C., ⁇ 50° C.
  • the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules does not decrease with increasing molecular weight of the polyhydroxyalkanoate copolymer molecules, and/or (f) the polyhydroxyalkanoate copolymer molecules are produced in a fermentation process using one or more carbon raw materials that, taken together, have a biobased content of ⁇ 80%, as described above.
  • the method can comprise culturing an organism in the presence of one or more carbon raw materials under conditions under which (a) the one or more carbon raw materials are converted to 3-hydroxybutyryl-CoA and 4-hydroxybutyryl-CoA and (b) the 3-hydroxybutyryl-CoA and the 4-hydroxybutyryl-CoA are polymerized to form the polyhydroxyalkanoate copolymer molecules, thereby forming the composition.
  • the culturing can comprise, for example, cultivating the organism by fermentation, shake-flask cultivation, and the like. Fermentation can be carried out, for example, at scales ranging from laboratory scale, e.g. 1 L, to industrial manufacturing scale, e.g. 20,000 to 100,000 L. Additional suitable culturing approaches are described in the Examples below.
  • the organism can be, for example, a microbial strain or an algal strain.
  • Suitable microbial strains include, for example, an Escherichia coli strain or a Ralstonia eutropha strain.
  • Suitable algal strains include, for example, a Chlorella strain. Additional suitable organisms are described in the Examples below.
  • the one or more carbon raw materials can comprise a carbon raw material that can be used in an industrial process, e.g. to supply a carbon or other energy source for cells of a fermentation process, and/or that is renewable, e.g. material derived from living organisms or their metabolic byproducts including material derived from biomass, often consisting of underutilized components like chaff or stover.
  • the one or more carbon raw materials can comprise a carbon source selected from the group consisting of glucose, levoglucosan, sucrose, lactose, fructose, xylose, maltose, arabinose, and mixtures thereof.
  • the one or more carbon raw materials can comprise one or more of molasses, starch, a fatty acid, a vegetable oil, a lignocellulosic material, ethanol, acetic acid, glycerol, a biomass-derived synthesis gas, and methane originating from a landfill gas.
  • the one or more carbon raw materials can consist essentially of a carbon source selected from the group consisting of glucose, levoglucosan, sucrose, lactose, fructose, xylose, maltose, arabinose, and mixtures thereof.
  • the one or more carbon raw materials can consist of a carbon source selected from the group consisting of glucose, levoglucosan, sucrose, lactose, fructose, xylose, maltose, arabinose, and mixtures thereof.
  • the one or more carbon raw materials can consist essentially of a single carbon source, e.g. glucose.
  • the one or more carbon raw materials can consist of a single carbon source, again e.g. glucose.
  • the one or more carbon raw materials can also exclude particular compounds, such as compounds that are immediate precursors of 4-hydroxybutyryl-CoA and/or compounds that are typically manufactured from nonrenewable resources, e.g. from petroleum, based on substantially lower cost in comparison to manufacture thereof from renewable resources, e.g. crops.
  • Incorporation of such compounds for production of polyhydroxyalkanoate copolymer molecules can be costly, particularly with respect to industrial manufacturing scale, e.g. by fermentation using 20,000 to 100,000 L vessels, based on requiring additional feeds and thus infrastructure and quality control, and can result in a need for tighter control in order to achieve polyhydroxyalkanoate copolymer compositions with structural consistency.
  • the one or more carbon raw materials can be, for example, ones that do not comprise ⁇ -butyrolactone, 1,4-butanediol, 4-hydroxybutyrate, 3-hydroxybutyrate, ⁇ -ketoglutarate, oxaloacetate, malate, fumarate, citrate, succinate, or 3-hydroxybutyrate, and thus that exclude each of these compounds.
  • the culturing of the organism can be carried out in the absence of ⁇ -butyrolactone, 1,4-butanediol, 4-hydroxybutyrate, 3-hydroxybutyrate, ⁇ -ketoglutarate, oxaloacetate, malate, fumarate, citrate, succinate, and 3-hydroxybutyrate, i.e. without adding any of these compounds exogenously before, during, or after the culturing.
  • the conditions can be conditions that are suitable, e.g. typical and/or optimal, for cultivation of the organism, e.g. with respect to temperature, oxygenation, initial titer of the organism, time of cultivation, etc. Exemplary suitable conditions are provided in the Examples below.
