Synthesis of novel boron‐containing epoxy–novolac resins and properties of cured products

Epoxy–novolac resins were synthesized by modifying a commercial novolac resin with epichlorohydrin. These epoxy–novolac resins were characterized and further modified with different contents of bis(benzo‐1,3,2‐dioxa‐borolanyl)oxide or bis(4,4,5,5‐tetramethyl‐1,3,2‐dioxa‐borolanyl)oxide. The boron‐containing epoxy–novolac resins were autocatalytically crosslinked or crosslinked with BF₃MEA and their thermal stability and flame retardancy were determined by thermogravimetric analysis and limiting oxygen index (LOI) values. These LOI values for the bis(benzo‐1,3,2‐dioxa‐borolanyl)oxide derivatives were higher than the boron‐free novolac resins, which shows the benefit of the presence of boron. To test the role of boron in the enhancement of flammability, scanning electronic microscopy and energy‐dispersive X‐ray spectroscopy images were made. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 6332–6344, 2006     

Preparation and properties of high performance epoxy–silsesquioxane hybrid resins prepared using a maleimide–alkoxysilane compound as a modifier

An alkoxysilane compound possessing maleimide moiety (MSM) was prepared from N‐(4‐hydroxyphenyl)maleimide and 3‐glycidoxypropyltrimethoxysilane and was used as a modifier of epoxy resins. In situ curing epoxy resins with MSM resulted in epoxy resins with good homogeneity. Just 5–10 wt % of MSM is sufficient to yield high glass transition temperature (165 °C), good thermal stability above 360 °C, and high flame retardancy (LOI = 30) to bisphenol‐A‐based epoxy resins. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 5787–5798, 2005     

Preparation,thermal properties,and flame retardance of epoxy–silica hybrid resins

A novel epoxy system was developed through the in situ curing of bisphenol A type epoxy and 4,4′‐diaminodiphenylmethane with the sol–gel reaction of a phosphorus‐containing trimethoxysilane (DOPO–GPTMS), which was prepared from the reaction of 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO) with 3‐glycidoxypropyltrimethoxysilane (GPTMS). The preparation of DOPO–GPTMS was confirmed with Fourier transform infrared, ¹H and ³¹P NMR, and elemental analysis. The resulting organic–inorganic hybrid epoxy resins exhibited a high glass‐transition temperature (167 °C), good thermal stability over 320 °C, and a high limited oxygen index of 28.5. The synergism of phosphorus and silicon on flame retardance was observed. Moreover, the kinetics of the thermal oxidative degradation of the hybrid epoxy resins were studied. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 2354–2367, 2003     

Preparation and properties of epoxy/amine hybrid resins from in situ polymerization

Homogeneous and transparent epoxy/amine hybrid resins were successfully obtained through the in situ curing of bisphenol A epoxy and hexakis(methoxymethyl)melamine with 2 wt % (3‐glycidoxypropyl)trimethoxysilane as a facial coupling agent. The hybrid resins showed good miscibility, high glass‐transition temperatures, good thermooxidative stability, and good flame retardance. The outstanding properties of the hybrid resins may lead to their use in high‐performance green electronic products. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 1868–1875, 2004     

Molecular dynamics in nanostructured polyimide–silica hybrid materials and their thermal stability

Molecular motion and thermal stability in two series of nanophase‐separated polyimide–silica (PI–SiO₂) hybrid materials with chemically bound components were studied. The hybrids were synthesized from p‐aminophenyltrimethoxysilane‐terminated poly(amic acid)s as PI precursors and tetramethoxysilane as a silica precursor via a sol–gel process. The hybrids differed in their PI chemical structure and chain length (number‐average molecular weight = 5.000, 7.500, or 10.000) and in their SiO₂ content, which ranged from 0 to 50 wt %. Differential scanning calorimetry, laser‐interferometric creep rate spectroscopy, and thermally stimulated depolarization current techniques were used for studying the dynamics from 100 to 650 K and from 10^?3 to 10^?2 Hz. Comparative thermogravimetric measurements were also carried out from 300 to 900 K. Silica nano‐ or submicrodomains that formed affected PI dynamics in two opposite directions. Because of the loosening of the molecular packing of PI chains confined to nanometer‐scale spaces between silica constraints, an enhancement of small‐scale motion, mostly at temperatures below the β‐relaxation region, occurred. However, a partial or total suppression of segmental motion could be observed above the β‐relaxation temperature, drastically so for the shortest PI chains at elevated silica contents and within or close to the glass‐transition range, because of the covalent anchoring of chain ends to silica domains. Large changes in thermal stability, including a 2.5‐fold increase in the apparent activation energy of degradation, were observed in the hybrids studied. A greater than 100 °C rise in long‐term thermal stability could be predicted for some hybrids with respect to pure PI. © 2002 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 40: 1056–1069, 2002     

