A bio-based epoxy resin derived from p-hydroxycinnamic acid with high mechanical properties and flame retardancy

Recent advances in epoxy resins have been forward to achieving high mechanical performance, thermal stability, and flame retardancy. However, seeking sustainable bio-based epoxy precursors and avoiding introduction of additional flame-retardant agents are still of increasing demand. Here we report the synthesis of p-hydroxycinnamic acid-derived epoxy monomer (HCA-EP) via a simple one-step reaction, and the HCA-EP can be cured with 4,4′-diaminodiphenylmethane (DDM) to prepare epoxy resins. Compared with the typical petroleum-based epoxy resin, bisphenol A epoxy resin, the HCA-EP-DDM shows a relatively high glass transition temperature (192.9 °C) and impressive mechanical properties (tensile strength of 98.3 MPa and flexural strength of 158.9 MPa). Furthermore, the HCA-EP-DDM passes the V-1 flammability rating in UL-94 test and presents the limiting oxygen index of 32.6%. Notably, its char yield is as high as 31.6% under N₂, and the peak heat rate release is 60% lower than that of bisphenol A epoxy resin. Such findings provide a simple way of using p-hydroxycinnamic acid instead of bisphenol A to construct high-performance bio-based thermosets.     

Recent advances in epoxy resins and composites derived from lignin and related bio-oils

This short critical review gives an insight on the potential that lignin and its bio-oils present towards the production of thermosetting epoxy polymers and composites. Green and sustainable ways of producing monomers and polymers from renewable sources are critical and lignin, as an underutilized bio-based waste material, presents a high exploitation potential. Due to its versatile and highly functional phenolic structure, the utilization of lignin or its depolymerized fractions (bio-oils) has been investigated in the last years as alternative for fossil-based epoxy resin pre-polymers and crosslinkers. Lignin can in fact be considered as a crosslinker for epoxy resins, especially after appropriate functionalization with amine groups or with additional hydroxyl groups, or it can be modified with epoxide groups towards the replacement of toxic BPA-based epoxy prepolymers. Furthermore, lignin derived pyrolysis or hydrogenolysis bio-oils may offer highly reactive soluble oligomers that after appropriate functionalization could be utilized as bio-based epoxy prepolymers. The lignin-based epoxy resins and composites exhibit similar or even better and novel properties, compared to those of pristine epoxy polymers, thus rendering lignin a highly valuable feedstock for further utilization in the thermoset polymer industry.     

Recent development on bio-based thermosetting resins

Due to the rapid depletion of crude oil and serious environmental pollution, the synthesis of polymers from renewable resource is becoming more and more important. Up to now, a great variety of biomass and bio-based platform compounds have been taken to prepare the polymers. However, as two representative thermosetting resins, epoxy and benzoxazine resin derived from renewable feedstocks only obtain limited attention compared with the popular bio-based plastics, including PLA, PBAT and PHBV etc. The reason might be that the properties of previously reported thermosetting resins directly obtained from biomass are usually unsatisfied, and their application fields are limited. In this paper, the latest development on the synthesis of high-performance bio-based epoxy and polybenzoxazine resins are reviewed. In addition, to further broaden their applications, the functionalization strategies are also summarized. The objective of this work is to help us fully aware the present situation of bio-based thermosetting resins and then promote their faster development, especially practical application.     