  • the one or more carbon raw materials can be converted to 3-hydroxybutyryl-CoA and 4-hydroxybutyryl-CoA by enzymes expressed by the organism, as discussed in detail in the Examples.
  • the 3-hydroxybutyryl-CoA and the 4-hydroxybutyryl-CoA also can be polymerized to form the polyhydroxyalkanoate copolymer molecules, thereby forming the composition, by enzymes expressed by the organism, again as discussed in detail in the Examples.
  • the organism has been genetically engineered to comprise enzymatic activities of a polyhydroxyalkanoate synthase, an acetyl-CoA acetyltransferase, an acetoacetyl-CoA reductase, a succinate semialdehyde dehydrogenase, a succinic semialdehyde reductase, and a CoA transferase, and to not comprise enzymatic activities of either an NAD+-dependent succinate-semialdehyde dehydrogenase or an NADP+-dependent succinate-semialdehyde dehydrogenase or both.
  • the organism can be genetically engineered to comprise the enzymatic activities of a polyhydroxyalkanoate synthase, an acetyl-CoA acetyltransferase, an acetoacetyl-CoA reductase, a succinate semialdehyde dehydrogenase, a succinic semialdehyde reductase, and a CoA transferase, for example, by transforming the organism with one or more genes encoding each of the enzymatic activities.
  • the genes can be stably incorporated into the organism, e.g. by introduction on one or more stable plasmids and/or by integration into the genome of the organism.
  • the organism can also be genetically engineered to comprise the enzymatic activities, for example, by altering the promoter regions of one or more genes encoding each of the enzymatic activities, for example by replacing naturally occurring promoters with stronger promoters and/or by eliminating repressor sequences.
  • combinations of these approaches and the like can be used. Using approaches such as these can result in integration of the genes in the organism with high stability, e.g. greater than 50 generations of the organism, and high expression, sufficient for industrial production, for example, by fermentation using 20,000 to 100,000 L vessels. Suitable exemplary approaches are discussed in more detail below.
  • the organism also can be genetically engineered to not comprise enzymatic activities of either an NAD+-dependent succinate-semialdehyde dehydrogenase or an NADP+-dependent succinate-semialdehyde dehydrogenase or both, for example, by introducing one or more inhibitory mutations or sequences in the organism to inhibit expression of either or both activities, by deleting from the genome of the organism the corresponding genes that encode either or both activities, by disrupting either or both of the corresponding genes partially or completely by homologous recombination, and/or by interfering with expression of either or both of the corresponding genes such as by expressing siRNAs that interfere with expression of the corresponding genes. Suitable exemplary approaches are discussed in more detail below.
  • the organism can further be genetically engineered to comprise enzymatic activities of an alpha-ketoglutarate decarboxylase or 2-oxoglutarate decarboxylase, and an L-1,2-propanediol oxidoreductase.
  • the organism also can be genetically engineered to not comprise enzymatic activities of one or more of a thioesterase II, a multifunctional acyl-CoA thioesterase I and protease I and lysophospholipase L, an acyl-CoA thioesterase, and an aldehyde dehydrogenase.
  • the one or more carbon raw materials, taken together have a biobased content of ⁇ 80%.
  • the amount of biobased carbon in the one or more carbon raw materials, taken together is ⁇ 80% of the weight (mass) of the total organic carbon of the one or more carbon raw materials, taken together.
  • the one or more carbon raw materials, taken together can have a biobased content of ⁇ 80% as measured in accordance with ASTM D6866-12. This can be accomplished, for example, by including at least one carbon raw material corresponding to a renewable resource, e.g.
  • the one or more carbon raw materials, taken together, can have, for example, a biobased content of ⁇ 95%, ⁇ 99%, or 100%.
  • the method can also comprise isolating the polyhydroxyalkanoate copolymer molecules from the organism, such that the polyhydroxyalkanoate copolymer composition is substantially free of the organism. Suitable exemplary approaches for such isolation are known in the art.
  • a polyhydroxyalkanoate copolymer composition made in accordance with the methods described above is also provided.
