Epoxy-modified, unsaturated polyester hybrid networks

Hybrid polymer networks (HPNs) based on unsaturated polyester resin (UPR) and epoxy resins were synthesized by reactive blending. The epoxy resins used were epoxidised phenolic novolac (EPN), epoxidised cresol novolac (ECN) and diglycidyl ether of bisphenol A (DGEBA). Epoxy novolacs were prepared by glycidylation of the novolacs using epichlorohydrin. The physical, mechanical, and thermal properties of the cured blends were compared with those of the control resin. Epoxy resins show good miscibility and compatibility with the UPR resin on blending and the co-cured resin showed substantial improvement in the toughness and impact resistance. Considerable enhancement of tensile strength and toughness are noticed at very low loading of EPN. Thermogravimetric analysis (TGA), dynamic mechanical analysis (DMA) and differential scanning calorimetry (DSC) were employed to study the thermal properties of the toughened resin. The EPN/UPR blends showed substantial improvement in thermal stability as evident from TGA and damping data. The fracture behaviour was corroborated by scanning electron microscopy (SEM). The performance of EPN is found to be superior to other epoxy resins.     

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     

Flame retardant polycyanurate thermosets from the cyanate esters of triphenylphosphine oxide

Three cyanate esters containing phosphorus are synthesized in good overall yields starting from bromoanisoles. Di‐ and tricyanates with meta configuration are most stable while para is less so. The para dicyanate ester isomer is particularly affected by water from the atmosphere. The meta dicyanate ester 2 has good thermal properties with glass transition at 268 °C and char yield of 65% in air at 600 °C. All three phosphorus‐containing cyanate esters are low flammability in an open flame. They make highly combustible cyanate esters resins less flammable simply by blending. Mixing 10 wt% dicyanate ester 2 into bisphenol A or E dicyanate esters makes them rate V‐0. Published 2018.^† J. Polym. Sci., Part A: Polym. Chem. 2018 , 56, 1100–1110     

A study on the kinetics of condensation reaction of cardanol and formaldehyde,part I

Novolac resins having cardanol‐to‐formaldehyde mole ratios of 1:0.4, 1:0.5, and 1:0.6 were prepared by using aromatic sulphonic acid as the catalyst at four different temperatures ranging between 90°C and 120°C, with an interval of 10°C. Free formaldehyde and free phenol contents were determined at regular time intervals to check the completion of the reaction. The synthesized novolacs were characterized by Fourier‐transform infrared spectroscopic analysis, nuclear magnetic resonance, and gel permeation chromatography. The reaction between cardanol and formaldehyde was found to follow second‐order kinetics. The overall rate constant (k) increased with the increase of temperature. On the basis of the value of k, various other activation parameters such as activation energy (E_a), change in enthalpy (ΔH), entropy (ΔS), and free energy (ΔG) of the reaction were also evaluated. It was found that the condensation reaction of cardanol and formaldehyde with aromatic sulphonic acid was nonspontaneous and irreversible. © 2009 Wiley Periodicals, Inc. Int J Chem Kinet 41: 559–572, 2009     

p-Nitrophenylcyanate—An efficient,convenient, and Nonhazardous substitute for cyanogen bromide as an activating agent for sepharose

The reaction of aromatic cyanates with agarose-based resins was investigated. Phenylcyanate yielded aliphatic-aromatic imidocarbonates as the major product, whereasp-nitrophenylcyanate acted as a cyanylating agent, yielding mainly cyanate esters on the resin. Such cyanate esters were recently also shown to be the active group on cyanogen bromide-activated Sepharose; hence, the stable and nonvolatilep-nitrophenylcyanate was found to be a very convenient substitute for the highly hazardous cyanogen bromide. Activations withp-nitrophenylcyanate could be done safely outside a hood. Employing triethylamine instead of the commonly used inorganic bases, an optimized activation procedure was developed that is about 10 times more efficient than conventional cyanogen bromide activation. Since both cyanogen bromide andp-nitrophenylcyanate-activated resins contain cyanate esters as active groups, the coupling of ligands proceeded in an identical fashion in both cases.     

