Polymer/boron nitride nanosheet composite with high thermal conductivity and sufficient dielectric strength

An efficient method was reported to fabricate boron nitride (BN) nanosheets using a sonication–centrifugation technique in DMF solvent. Then non‐covalent functionalization and covalent functionalization of BN nanosheets were performed by octadecylamine (ODA) and hyperbranched aromatic polyamide (HBP), respectively. Then, three different types of epoxy composites were fabricated by incorporation of BN nanosheets, BN‐ODA, and BN‐HBP. Among all three epoxy composites, the thermal conductivity and dielectric strength of epoxy composites using BN‐HBP nanosheets display the highest value, efficiently enhancing to 9.81 W/m K at 50 vol% and 34.8 kV/mm at 2.7 vol% (increase by 4057% and 9.4% compared with the neat epoxy), respectively. The significantly improved thermal conductivity and dielectric strength are attributed to the large surface area, which increases the contact area between nanosheets and nanosheets, as well as enhancement of the interfacial interaction between nanosheets and epoxy matrix. Copyright © 2015 John Wiley & Sons, Ltd.     

Improved mechanical properties of epoxy‐based composites with hyperbranched polymer grafting glass‐fiber

A glass‐fiber, grafted by hyperbranched polymer with hydroxyl group (GF‐HBPH), reinforced epoxy‐based composite was evaluated for mechanical properties and compared with the neat epoxy and silanized glass‐fiber, GF‐APS. The epoxy/GF‐HBPH composites were studied by attenuated total internal reflectance infrared spectroscopy, ¹H nuclear magnetic resonance spectroscopy, thermal gravimetric analysis, mechanical properties analysis, and field emission‐scanning electron microscopy. The results showed that the incorporation of GF‐HBPH could simultaneously enhance the mechanical properties of the epoxy composites. Field emission‐scanning electron microscopy images of the fracture surfaces of the test specimens were used to support the results and conclusions. Copyright © 2016 John Wiley & Sons, Ltd.     

Thermally conductive and electrically insulative nanocomposites based on hyperbranched epoxy and nano‐Al2O3 particles modified epoxy resin

Novel epoxy nanocomposites based on a diglycidyl ether of bisphenol A (DGEBA) epoxy, an epoxy functionalized hyperbranched polymer (HTTE) and nano‐Al₂O₃ were synthesized with the aim of determining the effect of the nano‐Al₂O₃ particles and HTTE on the structure and properties of epoxy nanocomposites. The mechanical properties, thermal conductivity, bulk resistivity, and thermal stability of the nano‐Al₂O₃/HTTE/DGEBA ternary composites were evaluated and compared with the corresponding matrix. The improvement in impact properties of these nanocomposites was explained in terms of fracture surface analysis by SEM. The results indicate that the incorporation of nanoparticles and hyperbranched epoxy effectively improved the toughness of epoxy composites without sacrificing thermal conductivity and bulk resistivity compared to the neat epoxy and Al₂O₃/DGEBA, obtaining a well dispersion of nanoparticles in epoxy matrix and solving the drawbacks for single fillers filled epoxy nanocomposite. Copyright © 2010 John Wiley & Sons, Ltd.     

Preparation of high thermal conductive aluminum nitride/cyanate ester nanocomposite using a new macromolecular coupling agent

Novel glycidyl methacrylate–butyl acrylate–maleic anhydride (GBM) terpolymers with different molecular weights were synthesized by radical polymerization and characterized using fourier transform infrared, nuclear magnetic resonance (¹H‐NMR and ¹³ C‐NMR), and gel permeation chromatography. Each GBM terpolymer was used to modify aluminum nitride (AlN), and the modified AlN, coded as AlN(GBM), was added to 2,2′‐bis(4‐cyanatophenyl)isopropylidene (CE) resin for preparing composites. Composites based on original AlN or γ‐(2,3‐epoxypropoxy)propyltrimethoxysilane‐modified AlN (AlN(K)) were also prepared for comparison. Although GBM and γ‐(2,3‐epoxypropoxy)propyltrimethoxysilane have similar reactive groups, the results indicate that GBM shows more attractive integrated advantages, reflected by the fact that CE/AlN(GBM) composites have better thermal stability, higher thermal conductivity, and higher glass transition temperature than those of CE/AlN(K). These properties result from better dispersion of fillers, improved interfacial adhesion between fillers and CE resin, and increased cross‐linking density. This study demonstrates that the nature of the coupling agents is an important factor to develop high performance composites for cutting‐edge industries. Copyright © 2011 John Wiley & Sons, Ltd.     