  • the polyhydroxyalkanoate copolymer composition can be one, for example, comprising a plurality of polyhydroxyalkanoate copolymer molecules, wherein the polyhydroxyalkanoate copolymer molecules (i) comprise 3-hydroxybutyrate monomers and 4-hydroxybutyrate monomers, (ii) have a monomeric molar percentage of 4-hydroxybutyrate monomers of 23.5 to 75%, and (iii) have a biobased content of ⁇ 80%.
  • the polyhydroxyalkanoate composition can be one, for example, wherein (a) the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules is 25 to 70%, 30 to 40%, 40 to 50%, 50 to 60%, or 60 to 70%, (b) the biobased content of the polyhydroxyalkanoate copolymer molecules is ⁇ 95%, ⁇ 99%, or 100%, (c) the polyhydroxyalkanoate copolymer molecules have a weight average molecular weight of 250 kDa to 2.0 MDa, 1.5 MDa to 2.0 MDa, or 1.7 MDa to 2.0 MDa, (d) the composition has a glass transition temperature of ⁇ 60° C. to ⁇ 5° C., ⁇ 50° C.
  • the monomeric molar percentage of 4-hydroxybutyrate monomers of the polyhydroxyalkanoate copolymer molecules does not decrease with increasing molecular weight of the polyhydroxyalkanoate copolymer molecules, and/or (f) the polyhydroxyalkanoate copolymer molecules are produced in a fermentation process using one or more carbon raw materials that, taken together, have a biobased content of ⁇ 80%, as described above.
  • the host strain is E. coli K-12 strain LS5218 (Spratt et al., J. Bacteriol. 146 (3):1166-1169 (1981); Jenkins and Nunn, J. Bacteriol. 169 (1):42-52 (1987)) or strain MG1655 (Guyer et al., Cold Spr. Harb. Symp. Quant. Biol. 45:135-140 (1981)).
  • Other suitable E. coli K-12 host strains include, but are not limited to, WG1 and W3110 (Bachmann Bacteriol. Rev. 36(4):525-57 (1972)).
  • E. coli K-12 strain LS5218 Spratt et al., J. Bacteriol. 146 (3):1166-1169 (1981); Jenkins and Nunn, J. Bacteriol. 169 (1):42-52 (1987)
  • strain MG1655 (Guyer et al., Cold Spr. Harb. Symp. Quant. Biol. 45:135-140 (1981)).
  • E. coli strain W (Archer et al., BMC Genomics 2011, 12:9 doi:10.1186/1471-2164-12-9) or E. coli strain B (Delbruck and Luria, Arch. Biochem. 1:111-141 (1946)) and their derivatives such as REL606 (Lenski et al., Am. Nat. 138:1315-1341 (1991)) are other suitable E. coli host strains.
  • exemplary microbial host strains include but are not limited to: Ralstonia eutropha, Zoogloea ramigera, Allochromatium vinosum, Rhodococcus ruber, Delftia acidovorans, Aeromonas caviae, Synechocystis sp.
  • PCC 6803 Synechococcus elongatus PCC 7942 , Thiocapsa pfenigii, Bacillus megaterium, Acinetobacter baumannii, Acinetobacter baylyi, Clostridium kluyveri, Methylobacterium extorquens, Nocardia corralina, Nocardia salmonicolor, Pseudomonas fluorescens, Pseudomonas oleovorans, Pseudomonas sp. 6-19, Pseudomonas sp.
  • Exemplary yeasts or fungi include species selected from Saccharomyces cerevisiae, Schizosaccharomyces pombe, Kluyveromyces lactis, Kluyveromyces marxianus, Aspergillus terreus, Aspergillus niger and Pichia pastoris.
  • Exemplary algal strains include but are not limited to: Chlorella strains, species selected from: Chlorella minutissima, Chlorella emersonii, Chlorella sorokiniana, Chlorella ellipsoidea, Chlorella sp., or Chlorella protothecoides.
  • Sources of encoding nucleic acids for a PHB-co-4HB pathway enzyme can include, for example, any species where the encoded gene product is capable of catalyzing the referenced reaction.
  • species include both prokaryotic and eukaryotic organisms including, but not limited to, bacteria, including archaea and eubacteria, and eukaryotes, including yeast, plant, insect, animal, and mammal, including human.
  • Exemplary species for such sources include, for example, Escherichia coli, Saccharomyces cerevisiae, Saccharomyces reteyveri, Synechocystis sp.
