Novel flame‐retardant thermosets: Phosphine oxide‐containing diglycidylether as curing agent of phenolic novolac resins

Phosphorus‐containing novolac–epoxy systems were prepared from novolac resins and isobutyl bis(glycidylpropylether) phosphine oxide (IHPOGly) as crosslinking agent. Their curing behavior was studied and the thermal, thermomechanical, and flame‐retardant properties of the cured materials were measured. The T_g and decomposition temperatures of the resulting thermosets are moderate and decrease when the phosphorous content increases. Whereas the phosphorous species decrease the thermal stability, at higher temperatures the degradation rates are lower than the degradation rate of the phosphorous‐free resin. V‐O materials were obtained when the resins were tested for ignition resistance with the UL‐94 test. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 3516–3526, 2004     

Recent advancement on polybenzoxazine—A newly developed high performance thermoset

Polybenzoxazine is a newly developed addition polymerized phenolic system, having a wide range of interesting features and the capability to overcome several shortcomings of conventional novolac and resole type phenolic resins. They exhibit (i) near zero volumetric change upon curing, (ii) low water absorption, (iii) for some polybenzoxazines T_g much higher than cure temperature, (iv) high char yield, (v) no strong acid catalysts required for curing, (vi) release of no byproduct during curing and also possess thermal and flame retarding properties of phenolics along with the mechanical performance. Though benzoxazine based materials possess several advantages, they have not yet became very attractive to the industries. To improve the mechanical properties and processibility several strategies have been reported including (i) synthesis of benzoxazine monomers with additional functionality, (ii) incorporation of benzoxazine in polymer chain, and (iii) benzoxazine based composites or alloys. In this article, we have discussed about the recent development of benzoxazine chemistry. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 47: 5565–5576, 2009     

Development of novel flame‐retardant thermosets based on boron‐modified phenol–formaldehyde resins

Boron‐containing novolac resins were prepared through the modification of a commercial novolac resin with different contents of bis(benzo‐1,3,2‐dioxaborolanyl) oxide. Their thermal and flame‐retardant properties were measured. Then, they were crosslinked with hexamethylenetetramine, and their thermal, thermodynamomechanical, and flame‐retardant properties were evaluated. Their modification degree was related to the segmental motion of the materials. The crosslinking of the boron‐modified novolac resins with hexamethylenetetramine was slower and not as extensive as that of commercial novolac resins because the nitrogen from intermediate species coordinated with boron. The thermal degradation of the boron‐containing novolac resins generated boric acid at high temperatures and gave an intumescent char that slowed the degradation and prevented it from being complete. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 3503–3512, 2006     

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     

Facile,one‐pot synthesis of aromatic diamine‐based benzoxazines and their advantages over diamines as epoxy hardeners

Three aromatic diamine‐based benzoxazines were successfully prepared by a facile, clean, one‐pot procedure from 1,4‐phenylenediamine ( 1 ), 4,4′‐diaminodiphenyl ether ( 2 ), and 4,4′‐diaminodiphenyl methane ( 3 ), respectively. Their structures were confirmed by NMR spectra and single crystal diffractogram. The effect of the reactivity of diamines on the purity of the resultant benzoxazines was discussed. The resultant benzoxazines were applied as hardeners for cresol novolac epoxy (CNE). The processing window, the latent curing characteristic, and the miscibility of benzoxazine/CNE systems were discussed. Compared with diamines ( 1 and 3 ), ( 1 and 3 )‐based benzoxazines show latent curing characteristic as epoxy hardeners, and wide processing windows can be obtained. Compared with diamine ( 2 ) which is immiscible with CNE in the molten state, ( 2 )‐based benzoxazine shows good miscibility with CNE. Dynamic mechanical analysis shows the T_gs of the benzoxazine/CNE thermosets are as high as 242–243 °C. Thermogravimetric analysis shows the outstanding thermal stability of the resultant thermosets. © 2010 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 2430–2437, 2010     

Novel flame‐retardant thermosets: Diglycidyl ether of bisphenol A as a curing agent of boron‐containing phenolic resins