Thermal properties and moisture absorption of nanofillers‐filled epoxy composite thin film for electronic application

This current study aimed to enhance the thermal conductivity of thin film composites without compromising other polymer qualities. The effect of adding high thermal conductivity nanoparticles on the thermal properties and moisture absorption of thin film epoxy composites was investigated. Three types of fillers in nanosize with high thermal conductivity properties, boron nitride (BN), synthetic diamond (SD), and silicon nitride (Si₃N₄) were studied. SN was later used as an abbreviation for Si₃N₄. The contents of fillers varied between 0 and 2 vol.%. An epoxy nanocomposite solution filled with high thermal conductivity fillers was spun at 1500–2000 rpm to produce thin film 40–60 µm thick. The effects of the fillers on thermal properties and moisture absorption were studied. The addition of 2 vol.% SD produced the largest improvement with 78% increment in thermal conductivity compared with the unfilled epoxy. SD‐filled epoxy thin film also showed good thermal stability with the lowest coefficients of thermal expansion, 19 and 124 ppm, before and after T_g, respectively, which are much lower compared with SN‐filled and BN‐filled epoxy thin film composites. However the SD‐filled epoxy film has its drawback as it absorbs more moisture compared with BN‐filled and SN‐filled epoxy film. Copyright © 2012 John Wiley & Sons, Ltd.     

Surface modification of carbon fiber for improving the interfacial adhesion between carbon fiber and polymer matrix

In this study, the reinforcing mechanism of amine functionalized on carbon fibers (CFs) has been precisely discussed, and the differences between aliphatic and aromatic compounds have been illustrated. Polyacrylonitrile‐based CFs were functionalized with ethylenediamine, 4,4‐diaminodiphenyl sulphone, and p‐aminobenzoic acid (PAB), and CF‐reinforced epoxy composites were prepared. The structural and surface characteristics of the functionalized CFs were investigated using X‐ray photoelectron spectroscopy (XPS), Fourier transform infrared spectroscopy (FT‐IR), and scanning electron microscopy (SEM). Mechanical properties in terms of tensile and flexural strengths and moduli were studied. The FT‐IR results confirm the success in bonding amines on the CF surface. After treatment of CFs, the oxygen and nitrogen contents as well as the N/C ratio showed an increase. XPS results provided evidence of the chemical reaction during functionalization, rather than being physically coated on the CF surface. Chemical modification of CF with diamines led to considerable enhancement in compatibility of CF filaments and epoxy resin, and remarkable improvements were seen in both tensile and flexural properties of the reinforced composites. SEM micrographs also confirmed the improvement of interface adhesion between the modified CFs and epoxy matrix. Finally, it can be concluded that PAB is a promising candidate to functionalize CF in order to improve interfacial properties of CF/epoxy composites. Copyright © 2015 John Wiley & Sons, Ltd.     

Effect of AlN content on the performance of brominated epoxy resin for printed circuit board substrate

Polymer matrix composites, based on brominated epoxy, a type of material widely used in printed circuit boards (PCBs), as matrix and AlN particle as filler were prepared. The influences of AlN content on the mechanical, thermal, and electrical properties of the composites were investigated by uniaxial tensile test, TMA, thermal conductivity measurement, DMA, and dielectric properties measurement. It was found that the properties of composites monotonically varied with AlN content except that maximum tensile strength and strain of composites corresponded to a filler content of 10 wt %. The results of DMA also showed the AlN reinforcement was more pronounced above T_g, and the peak area of tan δ versus T curves decreased with AlN content, which implied the damping capacity of the composite gradually decreased. The increase in T_g and decrease in damping were probably due to strong interaction between the AlN and epoxy matrix inhibiting the mobility of the epoxy chain. In addition, different theoretical models reported in the literature were used to predict the E, CTE, k, and D_k, and compared with the experimental data. Finally, suitable models were recommended in the present materials system. For the significant improvement of performance of epoxy, we can conclude that these composite materials may be promising for PCB substrate. © 2007 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 45: 1662–1674, 2007     

Effects of noncovalently functionalized multiwalled carbon nanotube with hyperbranched polyesters on mechanical properties of epoxy composites