  • PCC 6803 Synechococcus elongatus PCC 7942 , Synechococcus sp. PCC 7002 , Chlorogleopsis sp. PCC 6912 , Chloroflexus aurantiacus, Clostridium kluyveri, Clostridium acetobutylicum, Clostridium beijerinckii, Clostridium saccharoperbutylacetonicum, Clostridium perjringens, Clostridium difficile, Clostridium botulinum, Clostridium tyrobutyricum, Clostridium tetanomorphum, Clostridium tetani, Clostridium propionicum, Clostridium aminobutyricum, Clostridium subterminale, Clostridium sticklandii, Ralstonia eutropha, Mycobacterium bovis, Mycobacterium tuberculosis, Porphyromonas gingivalis
  • microbial hosts e.g., organisms having PHB-co-4HB biosynthetic production are exemplified herein with reference to an E. coli host.
  • the complete genome sequence available for now more than 550 species including 395 microorganism genomes and a variety of yeast, fungi, plant, and mammalian genomes
  • the identification of genes encoding the requisite PHB-co-4HB biosynthetic activity for one or more genes in related or distant species including for example, homologues, orthologs, paralogs and nonorthologous gene displacements of known genes, and the interchange of genetic alterations between organisms is routine and well known in the art.
  • Transgenic (recombinant) hosts for producing PHB-co-4HB are genetically engineered using conventional techniques known in the art.
  • the genes cloned and/or assessed for host strains producing PHB-co-4HB are presented below in Table 1A, along with the appropriate Enzyme Commission number (EC number) and references. Some genes were synthesized for codon optimization while others were cloned via PCR from the genomic DNA of the native or wild-type host.
  • “heterologous” means from another host. The host can be the same or different species.
  • FIG. 1 is an exemplary pathway for producing PHB-co-4HB.
  • beta-ketothiolase 2 phaB5 Acetoacetyl-CoA 1.1.1.36 P23238 reductase 3 sucD* Succinate semialdehyde 1.2.1.76 Gene/Protein dehydrogenase ID 1; U.S. Patent Appl. No.
  • SucD protein succinate semialdehyde dehydrogenase, from Clostridium kluyveri , EC No. 1.2.1.76, which acts on succinyl-CoA to produce succinate semialdehyde; protein acc. no. YP_001396394). Protein Accession Protein Name No.
  • PhaC3/C5 protein Polyhydroxyalkanoate synthase fusion protein from Pseudomonas putida and Zoogloea ramigera , EC No. 2.3.1.n, which acts on (R)-3-hydroxybutyryl-CoA or 4-hydroxybutyryl-CoA + [(R)-3-hydroxybutanoate-co-4-hydroxybutanoate] n to produce [(R)-3-hydroxybutanoate-co-4-hydroxybutanoate] (n+1) + CoA and also acts on 4-hydroxybutyryl-CoA + [4-hydroxybutanoate] n to produce [4-hydroxybutanoate] (n+1) + CoA).
  • PhaC3/C1 Polyhydroxyalkanoate synthase fusion protein from Pseudomonas putida and Ralstonia eutropha JMP134, EC No. 2.3.1.n, which acts on (R)-3-hydroxybutyryl-CoA or 4-hydroxybutyryl-CoA + [(R)-3-hydroxybutanoate-co-4-hydroxybutanoate] n to produce [(R)-3-hydroxybutanoate-co-4-hydroxybutanoate] (n+1) + CoA and also acts on 4-hydroxybutyryl-CoA + [4-hydroxybutanoate] n to produce [4-hydroxybutanoate] (n+1) + CoA).
  • PhaC3/C33 protein Polyhydroxyalkanoate synthase fusion protein from Pseudomonas putida and Delftia acidovorans 89-11-102, EC No. 2.3.1.n, which acts on (R)-3-hydroxybutyryl-CoA or 4-hydroxybutyryl-CoA + [(R)-3-hydroxybutanoate-co-4-hydroxybutanoate] n to produce [(R)-3-hydroxybutanoate-co-4-hydroxybutanoate] (n+1) + CoA and also acts on 4-hydroxybutyryl-CoA + [4-hydroxybutanoate] n to produce [4-hydroxybutanoate] (n+1) + CoA).
