Synthesis and properties of flame‐retardant epoxy resins based on DOPO and one of its analog DPPO

Two phosphorus‐containing heterocyclic flame retardants ‐9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO) and 2,8‐dimethyl‐phenoxaphosphin‐10‐oxide (DPPO) ‐ and their derivatives were characterized and incorporated in the backbone of epoxy novolac to obtain flame‐retardant epoxy resins. The structures and spectroscopic data including high‐resolution mass spectroscopy of these flame retardants were determined. Flame‐retardant epoxy resins with a phosphorus content of up to 2% based on heterocyclic DOPO and DPPO were cured with 4,4′‐diaminodiphenylmethane (DDM), and their features were examined by UL 94, LOI, and DSC. In this manner, high‐performance polymers with glass transition temperatures around 190°C and the UL 94 rating V0 were obtained. These polymers were compared with epoxy resins incorporating diphenyl phosphite and diphenyl phosphate, which are nonheterocyclic and do not pass the UL 94 test up to 2% phosphorus. DPPO has a similar flame retardancy like the commercially available DOPO. Furthermore, to explain the difference in the efficiency of the tested flame retardants, key experiments for the determination of the active species during the flame‐retarding process were performed and the PO radical was identified. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2007.     

Synthesis of wood‐based epoxy resins and their mechanical and adhesive properties

Wood‐based epoxy resins were synthesized from resorcinol‐liquefied wood. Wood was first liquefied in the presence of resorcinol with or without a sulfuric acid catalyst at high temperature. Because of the hydroxyl groups, the resorcinol‐liquefied wood was considered as a precursor for synthesizing wood‐based epoxy resin. Namely, the phenolic OH groups of the liquefied wood reacted with epichlorohydrin under alkali condition. By the glycidyl etherification, epoxy functionality was introduced to the liquefied wood. The epoxy functionality of the resins was controlled by the concentration of phenolic OH groups in the liquefied wood, which would be a dominant factor for crosslink density and properties of the cured epoxy resins. The flexural strength (150–180 MPa) and the modulus of elasticity (3.2 GPa) of the highly crosslinked wood‐based epoxy resin were equivalent to those of the commercially available epoxy resin, diglycidyl ether of bisphenol A (DGEBA). Also, the shear adhesive strength of the wood‐based epoxy resin was higher than that of DGEBA when plywood was used as the adhesive substrates. The mechanical and adhesive properties suggested that the wood‐based epoxy resins would be well suited for matrix resins of natural plant‐fiber reinforced composites. © 2006 Wiley Periodicals, Inc. J Appl Polym Sci 102: 2285–2292, 2006     

反应型DOPO基阻燃剂在环氧树脂中的应用

综述了近年来在反应型DOPO基(9,10-二氢-9-氧-10-磷杂菲-10-氧化物)阻燃剂中引入羟基、羧基、氨基等基团以及与氰酸酯加成得到具有阻燃性的环氧树脂固化剂以及在DOPO衍生物中引入环氧基,制备本质阻燃环氧树脂的研究进展。     

Fracture and mechanical properties of epoxy resins and rubber-modified epoxy resins

Fracture and mechanical property data on a wide range of epoxy resin systems are presented. The extent to which toughening can be induced by heterophase rubber inclusions depends more on the curing agent used than on the resin component. The greatest improvements in toughness were obtained by rubber modification of epoxy resins cured with an anhydride. A preformed ABS polymer can be used to toughen many epoxy resin systems. With one major exception (where a large improvement was found) only small changes in tensile properties occur when small amounts of rubber are present.     

Thermomechanical properties of arylamine‐based benzoxazine resins alloyed with epoxy resin

Effects of epoxy resin on various arylamine‐based benzoxazine resins, i.e., aniline (BA‐a), m‐toluidine (BA‐mt), and 3,5‐xylidine (BA‐35x), have been investigated. Processing windows of BA‐35x, BA‐mt, and BA‐a were found to be widened with the amount of the epoxy. Gel points of benzoxazine‐epoxy resin mixtures can be predicted by an Arrhenius equation, e.g., gel time of BA‐35x and epoxy mixture at 70:30 mass ratio can be estimated by t_gel = 0.7012 × 10^?7 exp (10.563/T). Glass transition temperature (T_g) of BA‐a and BA‐mt alloyed with epoxy exhibited a synergistic behavior with the maximum T_g value at the benzoxazine‐epoxy composition of 80:20 mass ratio. However, in the BA‐35x and epoxy mixture, the decreasing trend in T_g from 241°C to 223°C with an addition of epoxy was observed. Furthermore, flexural strength and strain‐at‐break of those alloys were found to increase with increasing amount of the epoxy while modulus increased with the polybenzoxazine mass fraction. POLYM. ENG. SCI., 2011. © 2011 Society of Plastics Engineers     

