PROGRESS IN PHASE INVERSION EMULSIFICATION FOR EPOXY RESIN WATERBORNE DISPERSIONS

In this review, our recent work in phase inversion emulsification （PIE） for polymer （especially epoxy resin） waterborne dispersions is summarized. Based on experimental results about PIE process, the physical model is proposed which can guide the synthesis of the waterborne dispersions such as polymer/nanoparticle composite dispersion. In the presence of a latent curing catalyst, PIE can give a crosslinkable epoxy resin waterborne dispersion. The dispersions can form cured transparent coatings with some unique properties such as UV shielding. They are promising in functional coatings, waterborne resin matrices for composites, and sizing for high performance fibers.     

Epoxy‐based composite adhesives: Effect of hybrid fillers on thermal conductivity,rheology, and lap shear strength

Thermal management is an important parameter in an electronic packaging application. In this work, three different types of fillers such as natural graphite powder (Gr) of 50‐μm particle size, boron nitride powder (h‐BN) of 1‐μm size, and silver flakes (Ag) of 10‐μm particle size were used for thermal conductivity enhancement of neat epoxy resin. The thermal properties, rheology, and lap shear strength of the neat epoxy and its composite were investigated. The analysis showed that the loading of different wt% of Gr‐based fillers can effectively increase the thermal conductivity of the epoxy resin. It has also been observed that the thermal conductivity of the hybrid filler (Gr/h‐BN/Ag) reinforced epoxy adhesive composite increased six times greater than that of neat epoxy resin composite. Further, the viscosity of hybrid filler reinforced epoxy resin was found to be increased as compared with its virgin counterpart. The adhesive composite with optimized filler content was then subsequently subjected to determine single lap shear strength. The degree of filler dispersion and alignment in the matrix were determined by scanning electron microscopy (SEM) analysis.     

Preparation and electromagnetic interference shielding characteristics of novel carbon‐nanotube/siloxane/poly‐(urea urethane) nanocomposites

Poly(urea urethane) (PUU) with a poly(dimethylsiloxane) soft segment was synthesized. Different types of conductive fillers—carbon nanotube (CNT), silver‐coated carbon nanotube (CNT–Ag), and nickel‐coated carbon nanotube (CNT–Ni)—were blended with PUU to form partially conductive polymer composites. The results showed that highly conductive metals could improve the conductivity of CNTs significantly. When the filler contents were 3, 4, and 5 parts per hundred parts of resin (phr), the PUU/CNT composites possessed electromagnetic interference shielding effectiveness (SE) at 8.5, 28.4, and 26.0 dB as the electromagnetic wave frequencies were 12.3, 16.2, and 15.9 GHz, respectively. SE of the composites that contained CNT–Ni and CNT–Ag increased with the filler loading. At the same modified‐CNT loading, the CNT–Ni‐filled composites had a higher SE than those filled with CNT–Ag. Tensile stresses ranged from 5.7 to 15.6 MPa (a 177.3% increase) when the CNT concentration reached 8 phr. © 2004 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 43: 345–358, 2005     

Silver Hollow Microspheres: Large-scale Synthesis, Characterization and Electromagnetic Shielding Property

A facile and large-scale synthesis method to fabricate silver hollow microspheres with controllable morphologies and shell thickness is described using low-cost glass microspheres as templates. The method mainly involves two steps of the preparation of silver-coated glass microsphere core-shell particles by a controllable liquid reduced reaction of Ag[(NH3)2]+ solution, which only produces silver nanoparticles anchored on the surface of the thiolated glass microsphere templates, and the removal of glass microspheres by wet chemical etching with HF solution. The products are well characterized by field emitted scanning electron microscopy (SEM), transmitted electron microscopy (TEM), X-ray photoelectron spectra (XPS), X-ray diffraction (XRD) and energy dispersive X-ray (EDX) etc. The as-prepared core-shell particles and hollow particles have even and compact silver shells. The electromagnetic shielding coatings based on the silver hollow microspheres are demonstrated to have high conductivity, excellent shielding effectiveness and long durability, suggesting that the silver hollow microspheres obtained here are a novel light-weight electromagnetic shielding filler and will have extensive applications in the electromagnetic compatibility fields.     