Alkaline hydrolysis of cured phenol–formaldehyde resins at high temperatures

Hydrolysis of cured phenolic resin, either straight or oil- or epoxy-modified, in dilute caustic at 280–320°C, gives novolac resins in 70–80% recovery. Infrared analysis indicates these novolacs have the same composition as conventional novolacs made by the acid-catalyzed phenol–formaldehyde condensation. Like the conventional novolacs, these recovered resins are soluble in oxygen-containing solvents and form crosslinked infusible thermoset materials when heated with 10% hexamethylenetetramine. Molecular weights of the recovered novolacs, determined by high-pressure liquid chromatography, are dependent on both time and temperature of the hydrolysis. The weight-average molecular weight varied from 270 to 770. The Lowry index values indicate that the molecular weight distribution is narrower for the recovered novolacs than that normally obtained for conventional novolacs. The recovered novolacs have higher melting temperatures than the corresponding commercial novolacs. This is believed to be due to the lower free phenol content of the recovered novolacs.     

High performance toughened cyanate ester resin with low injection temperature for RTM process

A high‐performance modified cyanate resin system with low injection temperature for fabricating advanced composites via resin transfer molding (RTM) was developed, which was made of bisphenol A dicyanate ester (BADCy) and diallyl phthalate (DAP). The processing characteristics, mechanical, and thermal properties of the resin were studied, and the effect of the content of DAP on the processing and performance parameters was discussed. The results show that the processing properties of the modified cyanate system are dependent on the content of DAP. All the formulations studied in this paper have good processing characteristics; their injection temperatures are between 30 and 40°C and the pot life is about 20 hr at 50°C. The cured resins exhibited good thermal stability, excellent toughness, and good hot–wet resistance, suggesting that the toughened cyanate resin is a potential high‐performance RTM matrix for advanced composites. Copyright © 2008 John Wiley & Sons, Ltd.     

Synthesis and characterization of novel low‐dielectric cyanate esters

For the purpose of increasing the mobility of residual bisphenol A dicyanate ester (BADCY) during the final stage of curing and achieving a complete reaction of cyanate groups, a small quantity of monofunctional phenol was added to BADCY to form an imidocarbonate, or a small quantity of monofunctional cyanate esters was added to form cyanate ester copolymers. The proposed structures were confirmed with Fourier transform infrared, elemental analysis, mass spectrometry, and NMR spectroscopy. The thermal properties of the cured cyanate esters were measured with dynamic mechanical analysis, thermogravimetric analysis, and dielectric analysis. These data were compared with those for the cured BADCY resin. The cured modified cyanate esters exhibited a lower dielectric constant, a lower dissipation factor, and lower moisture absorption than the cured BADCY system. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 2589–2600, 2004     

Synthesis and properties of a cyanate ester containing dicyclopentadiene(II)

A 2,6‐dimethyl phenol‐dicyclopentadiene novolac (DCPDNO) was synthesized from dicyclopentadiene and 2,6‐dimethyl phenol, and the resultant DCPDNO was reacted with cyanogen bromide into 2,6‐dimethyl phenol‐dicyclopentadiene cyanate ester (DCPDCY). The structures of the novolac and cyanate ester were confirmed with Fourier transform infrared spectroscopy, elemental analysis, mass spectrometry (MS), and nuclear magnetic resonance. For the purpose of increasing the mobility of residual DCPDCY during the final stage of curing and achieving a complete reaction of cyanate groups, a small quantity of a monofunctional cyanate ester, 4‐tert‐butylphenol cyanate ester (4TPCY), was added to DCPDCY to form the cyanate ester copolymer. The synthesized DCPDCY was then cured with 4TPCY at various molar ratios. The thermal properties of the cured cyanate ester resins were studied with dynamic mechanical analysis, dielectric analysis, and thermogravimetric analysis. These data were compared with those of the commercial bisphenol A cyanate ester system. Compared with the bisphenol A cyanate ester system, the cured DCPDCY resins exhibited lower dielectric constants (2.52–2.67 at 1 GHz), dissipation factors (0.0054–0.0087 at 1 GHz), glass‐transition temperatures (261–273 °C), thermal stability (5% degradation temperature at 406–450 °C), thermal expansion coefficients (4.8–5.78 × 10^?5/°C before the glass‐transition temperature), and moisture absorption (0.8–1.1%). © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 671–681, 2005     