A vanillin-derived flame retardant based on 2-aminopyrimidine for enhanced flame retardancy and mechanical properties of epoxy resin

In order to give epoxy resin good flame retardance, a novel bio-based flame retardant based on 2-aminopyrimidine (referred to as VAD) was synthesized from renewable vanillin as one of the starting materials. Its structure was confirmed by NMR and mass spectra. The epoxy resins containing VAD were prepared by utilizing 4,4-diaminodiphenylmethane (DDM) as a co-curing agent, and their flame-retardant, mechanical and thermal properties and corresponding mechanisms were studied. VAD accelerated the cross-linking reaction of DDM and E51 (diglycidyl ether of bisphenol A). 12.5 wt% VAD made the epoxy resin achieve UL-94 V-0 rating and its limited oxygen index (LOI) value increase from 22.4% to 32.3%. The cone calorimetric testing results revealed the decline in the values of total heat release (THR) and peak of heat release rate (pk-HRR) and the obvious enhancement of residue yield. A certain amount of VAD enhanced the flame inhibition, charring and barrier effects, resulting in good flame retardance of the epoxy resin. Furthermore, the tensile strength, flexural strength and flexural modulus of the epoxy resin with 12.5 wt% loading of VAD were 6.5%, 14.9%, 15.2% higher than those of EP, indicating the strengthening effect of VAD. This work guarantees VAD to be a promising flame retardant for enhancing the fire retardancy of epoxy resin without compromising its mechanical properties.     

Synthesis of a novel phosphorus‐containing curing agent and its effects on the flame retardancy,thermal degradation and moisture resistance of epoxy resins

A novel phosphorus‐containing compound diphenyl‐(1, 2‐dicarboxylethyl)‐phosphine oxide defined as DPDCEPO was synthesized and used as a flame retardant curing agent for epoxy resins (EP). The chemical structure of the prepared DPDCEPO was well characterized by Fourier transform infrared spectroscopy, and ¹H, ¹³C and ³¹P nuclear magnetic resonance. The DPDCEPO was mixed with curing agent of phthalic anhydride (PA) with various weight ratios into epoxy resins to prepare flame retardant EP thermosets. The flame retardant properties, combustion behavior and thermal analysis of the EP thermosets were respectively investigated by limiting oxygen index (LOI), vertical burning tests (UL‐94), cone calorimeter measurement, dynamic mechanical thermal analysis and thermogravimetric analysis (TGA) tests. The surface morphologies and chemical compositions of the char residues for EP thermosets were respectively investigated by scanning electron microscopy and X‐ray photoelectron spectroscopy (XPS). The water resistant properties of the cured EP were evaluated by putting the samples into distilled water at 70°C for 168 hr. The results revealed that the EP/20 wt% DPDCEPO/80 wt% PA thermosets successfully passed UL‐94 V‐0 flammability rating and the LOI value was as high as 33.2%. The cone test results revealed that the incorporation of DPDCEPO effectively reduced the combustion parameters of the epoxy resin thermosets, such as heat release rate and total heat release. The dynamic mechanical thermal analysis test demonstrated that the glass transition temperature (Tg) decreased with the increase of DPDCEPO content. The TGA results indicated that the incorporation of DPDCEPO promoted the decomposition of epoxy resin matrix ahead of time and led to a higher char yield and thermal stability at high temperatures. The surface morphological structures and analysis of the XPS of the char residues of EP thermosets revealed that the introduction of DPDCEPO benefited the formation of a sufficient, compact and homogeneous char layer with rich flame retardant elements on the epoxy resin material surface during combustion. The mechanical properties and water resistance of the cured epoxy resins were also measured. After water resistance tests, the EP/20 wt% DPDCEPO/80 wt% PA thermosets retained excellent flame retardancy, and the moisture adsorption of the EP thermosets decreased with the increase of DPDCEPO content in EP thermosets because of the existence of the P–C bonds and the rigid aromatic hydrophobic structure in DPDCEPO. Copyright © 2015 John Wiley & Sons, Ltd.     