Effects of sodium laurylsulfate on crystal structure of calcite formed from mixed solutions

This paper presents a solvent-based, mild method to prepare superhydrophobic, carbon nanofiber/PTFE-filled polymer composite coatings with high electrical conductivity and reports the first data on the effectiveness of such coatings as electromagnetic interference (EMI) shielding materials. The coatings are fabricated by spraying dispersions of carbon nanofibers and sub-micron PTFE particles in a polymer blend solution of poly(vinyledene fluoride) and poly(methyl methacrylate) on cellulosic substrates. Upon drying, coatings display static water contact angles as high as 158° (superhydrophobic) and droplet roll-off angles of 10° indicating self-cleaning ability along with high electrical conductivities (up to 309 S/m). 100 μm-thick coatings are characterized in terms of their EMI shielding effectiveness in the X-band (8.2-12.4 GHz). Results show up to 25 dB of shielding effectiveness, which changed little with frequency at a fixed composition, thus indicating the potential of these coatings for EMI shielding applications and other technologies requiring both extreme liquid repellency and high electrical conductivity.     

羰基铁粉/银核-壳粒子及其复合材料的制备与电磁特性

运用液相化学还原银技术, 制备了羰基铁粉/银核-壳复合粒子; 以该复合粒子为屏蔽填料, 制备了一种宽频、高效的新型电磁屏蔽橡胶材料. 分析了该屏蔽填料的表面形貌和组成, 研究了其电磁特性对电磁屏蔽橡胶材料屏蔽效能的影响规律. 结果表明, 具有完整核壳结构的羰基铁粉/银复合粒子兼具优异的磁性能和高导电率, 用其组成的电磁屏蔽橡胶材料对电磁波能同时产生较强的吸收损耗和反射损耗, 屏蔽效能(SE)优于传统的屏蔽橡胶材料.     

Preparation of nylon MXD6/EG/CNTs ternary composites with excellent thermal conductivity and electromagnetic interference shielding effectiveness

In this article,hybrid fillers with different dimensions,namely,2-dimensional (2-D) expanded graphite (EG) and 1-dimensional (1-D) multi-walled carbon nanotubes (CNTs),were added to aromatic nylon MXD6 matrix via melt-blending,to enhance its thermal and electrical conductivity as well as electromagnetic interference shielding effectiveness (EMI SE).For ternary composites of MXD6/EG/CNTs,the electrical conductivity reaches up nine orders of magnitude higher compared to that of the neat MXD6 sample,which tumed the polymer-based composites from an insulator to a conductor,and the thermal conductivity has been enhanced by 477％ compared with that of neat MXD6 sample.Meanwhile,the EMI SE of ternary composite reaches ～50 dB at the overall filler loading of only 18 wt％.This work can provide guidance for the preparation of polymer composites with excellent thermal and electrical conductivity via using hybrid filler.     

Effect of filler on kinetic characteristics of glass transition in polymer composite materials

Dynamic mechanical spectroscopy and differential scanning calorimetry were used to study the effect of various fillers (carbon fiber, glass fiber, and aramid fiber) on the kinetic characteristics of glass transition in polymer composite materials based on epoxy resin. It is shown that the composite based on carbon fiber is the most fragile among the materials studied, whereas the polymer composite material based on aramid fiber exhibits the lowest rate of variation of the relaxation time above the glass-transition temperature. A relationship is determined between the heat conductivity and fragility of polymer composite materials. The effect of various fillers on the curing kinetics of the epoxy matrix upon glass transition is prognosticated, with the difference in the degree of curing reaching a value of 4–5%. The strongest filler effect on the curing kinetics is observed in the chemically controlled region, which may be due to the catalytic effect of functional groups on the fiber surface.     

Effects of diameter and surface area of electrospun nanocomposite fibers on electromagnetic interference shielding

The effects of variation in average diameter and surface area of nanocomposite fibers on electromagnetic interference (EMI) shielding of multi-walled carbon nanotubes (MWCNTs)/polyvinylpyrrolidone (PVP) fibers were investigated in this paper. The EMI shielding effectiveness of electrospun nanocomposite fibers were measured in the X-band frequency range 8.2–12.4 GHz. The electrical conductivity and EMI shielding behaviors of the nanocomposite fibers were reported as function of average diameter and surface area of MWCNTs/PVP nanocomposite fibers. The electrical conductivity measurements demonstrate using thinner nanocomposite fibers results in a lower limit of electrical resistivity, better electrical conductivity performance. The EMI shielding efficiency of thinner nanocomposite fibers increased up to 42 dB. The EMI shielding data for MWCNTs/PVP nanocomposite fibers with various average diameter and surface area showed that absorption was the major shielding mechanism and reflection was the secondary shielding mechanism. It can be related to higher specific surface area of thinner electrospun MWCNTs/PVP nanocomposite fibers that means more surface area for radiative scatter and absorption leading to higher EMI shielding performance.     