Tailored thermal and mechanical properties of epoxy resins prepared using multiply hydrogen‐bonding reactive modifiers

In this study, we synthesized a phosphorus‐containing triply functionalized reactive modifier, DOPO‐tris(azetidine‐2,4‐dione), and a phosphorus‐free doubly functionalized reactive modifier, bis(azetidine‐2,4‐dione), and embedded them into epoxy resin systems. We characterized these synthesized reactive modifiers using Fourier transform infrared spectroscopy, nuclear magnetic resonance spectroscopy, elemental analysis, and mass spectrometry. During the thermosetting processes, we reacted the epoxy curing agents 4,4‐diaminodiphenylmethane and tris(4‐aminophenyl)amine with the multiply hydrogen‐bonding reactive modifiers and epoxy monomers. The introduction of the DOPO segment, strongly hydrogen bonding malonamide linkages, and hard aromatic groups into the backbones of the synthesized reactive modifiers resulted in epoxy networks exhibiting tailorable crosslinking densities, flexibilities, glass transition temperatures, thermal decomposition temperatures, and flame retardancies. Furthermore, dynamic mechanical analyses indicated that intermolecular hydrogen bonding of these reactive modifiers enhanced the thermal and physical properties of their epoxy resins through the formation of unique pseudocrosslinked polymer networks. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Synthesis of epoxy resins from alcohol‐liquefied wood and the mechanical properties of the cured resins

New wood‐based epoxy resins were synthesized from alcohol‐liquefied wood. Wood was first liquefied by the reaction with polyethylene glycol and glycerin. The alcohol‐liquefied wood with plenty of hydroxyl groups were precursors for synthesizing the wood‐based epoxy resins. Namely, the alcoholic OH groups of the liquefied wood reacted with epichlorohydrin under alkali condition with a phase transfer catalyst, so that the epoxy groups were put in the liquefied wood. The wood‐based epoxy resins and the alcohol‐based epoxy resins as reference materials were cured with polyamide amine. The glass transition temperature (Tg), the tensile strength, and the modulus of elasticity of the wood‐based epoxy resin were higher than those of the alcohol‐based epoxy resin. Also, the shear adhesive strength of the wood‐based epoxy resin to steel plates was higher than those of the alcohol‐based epoxy resins, which was equivalent to the level of petroleum‐based bisphenol‐A type epoxy resins. The higher Tg of the wood‐based epoxy resin than that of the alcohol‐based epoxy resin is one of the evidences that the wood‐derived molecules were chemically incorporated into the network structures. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Synergistic effects of phenethyl-bridged DOPO derivative with Al(OH)3 on flame retardancy for epoxy resins

ABSTRACT

Phenethyl-bridged DOPO derivative (DiDOPO) was combined with organo-modified aluminum hydroxide (OATH) in an epoxy resin (EP) to improve its flame retardancy. The results indicated that the introduction of only 10 wt% DiDOPO/60 wt% OATH in EP increased the limited oxygen index from 21.8% to 39.2%, thus the material met the UL 94 V-0 rating. Thermogravimetric analysis revealed that char yield increased in the presence of OATH to form thermally stable carbonaceous char. The evaluation of flame-retardant effect by cone calorimetry demonstrated that OATH improved the protective-barrier effect of the fire residue of EP/DiDOPO/OATH.     

Performance comparison of epoxy resins modified with diphenylphosphine oxide and DOPO

By curing the reaction mixture of diphenylphosphine oxide (DPO) and diglycidyl ether of bisphenol A with 4,4′‐diaminodiphenylsulfone, flame‐retardant epoxy resins (EP/DPO) were prepared. Flame‐retardant epoxy resins modified with 9,10‐dihydro‐9‐oxa‐10‐phosphaphenanthrene‐10‐oxide (DOPO) were similarly prepared (denoted as EP/DOPO). The limiting oxygen index value of pure epoxy resin, EP/DPO–P‐0.9 (with a phosphorus content of 0.9 wt%), and EP/DOPO–P‐0.9 are 23.0, 30.5, and 29.4%, respectively. EP/DPO–P‐0.9 reached a UL‐94 vertical burning test V‐0 rating, while EP/DOPO–P‐0.9 failed. The results of the cone calorimetry test, thermo‐oxidative degradation behavior study, and pyrolysis‐gas chromatography/mass spectrometry analysis indicated that both flame retardants mainly act through the gas‐phase activity mechanism. Together, the results of this study suggest that EP/DPO are high performance resins with good thermal stability, high glass transition temperature, and low water absorptivity for practical applications.     