In order to improve the dispersibility and interface properties of multi-walled carbon nanotubes (MWCNTs) in epoxy resin (EP), aromatic hyperbranched polyesters with terminal carboxyl (HBP) and aromatic hyperbranched polyesters with terminal amino groups (HBPN) were used for noncovalent functionalization of MWCNTs. Epoxy composites reinforced by different types of MWCNT were prepared. The effects of noncovalent functionalization of MWCNTs on the dispersibility, wettability, interface properties and mechanical properties of epoxy composites were investigated. The results show that the dispersibility and wettability of MWCNTs are significantly improved after noncovalent functionalization. A large number of terminal primary amines (NH₂) on noncovalently functionalized MWCNT with HBPN (HBPN-MWCNT) form covalent bonds with EP matrix, and thus the interfacial adhesion is enhanced significantly, resulting in high load transfer efficiency and substantial increase in mechanical properties. The interface with covalent bonding formed between the flexible hyperbranched polyester layer on the surface of HBPN-MWCNT and the EP matrix promotes plastic deformation of the surrounding EP matrix. The toughening mechanisms of HBPN-MWCNT are MWCNT pull-out and a large amount of plastic deformation of the surrounding EP matrix.     

Improved mechanical properties of epoxy composites reinforced with surface‐treated UHMWPE fibers

The surface treatment of ultra‐high molecular weight polyethylene fiber using potassium permanganate and the mechanical properties of its epoxy composites were studied. After treatment, many changes were happened in the fiber surface: more O‐containing groups (―OH, ―C═O, and ―C―O groups), drastically decreased contact angles with water and ethylene glycol, slightly increased melting point and crystallinity, and formed cracks. Different contents (0.1–0.5 wt%) ultra‐high molecular weight polyethylene fibers/epoxy composites were prepared. The results indicated that the surface treatment decreased the tensile strength of epoxy composites, but increased the bending strength. When the fiber content was 0.3 wt%, the above properties reached the maximum. At the same fiber content, the interlaminar shear strength of the composites was increased by 26.6% up to the as‐received fiber composites. Dynamic mechanical analysis of the composites suggested the storage modulus and tanδ were decreased due to the surface treatment. Fractured surface analysis confirmed that the potassium permanganate treatment was effective in improving the interface interaction.     

Synthesis and properties of iron oxide coated carbon nanotubes hybrid materials and their use in epoxy coatings

Multi‐walled carbon nanotubes (MWCNTs) were acidified with nitration mixture, and the Fe₂O₃‐MWCNTs (iron oxide coated multi‐walled carbon nanotubes) hybrid material via sol‐gel method then verified the results through scanning electron microscope, X‐ray diffraction, and thermal gravimetric analysis. We modified the hybrid material with silane coupling agent (KH560), Fe₂O₃‐MWCNTs/epoxy, MWCNTs/epoxy composites coating, and the pure epoxy coatings were respectively prepared. The properties of the composite coatings were tested through the electrochemical workstation (electrochemical impedance spectroscopy), shock experiments, and thermal gravimetric analysis. Finally, we used scanning electron microscope to observe the surface conditions of the coatings. The results show that Fe₂O₃‐MWCNTs have good dispersion in the epoxy resin, and the Fe₂O₃‐MWCNTs/epoxy composite coatings have enhanced mechanical properties and corrosion resistance. Copyright © 2015 John Wiley & Sons, Ltd.     

Alkoxysilane functionalized polycaprolactone/polysiloxane modified epoxy resin through sol-gel process

Incorporating elastic polysiloxane and/or an inorganic silica network in epoxy resin could result in the enhancement of physico-chemical properties due to the existence of Si-O bonds. To improve the compatibility between polysiloxane and epoxy matrices and intensively strengthen the properties of the modified system, here polysiloxane was introduced into epoxy resin through compatibilizing epoxy-immiscible polysiloxane with epoxy-miscible polycaprolactone segments via a sol-gel process. To fulfill the process, a blend containing alkoxysilane-functionalized polycaprolactone/polydimethylsiloxane (PCS-2Si) was firstly synthesized using direct nucleophilic addition between -OH groups of polydiol and -NCO of a silane. And then a series of modified epoxy resins were prepared in different epoxy/PCS-2Si weight ratios. All the modified composites were characterized by conventional methods, and their morphological, thermal degradation and surface properties were studied. The results showed that increasing the PCS-2Si content caused the changes of miscibility between epoxy and polysiloxane. Also, the thermal stability of the modified composites was greatly improved. As for the temperature value at 5% weight loss, it reached to 308.5 °C for the composite containing 50-60% (wt%) PCS-2Si, over 150 °C higher than that for neat amine-cured epoxy resin. Similarly, the modified composites showed good hydrophobicity. The improvement of these properties came from the improved interaction between PCS-2Si and epoxy, the forming of Si-O-Si network and the enrichment of siloxane chains on the surface of films. Therefore, it is believed that this modified epoxy appears promising as new high performance and highly functional materials.     