Influence of liquefied wood polyol on the physical-mechanical and thermal properties of epoxy based polymer

Epoxy resins are mostly produced from petroleum-based bisphenol A and epicholorhydrin. Bisphenol A is synthesized from non-renewable petroleum-based phenol and acetone. Biomass derived epoxy-based polymers (EBPs) are becoming the most promising alternative for petroleum-based counterparts, but still these biomass-based EBPs have inferior properties. In the present work, two types of epoxy resins were prepared with different weight percentages of resin (bisphenol A) and hardener. They were then modified with different weight percentages of liquefied wood from spruce sawdust. The derived EBPs were analysed in terms of tensile strength and tensile modulus, fractured surface morphology, thermal stability, long-term water adsorption and resistance to brown-rot fungus decay. The results revealed that the percentages of hardener and liquefied wood significantly influenced the overall properties of the EBPs.     

Thermal and flame retardant properties of epoxy resin cured by a novel phosphorus-containing 4,4′-bisphenol novolac curing agent

A novel flame retardant curing agent for epoxy resin (EP), i.e., a DOPO (9,10-dihydro-9-oxa-10-phosphaphenan-threne-10-oxide)-containing 4,4'-bisphenol novolac (BIP-DOPO) was synthesized and characterized by Fourier transform infrared (FTIR), ¹H NMR, ³¹P NMR spectroscopy, and gel permeation chromatography. The epoxy resin cured by BIP-DOPO itself or its mixture with a commonly used bisphenol A-formaldehyde novolac resin (NPEH720) was prepared. The flame retardancy of the cured EP thermosets were studied by limiting oxygen index (LOI), UL 94 and cone calorimeter test (CCT), and the thermal properties by thermal gravimetric analysis (TGA) and differential scanning calorimetry (DSC). The results show that the cured epoxy resin EPNP/BI/3/1, which contains 2.2% phosphorus, possesses a value of 26.2% and achieves the UL 94 V-0 rating. The data from cone calorimeter test demonstrated that the peak release rate, average heat release rate, total heat release decline sharply for the flame retarded epoxy resins, compared with those of pure ones. DSC results show that the glass-transition temperatures of cured epoxy resins decrease with increasing phosphorus content. TGA indicates that the incorporation of BIP-DOPO promotes the decomposition of epoxy resin matrix ahead of time and leads to higher char yield. The surface morphological structures of the char residues reveal that the introduction of BIP-DOPO benefits to the formation of a continuous and solid char layer on the epoxy resin material surface during combustion.     

Novel toughened cyanate ester resin with good dielectric properties and thermal stability by copolymerizing with hyperbranched polysiloxane and epoxy resin

A novel toughened cyanate ester (CE) resin with good dielectric properties and thermal stability was developed by copolymerizing 2,2′‐bis(4‐cyanatophenyl)iso‐propylidene (BCE) with a combined modifier (HBPSiEP) made up of hyperbranched polysiloxane (HBPSi) and epoxy (EP) resin. HBPSi was synthesized through the hydrolysis of 3‐(trimethoxysilyl)propyl methacrylate. The effect of differing stoichiometries of HBPSiEP on the curing characteristics and performance of BCE resin is discussed. Results show that the incorporation of HBPSiEP can not only effectively promote the curing reaction of BCE, but can also significantly improve the toughness of the cured BCE resin. In addition, the toughening effect of HBPSiEP is greater than single EP resin. For example, the impact strength of modified BCE resin with 30 wt% of HBPSiEP is 23.3 KJ/m², which is more than 2.5 times of that of pure BCE resin, while the maximum impact strength of EP/BCE resin is about 2 times of pure BCE resin. It is worthy to note that HBPSiEP/BCE resins also exhibit improved thermal stability, dielectric properties, and flame retardancy, suggesting that the novel toughened CE resins have great potentiality to be used as a matrix for advanced functional composites or electronic packing resins. Copyright © 2009 John Wiley & Sons, Ltd.     