  • succinate-semialdehyde dehydrogenase I ZP_05433422 succinate-semialdehyde dehydrogenase YP_001744810 (NAD(P)(+)) hypothetical protein CIT292_04137 ZP_03838093 succinate-semialdehyde dehydrogenase YP_002638371 succinate-semialdehyde dehydrogenase I YP_001333939 succinate-semialdehyde dehydrogenase I NP_742381 succinate-semialdehyde dehydrogenase YP_002932123 [NADP+] (ssdh) succinic semialdehyde dehydrogenase YP_001951927 succinate semialdehyde dehydrogenase YP_298405
  • Ppc protein phosphoenolpyruvate carboxylase, from Escherichia coli str. K-12 substr. MG1655, EC No. 4.1.1.31, which acts on phosphoenolpyruvate and carbon dioxide to produce oxaloacetate; protein acc. no. NP_418391).
  • Ppc protein phosphoenolpyruvate carboxylase, from Escherichia coli str. K-12 substr. MG1655, EC No. 4.1.1.31, which acts on phosphoenolpyruvate and carbon dioxide to produce oxaloacetate; protein acc. no. NP_418391).
  • TesA protein multifunctional acyl-CoA thioesterase I and protease I and lysophospholipase L1, from Escherichia coli K-12 substr. MG1655, EC No. 3.1.1.5 and 3.1.2.14, which acts on 4-hydroxybutyryl-CoA to produce 4-hydroxybutyrate; protein acc. no. NP_415027).
  • TesA protein multifunctional acyl-CoA thioesterase I and protease I and lysophospholipase L1, from Escherichia coli K-12 substr. MG1655, EC No. 3.1.1.5 and 3.1.2.14, which acts on 4-hydroxybutyryl-CoA to produce 4-hydroxybutyrate; protein acc. no. NP_415027).
  • TesB protein thioesterase II, from Escherichia coli K-12 substr. MG1655, EC No. 3.1.2.20, which acts on 4-hydroxybutyryl-CoA to produce 4-hydroxybutyrate; protein acc. no. ZP_08342109).
  • TesB protein thioesterase II, from Escherichia coli K-12 substr. MG1655, EC No. 3.1.2.20, which acts on 4-hydroxybutyryl-CoA to produce 4-hydroxybutyrate; protein acc. no. ZP_08342109).
  • acyl-CoA thioester hydrolase YP_002382845 acyl-CoA thioester hydrolase YP_001570262 thioesterase superfamily protein YP_005019613 acyl-CoA thioester hydrolase YP_050409 acyl-CoA thioester hydrolase YP_002151085 acyl-CoA thioester hydrolase YciA NP_777876 hypothetical protein VC1701 NP_231337 thioesterase superfamily protein YP_002893359 acyl-CoA thioester hydrolase ZP_11128814
  • a “vector,” as used herein, is an extrachromosomal replicon, such as a plasmid, phage, or cosmid, into which another DNA segment may be inserted so as to bring about the replication of the inserted segment.
  • Vectors vary in copy number, depending on their origin of replication, and size. Vectors with different origins of replication can be propagated in the same microbial cell unless they are closely related such as pMB1 and ColE1.
  • Suitable vectors to express recombinant proteins can constitute pUC vectors with a pMB1 origin of replication having 500-700 copies per cell, pBluescript vectors with a ColE1 origin of replication having 300-500 copies per cell, pBR322 and derivatives with a pMB1 origin of replication having 15-20 copies per cell, pACYC and derivatives with a p15A origin of replication having 10-12 copies per cell, and pSC101 and derivatives with a pSC101 origin of replication having about 5 copies per cell as described in the QIAGEN® Plasmid Purification Handbook (found on the world wide web at: //kirshner.med.harvard.edu/files/protocols/QIAGEN_QIAGENPlasmidPurification_EN.pdf).
  • a widely used vector is pSE380 that allows recombinant gene expression from an IPTG-inducible trc promoter (Invitrogen, La Jolla, Calif.).
  • Expression control sequences can include constitutive and inducible promoters, transcription enhancers, transcription terminators, and the like which are well known in the art.
  • Exemplary promoters are:
  • Recombinant hosts containing the necessary genes that will encode the enzymatic pathway for the conversion of a carbon substrate to PHB-co-4HB may be constructed using techniques well known in the art.