Modification of poly(benzimidazole‐amide) nanocomposites by the incorporation of amine‐functionalized ZnO nanoparticles: Thermal and morphological characterization

Fabrication, characterization, and properties of novel poly(benzimidazole‐amide)/functionalized ZnO nanocomposites (PBIA/APS‐ZnO NCs) were investigated. At first, an aromatic PBA containing 3 imidazole units per repeat unit was synthesized by direct polycondensation of 1,3‐bis(5‐carboxylic acid‐2‐benzimidazole)benzene (BCAB) with 5‐(2‐benzimidazole)‐1,3‐phenylenediamine (DAMI) with good yield as a polymeric matrix. The periphery of zinc oxide nanoparticles (ZnO NPs) was modified with 3‐aminopropyltriethoxysilane (APS) to have a better dispersion NPs and enhancing interactions between nanoparticles and PBIA matrix. Different percentages of functionalized NPs (0, 4, 8, and 12 wt.%) were then embedded in PBA matrix through ultrasonic irradiation technique. Fourier transform infrared and thermo‐gravimetric analysis (TGA) confirmed that APS was successfully attached on the ZnO NP surface. The obtained NCs were characterized by means of Fourier transform infrared, X‐ray diffraction, scanning electron microscopy, and TGA. The TGA of the PBIA/APS‐ZnO NCs showed the enhancement in the thermal stability in comparison with the neat PBIA and that this increase is higher when the NP content increases. Scanning electron microscopy analyses of NCs revealed that the dispersion of APS‐ZnO NPs was uniformly done in the PBIA matrix.     

Effect of Pickering emulsion on the mechanical performances and fracture toughness of epoxy composites

The improvement of mechanical properties and toughness of nanoparticles for epoxy composites was mostly dependent on the disperse state of nanoparticles in epoxy matrices. When the content of nanoparticles was higher than a threshold value, it was easy to aggregate and then affect the improvement effect. Pickering emulsion was prepared using SiO₂ nanoparticles as emulsifier and functional monomer as oil phase. The influence of Pickering emulsion on the curing process was investigated. The effect of Pickering emulsion on the mechanical properties, toughness, and glass transition temperature (Tg) was studied. Impact and tensile fracture surface were observed by scanning electron microscopy (SEM). Results from differential scanning calorimeter (DSC), tensile, impact, and fracture toughness tests are provided. The results indicated that the introduction of Pickering emulsion can eliminate the residual stress and accelerate curing reaction. Epoxy composites were capable of increasing tensile strength by up to 29.9%, impact strength of three‐fold, fracture toughness of 35%, and Tg of 20.7°C in comparison with the reference sample. SEM images showed that SiO₂ nanoparticles exhibit a good dispersion in epoxy matrix. The increases in mechanical properties, toughness, and Tg of epoxy composites were attributed to the “Second Phase Toughness” mechanism.     

Hyperbranched polytriazine grafted reduced graphene oxide and its application

In this article, cyanuric chloride (CC) and hexamethylenediamine (HMD) as raw material, the grafting of hyperbranched polytriazine onto reduced graphene oxide surface (HBP‐RGO) was achieved by the repeated nucleophilic substitution between chlorine groups of CC and amino groups of HMD, respectively. The Fourier transform infrared, X‐ray photoelectron spectroscopic, Raman, transmission electron microscopic, thermogravimetric, and atomic force microscopic analysis showed that HBP‐RGO had been successfully prepared and the HBP had a dendritic structure on the surface of RGO. And then, the HBP‐RGO was added into polystyrene (PS) and the HBP‐RGO/PS composite was prepared by solution mixing. The micro‐morphology, thermal stability, and electrical conductivity of RGO/PS and HBP‐RGO/PS composites were characterized and compared. The scanning electron microscopic analysis showed that the HBP‐RGO can uniformly disperse in PS. Meanwhile, the HBP‐RGO/PS composite showed good thermal stability and electrical conductivity, the percolation threshold of the composites is low as 0.32 vol %. © 2015 Wiley Periodicals, Inc. J. Polym. Sci., Part A: Polym. Chem. 2015 , 53, 2132–2140     