Preparation and thermomechanical properties of epoxy resins modified by octafunctional cubic silsesquioxane epoxides

The thermomechanical properties of octafunctional cubic silsesquioxane‐modified epoxy resins associated with dicycloaliphatic hardener (4,4′‐dimethyldiaminodicyclo hexyl methane) were studied using thermogravimetric analysis, differential scanning calorimetry, and dynamic mechanical analysis. The structures of epoxy resin containing cubic silsesquioxane epoxides were characterized by Fourier transform infrared spectroscopy and wide‐angle X‐ray scattering techniques. In this work, octa(dimethylsiloxybutylepoxide) octasilsesquioxane (OB), and octa(glycidyldimethyl‐siloxyepoxide) octasilsesquioxane (OG), were synthesized and used as additives to improve the properties of a commercial epoxy resin by exploring the effects of varying the ratio of OB or OG. The commercial Ciba epoxy resin (Araldite LY5210/HY2954) was used as a standard. It was found, by thermogravimetric analysis and dynamic mechanical analysis, that the highest thermal stability was observed at N = 0.5 (N = number of amine groups/number of epoxy rings). No glass transition temperature was observed by adding 20 mol % OB to the Ciba epoxy resin, indicating the reduction of chain motion in the presence of octafunctional cubic silsesquioxane epoxide. The storage modulus of the OB‐modified epoxy resin also increased, especially at higher temperatures, compared with the Ciba epoxy resin under identical curing conditions. Fourier transform infrared data elucidated the preservation of cubic silsesquioxane structure after curing at high temperature. In contrast, the OG/Araldite LY5210/HY2954 systems gave poorer thermomechanical properties. The low viscosity of OB at room temperature (～ 350 cPs) makes it suitable for composite processing and, when used in conjunction with the Ciba epoxy, lowers the viscosity of this system as well. © 2004 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 42: 3490–3503, 2004     

New fire retardant halogenfree polymers

Todays fire retardant plastics for high strength FRP (fibre-reinforced polymers) or electronic devices (printed circuit boards, PCB) are based on brominated epoxy resins (EP resins). The smoke gases of this resins are highly toxic and corrosive. A new class of fire retardant duroplastics, based on dihydrobenzoxazines, doesn't contain halogen, sulfur or phosphor. Processibility is equal to that of thermosetting epoxy resins. Mechanical and electrical properties are equal to brominated epoxy resin, heat resistance is considerably enhanced (glass temperature 180 - 280 °C), while density, toxicity and corrosivity of smoke are very low.     

聚硫橡胶和环氧树脂互穿网络和共聚网络

本文以丙烯酸酯封端的聚硫橡胶，环氧封端的聚硫橡胶分别同双酚环氧树脂合成互穿网络和共聚网络，并研究了它们的相结构和性能。结果表明，所有样品都具有低温柔性和良好的力学性。     

Preparation,flame retardancy,and thermal degradation of epoxy thermosets modified with phosphorous/nitrogen‐containing glycidyl derivative

Phosphorus/nitrogen‐containing advanced epoxy resins were obtained by chain‐extension of the diglycidyl ether of bisphenol‐A epoxy (DGEBA) resin with phosphorus‐modified triglycidyl isocyanurate (TGICP). The structure of TGICP was characterized by Fourier transform infrared spectroscopy (FTIR) and nuclear magnetic resonance (NMR). Differential scanning calorimetry revealed that the EP/TGICP composites possessed higher glass transition temperatures than that of phosphorus free EP. The thermal stability and flame retardant properties of the epoxy resin/TGICP systems were investigated by thermogravimetric analysis (TGA), limiting oxygen index (LOI), and vertical burning test (UL‐94) test. When the TGICP content was 10 wt%, the LOI value of epoxy resin system was as high as 35.0% and it can obtain the V‐0 grade in UL‐94 protocol. From microscale combustion calorimetry (MCC) measurement, it was found that the addition of TGICP reduced the value of peak heat release rate and total heat release. The thermal degradation process of EP and EP/TGICP composite was monitored by real time FTIR. Moreover, scanning electron microscopy (SEM) and X‐ray photoelectron spectroscopy (XPS) were used to explore the morphology and chemical components of the char residues. Copyright © 2010 John Wiley & Sons, Ltd.     