Thermal and water absorption properties of cyanate ester resins modified by fluoride‐containing and silicone‐containing components

In order to enhance the moisture resistance of cyanate ester resins, modifiers containing silicon or fluorine moieties were introduced. The curing behaviors of the obtained resins, as well as thermal, water absorption, and dielectric properties of all cured polymers, were investigated in detail. Results show that properties of fillers in polymer have great influence on the thermal property and of polymer. In all cases, modifier exhibited percolation threshold at 5 wt%. Compared with pristine cyanate ester resins (CE), when the methyl phenyl silicone resin B filler was added, the cured polymer exhibited water absorption as low as 0.39% and excellent thermal oxygen stability at 300°C. The introduction of silicon H improved thermal oxidative stability at 400°C without significant compromise in processability or mechanical properties.     

Thermal and physical properties of flame-retardant epoxy resins containing 2-(6-oxido-6H-dibenz〈c,e〉〈1,2〉oxaphosphorin-6-yl)-1,4-naphthalenediol and cured with dicyanate ester

2-(6-oxido-6H-dibenz(c,e)(1,2)oxaphosphorin-6-yl)-1,4-naphthalenediol (DOPONQ) was prepared by the addition reaction of 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) with 1,4-naphthoquinone. The phosphorus-containing diol (DOPONQ) was used as a reactive flame retardant by an advancement reaction with the diglycidyl ether of bisphenol-A epoxy (DGEBA) resin at various stoichiometric ratios. DOPONQ-containing advanced epoxy was separately cured with various dicyanate esters to form flame-retardant epoxy/cyanate ester systems. The effect of the phosphorus content and dicyanate ester structure on the curing characteristic, glass transition temperature, dimensional stability, thermal stability, flame retardancy, and dielectric property was studied and compared with that of the control advanced bisphenol-A epoxy system. The DOPONQ-containing epoxy/cyanate ester systems exhibited higher glass transition temperatures as well as better thermal dimensional and thermal degradation stabilities. The flame retardancy of the phosphorus-containing epoxy/dicyanate ester system increased with the phosphorus content, and a UL-94 V-0 rating could be achieved with a phosphorus content as low as 2.1%.     

Exploration of cardanol-based phenolated and epoxidized resins by size exclusion chromatography and MALDI mass spectrometry

Cardanol and cardanol derivatives are among the most important biobased materials currently investigated in green chemistry, as renewable and promising building blocks in lieu of traditional raw materials from non renewable resources, in particular owing to the olefinic linkages on the C15 alkyl side-chain. Despite the increasing interest they arouse, analytical chemistry dedicated to cardanol and associated resins has been rarely reported in the literature, found even poorer when dealing with chromatography and mass spectrometry. In this work, a thorough molecular characterization was conducted using matrix assisted laser desorption ionization (MALDI) mass spectrometry, size exclusion chromatography (SEC), and SEC–MALDI coupling to gain insights into the composition of phenolated, epoxidized, and epoxidized phenolated cardanol. A nomenclature was proposed to properly describe the numerous species found in these materials, while simulations of the unsaturation patterns and their comparison with the detected patterns in MALDI-MS gave useful details about the phenolation treatment expected to occur on the polyunsaturated C15 side chain. Finally, the SEC–MALDI off-line coupling allowed SEC peaks to be deconvoluted by mass spectrometry and MALDI artefacts related to matrix adduction to be pointed out.     

