PVT behavior of thermoplastic poly(styrene-co-acrylonitrile)-modified epoxy systems: relating polymerization-induced viscoelastic phase separation with the cure shrinkage performance

The volume shrinkage during polymerization of a thermoplastic modified epoxy resin undergoing a simultaneous viscoelastic phase separation was investigated for the first time by means of pressure-volume-temperature (PVT) analysis. Varying amounts (0-20%) of poly(styrene-co-acrylonitrile) (SAN) have been incorporated into a high-temperature epoxy-diamine system, diglycidyl ether of bisphenol A (DGEBA)-4,4'-diaminodiphenyl sulfone (DDS) mixture, and subsequently polymerized isothermally at a constant pressure of 10 MPa. Volume shrinkage is highest for the double-phased network-like bicontinuous morphology in the SAN-15% system. Investigation of the epoxy reaction kinetics based on the conversions derived from PVT data established a phase-separation effect on the volume shrinkage behavior in these blends. From subsequent thermal transition studies of various epoxy-DDS/SAN systems, it has been suggested that the behavior of the highly intermixed thermoplastic SAN-rich phase is the key for in situ shrinkage control. Various microscopic characterizations including scanning electron microscopy, atomic force microscopy, and optical microscopy are combined to confirm that the shrinkage behavior is manipulated by a volume shrinkage of the thermoplastic SAN-rich phase undergoing a viscoelastic phase separation during cure. Consequently, a new mechanism for volume shrinkage has been visualized for the in situ polymerization of a thermoplastic-modified epoxy resin.     

Phase separation and morphology development in a thermoplastic-modified toughened epoxy

The morphologies developed by blends based on a polystyrene modifier and an epoxy system polymerized with a monoamine and a diamine mixed in different proportions that are phase separated during the polymerization, were studied. The proportion of monoamine–diamine in the system affects the crosslinking degree of the material, which was controlled and continuously modified from a linear polymer to a highly crosslinked polymer. The effect of modifier proportion, polymerization temperature, and monoamine–diamine ratio on the final morphology was investigated. Different types of morphologies were developed depending mainly on the composition of modifier in the blend. The nature of the separated phases in the different types of morphologies was investigated and confirmed by experiments with a solvent and elemental analysis. Explanations for the developed morphologies as a function of the variables were proposed and discussed in detail.     

The morphology and dynamics of polymerization-induced phase separation

The morphology and dynamics of polymerization-induced phase separation in the initially homogeneous solution of a non-reactive component in reactive monomers are investigated by incorporating the reaction kinetics into the Cahn-Hilliard equation. Analytical results show that there is a reduction of the initial length scale in the early stage of phase separation. The reason is the increase of the molecule weight of emerging polymer, independent of the fact whether the system goes through the metastable region or not. The numerical results are in good agreement with theoretical prediction quite well.     

Polymerization-induced viscoelastic phase separation in polyethersulfone-modified epoxy systems

The polymerization-induced phase-separation process of polyethersulfone (PES)-modified epoxy systems was monitored in situ continuously on a single sample throughout the entire curing process by using optical microscopes, time-resolved light scattering (TRLS), scanning electronic microscopes (SEM), and a rheometry instrument. At specific PES content a viscoelastic transformation process of phase inversion morphology to bicontinuous was found with an optical microscope. The rheological behavior during phase separation corresponds well with the morphology development. Light-scattering results monitoring the phase-separation process of systems with final phase inversion morphology show a typical exponential decay procedure of scattering vector qm. The characteristic relaxation time of phase separation can be described well by the WLF equation.     

