Studies on the synthesis and curing of epoxidized novolac vinyl ester resin from renewable resource material

Cardanol-based epoxidized novolac vinyl ester resin (CNEVER) was synthesized by reacting cardanol-based epoxidized novolac (CNE) resin and methacrylic acid (MA) (CNE:MA molar ratio 1:0.9) in presence of triphenylphosphine as catalyst at 90 °C. The CNE resin was prepared by the reaction of cardanol-based novolac-type phenolic (CFN) resin and epichlorohydrin, in basic medium, at 120 °C. The CFN resin was synthesized by reacting cardanol (C) and formaldehyde (F) (C/F ratio = 1:0.7) with p-toluene sulphonic acid (PTSA) as catalyst (0.5 wt.%) at 120 °C for 7 h. The resin products were analyzed by Fourier-transform infra-red (FTIR) and nuclear magnetic resonance (NMR) spectroscopic analysis. The number-average molecular weight of the prepared CNEVER was found to be 859 gmol⁻¹ as determined by gel permeation chromatographic (GPC) analysis. The resin was cured by using the mixture of resin, benzoyl peroxide, and styrene at 120 °C. The CNEVER resin was found to be cured in 60 min at 120 °C. Differential scanning calorimetric (DSC) technique was used to investigate the curing behaviour. Single step mass loss in dynamic thermogravimetric (TG) trace of CNEVER was observed. Thermal stability of the vinyl ester sample containing 40 wt.% styrene was the highest amongst all other prepared systems.     

Metal compound-enhanced flame retardancy of intumescent epoxy resins containing ammonium polyphosphate

A series of intumescent flame-retardant epoxy resins (IFR-EPs) were prepared only by adding a 5 wt% total loading of ammonium polyphosphate (APP) and metal compounds. All the samples could achieve V-0 rating and did not generate dripping during UL-94 testing. The limiting oxygen index (LOI) values of the samples with 4.83 wt% APP and 0.17 wt% CoSA increase from 27.1 to 29.4, compared with epoxy resin containing 5 wt% APP. The samples also showed excellent water resistance of flame retardancy in 30 °C and 70 °C water for 168 h. The LOI results show that the composition of metal compounds (metal ions and ligands/anions) and the mass ratios of APP to metal compounds affect the flame retardancy of the samples. TG results indicate that the catalytic effect of CoSA on the decomposition of both APP and the epoxy resins containing APP is better than that of CuSAO. The fire behavior of epoxy resin and epoxy resins containing APP with/without CoSA were investigated by cone calorimeter. Cone calorimeter parameters of the samples such as HRR, THR, TSP and COP indicate that the addition of APP and CoSA improves the fire safety of epoxy resin significantly, and CoSA shows an obvious catalytic effect.     

Allylic monomers as reactive plasticizers of polyphenylene oxide. Part III – Rheological and mechanical properties

The chemorheology of blends of diallyl ortho-phthalate (DAOP) as reactive plasticizer of polyphenylene oxide (PPO) were monitored during their cure with either dicumyl peroxide (DCP) or tert-butyl hydroperoxide (TBHP), and their mechanical properties and morphology were studied. The steady shear and dynamic rheology behaviour was consistent with chemical gelation of DAOP in blends with low concentrations of PPO but the gelation behaviour at higher PPO concentrations was more complex. Dynamic mechanical thermal analysis of the blends of PPO:DAOP cured with either DCP or TBHP indicated a two phase structure. For PPO:DAOP/DCP, the lowest transition (between 150 °C and 200 °C) was attributed to a DAOP-rich phase and its T_g was higher than that for pure DAOP/DCP due to the presence of PPO in the DAOP-rich phase. The smaller damping shoulder near 250 °C was caused by a PPO-rich phase with a T_g that was lower than pristine PPO due to the presence of unpolymerized or polymerized DAOP. In contrast, the glass transition region of the PPO:DAOP/TBHP system was very broad due to an overlap of the transitions for DAOP-rich and PPO-rich phases caused by higher levels of unpolymerized DAOP. SEM observations of the blends revealed a two phase morphology with PPO-rich particles in a poly-DAOP matrix for blends with ?30 wt% PPO, a co-continuous morphology for blends with 40 wt% PPO, and a phase inverted morphology with more than 50 wt% PPO. These SEM observations agree with studies of the swelling, disintegration or dissolution of matrix of the blends in solvent.     