Studies on thermal and morphological properties of 1,1-bis(3-methyl-4-cyanatophenyl)cyclohexane-epoxy-bismaleimide matrices

A new cyanate ester monomer, 1,1-bis(3-methyl-4-cyanatophenyl)cyclohexane has been synthesized and characterized. Epoxy modified with 4, 8 and 12% (by weight) of cyanate ester were made using epoxy resin and 1,1-bis(3-methyl-4-cyanatophenyl)cyclohexane and cured by using diaminodiphenylmethane. The cyanate ester modified epoxy matrix systems were further modified with 4, 8 and 12% (by weight) of bismaleimide (N,N′-bismaleimido-4,4′-diphenylmethane). The formation of oxazolidinone and isocyanurate during cure reaction of epoxy and cyanate ester blend was confirmed by IR spectral studies. Bismaleimide-cyanate ester-epoxy matrices were characterized using differential scanning calorimetry (DSC), thermogravimetric analysis (TGA) and heat deflection temperature (HDT) analysis. Thermal studies indicate that the introduction of cyanate ester into epoxy resin improves the thermal degradation studies at the expense of glass transition temperature. Whereas the incorporation of bismaleimide into epoxy resin enhances the thermal properties according to its percentage content. However, the introduction of both cyanate ester and bismaleimide influences the thermal properties according to their percentage content. DSC thermogram of cyanate ester modified epoxy and bismaleimide modified epoxy show unimodel reaction exotherms. The thermal degradation temperature and heat distortion temperature of the cured bismaleimide modified epoxy and cyanate ester-epoxy systems increased with increasing bismaleimide content. The morphology of the bismaleimide modified epoxy and cyanate ester-epoxy systems were also studied by scanning electron microscopy. Copyright © 2003 John Wiley & Sons, Ltd.     

Inorganic esters of novolacs

Reaction of conventional novolacs with polyfunctional materials is known to yield crosslinked infusible products. Surprisingly, high proportions of polyfunctional phosphorus derivatives can be esterfied with o,o′-linked novolacs without encountering gelation. Soluble, fusible resins of high phosphate content, which possess improved flame retardance, are conveniently obtained. We attribute this result to the formation of cyclic esters in preference to crosslinking, as evidenced by the formation, in good yield, of the eight-membered heterocyclic compound C₂₇H₃₁O₄P from o,o′-methylenebis(p-tert-butylphenol) and phenyl phosphorodichloridate. Relatively large amounts of polyfunctional derivatives of boron and silicon can also be reacted with o,o′-linked novolacs, presumably in a similar manner. Novolacs partially reacted with phosphorus, boron, or silicon derivatives and retaining some phenolic hydroxyl cure readily with hexamethylenetetramine, yielding products exceptionally low in volatile loss at 400°C.     

Phosphorus Modified Cardanol: A Greener Route to Reduce VolaTile Organic Compounds and Impart Flame Retardant Properties to Alkyd Resin Coatings

Novel phosphorylated cardanol molecules based on phosphonate (PO₃CR) and phosphate (PO₄CR) functions were synthetized. Those molecules have two main actions which are described in this article: the reduction in volatile organic compounds (VOC) and the development of flame retardant (FR) properties conferred on alkyd resins used as coatings for wood specimen. Phosphorylated cardanol compounds have been successfully grafted by covalent bonds to alkyd resins thanks to an auto-oxidative reaction. The impact of the introduction of PO₃CR and PO₄CR on the film properties such as drying time and flexibility has been studied and the thermal and flame retardant properties through differential scanning calorimeter, thermogravimetric analysis and pyrolysis-combustion flow calorimeter. These studies underscored an increase in the thermal stability and FR properties of the alkyd resins. In the cone calorimeter test, the lowest pHRR was obtained with 3 wt% P of phosphate-cardanol and exhibited a value of 170 KW.m⁻², which represented a decrease of almost 46% compared to the PO_xCR-free alkyd resins. Moreover, a difference in the mode of action between phosphonate and phosphate compounds has been highlighted. The most effective coating which combined excellent FR properties and good coating properties has been obtained with 2 wt% P of phosphate-cardanol. Indeed, the film properties were closed to the PO_xCR-free alkyd resin and the pHRR decreased by 41% compared to the reference alkyd resin.     