Computational simulation of polymerization-induced phase separation under a temperature gradient

Polymerization-induced phase separation (PIPS) via spinodal decomposition (SD) under a temperature gradient for the case of a monomer polymerizing in the presence of a non-reactive polymer is studied using high performance computational methods. An initial polymer (A)/monomer (B) one-phase mixture, which has an upper critical solution temperature (UCST) and is maintained under a temperature gradient, phase-separates and evolves to form spatially inhomogeneous microstructures. The space-dependence of the phase-separated structures under the temperature gradient field is determined and characterized using quantitative visualization methods. It is found that a droplet-type phase-separated structure is formed in the high-temperature region, corresponding to the intermediate stage of SD. On the other hand, lamella or interconnected cylinder type of phase-separated structure is observed in the low-temperature region, corresponding to the early stage of SD structure, in the large or small temperature gradient field, respectively. The kinetics of the morphological evolution depends on the magnitude of the temperature gradient field. The non-uniform morphology induced by the temperature gradient is characterized using novel morphological techniques, such as the intensity and scale of segregation. It is found that significant non-uniform structures are formed in a temperature gradient in contrast to the uniform morphology formed under constant temperature.     

Thermodynamic analysis of polymerization-induced phase separation of a polystyrene in epoxy/monoamine–diamine systems. Effect of monoamine–diamine proportion on the phase diagram

Polymerization-induced phase separation of a polystyrene in various epoxy-amine systems where the amino groups were provided by a monoamine and a diamine mixed in different proportions was thermodynamically studied. A model based on the Flory–Huggins theory extended by Koningsveld and Staverman approach where the interaction parameter was dependent on temperature, composition and conversion, and polydispersity of the components was considered, was used. A general equation for the evolution during polymerization of the epoxy-amine species distributions according to the monoamine–diamine ratio was derived from the Stockmayer distribution. The interaction parameters continuously decreased with conversion. Phase diagrams of the blends were obtained and the critical composition was between 5 and 6 vol.% PS in all blends.     

Phase separation and rheological behavior in thermoplastic modified epoxy systems

The relationship between rheological behavior and phase separation in polyesterimide modified epoxy systems was studied by rheometry, time-resolved light scattering (TRLS), and Differential Scanning Calorimetry (DSC). The rheological behaviors of blends during phase separation showed an exponential grow of complex viscosity, while the phase separation was inhibited by the vitrification of the polyesterimide-rich matrix phase rather than gelation of dispersed epoxy-rich particles. The characteristic relaxation time obtained by the simulation of complex viscosity could be described well by the Williams–Landel–Ferry equation, which corresponded well with the light scattering results. Therefore, this work would further provide the experimental proofs that the exponential relaxation behavior of complex viscosity could be attributed to the viscoelastic flow of epoxy-rich escaping from polyesterimide-rich matrix during phase separation.     

Gelation behavior and phase separation of macroporous methylsilsesquioxane monoliths prepared by in situ two-step processing

An in situ two-step processing using an initial acid catalysis step accompanied by an epoxide-mediated condensation step in the presence of ammonium chloride (NH₄Cl) is reported, and macroporous cocontinuous methylsilsesquioxane (MSQ) monoliths have been successfully prepared by this processing. We explain the hydrolysis, gelation behavior and phase separation of MTMS(methyltrimethoxysilane)-MeOH(methanol)-HCl-PO(propylene oxide) system and the in situ effect of NH₄Cl, and examine the macroporous morphology and pore structures of MSQ monoliths obtained under different conditions. Macroporous MSQ monolith under optimized conditions possesses a narrow macropore size distribution between 3 to 10 μm, surface area as high as 366 m²·g^?1 and minimal shrinkage of only 1 %.     

The influence of polyetherimide on gelation and phase separation in epoxy systems

In the process of curing under thermostatic conditions, the time dependence of active and reactive components of the dielectric permittivity of epoxy amine compositions that contain a thermoplastic substance is studied in a wide range of electrical frequencies. The times of gelation and vitrification are calculated from the dielectric data and the onset of the phase separation is identified. The curing behavior established by dielectric spectroscopy is confirmed by viscometry and optical microscopy. During the phase separation, the morphology of the precipitating phase differs between samples depending on the chemical nature of the curing agent.     