Thermal and mechanical properties of in situ polymerized PS/EPDM blends

In situ polymerized PS/EPDM blends were prepared by dissolving poly(ethylene-co-propylene-co-2-ethylidene-5-norbornene) (EPDM) in styrene monomer, followed by bulk polymerization at 60 °C and 80 °C . EPDM has excellent resistance to such factors as weather, ozone and oxidation, attributed to its non-conjugated diene component, and it could be a good alternative for substituting polybutadiene-based rubbers in PS toughening. The in situ polymerized blends were characterized by dynamic mechanical analysis, thermogravimetric analysis, gel permeation chromatography, and tensile and Izod impact resistance tests. The PS/EPDM blends are immiscible and present two phases, a dispersed elastomeric phase (EPDM) in a rigid PS matrix whose phase behavior is strongly affected by the polymerization temperature. Mechanical properties of the blends are influenced by the increase in the average size of EPDM domains with the increase in the polymerization temperature and EPDM content. The blends polymerized at 60 °C containing 5 wt% of EPDM presents an increase in the impact resistance of 80% and containing 17 wt% of EPDM presents an increase in the strain at break of 170% in comparison with the value of PS. The blend polymerized at 80 °C containing 17 wt% of EPDM presents an increase in the strain at break of 480% and in impact resistance of 140% in comparison with the value of PS.     

Thermal, ozone and gamma ageing of styrene butadiene rubber and poly(ethylene-co-vinyl acetate) blends

Ageing behaviour of SBR/EVA blends due to the effects of heat, ozone, and gamma radiation was studied with reference to blend ratio, three crosslinking systems (sulfur, peroxide and mixed) and a compatibiliser (SEBS-g-MA). It was found that an increase in the EVA content of the blends enhanced the ageing characteristics. Among the different crosslinking systems, a peroxide cured system exhibited the best retention of properties even after severe ageing. Tensile strength of peroxide cured SBR/EVA blends increased slightly after ageing for three days at 70 °C due to continued crosslinking, whereas tensile strength of all blends decreased on ageing at 100 °C. Compatibilisation with SEBS-g-MA improved the thermal, gamma and water ageing resistance of SBR/EVA blends.     

A new route to obtain PVDF/PANI conducting blends

Electrically conductive poly(vinylidene fluoride)(PVDF) - polyaniline blends of different composition were synthesized by chemical polymerization of aniline in a mixture of PVDF and dimethylformamide (DMF) and studied by electrical conductivity measurement, UV-Vis-NIR and FTIR spectroscopy. The samples were obtained as flexible films by pressing the powder at 180 °C for 5 min. The electrical conductivity showed a great dependence on the syntheses parameters. The higher value of the electrical conductivity was obtained for the oxidant/aniline molar ratio equal to 1 and p-toluenesulfonic acid-TSA/aniline ratio between 3 and 6. UV-Vis-NIR and FTIR spectra of the blend are similar to the doped PANI, indicating that the PANI is responsible for the high electrical conductivity of the blend. The electrical conductivity of blend proved to be stable as a function of temperature decreasing about one order at temperature of 100 °C. The route used to obtain the polymer blend showed to be a suitable alternative in order to obtain PVDF/PANI-TSA blends with high electrical conductivity.     