  • the gene of interest may be chemically synthesized de novo in order to take into consideration the codon bias of the host organism to enhance heterologous protein expression.
  • Expression control sequences such as promoters and transcription terminators can be attached to a gene of interest via polymerase chain reaction using engineered primers containing such sequences.
  • Another way is to introduce the isolated gene into a vector already containing the necessary control sequences in the proper order by restriction endonuclease digestion and ligation.
  • BioBrickTM technology www.biobricks.org
  • multiple pieces of DNA can be sequentially assembled together in a standardized way by using the same two restriction sites.
  • genes that are necessary for the enzymatic conversion of a carbon substrate to PHB-co-4HB can be introduced into a host organism by integration into the chromosome using either a targeted or random approach.
  • the method generally known as Red/ET recombineering is used as originally described by Datsenko and Wanner ( Proc. Natl. Acad. Sci. USA, 2000, 97, 6640-6645).
  • Random integration into the chromosome involves using a mini-Tn5 transposon-mediated approach as described by Huisman et al. (U.S. Pat. Nos. 6,316,262 and 6,593,116).
  • the recombinant host is cultured in a medium with a carbon source and other essential nutrients to produce the PHB-co-4HB biomass by fermentation techniques either in batches or using continuously operating methods known in the art. Additional additives can also be included, for example, antifoaming agents and the like for achieving desired growth conditions. Fermentation is particularly useful for large scale production.
  • An exemplary method uses bioreactors for culturing and processing the fermentation broth to the desired product. Other techniques such as separation techniques can be combined with fermentation for large scale and/or continuous production.
  • feedstock refers to a substance used as a carbon raw material in an industrial process.
  • the term refers to the raw material used to supply a carbon or other energy source for the cells.
  • Carbon sources useful for the production of PHB-co-4HB include simple, inexpensive sources, for example, glucose, levoglucosan, sucrose, lactose, fructose, xylose, maltose, arabinose, and the like alone or in combination.
  • the feedstock is molasses, starch, a fatty acid, a vegetable oil, a lignocellulosic material, and the like, again alone or in combination.
  • the feedstock can be ethanol, acetic acid, glycerol, and the like, alone or in combination. It is also possible to use organisms to produce the PHB-co-4HB biomass that grow on synthesis gas (CO 2 , CO and hydrogen) produced from renewable biomass resources, i.e. a biomass-derived synthesis gas, and/or methane originating from a landfill gas.
  • synthesis gas CO 2 , CO and hydrogen
  • a “renewable” feedstock refers to a renewable energy source such as material derived from living organisms or their metabolic byproducts including material derived from biomass, often consisting of underutilized components like chaff or stover.
  • Agricultural products specifically grown for use as renewable feedstocks include, for example, corn, soybeans, switchgrass and trees such as poplar, wheat, flaxseed and rapeseed, sugar cane and palm oil.
  • As renewable sources of energy and raw materials agricultural feedstocks based on crops are the ultimate replacement for declining oil reserves. Plants use solar energy and carbon dioxide fixation to make thousands of complex and functional biochemicals beyond the current capability of modern synthetic chemistry. These include fine and bulk chemicals, pharmaceuticals, nutraceuticals, flavonoids, vitamins, perfumes, polymers, resins, oils, food additives, bio-colorants, adhesives, solvents, and lubricants.
  • PHB-co-4HB copolymer was extracted as described in U.S. Pat. Nos. 7,713,720 and 7,252,980.
  • PHA Molecular weight of PHA is estimated by Gel Permeation Chromatography using a Waters Alliance HPLC System equipped with a refractive index detector.
  • the column set is a series of three PLGel 10 ⁇ m Mixed-B (Polymer Labs, Amherst, Mass.) columns with chloroform as mobile phase pumped at 1 ml/min.
  • the column set is calibrated with narrow distribution polystyrene standards.
  • the PHA sample is dissolved in chloroform at a concentration of 2.0 mg/ml at 60° C.
  • the sample is filtered with a 0.2 ⁇ m Teflon syringe filter.
  • a 50 ⁇ -liter injection volume is used for the analysis.
  • the chromatogram is analyzed with Waters Empower GPC Analysis software. Molecular weights are reported as polystyrene equivalent molecular weights.