Thermal behavior of blends based on a thermoplastic-modified epoxy resin with a crosslinking density variation

The thermal behavior of blends based on a polystyrene (PS) and several epoxy-amine systems where amino groups were provided by a monoamine (MA) and a diamine (DA) mixed in different proportions was investigated. This way, the crosslinking density of epoxy-amine polymer was controlled and continuously changed from a linear polymer (epoxy-MA) to a highly crosslinked polymer (epoxy-DA). The effect of the MA–DA proportion and PS modifier on the thermal stability, glass transition, and polymerization reaction was studied by differential scanning calorimetry and thermogravimetric analysis. The MA–DA ratio and modifier proportion did not affect the reaction heat but affected the reactivity. The thermal stability and glass transition temperature increased by increasing the DA proportion in the blend as a result of the higher degree of crosslinking. A study of miscibility of blends based on glass transitions was performed. The thermoplastic-modified materials generally showed two glass transitions with values close to the those of the pure materials, indicating that the mixtures were separated into phases.     

Re-entrant phase behavior for systems with competition between phase separation and self-assembly

In patchy particle systems where there is a competition between the self-assembly of finite clusters and liquid-vapor phase separation, re-entrant phase behavior can be observed, with the system passing from a monomeric vapor phase to a region of liquid-vapor phase coexistence and then to a vapor phase of clusters as the temperature is decreased at constant density. Here, we present a classical statistical mechanical approach to the determination of the complete phase diagram of such a system. We model the system as a van der Waals fluid, but one where the monomers can assemble into monodisperse clusters that have no attractive interactions with any of the other species. The resulting phase diagrams show a clear region of re-entrance. However, for the most physically reasonable parameter values of the model, this behavior is restricted to a certain range of density, with phase separation still persisting at high densities.     

Gelation of PEO-PLGA-PEO triblock copolymers induced by macroscopic phase separation

The gelation behavior of aqueous solutions of poly(ethylene oxide-b-(DL-lactic acid-co-glycolic acid)-b-ethylene oxide) (PEO-PLGA-PEO) triblock copolymer containing short hydrophilic PEO end blocks is investigated using dynamic light scattering, rheology, small-angle neutron scattering (SANS), and differential scanning calorimetry (DSC). For polymer concentrations between 5 and 35 wt %, four distinct regions of the turbidity change depending on temperature were observed. Interestingly, in the turbid solution region, gel phase is formed for polymer concentrations above 14 wt % and an extremely slow relaxation was detected. In fact, a power law, which takes into account the dynamics of percolation clusters, dominates the correlation function. In rheological measurements, the local maximum in G' is observed at around the temperature of maximum turbidity. We further found that G" > G' and G' is highly dependent on frequency at the gel state implying viscoelastic characteristics, which is quite different from general concepts of gels, typically formed by the micellar packing. SANS profiles showing multiple peaks in the sol state rather than in the gel state as well as a DSC exotherm at the temperature of gels can also serve as the evidence of different gel states. Based upon the experimental data obtained in the present study, a new gelation mechanism induced by the macroscopic phase separation of triblock copolymers containing short hydrophilic PEO end blocks such as PEO-PLGA-PEO is proposed. The effect of the type ofhydrophobic middle blocks on the gelation is also discussed.     

Reaction-induced phase separation in rubber-modified epoxy resin

The phase separation mechanism,and structure development during curing of epoxy with a novel liquid rubber-ZR were investigated by time-resolved light scattering,optical microscope and differential scanning calonmetry (DSC) The mixture loaded with curing agent was a single-phase system in the early stage of curing.When the cure reaction proceeded,phase separation took place via the spinodal decomposition induced by polymerization of epoxy resin.This was supported by the characteristic change of light scattering profile with curing time.Cure reaction plays an important role in the progress of phase separation.The bigger the cure reaction rate is,the longer periodic distance will be.The overall two-phase structure was basically locked in when the conversion approached 80% estimated by DSC,and finally the co-continuous two-phase structure was successfully obtained.     