Effect of new hyperbranched polyester of varying generations on toughening of epoxy resin through interpenetrating polymer networks using urethane linkages

In this study, a previously unreported methodology is attempted to improve the inherent brittleness in diglycidyl ether of bisphenol-A based epoxy resin using hyperbranched polymers as toughening agents. Four different hyperbranched polyesters (HBPs) with increasing generations (1–4, denoted as HBP-G1 to HBP-G4) were synthesized by reacting calculated amount of dipentaerythritol (used as a core) and dimethylol propionic acid (AB₂ type monomer) through pseudo one-step melt polycondensation method. The newly synthesized HBPs were characterized using spectral, thermal and physical measurements, which confirmed the formation of highly branched structure and decreasing thermal stability with increasing HBP generations. Further, toughening of the epoxy resin is carried out by reacting each generation of the HBP with epoxy using hexamethylene diisocyanate as an intermediate linkage resulting in the formation of HBP-Polyurethane/Epoxy-g-Interpenetrating Polymer Networks (HBP-PU/EP-g-IPNs). A linear polyol-PU/EP-g-IPN is also synthesized for the purpose of comparison. It is found that the HBP modified epoxy samples exhibited higher toughness in comparison to that of neat epoxy and linear polyol based epoxy samples. On the other hand, flexural properties, thermal stability and glass transition temperature of the modified samples is lower than neat epoxy sample due to the existence of flexible urethane linkages and decrease in the cross-linking density of epoxy matrix. The toughening characteristics exhibited by the HBPs are corroborated from the existence of heterogeneous morphology using SEM data.     

Surface‐modified hydroxyapatite linked by L‐lactic acid oligomer in the absence of catalyst

A new surface modification method of hydroxyapatite nanoparticles (n‐HA) by surface grafting reaction of L ‐lactic acid oligomer with carboxyl terminal (LAc oligomer) in the absence of any catalyst was developed. The LAc oligomer with a certain molecular weight was directly synthesized by condensation of L ‐lactic acid. Surface‐modified HA nanoparticles (p‐HA) were attested by Fourier transformation infrared spectroscopy, ³¹P MAS‐NMR, and thermal gravimetric analysis (TGA). The results showed that LAc oligomer could be grafted onto the n‐HA surface by forming a Ca carboxylate bond. The grafting amount of LAc oligomer was about 13.3 wt %. The p‐HA/PLLA composites showed good mechanical properties and uniform microstructure. The tensile strength and modulus of the p‐HA/PLLA composite containing 15 wt % of p‐HA were 68.7 MPa and 2.1 GPa, respectively, while those of the n‐HA/PLLA composites were 43 MPa and 1.6 GPa, respectively. The p‐HA/PLLA composites had better thermal stability than n‐HA/PLLA composites and neat PLLA had, as determined by isothermal TGA. The hydrolytic degradation behavior of the composites in phosphate buffered saline (PBS, pH 7.4) was investigated. The p‐HA/PLLA composites lost their mechanical properties more slowly than did n‐HA/PLLA composites in PBS because of their reinforced adhesion between the HA filler and PLLA matrix. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 5177–5185, 2005     

Effect of Chemical Treatment and Fiber Loading on Mechanical Properties of Borassus (Toddy Palm) Fiber/Epoxy Composites

The aim of the present study was to investigate and compare the mechanical properties of untreated and chemically modified Borassus fiber–reinforced epoxy composites. Composites were prepared by the hand lay-up process by reinforcing Borassus fibers with epoxy matrix. To improve the fiber-matrix adhesion properties, alkali (NaOH) and alkali combined with silane (3-aminopropyltriethoxysilane) treatment of the fiber surface was carried out. Examinations through Fourier transform-infrared spectroscopy and scanning electron microscopy (SEM) were conducted to investigate the structural and physical properties of the Borassus fibers. Tensile properties such as modulus and strength of the composites made with chemically modified and untreated Borassus fibers were studied using a universal testing machine. Based on the experimental results, it was found that the tensile properties of the Borassus-reinforced epoxy composites were significantly improved as compared with the neat epoxy. It was also found that the fiber treated with a combination of alkali and silane exhibited superior mechanical properties to alkali-treated and untreated fiber composites. The nature of the fiber/matrix interface was examined through SEM of cryo-fractured samples. Chemical resistance of composites was also found to be improved with chemically modified fiber composites.     