  • the glass transition of PHB-co-4HB copolymers was measured using a TA Instruments Q100 Differential scanning calorimeter (DSC) with autosampler. 8-12 mg of a PHA sample was carefully weighed into an aluminum pan and sealed with an aluminum lid. The sample was then placed in the DSC under a nitrogen purge and analyzed using a heat-cool-heat cycle. The heating/cooling range was ⁇ 80° C. to 200° C. with a heating rate of 10° C./min and cooling rate of 5° C./min.
  • the biobased content of the PHB-co-4HB copolymer was measured by radiocarbon dating based on ASTM D6866.
  • ASTM D6866 is the method approved by the U.S. Department of Agriculture for determining the renewable/biobased content of natural range materials. The method provides a percentage determination of fossil carbon content versus renewable or biomass carbon content of a product or fuel blend.
  • ASTM D6866 is used extensively to certify the biobased content of bioplastics.
  • This example shows PHB-co-4HB production with 50% or higher 4HB co-monomer content from glucose as sole carbon source in engineered E. coli host cells.
  • the strains used in this example are listed in Table 2. All these strains were constructed using the well-known biotechnology tools and methods described above. They all contained chromosomal deletions of yneI and gabD with the exception of strains 31 and 32 which also contained chromosomal deletions of tesB, tesA, yciA, and astD.
  • the strains were evaluated in a shake plate assay.
  • the production medium consisted of 1 ⁇ E2 minimal salts, 1 ⁇ E0 minimal salts, 5 mM MgSO 4 , and 1 ⁇ Trace Salts Solution.
  • the carbon source consisted of 40 g/L glucose for strains 31, 32, and 33, whereas for all other strains in Examples 1 to 5, glucose concentration was 20 g/L.
  • 50 ⁇ E2 stock solution consists of 1.28 M NaNH 4 HPO 4 .4H 2 O, 1.64 M K 2 HPO 4 , and 1.36 M KH 2 PO 4 .
  • 50 ⁇ E0 stock solution consists of 1.28 M Na 2 HPO 4 , 1.64 M K 2 HPO 4 and 1.36 M KH 2 PO 4 .
  • 1000 ⁇ Trace Salts Solution is prepared by adding per 1 L of 1.5 N HCl: 50 g FeSO 4 .7H 2 O, 11 g ZnSO 4 .7H 2 O, 2.5 g MnSO 4 .4H 2 O, 5 g CuSO 4 .5H 2 O, 0.5 g (NH 4 ) 6 Mo 7 O 24 .4H 2 O, 0.1 g Na 2 B 4 O 7 , and 10 g CaCl 2 .2H 2 O.
  • the strains were cultured in triplicate overnight in sterile tubes containing 3 mL of LB and appropriate antibiotics. After culturing was complete, 60 ⁇ L was removed from a tube and then added to 1440 ⁇ L of production medium. The resulting 1500 ⁇ L cultures were then added to three wells of a Duetz deep-well plate as 500 ⁇ L aliquots. The shake plate was incubated at 37° C. with shaking for 6 hours and then shifted to 30° C. for 40 hours with shaking for all strains in Examples 1 to 5, except for strains 31, 32, and 33 which were incubated at 37° C. with shaking for 6 hours and then shifted to 28° C. for 42 hours with shaking.
  • cultures from the three wells were combined (1.5 mL total) and analyzed for polymer content.
  • cultures were spun down at 4150 rpm, washed once with distilled water, frozen at ⁇ 80° C. for at least 30 minutes, and lyophilized overnight.
  • a measured amount of lyophilized cell pellet was added to a glass tube, followed by 3 mL of butanolysis reagent that consists of an equal volume mixture of 99.9% n-butanol and 4.0 N HCl in dioxane with 2 mg/mL diphenylmethane as internal standard. After capping the tubes, they were vortexed briefly and placed on a heat block set to 93° C.
  • GC-FID gas chromatography-flame ionization detection
  • the 4HB standard curve was generated by adding different amounts of a 10% solution of ⁇ -butyrolactone (GBL) in butanol to separate butanolysis reactions.
  • the 3HB standard curve was generated by adding different amounts of 99% ethyl 3-hydroxybutyrate to separate butanolysis reactions.