Novel phenolic resins with improved mechanical and toughness properties

Novel phenolic type of thermoset resins were synthesized, and their mechanical and toughness properties were evaluated. Phenol Formaldehyde (PF) phenolic resins were modified to broaden their applications for modern composite structures. A first modification consisted of copolymerization of Phenol with Cardanol during the synthesis of resole phenolic (CPF) resins. The modified phenolic resins (CPF) were prepared at various molar ratios of total Phenol to Formaldehyde (F : P ratio) and with different weight ratios of Phenol to Cardanol. CPF resins with a maximum content of 40 wt % of Cardanol were synthesized and used. The CPF resins were applied as a plasticizer and toughening agent to the base PF resins. Both resins (CPF/PF) were mixed in different proportions, and their thermal and mechanical properties were then established. A full miscibility of the two resins was observed with the formation of a single‐phase system. An increase in the content of Cardanol resulted in a proportional increase of the flexural strength and fracture toughness together with a decrease of the flexural modulus of the cured CPF/PF resins. Further increased plasticizing and toughening effect was also observed by the blending of the CPF resins with propylene glycol. The higher toughness and flexibility effect of the CPF resins was obtained with a F : P molar ratio equal to 1.25 and with a Cardanol content of 40% (w/w). © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2012     

Preparation and mechanical properties of modified epoxy resins with flexible diamines

Diglycidyl ether of bisphenol A (DGEBA) is one of the most widely used epoxy resins for many industrial applications, including cryogenic engineering. In this paper, diethyl toluene diamine (DETD) cured DGEBA epoxy resin has been modified by two flexible diamines (D-230 and D-400). The cryogenic mechanical behaviors of the modified epoxy resins are studied in terms of the tensile properties and Charpy impact strength at cryogenic temperature (77 K) and compared to their corresponding properties at room temperature (RT). The results show that the addition of flexible diamines generally improves the elongation at break and impact strength at both RT and 77 K. The exception is the impact strength at 77 K filled with 21 wt% and 49 wt% D-400. Further, two interesting observations are made: (a) the cryogenic tensile strength increases with increasing the flexible diamine content; and (b) the RT tensile strength can only be improved by adding a proper content of flexible diamines. It is concluded that the addition of a selected amount namely 21–78 wt% of D-230 can simultaneously strengthen and toughen DGEBA epoxy resins at both RT and 77 K. However, only the addition of 21 wt% D-400 can simultaneously enhance the strength and ductility/impact strength of DGEBA epoxy resins at RT. The impact fracture surfaces are examined using scanning electron microscopy (SEM) to explain the impact strength results. Finally, differential scanning calorimetry (DSC) analysis shows that the glass transition temperature (T_g) decreases with increasing the flexible diamine content. The presence of a single T_g reveals that the flexible diamine-modified epoxy resins have a homogeneous phase structure.     

Preparation and properties of polydimethylsiloxane‐modified epoxy resins

In this work, polydimethylsiloxane (PDMS) with different molecular weight were used to modify diglycidyl ether of bisphenol A (DGEBA). A PDMS‐block‐DGEBA copolymer that acted as a compatibilizer was prepared via DGEBA, hydroxy terminated PDMS, and silane coupling agent in the presence of a catalyst. The reaction mechanisms and compatibilizing effects of the block copolymer were studied by means of Fourier transform infrared (FTIR) spectrum analysis and observation under scanning electron microscopy (SEM). The thermal and mechanical behaviors were analyzed as well. Results indicated that the block copolymer has good compatibilizing effect, and PDMS with low molecular weight could be dispersed in the DGEBA matrix more evenly. Moreover, the PDMS modified DGEBA systems had higher impact strength and lower weight loss rate than those of the pristine DGEBA system. © 2000 John Wiley & Sons, Inc. J Appl Polym Sci 76: 1683–1690, 2000     

Thermal and mechanical properties of anhydride‐cured epoxy resins with different contents of biobased epoxidized soybean oil

