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     

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     

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     

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     

Nanoclay modified silica phenolic composites: mechanical properties and thermal response under simulated atmospheric re‐entry conditions

Ablative nanocomposites based on nanoclay‐dispersed addition curable propargylated phenolic novolac (ACPR) resin, reinforced with chopped silica fiber, were investigated for their thermal response behavior under simulated heat flux conditions corresponding to typical atmospheric re‐entry conditions. Organically modified nanoclay (Cloisite 30B) was incorporated to different extents (1–10%) in the ACPR resin matrix containing silica fiber to form the composite. The composites displayed optimum mechanical properties at around 3 wt% of nanoclay loading. The resultant composites were evaluated for their ablative characteristics as well as mechanical, thermal and thermo‐physical properties. The reinforcing effect of nanoclay was established and correlated to the composition. The mechanical properties of the composites and its pyrolysed product improved at moderate nanoclay incorporation. Plasma arc jet studies revealed that front wall temperature is lowered by 20°C and that at backwall by 10–13°C for the 3 wt% nanoclay‐incorporated composites due to impedance by nanoclay for the heat conduction. Nanoclay diminished the coefficient of thermal expansion by almost 50% and also reduced the flammability of the composites. The trend in mechanical properties was correlated to the microstructural morphology of the composites. The nanomodification conferred better strength to the pyrolysed composites. Copyright © 2014 John Wiley & Sons, Ltd.     

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.     

Synthesis and characterization of multifunctional propenyl‐endcapped aromatic co‐monomers and their use as bismaleimide modifiers

A series of novel modifiers for bismaleimide, bearing propenyl and phenoxy functional groups has been synthesized. Structural information of the monomers was obtained through Fourier transform infrared spectroscopy (FT‐IR), nuclear magnetic resonance (NMR) spectroscopy and elemental analysis. Polymerization characteristics demonstrate that all four systems prepared have a cure temperature below 210°C. This remarkably lower cure temperature compared to that of other polymerization reactions involving diallyl bisphenol A and bismaleimide (DBMI) originates from propenyl groups being present in the structures as well as their larger free volume. The rheological behaviors leading to low melt viscosities and the wide process window of the prepolymer are particularly suitable characteristics for the production of performance resin‐based composite materials via resin transfer molding processes. The dynamic mechanical analysis of the materials reveals glass transition temperatures in a range between 260°C and 293°C. Thermal stabilities show a 5% weight loss at temperatures ranging from 363°C to 428°C with the production of char ranging from 38.5% to 57.6% at 800°C under nitrogen. The latter is a clear indication for the excellent thermal stabilities featured by the cured resins. Furthermore, the dielectric properties exhibit a significantly lower dielectric constant and dissipation factors of the propenyl‐modified cured systems compared to those of DBMI resins at 10 GHz. Copyright © 2015 John Wiley & Sons, Ltd.     

Propargyl silicon‐cyclopentadiene oligomeric resin with high temperature resistance

Multiple propargyl substituted cyclopentadiene was synthesized by phase transfer reaction between cyclopentadiene and propargyl bromide in an aqueous solution mediated by sodium hydroxide. It was found that propargylated cyclopentadiene (PCp) could be thermally cured with a mass loss of ca 28%, while the cured material showed a high char yield of ca 76% at 900°C. In order to overcome the processing problems of PCp, a condensation reaction between PCp di‐anion and dimethyldichlorosilane was performed to make a silicon‐PCp (SiPCp) oligomeric resin. SiPCp resin has an acceptable processability, attributed to its organosolubility, low viscosity, and broad processing window. SiPCp resin can readily undergo thermal cure via addition polymerization of ethynyl groups in the temperature range of 170–270°C with an exothermic maximum at ca 240°C, and the mass loss upon cure was less than 5%. Evidenced by the results of dynamic mechanical analysis (DMA) and thermogravimetric analysis (TGA) in a nitrogen atmosphere, the cured SiPCp resin exhibited stable thermo‐mechanical properties up to 320°C, and possessed an anerobic char yield of ca 77% at 900°C. The results of TGA in air atmosphere revealed the higher oxidation resistance of SiPCp resin. Copyright © 2008 John Wiley & Sons, Ltd.     