  • This example shows PHB-co-4HB production with 4HB co-monomer content between 40 and 50% from glucose as sole carbon source in engineered E. coli host cells.
  • the strains used in this example are listed in Table 4. All these strains were constructed using the well-known biotechnology tools and methods described above. They all contained chromosomal deletions of yneI and gabD.
  • This example shows PHB-co-4HB production with 4HB co-monomer content between 30 and 40% from glucose as sole carbon source in engineered E. coli host cells.
  • the strains used in this example are listed in Table 6. All these strains were constructed using the well-known biotechnology tools and methods described above. They all contained chromosomal deletions of yneI and gabD.
  • This example shows PHB-co-4HB production with 4HB co-monomer content between 20 and 30% from glucose as sole carbon source in engineered E. coli host cells.
  • the strains used in this example are listed in Table 8. All these strains were constructed using the well-known biotechnology tools and methods described above. They all contained chromosomal deletions of yneI and gabD.
  • This example shows PHB-co-4HB production with 4HB co-monomer content between 1 and 20% from glucose as sole carbon source in engineered E. coli host cells.
  • the strains used in this example are listed in Table 10. All these strains were constructed using the well-known biotechnology tools and methods described above. They all contained chromosomal deletions of yneI and gabD.
  • Biomass Titer PHA Titer PHA Composition Strains (g/L) (g/L) (% 4HB) 13 5.4 ⁇ 0.1 2.4 ⁇ 0.1 18.8 ⁇ 0.4 12 6.1 ⁇ 0.1 3.2 ⁇ 0.2 10.1 ⁇ 0.7 14 5.4 ⁇ 0.1 2.5 ⁇ 0.1 6.4 ⁇ 0.5 30 4.1 ⁇ 0.2 1.7 ⁇ 0.1 1.8 ⁇ 0.3 15 4.5 ⁇ 0.1 1.4 ⁇ 0.1 1.4 ⁇ 0.3 0.3
  • strains 1, 5 and 12 with various PHA compositions as shown in Example 1 were first grown in 20 mL LB medium in 250 mL shake flasks at 37° C. overnight. The entire volume was then transferred into 1 L baffled shake flasks containing 500 mL of a production medium comprised of 1 ⁇ E2 minimal salts, 1 ⁇ E0 minimal salts, 5 mM MgSO4, 30 g/L glucose, and 1 ⁇ Trace Salts Solution. E2 and E0 minimal salts and Trace Salts Solution are described in Example 1. The 500 mL cultures were incubated at 37° C. with shaking for 6 hours and then shifted to 28° C. for 70 hours with shaking. Thereafter, cultures were spun down at 6000 ⁇ g, washed once with distilled water, frozen at ⁇ 80° C. for at least 30 minutes, and lyophilized overnight.
  • the copolymer of strains 1, 5 and 12 were purified from dried biomass by first extracting with cyclo-hexanone at 65-70° C. for 30 min before spinning down at 2000 ⁇ g for 5 min. Afterwards, the supernatant was decanted and mixed with an equal volume of heptane at 5-10° C. The resulting precipitated polymer was filtered and dried overnight at room temperature.
  • the molecular weights of the purified copolymers were determined using gel permeation chromatography (GPC) using a Waters Alliance HPLC System.
  • Table 12 shows the weight average molecular weights (Mw), the number average molecular weights (Mn), and the polydispersity index (PD) measured from the copolymers purified from strains 1, 5 and 12.
  • the copolymers purified from strains 1, 5 and 12 as described in Example 6 were used to determine the PHA composition as outlined in Example 1.
  • the glass transition temperature (T g ) was measured using differential scanning calorimetry (DSC) analysis.
  • Table 13 lists the 4HB content and the T g measured from the copolymers purified from strains 1, 5 and 12. The glass transition temperature decreased with higher 4HB content in the copolymer.
  • the copolymer purified from strain 1 as described in Example 6 was used to determine the biobased content by radiocarbon dating based on ASTM D6866 by Beta Analytic (Miami, Fla., USA).
  • the purified copolymer from strain 1 was determined to contain a biobased content of 97%.
  • Strains 1 and 6 were grown and polymer content analyzed in the same manner as described in Example 1 with the exception that the carbohydrate fed was 30 g/L glycerol instead of 20 g/L glucose. A representative result for both strains is shown in Table 14.

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