Rheological behaviors and structural transitions in a polyethersulfone-modified epoxy system during phase separation

The rheological behaviors and gelation transitions in a polyethersulfone (PES)-modified epoxy system during phase separation were studied by rheometry, time-resolved light scattering, and differential scanning calorimetry. Two separate structural transitions in the curing process of the blend were identified as the first one because of phase separation and the second one related to cross-linking reaction of epoxy resin. Both the times of the two structural transition at different temperatures could be described well by the Arrhenius type equation. The complex viscosity exhibits an exponential growing process during phase separation at various temperatures, correlating to the light-scattering results. The exponential behavior of complex viscosity could be attributed to the viscoelastic flow of epoxy-rich escaping from PES-rich during phase separation process.     

Polymerization-induced phase separation in polyether-sulfone modified epoxy resin systems: effect of curing reaction mechanism

Polyethersulfone (PES)-modified epoxy systems with stepwise reaction were studied throughout the entire curing process by using optical microscopes, time-resolved light scattering (TRLS), and a rheolometry instrument compared with that of chainwise polymerization. The results suggested that the phase separation process is mainly controlled by the diffusion of epoxy oligomers for stepwise mechanism system and by that of epoxy monomers for chainwise mechanism system. In case of high PES content (SPES-20%) light-scattering results showed a viscoelastic phase separation and the characteristic relaxation time of phase separation can be described well by the WLF equation. However, in the case of low PES content (SPES-14%) secondary phase separation phenomenon was observed by Optical Microscope and further demonstrated by rheological study.     

Hierarchical porous polymer beads prepared by polymerization-induced phase separation and emulsion-template in a microfluidic device

Porous polymer beads（PPBs） containing hierarchical bimodal pore structure with gigapores and meso-macropores were prepared by polymerization-induced phase separation（PIPS） and emulsion-template technique in a glass capillary microfluidic device（GCMD）. Fabrication procedure involved the preparation of water-in-oil emulsion by emulsifying aqueous solution into the monomer solution that contains porogen. The emulsion was added into the GCMD to fabricate the（water-in-oil）-in-water double emulsion droplets. The flow rate of the carrier continuous phase strongly influenced the formation mechanism and size of droplets. Formation mechanism transformed from dripping to jetting and size of droplets decreased from 550 μm to 250 μm with the increase in flow rate of the carrier continuous phase. The prepared droplets were initiated for polymerization by on-line UV-irradiation to form PPBs. The meso-macropores in these beads were generated by PIPS because of the presence of porogen and gigapores obtained from the emulsion-template. The pore morphology and pore size distribution of the PPBs were investigated extensively by scanning electron microscopy and mercury intrusion porosimetry（MIP）. New pore morphology was formed at the edge of the beads different from traditional theory because of different osmolarities between the water phase of the emulsion and the carrier continuous phase. The morphology and proportion of bimodal pore structure can be tuned by changing the kind and amount of porogen.     

Preparation of epoxy monoliths via chemically induced phase separation

Epoxy porous monoliths were prepared from a commercial epoxy resin, D.E.R. 331, that cured with a tertiary amine, 2,4,6-tris-(dimethylaminomethyl) phenol, in the presence of a solvent, diisobutyl ketone (DIBK). During the curing process, polymers were formed and a decrease in its solubility in DIBK; the solution thus phase-separated, usually referred to as chemically induced phase separation. The phase separation formed interconnected polymer-poor phase that then became interconnected pores after the removal of DIBK. By varying the content of DIBK from 32 to 40 vol.%, epoxy monoliths with interconnected pores were prepared, with surface pore size ranging from 0.20 to 2.33 μm, overall porosity from 0.41 to 0.60, and ethanol permeability from 10 to 4,717 L/(m²?h^?1?bar^?1). The glass transition temperatures of the epoxy monoliths, measured with differential scanning calorimetry, were all higher than 100 °C, and temperatures of 5 % weight loss, analyzed by thermal gravimetry, were higher than 350 °C, evidencing the monoliths’ high thermal stability. Also, the monolith morphology was found to be strongly related to the reaction mechanism of polymerization. The results indicate that the mechanism of chain initiation and propagation associated with the tertiary amine can effectively form monoliths with interconnected pores, which cannot be easily prepared with a stepwise polymerization mechanism associated with using primary amine as the curing agent.     