DNQ–novolac photoresists revisited: 1H and 13C NMR evidence for a novel photoreaction mechanism

Photoactive compounds, such as diazonaphthoquinone (DNQ) esters, blended with novolac resins, solvents and certain additives, serve as photoresists. These are used for printing of electronic circuits at the micron or sub‐micron level. Patterns are generated based on changes in the physical and chemical properties of the exposed and unexposed photoresist surfaces (printed circuit boards). The huge polarity change between the exposed and unexposed photoresists is exploited in the technique of microlithography. It is believed that the large polarity difference is due to acid formation in the exposed photoresist by a photochemical reaction of DNQ on exposure to light. However, it has also been suggested that in the unexposed part of a photoresist, the novolac resin undergoes an azo coupling reaction with DNQ, leading to an increase in the molecular weight of the resin, rendering it more insoluble in base. The protons in the para positions of the m‐cresol units incorporated in the novolac resin are believed to take part in this azo coupling reaction with DNQ. In this paper, we propose a novel mechanism of action of positive photoresists in the unexposed part of photoresists for dissolution inhibition using molecular modelling, ¹H NMR, ¹³C NMR and DEPT‐135 NMR spectroscopic techniques. Our results enable us to propose that the diazo group of DNQ attacks the methylene bridges rather than the aromatic moiety of the resin. This mechanism explains the pattern formation observed using even p‐cresol‐based resins, where no free para positions are present in the aromatic ring. Copyright © 2003 John Wiley & Sons, Ltd.     

Structure characteristics contributing to flame retardancy in diazo modified novolac resins

The physical characteristics of two modified novolac resins (carbonyl phenyl azo novolac resin; CPAN and 4-(4-hydroxyphenyl azo) benzyl ester novolac resin; HPDEN) bearing nitrogen and aromatic functional groups by diazo-coupling or esterification in the branch structure of phenol novolac resin were examined. Presence of the modifiers raised the phenolic decomposition temperature (5% weight loss) from 300 °C (pure Phenolic) to 330 °C and 380 °C, while the char residue increased from 45% to 56% and 68%, respectively. The kinetics for thermal degradation energies (E_a) also rose from 151 kJ/mol K to 254 kJ/mol K (CPAN) and 273 kJ/mol K (HPDEN). The retarded decomposition kinetics is attributed both to the increase of crosslink densities and high aromatic content in the derivative resins. On the other hand, the diazo-coupling or phenyl diazenyl ester produces non-combustible gases (N₂, CO₂ and CO) during formation of aromatic char which dilute the ambient oxygen gas. Both the production of gases and the retarded kinetics due to cross-linking are definitive for the improved flame resistance.     

Synthesis and application of modified poly (styrene‐alt‐maleic anhydride) networks as a nano chelating resin for uptake of heavy metal ions

A chelating resin based on modified poly (styrene‐alt‐maleic anhydride) with 3‐aminobenzoic acid was synthesized. This modified resin was further reacted by 1,2‐diaminoethane or 1,3‐diaminopropane in the presence of ultrasonic irradiation to prepare tridimensional chelating resin for the removal of heavy metal ions from aqueous solutions. The adsorption behavior of Fe(II), Cu(II), Zn(II) and Pb(II) ions was investigated by synthesized chelating resins in various pH. Among the synthesized resins, CSMA‐AB1 and CSMA‐AB2 demonstrated a high affinity for the selected metal ions compared to SMA‐AB, and the order of removal percentage changes as follow: Fe(II) > Cu(II) > Zn(II) > Pb(II). The adsorption of all metal ions in acidic medium was moderate, and it was favored at the pH value of 6 and 7. Also, the prepared resins were examined for removal of metal ions from industrial wastewater and were shown to have a very efficient adsorption in the case of Cu(II), Fe(II) and Pb(II); however, the adsorption of Zn(II) was lower than others. The resin was characterized by Fourier transform infrared spectroscopy, scanning electron microscopy, X‐ray diffraction analysis and thermogravimetric analysis/derivative thermogravimetry. Copyright © 2012 John Wiley & Sons, Ltd.     

A flame‐retardant DOPO‐MgAl‐LDH was prepared and applied in poly (methyl methacrylate) resin

A novel inorganic and organic composite flame retardant (9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide [DOPO]–layered double hydroxide [LDH]) was synthesized via grafting DOPO with organic‐modified Mg/Al‐LDH, which was introduced into poly (methyl methacrylate) (PMMA) resin to prepare the flame‐retardant PMMA composites. Thermogravimetric analyzer (TGA) showed that the T_‐50% of DOPO‐LDH/PMMA composites enhanced by about 20°C, and with the 20% flame retardant, the residual char content can be increased by 39.8% in the air atmosphere compared with LDH/PMMA composites. In the UL‐94 and the limiting oxygen index (LOI) tests, it can be found that compared with LDH/PMMA composites, the LOI value of DOPO‐LDH/PMMA composites were raised evidently with the increased flame retardants, and the droplet combustion was greatly improved. These results could be ascribed to the action of DOPO free‐radical, catalytic charring of polymer and the effect of LDH physical barrier. Moreover, the novel DOPO‐LDH not only given PMMA a good flame‐retardant property and thermal stability, but also have higher visible light transmittance, ultraviolet‐shielding effect, and low loss of mechanical properties, which could further facilitate the wide application of inorganic environment‐friendly flame retardants in general resins and engineering resins and broaden the application of polymers.     