Miscibility and hydrolytic degradation in alkaline solution of poly(l-lactide) and poly(p-vinyl phenol) blends

Poly(l-lactide) (PLLA) was melt-blended with poly(p-vinyl phenol) (PVPh) using a two-roll mill, and the miscibility between PLLA and PVPh and degradation of the blend films were investigated. It was found that PLLA/PVPh blend has miscibility in the amorphous state because only single T_g was observed in the DSC and DMA measurements. The T_g of the PLLA/PVPh blend could be controlled in the temperature range from 55 °C to 117 °C by changing the PVPh weight fraction. In alkaline solution, degradation rate of PLLA/PVPh blends was faster than that of neat PLLA because PVPh could dissolve in alkaline solution. The surface morphology of degraded PLLA and PLLA/PVPh blend were observed by SEM. The surface morphology of degraded PLLA/PVPh blend was finer than that of PLLA. Young's modulus of PLLA/PVPh blend increased with increasing PVPh content. Yield stress of PLLA/PVPh blends whose PVPh content was less than 30 wt% kept the level of about 55 MPa and that of PLLA/PVPh blend whose PVPh content was 40 wt% is much lower than that of neat PLLA.     

Effect of fluorine functional groups on surface and mechanical interfacial properties of epoxy resins

To improve the surface and mechanical interfacial properties of epoxy resins, fluorine-containing epoxy resin (FEP) was prepared and blended with a commercially available tetrafunctional epoxy resin (TGDDM). As a result, when the fluorine content increased, the total surface energy of TGDDM/FEP blends was gradually decreased, while the water repellency of the blends was increased. The glass transition temperature and thermal stability factors of the blends showed maximum values at 20-40 wt% FEP compared with neat TGDDM epoxy resins. And the mechanical interfacial properties of the blend specimens were significantly increased with increasing the FEP content, which could be attributed to the intermacromolecular interactions in the cured TGDDM/FEP blends. These results indicate that the water repellency and toughness improvements have been achieved without significantly deterioration of the thermal properties in the TGDDM/FEP blends.     

Thermal stability and ageing properties of sulphur and gamma radiation vulcanized natural rubber (NR) and carboxylated styrene butadiene rubber (XSBR) latices and their blends

The thermal stability of natural rubber (NR) and carboxylated styrene butadiene rubber (XSBR) latices and their blends was studied by thermogravimetric methods. Ageing characteristics of these latex blends were studied by applying hot air oven thermal ageing for seven days at 70 °C. The mechanical properties of the aged samples were studied. Thermal degradation and ageing properties of these individual latices and their blends were investigated with special reference to blend ratio and vulcanization techniques. As the XSBR content in the blends increased their thermal stability was also found to increase. Among sulphur and radiation-vulcanized samples, radiation cured possesses higher thermal stability due to the higher thermal stability of carbon-carbon crosslinks. DTG curves were used for the determination of different stages involved in the degradation. Activation energy for degradation was determined from Coats-Redfern plot. The properties of aged samples were found to decrease due to chain depletion. However, the moduli of XSBR and NR/XSBR blends were found to increase owing to the formation of crosslinks upon ageing.     

Phenylethynyl terminated oligoimides derived from 3,3′,4,4′-diphenylsulfonetetracarboxylic dianhydride and their adhesive properties

A series of phenylethynyl terminated oligoimides based on 3,3′,4,4′-diphenylsulfonetetracarboxylic dianhydride (DSDA), m-phenylene diamine (m-PDA) or/and 1,4-bis(4-amino-2-trifluoromethylphenoxy)benzene (6FAPB) with calculated molecular weight of 5000 g mol⁻¹ were synthesized. The effect of molecular structure on solubility and melt viscosity of oligoimides as well as the thermal properties of cured polyimide resins was investigated. Experimental results indicated that the oligoimides have good solubility in strong polar solvents to afford homogeneous solutions with the solid content as high as 50 wt%. The oligoimides exhibited better solubility and lower minimum melt viscosity at relatively lower temperature with the incorporation of flexible 6FAPB. These oligoimides could be thermally cured at 320-380 °C to give thermosetted resins. The cured resins have good thermal stability with the glass transition temperatures of 278-329 °C and the onset decomposition temperatures higher than 500 °C. Adhesive properties of polyimides adhered to stainless steel at various conditions were evaluated by lap shear strength test. It was found that the LSS at room temperature increased with the molar ratio of 6FAPB increasing. The polyimides with combination of rigid and flexible structures exhibited good adhesive properties. With the increasing of curing temperature, the lap shear strength of polyimides at elevated temperature maintained at a high level due to the formation of strong bond.     