Thermosetting resins were synthesized by the partial replacement of the synthetic epoxy prepolymer based on diglycidyl ether of bisphenol A (DGEBA) with increasing amounts of epoxidized soybean oil (ESO) with methyltetrahydrophthalic anhydride as a crosslinking agent and 1‐methyl imidazole as an initiator. Calorimetric studies showed a drop in the reaction heat with ESO content; this was associated with the lower reactivity of oxirane rings in ESO due to steric constrains. The effects of the replacement of increasing amounts of synthetic DGEBA with ESO on the network properties, such as the storage modulus (E′) in the glassy and rubbery regions, glass‐transition temperature (T_g), and impact and compressive properties were examined. All formulations were transparent, although phase‐separated morphologies were evidenced by scanning electron microscopy observations. The intensity of the transmitted light passed to a minimum at a short reaction time associated with the cloud point and then increased continuously until the refractive index of the dispersed phase approximated that of the continuous phase at complete conversion. The combination of DGEBA with 40 wt % ESO resulted in a resin with an optimum set of properties; E′ in the glassy state was 93% of that of the neat DGEBA resin, T_g decreased only about 11°C, and the impact strength increased about 38% without a loss of transparency. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Synthesis,phase behaviors,and mechanical properties of biphenyl‐type epoxy resins and composites

Diglycidyl ether of 3,3′,5,5′‐tetramethyl‐4,4′‐biphenyl (TMBPDGE) which has been found great applications in semiconductor packaging was synthesized. The liquid crystalline phases of diglycidyl ether of 4,4′‐dihydroxybiphenol (BPDGE) cured with phenol novolac (PN) were studied by wide angle X‐ray diffraction (WAXD) and polarized optical microscopy (POM). BPDGE was in situ copolymerized with TMBPDGE to improve its thermal and mechanical properties by means of the LC domains retained in the crosslinked networks. The results indicated that a nematic phase was formed and fixed with proper curing schedule when BPDGE was cured with PN that had no neighboring active hydrogens and the LC domains could also be efficiently embedded into the composite systems. Dynamic mechanical properties showed that epoxy networks containing LC domains displayed higher α‐relaxation temperature and linear elastic modulus traces. The impact toughness and T_g were improved with the addition of BPDGE. Scanning electron microscope observation of the fracture surfaces showed that there was a change in failure mechanism in the composite systems. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2007     

Biolignin™ based epoxy resins

Wheat straw Biolignin? was used as a substitute of bisphenol‐A in epoxy resin. Synthesis was carried out in alkaline aqueous media using polyethyleneglycol diglycidyl ether (PEGDGE) as epoxide agent. Structural study of Biolignin? and PEGDGE was performed by solid‐state ¹³C NMR and gel permeation chromatography, respectively, before epoxy resin synthesis. Biolignin? based epoxy resins were obtained with different ratios of Biolignin? : PEGDGE and their structures were analyzed by solid‐state ¹³C NMR. The crosslinking of PEGDGE with Biolignin? was highlighted in this study. Properties of Biolignin? based epoxy resins were analyzed by differential scanning calorimetry and dynamic load thermomechanical analysis as well as compared with those of a bisphenol‐A epoxy‐amine resin. Depending on the epoxy resin formulation, results confirmed the high potential of Biolignin? as a biosourced polyphenol used in epoxy resin applications. © 2012 Wiley Periodicals, Inc. J. Appl. Polym. Sci., 2013     

Toughening of epoxy resin systems using low‐viscosity additives

This study has evaluated three low‐viscosity epoxy additives as potential tougheners for two epoxy resin systems. The systems used were a lower‐reactive resin based upon the diglycidyl ether of bisphenol A (DGEBA) and the amine hardener diethyltoluene diamine, while the second epoxy resin was based upon tetraglycidyl methylene dianiline (TGDDM) and a cycloaliphatic diamine hardener. The additives evaluated as potential tougheners were an epoxy‐terminated aliphatic polyester hyperbranched polymer, a carboxy‐terminated butadiene rubber and an aminopropyl‐terminated siloxane. This work has shown that epoxy‐terminated hyperbranched polyesters can be used effectively to toughen the lower cross‐linked epoxy resins, i.e. the DGEBA‐based systems, with the main advantage being that they have minimal effect upon processing parameters such as viscosity and the gel time, while improving the fracture properties by about 54 % at a level of 15 wt% of additive and little effect upon the T_g. This result was attributed to the phase‐separation process producing a multi‐phase particulate morphology able to initiate particle cavitation with little residual epoxy resin dissolved in the continuous epoxy matrix remaining after cure. The rubber additive was found to impart similar levels of toughness improvement but was achieved with a 10–20 °C decrease in the T_g and a 30 % increase in initial viscosity. The siloxane additive was found not to improve toughness at all for the DGEBA‐based resin system due to the poor dispersion within the epoxy matrix. The TGDDM‐based resin systems were found not to be toughened by any of the additives due to the lack of plastic deformation of the highly cross‐linked epoxy network Copyright © 2003 Society of Chemical Industry     