Curing mechanism for phenol—formaldehyde resins

A pressure DTA method was used to study the curing of resins. The hardening of novolacs by hexamine was studied at pressures up to 5000 kg/cm². The application of the pressure DTA method to the thermal curing of some dioxymethylated para-substituted phenols indicates that the endothermic peak observed at about 75°C at ambient pressure is due to the superposition of two peaks due to melting of the substance and formation of ester bonds.     

Synthesis,characterization, and thermal studies of cardanol-based polyphosphate esters

Polyphosphate esters were synthesized from derivatives of cardanol phosphorodichloridateates and dihydric phenols by interfacial polycondensation using a phase transfer catalyst. The polymers were characterized by IR, ¹H-, ¹³C-, and ³¹P-NMR spectroscopy, and GPC. The thermal stability and thermal degradation kinetics of the polymers were determined by thermogravimetry. The flammability of the polymers was evaluated by limiting oxygen index values. © 1993 John Wiley & Sons, Inc.     

Thermal behaviour of cardanol-based benzoxazines

A novel benzoxazine monomer (Bz-C) based on agrochemical renewable resource—cardanol (by-product of cashew nut tree, Anacardium occidentale) was synthesized. Bz-C, a liquid monomer, was used as reactive diluent for the solventless synthesis of bisphenol-A benzoxazine monomer (Bz-A). Benzoxazine monomer based on cardanol and bisphenol-A in 3:1, 1:1 and 1:3 blend ratio were prepared by this method. The resins had Brookfield viscosity at 316 K in the range of 145–81,533 mPa s. The resins were characterized by ¹H-NMR, FTIR and elemental analysis. Curing characteristics were studied by DSC analysis. Thermal stability of cured resins was found to improve with increase in Bz-C content in the blends.     

Renewable epoxidized cardanol‐based acrylate as a reactive diluent for UV‐curable resins

A novel kind of biobased monomer, epoxidized cardanol‐based acrylate (ECA), was successfully synthesized from cardanol via acrylation and epoxidization. The chemical structure was confirmed by Fourier transform infrared spectroscopy and proton nuclear magnetic resonance. Then, the ECA was employed to produce UV‐curable films and coatings copolymerized with castor oil‐based polyurethane acrylate. Compared to coatings from petroleum‐based diluent hydroxyethyl acrylate‐based castor oil‐based polyurethane acrylate resins, ECA‐based biomaterials exhibited a little inferior dilution ability but overcome the drawback of high volumetric shrinkage with a special lower value. Moreover, ultimate properties of the UV‐cured biomaterials such as thermal, mechanical, coating, swelling, and hydrophobic properties were investigated. The UV‐curing behavior was investigated using real‐time IR, and the overall double bond conversion was more than 90%. This biobased UV‐curable cardanol‐based diluent shows a promise in “green + green” materials technologies.     

Studies on the process variables of the condensation reaction of cardanol and formaldehyde by response surface methodology

Different types of cardanol-based novolac-type phenolic resins are produced under a wide range of operating conditions for the application in the resin producing industries. Different operating conditions employed for the production of such resins result in different extent of conversion. In order to understand the system behavior, mathematical relationship between the process variables and the extent of conversion was established by employing the ‘Response surface methodology’. Geometrical representation of the mathematical models in three-dimensional surface plots served as a good aid in understanding the behaviour of reaction under different operating conditions. The maximum extent of conversion of the condensation reaction of cardanol and formaldehyde was found to be 93.0 percent at optimum sets of condition of reaction temperature, time, catalyst concentration and pH of the reaction mixture. All the predicted values for optimum process conditions were in good agreement with experimental data.