Rice Husk‐derived Hierarchical Micro/Mesoporous Carbon–Silica Nanocomposite as Superior Filler for Green Electronic Packaging Material

In this study, a carbon‐controllable hierarchical micro/mesoporous carbon–silica material derived from agricultural waste rice husk was easily synthesized and utilized as filler in an epoxy matrix for electronic packaging applications. Scanning electron microscopy, thermogravimetric analysis, and N₂ adsorption/desorption isotherms were used to characterize the morphology, thermal stability, carbon content, and porous structural properties, respectively, of the as‐obtained carbon–silica material, namely rice husk char (RHC ). As a filler material, the uniformly dispersed RHC filler in the epoxy/RHC composite was easily prepared through hydrogen bonding of the silanol group of silica with the epoxy matrix. For electronic packaging applications, the thermal conductivity and thermomechanical properties (storage modulus and coefficient of thermal expansion) of the epoxy/RHC composites improved with increasing carbon content. Moreover, loading of the 40% RHC filler substantially enhanced the storage modulus of the epoxy/RHC composite (5735 MPa ) compared to the epoxy with 40% commercial silica filler (3681 MPa ). Considerable commercial potential is expected for the carbon–silica composite because of the simple synthesis process and outstanding performance of the prepared packaging material.     

Adhesives and coatings based on phenolic/epoxy resins

Low molecular weight epoxy resin based on bis (4‐hydroxy phenyl) 1,1 cyclohexane was prepared and modified with various types of the prepared phenolic resins. Phenol–, cresol–, resorcinol–and salicylic acid–formaldehyde resins were used. The optimum conditions of formulation and curing process were studied to obtain modified wood adhesives characterized by high tensile shear strength values. This study indicated that the more suitable conditions are 1:2 weight ratio of phenol–or cresol–formaldehyde to epoxy resin in the presence of phthalic anhydride (20 wt%) of the resin content as a curing agent at 150°C for 80 min. Resorcinol–or salicylic acid–formaldehyde/epoxy resins formulated at 1:2 weight ratio were cured in the presence of paraformaldehyde (20 wt%) at 150°C for 60 min. The effect of the structure of phenolic resins on the tensile shear strength values of formulated resin samples, when mixed with the epoxy resins and cured under the previously mentioned optimum conditions for different times, was investigated. Metallic and glass coatings from the previous resins were also prepared and evaluated as varnishes or paints. Copyright © 1999 John Wiley & Sons, Ltd.     

Polymerization and characterization of high conductivity and good adhension polypyrrole films for electromagnetic interference shielding

<正>Polypyrrole(PPy) shows a favorable application in the electromagnetic interference(EMI) shielding due to its good electrical conductivity and outstanding air stability.Conducting PPy films with high conductivity and good adhesion were successfully polymerized on the surface of insulating epoxy resin substrates using chemical polymerization.The factors affecting the properties of PPy films,such as the surface morphology,adhesion between PPy film and substrate,electrical conductivity,EMI shielding effectiveness(SE),were investigated.The adhesion was improved significantly through a three-step surface pretreatment of epoxy resin substrates including removing impurities,roughening,and surface modification with silane coupling agent.An enhancement in the conductivity of PPy films of about one order of magnitude was achieved by adding dopant in FeCl_3 solution.The higher the conductivity,the better the shielding effectiveness.Taking sodium p-toluenesulfonate doped PPy film as example,EMI SE was in the practically useful range of about 30 dB over a wide frequency range from 30 MHz to 1500 MHz.The PPy film samples were characterized by scanning electron microscopy (SEM),infrared spectra(IR),X-ray photoelectron spectroscopy(XPS) and the flange coaxial transmission device.The fourpoint probe method was used to measure conductivity of PPy films.     

High-electromagnetic-shielding cotton fabric prepared using multiwall carbon nanotubes/nickel–phosphorus electroless plating

High-electromagnetic-shielding cotton fabric (CF) was prepared using carboxyl-functionalized multiwall carbon nanotubes (MWCNTs-COOH)/nickel–phosphorus (Ni-P) electroless plating. Firstly, MWCNTs-COOH was loaded on CF used to chelate the metal catalyst followed by electroless plating to impart outstanding electrical conductivity and electromagnetic shielding properties. The intermediate MWCNTs-COOH layer not only improves the bonding strength via the chelating effect, but also can be used as a conductive material. This synergistic action of MWCNTs-COOH and Ni-P layer can work together to improve the electromagnetic interference shielding performance. The features of Ni-P/MWCNTs-COOH/CF were characterized using scanning electron microscopy, energy-dispersive spectroscopy, X-ray photoelectron spectroscopy and X-ray diffraction. The resulting Ni-P/MWCNTs-COOH/CF fabrics show high surface resistance of 1.66 Ω sq⁻¹ and robust electromagnetic shielding effectiveness of 40.2 dB. Furthermore, benefiting from the strong interface interaction, the as-prepared composite fabrics retain stable performances after undergoing a series of physical and chemical tests, confirming promising practical applications even under harsh conditions.     