Micellar structure and mechanical properties of block copolymer‐modified epoxies

Amphiphilic block copolymers provide a unique means for toughening epoxy resins because they can self‐assemble into different inclusion shapes before epoxy curing. The two examples reported here are spherical micelles and vesicles, which form in blends containing epoxy and symmetric or asymmetric poly(ethylene oxide)–poly(ethylene‐alt‐propylene) (PEO–PEP) block copolymer with PEO volume fractions of 0.5 and 0.26, respectively. The vesicles and spherical micelles were characterized by transmission electron microscopy and small‐angle X‐ray scattering (SAXS), respectively. SAXS data from the spherical micelles were fit to the Percus–Yevick model for a liquid‐like packing of spheres with hard‐core interactions. Mechanical properties of spherical‐micelle‐modified and vesicle‐modified epoxies in the dilute limit are compared. The glass‐transition temperature and Young's (storage) modulus were tested with dynamic mechanical spectroscopy, and compact‐tension experiments were performed to determine the critical plane‐strain energy release rate for fracture. Vesicles were most effective in improving the epoxy fracture resistance. © 2001 John Wiley & Sons, Inc. J Polym Sci Part B: Polym Phys 39: 2996–3010, 2001     

Epoxy resins from novel monomers with a bis‐(9,10‐dihydro‐9‐oxa‐10‐oxide‐10‐phosphaphenanthrene‐10‐yl‐) substituent

A new diepoxide and a new diamine, both bearing bis‐(9,10‐dihydro‐9‐oxa‐10‐oxide‐10‐phosphaphenanthrene‐10‐yl‐)‐substituted methylene linkages, were prepared through the reaction of 9,10‐dihydro‐oxa‐10‐phosphaphenanthrene‐10‐oxide with benzophenone derivatives via a simple addition reaction followed by a dehydration reaction. These two compounds were used as monomers for preparing cured epoxy resins with high phosphorus contents. The resultant epoxy resins showed high glass‐transition temperatures (between 131 and 196 °C). All of the cured epoxy resins exhibited high thermal stability, with 5% weight loss temperatures over 316 °C, and excellent flame retardancy, with limited oxygen index values of 37–50. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 40: 359–368, 2002     

Thermomechanical properties and phase structure of epoxy/silica nano‐hybrid materials constructed from a linear silicone oligomer

Epoxy‐grafted silicone oligomer (ESO), which has a linear silicone chain in the backbone moiety, was synthesized from a trifunctional alkoxysilane via a sol–gel reaction. Characterization of ESO was performed with ¹H and ²⁹Si NMR, Fourier transform infrared, and gel permeation chromatography. The number‐average molecular weight of ESO was 3300. By adding the silicone oligomer as the inorganic source in the curing process of the epoxy resin, novel epoxy/silica hybrid materials were prepared. It was observed by transmission electron microscope that fine silica‐rich domains of about 5‐nm diameter were uniformly dispersed in the cured epoxy matrix. Thermomechanical properties of the hybrid materials were also investigated. The storage modulus in the rubbery region and the peak area of the tan δ curve at the glass‐transition region increased and decreased, respectively, with the hybridization of the silica network. The mobility of the epoxy network chains should be considerably suppressed by the hybridization with the silica network. © 2005 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 1631–1639, 2005     

Organic–inorganic bonding in chitosan–silica hybrid networks: Physical properties