Boron‐containing novolac resins were synthesized by the modification of a commercial novolac resin with different contents of bis(benzo‐1,3,2‐dioxaborolanyl)oxide. These novolac resins were crosslinked with diglycidyl ether of bisphenol A (DGEBA), and their thermal, thermodynamomechanical, and flame‐retardant properties were evaluated. The boron‐containing novolac resins were less thermally stable than the unmodified novolac resin. Their modification degree and DGEBA content were related to the crosslinking density of the materials. The boron‐containing novolac resins generated boric acid at high temperatures and gave an intumescent char that slowed down the degradation and prevented it from being total. They also showed good flame‐retardant properties. © 2006 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 44: 1701–1710, 2006     

Degradable and chemically recyclable epoxy resins containing acetal linkages: Synthesis,properties, and application for carbon fiber‐reinforced plastics

Four sorts of epoxy resins containing degradable acetal linkages were synthesized by the reaction of bisphenol A (BA) or cresol novolak (CN) resin with vinyl ethers containing a glycidyl group [4‐vinlyoxybutyl glycidyl ether (VBGE) and cyclohexane dimethanol vinyl glycidyl ether (CHDMVG)] and cured with known typical amine‐curing agents. The thermal and mechanical properties of the cured resins were investigated. Among the four cured epoxy resins, the CN‐CHDMVG resin (derived from CN and CHDMVE) exhibited relatively high glass transition temperature (T_g = ca. 110 °C). The treatment of these cured epoxy resins with aqueous HCl in tetrahydrofuran (THF) at room temperature for 12 h generated BA and CN as degradation main products in high yield. Carbon fiber‐reinforced plastics (CFRPs) were prepared by heating the laminated prepreg sheets with BA‐CHDMVG (derived from BA and CHDMVE) and CN‐CHDMVG, in which strands of carbon fibers are impregnated with the epoxy resins containing conventional curing agents and curing accelerators. The obtained CFRPs showed good appearance and underwent smooth breakdown with the aqueous acid treatment in THF at room temperature for 24 h to produce strands of carbon fiber without damaging their surface conditions and tensile strength. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2012     

Synthesis of high thermal stability polybenzoxazoles via ortho‐imide‐functional benzoxazine monomers

We report our work for preparing cross‐linked polyimide via a series of imide functional benzoxazine resins as precursors. The structures of synthesized monomers have been confirmed by ¹H NMR and FT‐IR. Among this class of benzoxazine monomers, the ortho‐imide functional benzoxazine resins show useful features both in the synthesis of benzoxazine monomers and the properties of the corresponding thermosets. For the cross‐linked polyimides based on ortho‐imide functional benzoxazine, an additional route is adopted to form a more thermally stable cross‐linked polybenzoxazole with the release of carbon dioxide. The ortho‐imide functional benzoxazine resins show the possibility to form high performance and even super high performance thermosets with low cost and easy processability. The thermal properties are evaluated by DSC and TGA. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 1330–1338     

Facile preparation of novel epoxy curing agents and their high‐performance thermosets

Two flame‐retardant epoxy curing agents, 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐yl‐tris(4‐hydroxyphenyl)methane (1) and 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐yl‐ (4‐aminophenyl)‐bis(4‐hydroxyphenyl)methane (2), were prepared by a facile, economic, one‐pot procedure. The structures of the curing agents were confirmed by IR, high‐resolution mass, 1‐D, and 2‐D NMR spectra. A reaction mechanism was proposed for the preparation, and the effect of electron withdrawing/donating effects on the stabilization of the carbocation was discussed. (1‐2) served as curing agents for diglycidyl ether of bisphenol A (DGEBA), dicyclopentadiene epoxy (HP‐7200), and cresol novolac epoxy (CNE). Properties such as glass transition temperature, coefficient of thermal expansion, thermal decomposition temperature, and flame retardancy of the resulting epoxy thermosets were evaluated. The resulting epoxy thermosets show high T_g, low thermal expansion, moderate thermostability, and excellent flame retardancy. The bulky biphenylene phosphinate pendant makes polymer chains difficult to rotate, explaining the high T_g and low thermal expansion characteristic. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 7898–7912, 2008     

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     

Flame‐retardant epoxy resins with high glass‐transition temperatures from a novel trifunctional curing agent: Dopotriol