Cure study of addition-cure-type and condensation-addition-type phenolic resins

By the incorporation of propargyl and methylol groups on to novolac backbone, a series of addition-curable phenolic resins and condensation-addition dual-cure type phenolic resins (novolac modified by propargyl groups referred as PN, and novolac modified by propargyl and methylol groups simultaneously referred as MPN) were synthesized. The processing characteristics, thermal cure and catalytic cure behavior for both resins were investigated mainly by means of viscosity measurement and non-isothermal differential scanning calorimetry (DSC) techniques. The effect of propargyl and methylol content of PN and MPN, the molecular weight and the configuration of the parent novolac, on the processing and cure behavior was studied in details. Processing parameters and curing kinetic parameters were obtained. Both resins exhibit excellent processing properties. Thermal cure of PN resins possessed one cure mechanism and that of MPN resins possessed two cure mechanisms according to DSC analysis. The dual-cure-type mechanism made MPN resins superior to PN resins in terms of a mild and controllable cure process. Compared with thermal cure, catalytic cure of PN resins showed lower initiation temperature and cure temperature by about 60 °C. These novel resins have a bright prospect of application as matrix for thermal-structural composite materials.     

Thermo-oxidative dehydrochlorination of rigid and plasticised poly(vinyl chloride)/poly(methyl methacrylate) blends

The aim of this work was to study the thermo-oxidative dehydrochlorination of rigid and plasticised poly(vinyl chloride)/poly(methyl methacrylate) blends. For that purpose, blends of variable compositions from 0 to 100 wt% were prepared in the presence (15, 30 and 50 wt%) and in the absence of diethyl-2-hexyl phthalate as plasticiser. Their miscibility was investigated by using differential scanning calorimetry (DSC) and Fourier transform infrared spectroscopy (FTIR). Their thermo-oxidative degradation at 180 ± 1 °C was studied and the amount of HCl released from PVC was measured by a continuous potentiometric method. Degraded samples were characterised, after purification, by FTIR spectroscopy and UV-visible spectroscopy. The results showed that the two polymers are miscible up to 60 wt% of poly(methyl methacrylate) (PMMA). This miscibility is due to a specific interaction of hydrogen bonding type between carbonyl groups (CO) of PMMA and hydrogen (CHCl) groups of PVC as shown by FTIR analysis. On the other hand, PMMA exerted a stabilizing effect on the thermal degradation of PVC by reducing the zip dehydrochlorination, leading to the formation of shorter polyenes.     

Preparation and Characterization of DGEBA/EPN Epoxy Blends with Improved Fracture Toughness

The physical and mechanical properties of blends composed of two kinds of epoxy resins of different numbers of functional groups and chemical structure were studied.One of the resins was a bifunctional epoxy resin based on diglycidyl ether ofbisphenol A and the other resin was a multifunctional epoxy novolac resin.Attempt was made to establish a correlation between the structure and the final properties of cured epoxy samples.The blend samples containing high fraction of multifunctional epoxy resin showed higher solvent resistance and lower flexural modulus compared with the blends containing high fraction of bifunctional epoxy resin.The epoxy blends showed significantly higher ductility under bending test than the neat epoxy samples.The compressive modulus and strength increased with increasing of multifunctional epoxy in the samples,probably due to enhanced cross-link density and molecular weight.Morphological analysis revealed the presence of inhomogeneous sub-micrometer structures in all samples.The epoxy blends exhibited significantly higher fracture toughness (by 23％ at most) compared with the neat samples.The improvement of the fracture toughness was attributed to the stick-slip mechanism for crack growth and activation of shear yielding and plastic deformation around the crack growth trajectories for samples with higher content of bifunctional epoxy resin as evidenced by fractography study.     