A study on the kinetics of condensation reaction of phenol‐modified cardanol–formaldehyde resin

Phenol‐modified cardanol–formaldehyde novolac resins have been synthesized using equal proportions of phenol and cardanol. To this mixture of phenol and cardanol, 0.6 and 0.8 mol of formaldehyde were added separately, under acidic conditions, at five different temperatures ranging between 80 and 120°C with an interval of 10°C. This was carried out for a maximum period of 6 h. The free formaldehyde and free phenol contents were determined at regular time intervals to check the completion of the reaction. The synthesized novolacs have been studied by infrared spectroscopic analysis (FT‐IR). The reaction between cardanol, phenol, and formaldehyde was found to follow a second‐order rate kinetics. The overall rate constant (k) increased with the increase of temperature. Based on the value of rate constants, various other parameters such as activation energy (E_a), change in enthalpy (Δ H) and entropy (Δ S), and free energy change (Δ G) of the reaction were also evaluated. It was found that the condensation reaction of phenol and cardanol with formaldehyde was nonspontaneous and irreversible. © 2010 Wiley Periodicals, Inc. Int J Chem Kinet 42: 380–389, 2010     

Photo‐induced cross‐linking mechanism in azide–novolac negative photoresists: molecular level investigation using NMR spectroscopy

Negative photoresists are composed of a photoactive component (aromatic azides/bisazides) and cyclized rubber or novolac resin dissolved in an organic solvent. Hydrogen abstraction and/or insertion reaction of the reactive nitrene intermediate formed during photoirradiation of the azide result in a cross‐linked network of the novolac resin. The molecular weight of novolac resin in the exposed part of the photoresist film thus increases compared with that of the unexposed part. This makes the exposed part insoluble in the alkaline developer. Exploiting this change in physical property, a pattern can be transferred to a substrate from a mask. A better understanding of the exact mechanism of cross‐linking reactions is very important to the design of a high‐performing negative photoresist. A quinone–imine‐type complex has been proposed earlier involving the aromatic moiety of novolac resin as the reaction site. A more recent study focuses the attack of nitrene on the methylenic bridge and hydroxyl group of novolac resins, which were found to be responsible for the cross‐linking reaction along with the aromatic moiety of novolac resin. However, in our study no evidence was found for the involvement of a methylenic hydrogen or aromatic moiety of novolac resin in the cross‐linking reaction. The ¹H NMR, ¹³C NMR and DEPT‐135 spectra before and after photolysis indicate that the cross‐linking site is predominantly the hydroxyl group of novolac resin. Multiple reaction sites of attack for the nitrene intermediate have been demonstrated in cashew nut shell liquid (CNSL)‐based novolac resin by ¹H NMR spectroscopy, which in turn further increases the cross‐linked network in the exposed part of a negative photoresist. Copyright © 2003 John Wiley & Sons, Ltd.     

Degradation kinetics of functionalized novolac resins

We report the relationships between the degradation behaviors (i.e. the degradation kinetics, degradation activation energy, weight loss conversion, and char formation) and the structure features in three modified novolac resins bearing different curable functional groups and aromatic units i.e. Carbonyl phenyl azo novolac resin (CPAN), 4-(4-hydroxyphenyl azo) benzyl ester novolac resin (HPDEN) and Carbonyl phenyl 4-(4-hydroxyphenyl azo) benzyl ester novolac resin (CHABN). These modifications enhanced the thermal stability of the cured novolac resins by delaying the decomposition temperature up to 30-100 °C and produced prominent residue char yield up to 68% (CPAN), 56% (HPDEN) and 64% (CHABN), respectively. The two heavily cross-linked samples, CPAN and CHABN displayed even higher Ea than HPDEN. All modified novolacs displayed much higher decomposition activation energy (over 237 KJ/mol*K) compared with the generic phenolic (PN).     

Synthesis and properties of a deuterated phenolic resin

A highly deuterated novolac‐type phenolic resin was prepared by polycondensation of deuterated phenol and formaldehyde using oxalic acid as an acid catalyst. The polycondensation of deuterated monomers and the formation of the highly deuterated phenolic resin were confirmed by the gel permeation chromatography, IR, and ¹H NMR analyses. With the exception of hydroxyl groups, the degree of deuteration was estimated to be more than 98%. The polymer conformation in THF solution was evaluated by the scaling exponent of the Mark–Houwink–Sakurada equation. The exponent of the deuterated phenolic resin is 0.26 in THF at 40 °C and is close to that of a nondeuterated phenolic resin, which suggests that phenolic resins behave like a compact sphere irrespective of deuteration. The curing behavior of the deuterated phenolic resin with hexamethylenetetramine was confirmed by differential scanning calorimetry analysis. The cured highly deuterated phenolic resin exhibits a lower incoherent neutron scattering background than that of the nondeuterated phenolic resin, which suggests that the former is suitable for matrix resins with low incoherent backgrounds for small‐angle neutron scattering studies of thermosetting resins. © 2011 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2011.     