Novel biomaterials are needed for bone tissue repair with improved mechanical performance compared to classical bioceramics. The objective of this work was to characterize a hybrid filler material, which is capable to coat as a thin film porous scaffolds improving their mechanical properties for bone tissue engineering. The hybrid filler material is a blend of chitosan and silica network formed through in situ sol–gel using tetraethylortosilicate and 3‐glycidoxypropyltrimethoxysilane (GPTMS) as silica precursors. The hypothesis was that the epoxy ring of GPTMS could react with the amino groups of chitosan in acidic media while it is also reacting the siloxane groups of hydrolyzed silica precursors. The formation of the hybrid organic–inorganic network was assessed by different physical techniques revealing changes in molecular mobility and hydrophilicity upon chemical reaction. Finally, the cytotoxicity of the samples was also evaluated by MTT assay. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2015 , 53, 1391–1400     

Imidazole‐type thermal latent curing agents with high miscibility for one‐component epoxy thermosetting resins

Epoxy resins are important thermosetting resins widely employed in industrial fields. Although the epoxy–imidazole curing system has attracted attention because of its reactivity, solidification of a liquid epoxy resin containing imidazoles proceeds gradually even at room temperature. This makes it difficult to use them for one‐component epoxy resin materials. Though powder‐type latent curing agents have been used for one‐component epoxy resin materials, they are difficult to apply for fabrication of fine industrial products due to their poor miscibility. To overcome this situation and to improve the shelf life of epoxy–imidazole compositions, we have developed a liquid‐type thermal latent curing agent 1 , generating an imidazole with a thermal trigger via a retro‐Michael addition reaction. The latent curing agent 1 has superior miscibility toward epoxy resins; in addition, it was confirmed that the epoxy resin composition has both high reactivity at 150 °C, and long‐term storage stability at room temperature. © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2016 , 54, 2680–2688     

Flame‐retardant epoxy resins from o‐cresol novolac epoxy cured with a phosphorus‐containing aralkyl novolac

A novel phosphorus‐containing aralkyl novolac (Ar‐DOPO‐N) was prepared from the reaction of 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO) first with terephthaldicarboxaldehyde and subsequently with phenol. The chemical structures of the synthesized compounds were characterized with Fourier transform infrared, ¹H and ³¹P NMR, and elemental analysis. Ar‐DOPO‐N blended with phenol formaldehyde novolac was used as a curing agent for o‐cresol formaldehyde novolac epoxy, resulting in cured epoxy resins with various phosphorus contents. The epoxy resins exhibited high glass‐transition temperatures (159–177 °C), good thermal stability (>320 °C), and retardation on thermal degradation rates. High char yields and high limited oxygen indices (26–32.5) were observed, indicating the resins' good flame retardance. Using a melamine‐modified phenol formaldehyde novolac to replace phenol formaldehyde novolac in the curing composition further enhanced the cured epoxy resins' glass‐transition temperatures (160–186 °C) and limited oxygen index values (28–33.5). © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 2329–2339, 2002     

Immobilization of flame retardant onto silica nanoparticle surface and properties of epoxy resin filled with the flame retardant‐immobilized silica

To prepare silica nanoparticle having flame retardant activity, the immobilization of flame retardant onto hyperbranched poly(amidoamine) (PAMAM)‐grafted silica was investigated. Grafting of PAMAM onto a silica surface was achieved in a solvent‐free dry‐system using PAMAM dendrimer synthesis methodology. The immobilization of bromine flame retardant, poly(2,2′,6,6′‐tetrabromobisphenol‐A) diglycidyl ether (PTBBA), was successfully achieved by the reaction of terminal amino groups of PAMAM‐grafted silica (Silica‐PAMAM) with epoxy groups of PTBBA. The immobilization of PTBBA was confirmed by FTIR and thermal decomposition GC‐MS. The amount of PTBBA immobilized onto Silica‐PAMAM was determined to be 60 wt %. PTBBA‐immobilized Silica‐PAMAM (Silica‐PAMAM‐PTBBA) was dispersed uniformly in a epoxy resin, and the epoxy resin was cured in the presence of hexamethylenediamine. Flame retardant activity of the epoxy resin filled with Silica‐PAMAM‐PTBBA was estimated by limiting oxygen index (LOI). The LOI of epoxy resin filled with Silica‐PAMAM‐PTBBA was higher than that filled with untreated silica and free PTBBA. It was confirmed that the flame retardant activity of epoxy resin was improved by the addition of the Silica‐PAMAM‐PTBBA. The elimination of PTBBA from the epoxy resin filled with Silica‐PAMAM‐PTBBA into boiling water was hardly observed by immobilization of PTBBA onto silica surface. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 6145–6152, 2009     