Segregated reduced graphene oxide polymer composite as a high performance electromagnetic interference shield

Herein, we report the synthesis of a graphene/polymer composite via a facile and straightforward approach for electromagnetic interference (EMI) shielding applications. Polystyrene (PS) beads were added in graphene oxide (GO)/water solution followed by the addition of hydroiodic acid (HI) for in situ reduction of GO. The composite solution (rGO/PS) was filtered, hot compressed and tested for EMI shielding and dielectric measurements. A 2-mm thick segregated rGO/PS sample with 10 wt% filler loading delivered a high EMI shielding effectiveness (SE) of 29.7 dB and an AC electrical conductivity of 21.8 S m^?1, which is well above the commercial requirement for EMI shielding applications. For comparison with the segregated rGO/PS composite, a control polymer composite sample utilizing a thermally reduced graphene oxide was synthesized by following a conventional coagulation approach. The as-synthesized conventional rGO/PS yield an EMI SE of 14.2 dB and electrical conductivity of 12.5 S m^?1. The high EMI shielding of segregated rGO/PS is attributed to the better filler-to-filler contact among graphene layers surrounded by PS beads and also to the better reduction and preservation of graphene structure during reduction process that makes the low temperature chemically reduced segregated rGO/PS approach a viable route compared to high temperature thermally reduced conventional rGO/PS approach.     

Enhanced Thermal Stability in SiO2/Carbon Filler Derived from Rice Husk via Microwave Treatment for Electronic Packaging Application

Here we report the effect of microwave treatment on a silica–carbon (SiO₂ /C) filler derived from rice husk and the function of the microwave‐treated filler in an epoxy matrix for electronic packaging applications. Thermogravimetric analysis revealed improved thermal stability of the SiO₂ /C filler upon microwave treatment. X‐ray diffraction analysis indicated partial SiC formation after the microwave treatment. For packaging applications, compared to that of the pure epoxy polymer, the thermal conductivity of the epoxy–SiO₂ /C composite was improved by 178% at 40 wt % content of the microwave‐treated SiO₂ /C filler. Furthermore, an improvement of 149% in storage modulus and 17.6°C in glass transition temperature of the epoxy–SiO₂ /C composites was realized. The improvement in thermal stability of SiO₂ /C filler could be achieved via a simple microwave treatment, which in turn enhanced the thermal stability, thermal conduction, and thermomechanical strength of the electronic packaging materials.     

Towards efficient electromagnetic interference shielding performance for polyethylene composites by structuring segregated carbon black/graphite networks

An electromagnetic interference (EMI) shielding composite based on ultrahigh molecular weight polyethylene (UHMWPE) loaded with economical graphite-carbon black (CB) hybrid fillers was prepared via a green and facile methodology, i.e., high-speed mechanical mixing combined with hot compression thus avoiding the assistance of the intensive ultrasound dispersion in volatile organic solvents. In this composite, the graphite-CB hybrid fillers were selectively distributed in the interfacial regions of UHMWPE domains resulting a typical segregated structure. Thanks to the specific morphology of segregated conductive networks along with the synergetic effect of large-sized graphite flakes and small-sized CB nanoparticles, a low filler loading of 7.7 vol% (15 wt%) yielded the graphite-CB/UHMWPE composites with a satisfactory electrical conductivity of 33.9 S/m and a superior shielding effectiveness of 40.2 dB, manifesting the comparable value of the pricey large-aspect-ratio carbon nanofillers (e.g., carbon nanotubes and graphene nanosheets) based polymer composites. More interestingly, with the addition of 15 wt% graphite-CB (1/3, W/W) hybrid fillers, the tensile strength and elongation at break of the composite reached 25.3 MPa and 126%, respectively; with a remarkable increase of 58.1% and 2420% over the conventional segregated graphite/UHMWPE composites. The mechanical reinforcement could be attributed to the favor of the small-sized CB particles in the polymer molecular diffusion between UHMWPE domains which in turn provided a stronger interfacial adhesion. This work provides a facile, green and affordable strategy to obtain the polymer composites with high electrical conductivity, efficient EMI shielding, and balanced mechanical performance.     