Scaling behavior of nonisothermal phase separation

The phase separation process in a critical mixture of polydimethylsiloxane and polyethylmethylsiloxane (PDMS/PEMS, a system with an upper critical solution temperature) was investigated by time-resolved light scattering during continuous quenches from the one-phase into the two-phase region. Continuous quenches were realized by cooling ramps with different cooling rates kappa. Phase separation kinetics is studied by means of the temporal evolution of the scattering vector qm and the intensity Im at the scattering peak. The curves qm(t) for different cooling rates can be shifted onto a single mastercurve. The curves Im(t) show similar behavior. As shift factors, a characteristic length Lc and a characteristic time tc are introduced. Both characteristic quantities depend on the cooling rate through power laws: Lc approximately kappa(-delta) and tc approximately kappa(-rho). Scaling behavior in isothermal critical demixing is well known. There the temporal evolutions of qm and Im for different quench depths DeltaT can be scaled with the correlation length xi and the interdiffusion coefficient D, both depending on DeltaT through critical power laws. We show in this paper that the cooling rate scaling in nonisothermal demixing is a consequence of the quench depth scaling in the isothermal case. The exponents delta and rho are related to the critical exponents nu and nu* of xi and D, respectively. The structure growth during nonisothermal demixing can be described with a semiempirical model based on the hydrodynamic coarsening mechanism well known in the isothermal case. In very late stages of nonisothermal phase separation a secondary scattering maximum appears. This is due to secondary demixing. We explain the onset of secondary demixing by a competition between interdiffusion and coarsening.     

Study of micellar and phase separation behavior of mixed systems of triblock polymers

Cyclic voltammetric (CV) techniques have been employed to study the mixed micellar behavior of binary mixtures of triblock polymers (TBP) such as F127+P85, F127+P85, F88+P85, and F88+P123 using 2,2,6,6-tetramethyl-1-piperidinyloxy (Tempo) as an electroactive probe. Critical micellar concentration (cmc) has been obtained for pure triblock polymers and their mixed systems from the plots of peak current (i_p) variation versus the total concentration. Diffusion coefficients of the electroactive species have been determined from the Randles–Sevcik equation. The interaction parameter (β) for the mixed micelles was obtained from the regular solution theory. The values of β suggest that the synergism does exist especially with the F88+P123 system. Cloud point measurements have also been made on the binary mixtures of triblock polymers following similar mixing criteria. An effort has been made to correlate the micellar behavior and phase separation (cloud point) phenomenon. From the correlation, it can be concluded that in the systems studied, an increase in cmc increases the cloud point of mixed systems of triblock polymers.     

Phase separation behavior of epoxy resin modified with crosslinked rubber

Low molecular weight liquid rubber (ATBN = amine terminated butadiene acrylonitrile copolymer or CTBN = carboxyl terminated butadiene acrylonitrile copolymer)–DGEBA (diglycidyl ether of bisphenol A) blends indicated upper critical solution temperature (UCST) behavior. The phase separation behavior of the neat and crosslinked rubber (ATBN, CTBN)–epoxy blends was analyzed by a laser light scattering experiment. Lauryl peroxide (LPO) was employed to crosslink the rubber during the initial annealing stage. The onset point of the phase separation in the crosslinked ATBN–epoxy system occurred later than in the case of the neat ATBN–epoxy system. However, the onset point of the phase separation process started earlier in the case of the crosslinked CTBN–epoxy system. The domain correlation length of the crosslinked rubber-added system was smaller than that of the neat rubber-added system.