Preparation and properties of one‐pack polybenzoxazine‐modified polyurethanes with improved thermal stability and electrical insulating properties

A novel method has been developed for the combination of polyurethanes and polybenzoxazines. For this purpose, firstly, p‐nitrophenol blocked polyurethanes (BPUs) were prepared via the reaction of poly(tetramethylene ether) glycol of various molecular weights, 2,4‐tolylene diisocyanate and p‐nitrophenol. The BPUs were then mixed with 2,2‐bis(3,4‐dihydro‐3‐phenyl‐2H‐1,3‐benzoxazine)propane (Ba) at various weight ratios. To prepare poly(urethane‐co‐benzoxazine) networks, the BPU/Ba mixtures were subjected to a heating programme derived from detailed differential scanning calorimetry and gel content measurements. Results showed about 30 to 40 °C reduction of polymerization temperature for complete curing of BPU/Ba mixtures in comparison to neat Ba. This phenomenon was related to catalytic action of librated p‐nitrophenol molecules. The thermal, mechanical, viscoelastic and electrical properties of prepared thermoset polymers were measured and correlated with their chemical structures. A significant improvement of thermal stability and dielectric strength in comparison to neat polyurethanes was found. Also, enhancement of tensile properties, ease of curing and ability to be transformed into thin films are fascinating features of these newly developed materials in comparison to neat polybenzoxazines. Therefore, these polymers have potential applicability as high‐performance materials in modern electrical industries. Copyright © 2010 Society of Chemical Industry