New strategy to reinforce and toughen composites via introducing thorns-like micro/nanofibers

In this work, we report a new strategy of introducing thorns-like fiber into composites, so that the resultant composites substantially benefit from strong fiber–matrix interface adhesion. Specifically, the “thorns” could increase in interlocking molecules chains and entangle with the surrounding matrix resin, which could impede the mobility of polymer chains, as like the roots with uplift capacity. Strong interfacial adhesion between fibers and matrices is suggested by the SEM images and the DMA studies. After the thorns-like fibers are embedded into epoxy resin, the glass transition temperature (T_g) and the storage modulus (E′) are higher than these of neat epoxy and untreated fibers-reinforced epoxy, respectively, and the flexural properties of the composites reinforced with thorns-like fibers are significantly increased. Therefore these novel three dimensional thorns-like fibers will be applicable for composite materials based upon its unique architecture, making it an attractive alternative to increase the performance of any matrix resin.     

三明治结构多壁碳纳米管/聚醚醚酮电磁屏蔽复合材料的制备

以聚醚砜(PES)为黏结剂, 多壁碳纳米管(MWCNTs)为芯层, 聚醚醚酮(PEEK)薄膜为皮层, 制备了具有 三明治结构的MWCNTs/PEEK电磁屏蔽复合材料. 研究结果表明, 将适量的黏结剂PES引入到MWCNTs芯 层中, 当芯层层数增加到3层时, 复合材料的平均厚度仅有0.28 mm, 其密度、 拉伸强度、 5%热失重温 度(T_d,5%)、 导电率、 电磁屏蔽值及比电磁屏蔽值分别可以达到1.349 g/cm³, 80 MPa, 581.8 ℃, 2.6 S/cm, 32 dB及115 dB/mm, 是一种质量轻、 厚度薄、 机械性能好且电磁屏蔽性能高的复合材料. 其优异的综合性能主要归因于在三明治结构MWCNTs/PEEK复合材料的制备过程中, 在碳纳米管芯层中引入适量的聚醚砜作为黏结剂可以改善芯层内部碳纳米管之间及芯层与聚醚醚酮皮层之间的界面作用, 有利于芯层及芯层与皮层黏结成一个整体, 从而提高复合材料的机械性能; 同时, 芯层中碳纳米管互相搭接成密集导电网络又可以使得复合材料拥有较高的电磁屏蔽性能.     

Reactive copolymer functionalized graphene sheet for enhanced mechanical and thermal properties of epoxy composites

Uniform dispersion of graphene nanosheets (GNS) in a polymer matrix with strong filler–matrix interfacial interaction, preserving intrinsic material properties of GNS, is the critical factor for application of GNS in polymer composites. In this work, a novel reactive copolymer VCz–GMA containing carbazole and epoxide group was designed, synthesized and employed to noncovalently functionalize GNS for preparing epoxy nanocomposites with enhanced mechanical properties. The presence of carbazole groups in VCz–GMA enables the tight absorption of copolymer on to graphene surface via π–π stacking interaction, as evidenced by Raman and fluorescence spectroscopy, whereas the epoxide segments chemically reacts with the epoxy matrix, improving the compatibility and interaction of graphene with epoxy matrix. As a result, the VCz–GMA–GNS/epoxy composite showed a remarkable enhancement in both mechanical and thermal property than either the pure epoxy or the graphene/epoxy composites. The incorporation of 0.35 wt % VCz–GMA–GNS yields a tensile strength of 55.72 MPa and elongation at break of 3.45, which are 42 and 191% higher than the value of pure epoxy, respectively. Increased glass transition temperature and thermal stability of the epoxy composites were also observed. In addition, a significant enhancement in thermal conductivity was achieved with only 1 wt % VCz–GMA–GNS loading. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 2776–2785     

Tough and Conductive Nacre-inspired MXene/Epoxy Layered Bulk Nanocomposites

A long-standing quest in materials science has been the development of tough epoxy resin nanocomposites for use in numerous applications. Inspired by nacre, here we report tough and conductive MXene/epoxy layered bulk nanocomposites. The orientation of MXene lamellar scaffolds is enhanced by annealing treatment. The improved interfacial interactions between MXene lamellar scaffold and epoxy through surface chemical modification resulted in a synergistic effect. Tailoring the interlayer spacing of MXene nanosheets to a critical distance resulted in a fracture toughness about eight times higher than that of pure epoxy, surpassing other epoxy nanocomposites. Our nacre-inspired MXene/epoxy layered bulk nanocomposites also show high electrical conductivity that provides self-monitoring capability for structural integrity and exhibits an excellent electromagnetic interference shielding efficiency. Our proposed strategy provides an avenue for fabricating high-performance epoxy nanocomposites.