Influence of fluorine-containing lubricant on properties of NR/BR rubber

K95 experimental lubricant being a product of fluorine reaction with a blend of mutually soluble poly(fluorine alcohols) and poly(fluorine esters) with molecular weight 240-900 g/mol was studied as an additive for rubber compounds based on blend of NR and BR. It was thermally stable till 270-300 °C. For comparison, it was tested simultaneously with homogenizing agent, Struktol MS40. Lubricant K95 added in a quantity of 0.5 wt% reduced the viscosity of rubber compound; it also improved compound flow in the mold. Mechanical properties of cured rubber not decrease while resistance to abrasion and fatigue increased. K95 participated in forming strong physical junctions (lower molecular weight between junctions of thermally stable network) while Struktol MS40 reduced the networking degree of rubber. As a result, it acts a multifunctional additive for NR/BR rubber.     

Synthesis and properties of poly(bisphenol A acryloxyethyl phosphate) as a UV curable flame retardant oligomer

Poly(bisphenol A acryloxyethyl phosphate) (BPAAEP) being used for UV curable flame retardant coatings and adhesives, was synthesized from phosphorus oxychloride, hydroxylethyl acrylate and bisphenol A as raw materials, and characterized using ¹³C NMR, ³¹P NMR, FTIR, MS and GPC measurements. A series of formulations with different ratios of BPAAEP to urethane acrylate, EB220, were prepared to obtain flame retardant resins. The flame retardancy of the UV cured films was investigated by the limiting oxygen index (LOI). A synergistic effect between phosphorus and nitrogen was observed when 1.5 wt% phosphorus was presented in the resin. Their maximum photopolymerization rates and final unsaturation conversion (P^f) in the cured films at the presence of a 3 wt% photofragmenting initiator were investigated. The results showed that the P^f increased with increasing EB220 content photo-DSC analysis. The data from dynamic mechanical thermal analysis showed that BPAAEP has good miscibility with EB220. Moreover, the crosslink density and T_g of the cured film decreased along with the content of BPAAEP in the blend.     

Acetylene-grafted resins derived from phenolics via azo coupling reaction

Novel phenolic resins with high ethynyl contents were realized via azo coupling reaction between phenol units and diazonium of 3-ethynylaniline. If Novolac and high-ortho Novolac resins were used as the starting materials directly, the ratio of ethynyl groups to phenolic rings was ca 70%; while the ratio was 100% for the resin from Friedel-Craft polycondensation of 4-(3-ethynylphenyl)salicyl alcohol. All the resins were readily soluble in acetone and ethanol, and meltable at temperatures below 100 °C. The resins underwent thermal addition-type cure with a broad exotherm of around 140-280 °C, and the starting curing temperature showed a downward drift with increase in the ethynyl content. The thermal properties of the cured resins, determined from thermogravimetric analysis (TGA), were considerably superior to those of Novolac- and Resole-type phenolic resins. The initial decomposition temperatures were at ca 400 °C, and the anaerobic carbon yields were ca 80% for all the resins.     