Fabrication of high thermal stable cured novolac/Cloisite 30B nanocomposites by chemical modification of resin structure

Cloisite 30B as a modified kind of nanoclay was utilized for the formation of 3D network based on novolac resin with high thermal stable properties. Two types of phenolic resins including neat novolac (NR) and modified novolac resin were used to create a compatible matrix with nanoclay. For this purpose, NR modified with (3‐chloropropyl)triethoxysilane (CPTES) to form SiNR. For improvement of thermal behaviors, Cloisite 30B was dispersed in matrix via ultrasonic waves and cured with hexamethylenetetramine (HMTA) to form 3D network. X‐ray diffraction (XRD) analysis was used to measure the d‐spacing in intercalated systems and results indicated the optimum amount of clay for appropriate thermal properties. Investigation of the thermal properties of the samples by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) showed that the presence of Cloisite 30B in matrix resulted in much higher thermal stability and char yield with respect to modification of novolac resin originated from formation of 3D Si–O–Si network. Also, cured modified resin and its nanocomposites showed much higher thermal stability than cured NR and its nanocomposites. Such nanocomposite materials with high thermal stability have potential applications in advanced fields such electronic, industrial molds, coatings, adhesives, and aerospace composites.     

Synthesis and characterization of itaconic‐based epoxy resins

A trifunctional epoxy resin from itaconic acid (TEIA) was synthesized from a renewable resource‐based itaconic acid by allylation of itaconic acid to form diallyl itaconate by using m‐chloroperoxybenzoic acid as oxidizing agents followed by epoxidation of allylic C═C bond of diallyl itaconate methylhexahydropthalic anhydride as curing agent in the presence of 2‐methyl imidazole as a catalyst. The chemical structure of the synthesized resins was confirmed by Fourier transform infrared and nuclear magnetic resonance (¹H‐NMR and ¹³C‐NMR) spectroscopy analysis. The mechanical, thermal, and rheological performances of the TEIA were also investigated and compared with diglycidyl ether of bisphenol A and a plant‐based epoxidized soybean oil bioresin cured with the same curing agent. The higher epoxy value of 1.02, lower viscosity (0.96 Pa s at 25°C), higher mechanical, and higher curing reactivity toward methylhexahydropthalic anhydride of TEIA as compared with epoxidized soybean oil and comparable with diglycidyl ether of bisphenol A demonstrated significant evidence to design and develop a novel bio‐based epoxy resin with high performance to substitute the petroleum‐based epoxy resin.     

Development of novel flame‐retardant thermosets based on benzoxazine–phenolic resins and a glycidyl phosphinate

Modified novolac resins with benzoxazine rings were prepared and copolymerized with a glycidyl phosphinate. Their curing behavior and the thermal properties of the curing resins were studied. Copolymerization was studied with model compounds considering the functionality of the benzoxazine‐based phenolic resins and the easy isomerization of the glycidyl phosphinate. Phenolic novolac resin acts as an initiator but p‐toluensulfonic acid had to be used to decrease the curing temperature and to prevent glycidyl phosphinate from isomerizing. The materials obtained exhibited high glass‐transition temperatures and retardation on thermal degradation rates. V‐0 materials were obtained when the materials were tested for ignition resistance with the UL‐94 test. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 279–289, 2004     

Polystyrene‐modified novolac epoxy resin/clay nanocomposite: Synthesis,and characterization

A polystyrene‐modified epoxidized novolac resin/montmorillonite nanocomposite was fabricated and characterized successfully. For this purpose, novolac resin (NR) was epoxidized through the reaction of phenolic hydroxyl group with epichlorohydrin in super basic medium to produce epoxidized novolac resin (ENR). Afterward, a polystyrene was synthesized by atom transfer radical polymerization (ATRP) technique, and then brominated at the benzylic positions using N‐bromosuccinimide (NBS). The brominated polystyrene (PSt‐Br) was reacted with ethanolamine in basic medium in order to afford an amine‐functionalized polystyrene (PSt‐NH₂). An organo‐modified montmorillonite (O‐MMT) was synthesized through the treatment of MMT with hexadecyl trimethyl ammonium chloride salt. Finally, ENR‐PSt/MMT nanocomposite was fabricated through curing a mixture of ENR (70 wt.%) and O‐MMT (5 wt.%) with PSt‐NH₂ (25 wt.%). Transition electron microscopy (TEM) and powder X‐ray diffraction (XRD) analysis revealed that the fabricated nanocomposite has an exfoliated structure. Thermal property studies using thermogravimetric analysis (TGA) showed that the curing of ENR by PSt‐NH₂, as well as incorporation of a small amount of MMT have synergistic effect on the thermal stability of the ENR resin.