Filler–polymer interactions in both silica and carbon black‐filled styrene–butadiene rubber compounds

Bound rubber in a filled rubber compound is formed by physical adsorption and chemisorption between the rubber and the filler. Styrene–butadiene rubber (SBR) is composed of four components of styrene, cis‐1,4‐, trans‐1,4‐, and 1,2‐units. Filler–polymer interactions in both silica and carbon black‐filled SBR compounds were studied by analyzing microstructures of the bound rubbers with pyrolysis‐gas chromatography. Differences in the filler–polymer interactions of the styrene, cis‐1,4‐, trans‐1,4‐, and 1,2‐units were investigated. The filler–polymer interactions of the butadiene units were found to be stronger than that of the styrene unit. The interactions of the cis‐1,4‐ and trans‐1,4‐units were stronger with carbon black than with silica, whereas the 1,2‐unit interacted more strongly with silica than with carbon black. © 2001 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 39: 439–445, 2001     

Synthesis of UV‐cured acrylic–silica hybrid nanocomposites from dendritic acrylic oligomer and acrylic‐functionalized silica

An acrylic–silica hybrid polymeric nanocomposite, comprising well‐distributed silica nanoparticles in acrylic matrix, has been synthesized at a markedly rapid rate from a dendritic acrylic oligomer (DAO) and an acrylic‐functionalized silica (A‐silica) via UV‐curing. A‐silica was made by functioning colloidal silica nanoparticles with 3‐methacryloxypropyltrimethoxysilane (MATMS) and DAO was formed by reacting 1,5‐diamino‐2‐methylpentane (MPMDA) with trimethylopropane triacrylate (TMPTA). The MATMS has been found either doubly or singly bonded to silica nanoparticles but not triply bonded, and the inclusion of MATMS into the siloxane network structure increases the size of silica nanoparticles. The well distribution of A‐silica and its good compatibility with DAO cause an increase in T_d of the acrylic–silica hybrid material. Silica nanoparticles are too small to cause any significant light scattering, and do not have deleterious effects on transparency. The “hybrid‐on‐polyethylene terephathalate” films exhibited satisfactory hardness and surface roughness because of silica nanoparticles. The preparation as well as the characterization of the constituting species and the final hybrid material are described in detail. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 8149–8158, 2008     

Advanced flame‐retardant epoxy resins from phosphorus‐containing diol

Phosphorus‐containing epoxy systems were prepared from isobutylbis(hydroxypropyl)phosphine oxide (IHPO) and diglycidyl ether of bisphenol A (DGEBA). Diethyl‐N,N‐bis(2‐hydroxyethyl) aminomethyl phosphonate (Fyrol 6) could not be incorporated into the epoxy backbone by a reaction with either epichlorohydrin or DGEBA because intramolecular cyclization took place. The curing behavior of the IHPO–DGEBA prepolymer with two primary amines was studied, and materials with moderate glass‐transition temperatures were obtained. V‐0 materials were obtained when the resins were tested for ignition resistance with the UL‐94 test. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 3510–3515, 2005     

Structure and property relationships in model diglycidyl ether of bisphenol‐a and diglycidyl ether of tetramethyl bisphenol‐a epoxy systems. I. Mechanical property characterizations

Model epoxy networks, with variations in crosslink density and in epoxy monomer rigidity, were prepared to study how the network structure affects modulus, T_g, and toughness/toughenability of epoxy resins. Diglycidyl ether of bisphenol‐A and diglycidyl ether of tetramethyl‐bisphenol‐A, along with the corresponding chain extenders, were chosen to study how monomer backbone rigidity and crosslink density affect physical and mechanical properties of epoxies. The present study indicates that, as expected, the backbone rigidity of the epoxy network, not the crosslink density alone, will strongly influence modulus and T_g of epoxy resins. Upon rubber toughening, it is found that the rigidity of the epoxy backbone and/or the nature of the crosslinking agent utilized are most critical to the toughenability of the epoxy. That is, the well‐known correlation between toughenability and the average molecular weight between crosslinks (M_c) does not necessarily hold true when the nature of epoxy backbone molecular mobility is altered. The potential significance of the present findings for a better design of toughened thermosets for structural applications is discussed. © 1999 John Wiley & Sons, Inc. J Polym Sci B: Polym Phys 37: 2137–2149, 1999     