Shear-induced change of phase morphology and tensile property in injection-molded bars of high-density polyethylene/polyoxymethylene blends

It is feasible to control the phase morphology and phase inversion for immiscible polymer blends to manipulate their properties. In this work, the blend of high-density polyethylene (HDPE)/polyoxymethylene (POM) was used as an example, to demonstrate the effect of shear on the phase morphology and resultant mechanical properties in immiscible polymer blends. To do so, a well defined “in-process morphology control” process during injection molding was conducted. That was: after making the blends via melt mixing, the injection-molded bars were prepared via a so-called dynamic packing injection molding equipment to impose a prolonged shearing on the melts during the solidification stage. Phase morphologies and crystal structures of the blends were estimated mainly through scanning electron microscopy, differential scanning calorimetry and 2D wide-angle X-ray scattering, respectively. For in-process morphology controlled samples, co-continuous structures, especially subinclusions inside another continuous phase induced by shear, were observed when the HDPE content was between 30 wt% and 50 wt%, leading to much early occurrence of phase inversion and also the lowest degree of orientation for both HDPE and POM. However, for samples obtained via conventional injection molding, a droplet morphology was always observed with HDPE dispersed in POM as the content of HDPE was up to 30 wt%, but with POM dispersed in HDPE as the content of HDPE was 50 wt%. The performances of injection-molded bars were mainly respect to the phase morphologies for samples obtained via conventional injection molding in which tensile properties continuously decreased with increasing of HDPE content up to 30 wt% and then increased with further increasing of HDPE content. For the in-process morphology controlled samples, the tensile properties depended not only on the phase morphology, but more importantly on the degree of orientation. One observed only a slight decrease of tensile property as the content of HDPE was less than 15 wt%, while an abrupt decrease when the content of HDPE was between 30 wt% and 50 wt%, probably due to the lowest degree of orientation in this composition range.     

Synthesis and properties of novel fluorinated epoxy resins based on 1,1-bis(4-glycidylesterphenyl)-1-(3′-trifluoromethylphenyl)-2,2,2-trifluoroethane

A novel fluorinated epoxy resin, 1,1-bis(4-glycidylesterphenyl)-1-(3′-trifluoromethylphenyl)-2,2,2-trifluoroethane (BGTF), was synthesized through a four-step procedure, which was then cured with hexahydro-4-methylphthalic anhydride (HMPA) and 4,4′-diaminodiphenyl-methane (DDM). As comparison, a commercial available epoxy resin, bisphenol A diglycidyl ether (BADGE), cured with the same curing agents was also investigated. We found that the BGTF gave the exothermic starting temperature lower than BADGE no mater what kind of curing agents applied, implying the reactivity of the former is higher than the latter. The fully cured fluorinated BGTF epoxy resins have good thermal stability with glass transition temperature of 170-175 °C and thermal decomposition temperature at 5% weight loss of 370-382 °C in nitrogen. The fluorinated BGTF epoxy resins also showed the mechanical properties as good as the commercial BADGE epoxy resins. The cured BGTF epoxy resins exhibited improved dielectric properties as compared with the BADGE epoxy resins with the dielectric constants and the dissipation factors lower than 3.3 and dissipation 2.8 × 10⁻³, respectively, which is related to the low polarizability of the C-F bond and the large free volume of CF₃ groups in the polymer. The BGTF epoxy resins also gave low water absorption because of the existence of hydrophobic fluorine atom.     

Structural and optical characterization of pyrolytic carbon derived from novolac resin

The structural and optical properties of technologically interesting pyrolytic carbons formed from cured novolac resin and cured novolac/biomass composites were studied by X-Ray Diffraction Analysis (XRD), and Fourier Transform Infrared (FTIR), Raman and Photoluminescence (PL) spectroscopy. Pyrolysis of the cured materials took place at temperatures in the range 400–1000 °C. The most important weight loss, shrinkage and structural changes of pyrolyzed composites are observed at temperatures up to 600 °C due to the olive stone component. In the same temperature range, the changes in pyrolyzed novolac are smaller. The spectroscopic analysis shows that novolac pyrolyzed up to 900 ^°C has less defects and disorder than the composites. However, above 900 ^°C, pyrolyzed novolac becomes more disordered compared to the pyrolyzed composites. It is concluded that partial replacement of novolac by olive stone in the composite materials leads to the formation of a low cost, good quality product.