A novel phosphorus‐containing trifunctional novolac (dopotriol) was synthesized through the addition reaction of 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene 10‐oxide and rosolic acid. The structure of dopotriol was confirmed with NMR spectroscopy and elemental analyses. The dopotriol was blended with phenol novolac in the ratios of 10/0, 8/2, 6/4, 4/6, 2/8, and 0/10 to serve as a curing agent for diglycidyl ether of bisphenol A. Thermal properties, such as the glass‐transition temperature, thermal decomposition temperature, and flame retardancy, moisture absorption, and dielectric properties of the cured epoxy resins were evaluated. The activity and activation energy of curing were studied with the methods of Kissinger and Ozawa by dynamic differential scanning calorimetry scans. The glass‐transition temperatures of the cured epoxy resins were 138–159 °C, increasing with the phosphorus content. This is rarely seen in the literature after the addition of a flame‐retardant element. The flame retardancy increased with the phosphorus content, and a UL‐94 V‐0 grade was achieved with a phosphorus content of 1.87%. Similar dielectric properties and moisture absorption were observed for these phosphorus‐containing epoxy resins, and this implied that the addition of phosphorus to epoxy did not affect the dielectric properties and moisture absorption. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 2862–2873, 2005     

Mechanistic study of ring‐opening copolymerization of ɛ‐caprolactam with epoxide: Development of novel thermosetting epoxy resin system

We investigated the mechanism of the ring‐opening copolymerization of ?‐caprolactam (?‐CL) with glycidyl phenyl ether (GPE) to afford poly(?‐CL‐co‐GPE) as a model reaction of the thermal curing of certain epoxy resins with ?‐CL. The reaction of ?‐CL and GPE proceeded efficiently in the presence of 1,8‐diazabicyclo[5.4.0]undec‐7‐ene (DBU) at 170^°C for 2 h. The monomer reactivities r₁ of ?‐CL and r₂ of GPE calculated according to the Fineman‐Ross method and the Kelen‐Tüdös method were 0.58 and 5.52, respectively. These values indicate that poly(?‐CL‐co‐GPE) has a pseudo‐block gradient copolymer. Based on these results, we examined the thermal curing reactions of certain epoxy resins with ?‐CL. The corresponding novel cured products were obtained quantitatively, and each of them showed a high glass transition temperature and high thermal stability, presumably due at least in part to a pseudo‐block gradient primary structure resembling that of poly(?‐CL‐co‐GPE). © 2016 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2016 , 54, 2220–2228     

Chemistry of novolac resins. X. Polymerization studies of HMTA and strategically synthesized model compounds

The reactions between hexamethylenetetramine (HMTA) and compounds which model novolac resins have been studied by ¹³C‐ and ¹⁵N‐NMR techniques. The dimer and tetramer compounds vary in molecular size and structure and react with HMTA to yield benzylamines and benzoxazine as the major initial‐formed intermediates and convert to methylene linked compounds at increased temperatures. The reaction of the compounds with only ortho reactive sites paralleled the 2,4‐xylenol–HMTA case reported by us previously; however, increasing molecular weight favored the formation of benzylamines and not benzoxazines. Those compounds with only para reactive sites paralleled the 2,6‐xylenol–HMTA case. The reactivity of the systems containing both ortho and para reactive sites depends on the ratio of ortho/para sites and various aspects such as the chemical structure and molecular weight of the compound, the HMTA level, and the melting point and pH of the system. These results parallel those obtained from novolac/HMTA systems. The xylenol/HMTA reactions formed similar products but showed quite different relative reaction rates by varying the HMTA ratio and structures of the materials. The importance of careful selection of model systems is also discussed. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 1347–1355, 1999     

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     

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     

A conjugated alkyne functional bicyclic polybenzoxazine with superior heat resistance

A difunctional benzoxazine (coPh‐apa) with a conjugated alkyne group is synthesized by the oxidative coupling reaction from a monocycle‐benzoxazine (Ph‐apa) containing an alkyne group. A model compound, 1,4‐diphenylbutadiyne (coPa), is used to study the curing reaction process of coPh‐apa by DSC, Fourier transform infrared spectroscopy, and ¹³C NMR, and the results suggest that the conjugated alkyne groups are involved in the crosslinking reaction via the trimerization reaction of the conjugated alkynyl groups and the Diels–Alder reaction. Furthermore, thermal properties of the polybenzoxazine are studied by dynamic thermomechanical analysis and thermogravimetric analysis. A glass‐transition temperature (T_gs) of as high as 412 °C and a char yield of 75.6% at 800 °C under nitrogen are obtained with the aid of the conjugated alkyne groups. Its excellent heat resistance dominates most thermosetting resins and will serve for heat shields. © 2019 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2019, 57, 1587–1592     