A phosphorus‐containing phenolic derivative and its application in benzoxazine resins: Curing behavior,thermal, and flammability properties

In this work, flame‐retardant benzoxazine resins were prepared by copolymerization of bisphenol A based benzoxazine (BA‐a) and a phosphorous‐containing phenolic derivative (DOPO‐HPM). The curing behavior, thermal stability, and flame resistance of BA‐a/DOPO‐HPM composites were studied by differential scanning calorimeter (DSC), thermogravimetric analysis (TGA), limited oxygen index (LOI) measurement, UL94 test, and cone calorimeter. The DSC results indicated that DOPO‐HPM catalyzed the curing reaction because of its acidity. The TGA results revealed that the BA‐a/DOPO‐HPM thermosets possessed higher decomposition temperatures (T_5%) and char yields than that of BA‐a. The combustion tests indicated that the flame retardant properties of BA‐a/DOPO‐HPM thermosets were enhanced. The BA‐a/DOPO‐HPM‐20 sample acquired the highest LOI value of 32.6% and UL94 V‐0 rating. Moreover, the average of heat release rate (av‐HRR), peak of heat release rate (pk‐HRR), average of effective heat of combustion (av‐EHC) and total heat release (THR) of BA‐a/DOPO‐HPM‐20 were decreased by 24.6%, 53.1%, 14.9%, and 22.1%, respectively, compared with BA‐a. The attractive performance of BA‐a/DOPO‐HPM blends was attributed to the molecular structure of DOPO‐HPM composed of DOPO group with excellent flame‐retardant effect and phenolic hydroxyl group with catalysis. © 2016 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2016 , 133, 43403.     

Synthesis and flammability testing of epoxy functionalized phosphorous‐based flame retardants

Several potential new phosphorus‐containing flame retardant molecules were evaluated for heat release reduction potential by incorporation of the molecules into a polyurethane, generated from methylene diphenyl diisocyanate and 1,3‐propane diol. The heat release reduction potential of these substances was evaluated using the pyrolysis combustion flow calorimeter (PCFC). The polyurethanes were prepared in the presence of the potential flame retardants via solvent mixing and copolymerization methods to qualitatively evaluate their potential reactivity into the polyurethane prior to heat release testing. The functionality of the flame retardants was epoxide based that would potentially react with the diol during polyurethane synthesis. Flammability testing via PCFC showed that the heat release reduction potential of each of the flame retardants was structure dependent, with phosphates tending to show more effectiveness than phosphonates in this study, and alkyl functionalized phosphorus groups (phosphate or phosphonate) being more effective at heat release reduction than cyclic functionalized groups. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42296.     

Relationship between structure and mechanical properties in rubber-toughened epoxy resins

Toughened polymers were prepared by adding CTBN rubbers to DGEBA-type epoxy resins. Structure was varied by altering the type and concentration of hardener, the initial molecular weight of the resin, the amount of Bisphenol A added, and the conditions of cure. Electron microscopy showed that these factors affected both particle size and degree of phase separation: rapid curing inhibited phase separation, and produced small particles. Increasing the molecular weight of the resin, either directly or by reaction with Bisphenol A, improved phase separation. Dynamic mechanical measurements of rubber phase volume proved possible, although T_g of the CTBN rubber coincided with a β process in the epoxy resin. Fracture resistance, measured by G_IC, increased linearly with rubber phase volume. Creep and yield behaviour were also affected by the degree of phase separation.     

Photocurable bulk epoxy resins based on resorcinol derivative through cationic polymerization

Bio-sourced epoxy resins from resorcinol diglycidyl ether (RDGE) have been obtained by using cationic photopolymerization under UV-light exposure. The photoinduced bulk resin samples were characterized by three-point bending tests, dynamic mechanical analysis, as well as differential scanning calorimetry analysis, and thermogravimetric analysis. The influence of processing parameters, that is, reactant contents, UV irradiation time, and postcuring conditions on the thermomechanical behavior has been pointed out. For instance, the flexural modulus of the most performing materials reaches 4.1 GPa with the flexural strength and the glass-transition temperature of around 105 MPa and 99°C, respectively. Interestingly, our optimized protocol has led to the synthesis of new bio-based materials with more valuable thermal and mechanical properties than those of thermocured materials obtained from petroleum-based commercial epoxy resins. Focus has been given on processing parameters to optimize the final properties of the material and to open an interesting alternative for sustainable building materials.