Synthesis of methacrylic copolymers with nona‐1‐butoxy trititanosiloxane as side groups and its application as a thermosetting resin

Methacrylic copolymers with a hydroxyl group on one end of the main chain and nona‐1‐butoxytrititanosiloxane as side groups (called methacrylic hybrid copolymers) were synthesized for use as baked‐finish‐type coating resins. The chemical structures of the side groups in the methacrylic hybrid copolymers were confirmed with the ash weight of the copolymers after combustion, the elemental ratio analysis of Si and Ti in the ash determined by inductively coupled plasma emission spectrometry, and the characteristic absorption band determined by Fourier transform infrared spectrophotometry. The methacrylic hybrid copolymers were cured at temperatures less than 150 °C in the absence of a curing accelerator. The cured copolymers exhibited a high thermal stability. The curing temperature of the copolymers was determined by the change in the absorption peak strength (peak area) of the 1655 cm⁻¹ band in the IR difference spectrum. The thermal stability of the copolymers was evaluated as the thermal‐degradation temperature measured by thermogravimetric analysis. The methacrylic hybrid copolymers were then be used as effective curing resins. The mixture, consisting of thermoplastic methacrylic terpolymer with hydroxyl and carboxyl groups and the methacrylic hybrid copolymers, were cured at less than 150 °C in the absence of a curing accelerator and exhibited a higher thermal‐degradation temperature than the copolymers. © 2001 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 39: 1090–1098, 2001     

Effect of the organophosphate structure on the physical and flame‐retardant properties of an epoxy resin

2‐(6‐Oxido‐6H‐dibenzo〈c,e〉〈1,2〉oxa‐phosphorin‐6‐yl)1,4‐benzenediol (ODOPB) and bis(3‐dihydroxyphenyl) phenyl phosphate (BHPP) were successfully synthesized and used as reactive flame retardants in o‐cresol formaldehyde novolac epoxy resin. Because of the rigid, cyclic, side‐chain structure of ODOPB, the resultant phosphorus‐containing epoxy resin exhibited a higher glass‐transition temperature, better flame retardancy, higher modulus, and greater thermal stability than the regular bromine‐containing tetrabromobisphenol A epoxy resin and the linear, main‐chain, phosphorus‐containing BHPP epoxy resin. A UL‐94VO rating was achieved with a phosphorus content as low as 1.1% with ODOPB (comparable to a bromine content of 12% and a phosphorus content of 2.2% with BHPP) in the cured resins, and no fumes or toxic gas emissions were observed. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 40: 369–378, 2002     

Oxetane‐terminated telechelic epoxy‐functional polyesters as cationically polymerizable thermoset resins: Tuning the reactivity with structural design

A series of epoxy‐functional telechelic oligomers containing oxetane end groups have been synthesized. The precursor monomer, extracted from outer Birch bark, was first polymerized through enzyme‐catalyzed esterification to form oligomers having epoxy and/or oxetane groups in the structures. The oligoesters were subsequently crosslinked through cationic polymerization either by epoxy or oxetane homopolymerization or copolymerization when both functionalities were present. A study of the polymerizations of the resins was performed “in situ” using real‐time Fourier transform infrared spectroscopy revealing a preferred copolymerization when compared with the homopolymerization. By tailoring the different structures, it was possible to control the final mechanical properties of the networks. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 2258–2266     

Development of novel phosphorus‐containing epoxy resins from renewable resources

Novel biobased epoxy resins were prepared from two fatty acid derivatives; epoxidized 10‐undecenoyl triglyceride and epoxidized methyl 3,4,5‐tris(10‐undecenoyloxy)benzoate, with 4,4′‐diaminodiphenylmethane as a crosslinking agent. The flame retardancy of these epoxy resins was improved by the addition of 10‐[2′, 5′‐bis(9‐oxiranyl‐nonayloxy)phenyl]‐9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide and by crosslinking with a phosphorus‐containing curing agent, bis(m‐aminophenyl)methylphosphine oxide. The thermal, thermomechanical, and flame‐retardant properties of the cured materials were measured with differential scanning calorimetry, thermogravimetric analysis, dynamic mechanical analysis, and the limiting oxygen index. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 6717–6727, 2006