Tough epoxy resins cured with aminimides

Aminimide compounds ( 1–4 ) thermally generating isocyanates and tertiary amines were found to be excellent curing agents for epoxy resin. Tensile behavior, glass transition temperature, and degree of curing for the combination of EPIKOTE 828 prepolymer with a series of curing agents ( 1–4 ) are reported. The resins exhibit a large elongation at breakage and a high fracture energy per unit volume. The epoxy resins (EP-AI) cured with 3 or 4 containing no hydroxyl group showed larger ultimate elongations (up to 15%) and higher fracture energies (ca. 8 J/cm³) than the resins (EP–AI_OH) cured with 1 or 2 . The curing reaction depends on the structure of aminimide (presence of hydroxyl group and generation of mono- or bisisocyanates). The origin of toughness and dependence of physical properties on the curing condition and the structure of aminimides were discussed. It was concluded that relatively slow curing at elevated temperature controlled by thermal decomposition of aminimides was a reason for the toughness.     

Influence of silica fillers during the electron irradiation of DGEBA/TETA epoxy resins, part II: Study of the thermomechanical properties

This work describes the influence of silica fillers on the thermomechanical properties of diglycidyl ether of bisphenol A/triethylenetetramine (DGEBA/TETA) epoxy resins during ageing under electron beam irradiation. Whatever be the silica filler (pure micrometric ground and spherical silicas, nanometric silicas and coupling agent treated silicas), the glass transition temperature of the epoxy resins decreases with increasing irradiation dose, meaning that the main effect of the irradiation is chain scission. No influence of the silica fillers has been detected from the changes in the glass transition temperature with the increase in the irradiation dose. The disappearance of the cooperativity of the γ relaxation, the decrease of the α relaxation and the decrease of the elastic modulus at the rubbery plateau observed by dynamic mechanical analyses involve a decrease in the crosslink density of the epoxy resins. The occurrence of chemical reactions between the epoxy resin and the silica surface at high irradiation doses has been shown. Moreover, we show evidence that chemical reactions between the epoxy resin and the silica surface occur at high irradiation dose.     

Free volume hole size of Cyanate ester resin/Epoxy resin interpenetrating networks and its correlations with physical properties

Cyanate ester (CE) resin was blended with epoxy resin (EP) at different mass ratios (CE/EP: 100/0, 90/10, 70/30, 50/50, 30/70, 10/90, and 0/100). The curing process of the blend system was characterized by Fourier transform infrared spectrometry (FTIR) and differential scanning calorimetry (DSC). Examination of the mechanical properties, thermal stability, and morphology of the blend systems showed that addition of epoxy resin resulted in improved toughness but a little sacrifice in thermal stability when compared with neat CE. The free volume size of the blend system determined by positron annihilation lifetime spectroscopy (PALS) decreased with the epoxy resin content, which is consistent with the chemical structure changes for the copolymerization between CE and EP. The crosslinking units of curing products (oxazoline, oxazolidinone, and polyether network) of the blends are all smaller in size than those of triazine ring structure from neat CE. Therefore, the free volume size of the blends decreases with increase of EP content. The correlations between the free volume properties and other physical properties (thermal stability and mechanical properties) have also been discussed.     

New powder coatings with low curing temperature and enhanced mechanical properties obtained from DGEBA epoxy resins and Meldrum acid using erbium triflate as curing agent

New low curing temperature powder coatings obtained by copolymerization of epoxy resins with Meldrum acid (MA) initiated by erbium (III) trifluoromethanesulfonate have been formulated. Their mechanical and thermomechanical properties have been studied and compared with a commonly used industrial system (o-tolylbiguanide/epoxy resin) and with an already formulated epoxy powder coating homopolymerized by erbium trifluoromethanesulfonate. Systems containing low proportions of MA and initiated by erbium trifluoromethanesulfonate lead to a great reduction of curing conditions (temperature/time). Moreover, the new formulated systems present very good mechanical properties, adhesion, and impact resistance. © 2007 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 45: 2316–2327, 2007     