Isothermal cure kinetics of epoxy/phenol‐novolac resin blend system initiated by cationic latent thermal catalyst

The investigation of the cure kinetics of a diglycidyl ether of bisphenol A (DGEBA)/phenol‐novolac blend system with different phenolic contents initiated by a cationic latent thermal catalyst [N‐benzylpyrazinium hexafluoroantimonate (BPH)] was performed by means of the analysis of isothermal experiments using a differential scanning calorimetry (DSC). Latent properties were investigated by measuring the conversion as a function of curing temperature using a dynamic DSC method. The results indicated that the BPH in this system for cure is a significant thermal latent initiator and has good latent thermal properties. The cure reaction of the blend system using BPH as a curing agent was strongly dependent on the cure temperature and proceeded through an autocatalytic kinetic mechanism that was accelerated by the hydroxyl group produced through the reaction between DGEBA and BPH. At a specific conversion region, once vitrification took place, the cure reaction of the epoxy/phenol‐novolac/BPH blend system was controlled by a diffusion‐control cure reaction rather than by an autocatalytic reaction. The kinetic constants k₁ and k₂ and the cure activation energies E₁ and E₂ obtained by the Arrhenius temperature dependence equation of the epoxy/phenol‐novolac/BPH blend system were mainly discussed as increasing the content of the phenol‐novolac resin to the epoxy neat resin. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 2945–2956, 2000     

Thermally curable polyvinylchloride via click chemistry

Novel side‐chain benzoxazine functional polyvinylchloride (PVC‐Benzoxazine) was synthesized by using “Click Chemistry” strategy. First, approximately 10% of chloro groups of PVC were converted to azido groups by using NaN₃ in N,N‐dimethylformamide. Propargyl benzoxazine was prepared independently by a ring closure reaction between p‐propargyloxy aniline, paraformaldehyde, and phenol. Finally, azidofunctionalized PVC was coupled to propargyl benzoxazine with high efficiency by click chemistry. The spectral and thermal analysis confirmed the presence of benzoxazine functionality in the resulting polymer. It is shown that PVC containing benzoxazine undergoes thermally activated curing in the absence of any catalyst forming PVC thermoset with high thermal stability. © 2008 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 46: 3512–3518, 2008     

New poly(ether‐ester) thermosets obtained by cationic curing of DGEBA and 7,7‐dimethyl‐6,8‐dioxaspiro[3.5] nonane‐5,9‐dione with several Lewis acids as initiators

Scandium, ytterbium, and lanthanum triflates and boron trifluoride monoethylamine were used as cationic initiators to cure a mixture 2:1 (mol/mol) of diglycidylether of bisphenol A (DGEBA) and 7,7‐dimethyl‐6,8‐dioxaspiro[3.5]nonane‐5,9‐dione (MCB). The evolution of the epoxy and lactone during curing and the linear ester groups in the final materials were evaluated by Fourier Transform Infrared in the attenuated‐total‐reflection mode. The kinetic parameters of the curing process were calculated from DSC analysis applying isoconversional procedures. The shrinkage on curing and the thermal degradability of the materials on varying the initiator used were evaluated. The expandable character of MCB was confirmed. The materials obtained were more degradable than conventional epoxy resins due to the tertiary ester groups incorporated in the network by copolymerization. © 2008 Wiley Periodicals, Inc J Polym Sci Part A: Polym Chem 46: 1229–1239, 2008     

Self‐healing of poly(propylene oxide)‐polybenzoxazine thermosets by photoinduced coumarine dimerization

In this work, a self‐healing strategy for poly(propylene oxide)s bearing coumarine‐benzoxazine units (PPO‐CouBenz)s based on light induced coumarine dimerization reactions is described. Four different types of poly(propylene oxide) amines with molecular weights ranging from 440 to 5000 Da were reacted with formaldehyde and 4‐methyl‐7‐hydroxycoumarin to yield desired (PPO‐CouBenz)s. The crosslinked polymer films were prepared by solvent casting of various compositions of PPO‐CouBenzs in chloroform followed by thermal ring opening reaction of benzoxazine groups at 210–240 °C. Thermal curing and thermal stability of the initial PPOs and final products were investigated. Using allyl benzoxazine in the formulation, it was demonstrated that the toughness of the films was improved. Photoinduced healing of coumarin‐based cured PPO‐CouBenz polymer films was investigated. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2014 , 52, 2911–2918