Novel toughened automotive clearcoats modified by a polyester‐amide hyperbranched polymer: structural and mechanical aspects

The present work attempts to study the mechanical properties and toughness behavior of a typical acrylic melamine clearcoat modified by a polyester‐amide hyperbranched polymer (HBP). Formulations were such that 0, 5, 10, 25 and 50% (molar percent) of total acrylic hydroxyl groups were stoichiometrically substituted by those of HBP. Bulk and surface of the clearcoats were studied by various mechanical techniques including hardness, tensile, dynamic mechanical thermal analysis (DMTA), nano‐indentation and scratch tests. In addition a scanning electron microscope (SEM) was utilized to observe the morphology of the fractured films. The bulk mechanical properties showed that a low loading (5 molar %) of HBP was sufficient to considerably increase the bulk hardness, cross‐linking density and toughness. DMTA and SEM results proved the occurrence of a single‐phase blend and that the shear deformation was the main toughening mechanism of HBP modified clearcoats. In general, it was revealed that the HBP not only could act as an excellent compatible toughening agent, but also maintained the clarity of the clearcoat and increased its scratch resistance. Copyright © 2013 John Wiley & Sons, Ltd.     

ATR‐FTIR Kretschmann spectroscopy for interfacial studies of a hidden aluminum surface coated with a silane film and epoxy I. Characterization by IRRAS and ATR‐FTIR

Interfacial analysis is essential in many areas of interest, for instance within the ongoing research on environmentally friendly pretreatments of metal surfaces. While studies of the hidden interface between a metal and polymer top‐coat are of great importance, properties of a surface confined between two media are difficult to analyze in detail. Within the two parts of this study, ATR‐FTIR spectroscopy in the Kretschmann geometry is employed as the main analytical tool to study the interface between a thermo‐cured epoxy and aluminum pretreated with a silane film. The technique requires model systems based on thin metal films, but in contrast to most analytical techniques it permits the analysis of a hidden interface. Initial characterization of the silane film formed from a pH‐regulated γ‐APS and BTSE solution was conducted by both ATR‐FTIR Kretschmann and IRRAS spectroscopy. Absorption bands were obtained at 1250–900 cm^?1, assigned to Si? O functionalities, and at ～1570 and ～1410 cm^?1 assigned to acetate existing as a counter‐ion to γ‐APS. After application of the epoxy film, interfacial alterations were detected upon thermal curing including the densification of the epoxy film, the dehydration of aluminum and the formation of molecular epoxy reaction products. Few alterations could be assigned to the silane film. Calculated spectra derived from optical data can verify experimental results and aid data interpretation, and effects of metal oxidation of aluminum were confirmed by introducing gold as an additional substrate. The results showed that ATR‐FTIR Kretschmann spectroscopy is clearly a valuable tool for the study of hidden interfaces of stratified media. Copyright © 2011 John Wiley & Sons, Ltd.     

Phase separation,porous structure,and cure kinetics in aliphatic epoxy resin containing hyperbranched polyester

Thermosetting blends of an aliphatic epoxy resin and a hydroxyl‐functionalized hyperbranched polymer (HBP), aliphatic hyperbranched polyester Boltorn H40, were prepared using 4,4′‐diaminodiphenylmethane (DDM) as the curing agent. The phase behavior and morphology of the DDM‐cured epoxy/HBP blends with HBP content up to 40 wt % were investigated by differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), and scanning electron microscopy (SEM). The cured epoxy/HBP blends are immiscible and exhibit two separate glass transitions, as revealed by DMA. The SEM observation showed that there exist two phases in the cured blends, which is an epoxy‐rich phase and an HBP‐rich phase, which is responsible for the two separate glass transitions. The phase morphology was observed to be dependent on the blend composition. For the blends with HBP content up to 10 wt %, discrete HBP domains are dispersed in the continuous cured epoxy matrix, whereas the cured blend with 40 wt % HBP exhibits a combined morphology of connected globules and bicontinuous phase structure. Porous epoxy thermosets with continuous open structures on the order of 100–300 nm were formed after the HBP‐rich phase was extracted with solvent from the cured blend with 40 wt % HBP. The DSC study showed that the curing rate is not obviously affected in the epoxy/HBP blends with HBP content up to 40 wt %. The activation energy values obtained are not remarkably changed in the blends; the addition of HBP to epoxy resin thus does not change the mechanism of cure reaction of epoxy resin with DDM. © 2006 Wiley Periodicals, Inc. J Polym Sci Part B: Polym Phys 44: 889–899, 2006