Preparation and Characterization of DGEBA/EPN Epoxy Blends with Improved Fracture Toughness

The physical and mechanical properties of blends composed of two kinds of epoxy resins of different numbers of functional groups and chemical structure were studied.One of the resins was a bifunctional epoxy resin based on diglycidyl ether ofbisphenol A and the other resin was a multifunctional epoxy novolac resin.Attempt was made to establish a correlation between the structure and the final properties of cured epoxy samples.The blend samples containing high fraction of multifunctional epoxy resin showed higher solvent resistance and lower flexural modulus compared with the blends containing high fraction of bifunctional epoxy resin.The epoxy blends showed significantly higher ductility under bending test than the neat epoxy samples.The compressive modulus and strength increased with increasing of multifunctional epoxy in the samples,probably due to enhanced cross-link density and molecular weight.Morphological analysis revealed the presence of inhomogeneous sub-micrometer structures in all samples.The epoxy blends exhibited significantly higher fracture toughness (by 23％ at most) compared with the neat samples.The improvement of the fracture toughness was attributed to the stick-slip mechanism for crack growth and activation of shear yielding and plastic deformation around the crack growth trajectories for samples with higher content of bifunctional epoxy resin as evidenced by fractography study.     

Thermal degradation and flame retardancy of epoxy resins containing intumescent flame retardant

Pentaerythritol diphosphonate melamine-urea-formaldehyde resin salt, a novel cheap macromolecular intumescent flame retardants (IFR), was synthesized, and its structure was a caged bicyclic macromolecule containing phosphorus characterized by IR. Epoxy resins (EP) were modified with IFR to get the flame retardant EP, whose flammability and burning behavior were characterized by UL 94 and limiting oxygen index (LOI). 25 mass% of IFR were doped into EP to get 27.2 of LOI and UL 94 V-0. The thermal properties of epoxy resins containing IFR were investigated with thermogravimetry (TG) and differential thermogravimetry (DTG). Activation energy for the decomposition of samples was obtained using Kissinger equation. The resultant data show that for EP containing IFR, compared with EP, IFR decreased mass loss, thermal stability and R _max, increased the char yield. The activation energy for the decomposition of EP is 230.4 kJ mol⁻¹ while it becomes 193.8 kJ mol⁻¹ for EP containing IFR, decreased by 36.6 kJ mol⁻¹, which shows that IFR can catalyze decomposition and carbonization of EP.     

PHASE STRUCTURE AND PROPERTIES OF EPOXY RESIN MODIFIED BY POLYSILOXANE BEARING PENDANT AMINO GROUPS

Polysiloxane-modified epoxy resins were prepared through the reaction of epoxy resin with polydimethylsiloxanesbearing pendant N-(β-aminoethyl)-γ-aminopropyl groups. The morphology and properties of the cured epoxy resins modifiedby the polysiloxanes were investigated. It was found that the phase structure and properties of the cured epoxy resins dependmainly on the amino group content in the polydimethylsiloxane and the level of the modifier. The change of phase structurein the cured epoxy resin systems was responsible for the dramatic change in their mechanical and surface properties.     

Modelling the effect of moisture absorption on the thermomechanical relaxation spectra for thermoset/thermoplastic resin blends

The principles of molecular modelling have been combined with Group Interaction Modelling (GIM) for the prediction of properties of thermoset/thermoplastic resins. The glass transition temperature of the systems was modelled and thermomechanical properties of epoxy resin polyether sulphone blends were discussed. As a result a full envelope of Dynamic Mechanical Thermal Analysis Relaxation (DMTA) curve for wet and dry material was predicted. Differential Scanning Calorimetry (DSC) and DMTA experimental methods were used to validate the modelling results.