Effect of SiO2on rheology, morphology, thermal, and mechanical properties of high thermal stable epoxy foam

The Preparation and Performance of Epoxy/Acetylene Carbon Black Wave-Absorbing Foam

The epoxy foam material filled with an absorbing agent effectively absorbs electromagnetic waves. In this study, epoxy resin was used as the matrix, and acetylene carbon black was used as the magnetic absorbing agent to prepare an absorbing foam material (epoxy/CB). The microstructure of acetylene carbon black (CB) and its distribution in epoxy resin, as well as the effects of pre-polymerization time and CB content on the foam structure, were systematically characterized. Additionally, two dispersion methods, the hot-melt in situ stirring dispersion method and the three-roll milling dispersion method, were studied for their effects on the foaming process and absorbing properties of epoxy/CB. The results showed that with the prolongation of pre-polymerization time, the pore size decreased from 1.02 mm to 0.4 mm, leading to a more uniform pore distribution. Compared to the hot-melt in situ stirring dispersion method, the three-roll milling dispersion method effectively improved the dispersion of CB in epoxy resin, reducing the aggregate size from 300-400 nm to 70-80 nm. The pore diameter also decreased from 0.453 mm to 0.311 mm, improving the uniformity of particle size distribution. However, the absorbing material prepared with the three-roll milling dispersion method exhibited unsatisfactory absorption performance, with values close to 0 dB at mid-low frequencies and around -1 dB at high frequencies. In contrast, the absorbing material prepared with the hot-melt in situ stirring dispersion method showed better absorption performance at high frequencies, reaching around -9 dB.

Fully Biobased Degradable Vitrimer Foams: Mechanical Robust, Catalyst-Free Self-Healing, and Shape Memory Properties

Thermosetting foams have limited capabilities for recycling, reprocessing, or reshaping. Moreover, most of the foaming agents currently employed in these foams are derived from organic compounds sourced from petrochemicals, thereby posing a significant environmental threat due to heightened pollution. To solve these problems, a fully biobased degradable vitrimer foam (EPC-X) was fabricated using an environmentally friendly all-in-one foaming strategy by cross-linking epoxidized malepimaric anhydride (EMPA), 1,5-diaminopentane (PDA), and 1,5-diaminopentane carbamate (PDAC) as a latent curing-blowing agent. To our delight, the vitrimer foams exhibit excellent mechanical properties (2.86 ± 0.11 MPa compressive strength) owing to their unique rigid rosin backbone and cross-linking networks. The presence of dynamic β-hydroxy ester bonds and the self-catalytic behavior of tertiary amine groups facilitate network rearrangement without requiring additional catalysts, thereby resulting in the development of EPC-X with rapid self-healing and shape memory properties. The self-healing foam could support a weight of 500 g (approximately 562 times its own mass). Moreover, these high-performance vitrimer foams can also be easily degraded in an ethanolamine (EA) or NaOH solution under mild conditions. Such a design strategy offers an alternative approach for developing superior degradable and thermal stimuli-responsive thermosetting foams.

Tailoring Epoxy Resin Foams by Pre-Curing with Neat Amine Hardeners and Its Derived Carbamates

The use of amine-based carbamates with their dual function, acting as amine curing agents and CO2 blowing agents after their decomposition without by-products, are promising for ecofriendly epoxy foams as high-performance materials. However, controlling cell morphology requires a proper adjustment of the viscosity at the foaming step. The viscosity is altered not only by blending neat amine and its derived carbamate at a fixed pre-curing time, but also by changing the pre-curing time at a fixed blend ratio. Within this study, diglycidylether of bisphenol A (DGEBA) epoxy resin is mixed with different blend ratios of isophorone diamine (IPDA) and its derived carbamate (B-IPDA). The systems are characterized by DSC and rheology experiments to identify the pre-curing effects on the derived epoxy foams. Epoxy foams at a blend ratio of 30/70w IPDA/B-IPDA showed the best foam morphology and an optimum Tg compared to other blend ratios. Furthermore, it was found that both pre-curing times, 2 h and 3 h, for the 30/70w IPDA/B-IPDA system reveal a more homogeneous cell structure. The study proves that the blending of neat amine and carbamate is beneficial for the foaming performance of carbamate systems.

Air Templated Macroporous Epoxy Foams with Silica Particles as Property-Defining Additive

Nonaqueous foams were successfully produced by mechanically beating air into liquid epoxy resin, surfactant, and silica particle mixtures and used as templates to produce macroporous polymers. The air bubbles introduced into the epoxy formulations served as templates for the pores of the cured epoxy foams. The addition of silica particles into the resin mixture resulted in an increased viscosity of the formulation, thus enhancing the stability of the liquid epoxy froths, which could then be thermally cured at 60 °C. Increasing the silica loading in the formulation resulted in an increase of the foam density and decrease of the average pore size of the epoxy foams. The epoxy foams containing silica exhibited a hierarchical pore structure, where large pores were surrounded by smaller pores, and enhanced stiffness as compared to the control epoxy foams with a monomodal pore size distribution.

Mechanical and Thermal Properties of Epoxy Composites Containing Zirconium Oxide Impregnated Halloysite Nanotubes

Liquid epoxy resins have received much attention from both academia and the chemical industry as eco-friendly volatile organic compound (VOC)-free alternatives for applications in coatings and adhesives, especially in those used in households. Epoxy resins show high chemical resistance and high creep resistance. However, due to their brittleness and lack of thermal stability, additional fillers are needed for improving the mechanical and thermal properties. Halloysite nanotubes (HNTs) are naturally abundant, inexpensive, and eco-friendly clay minerals that are known to improve the mechanical and thermal properties of epoxy composites after suitable surface modification. Zirconium is well known for its high resistance to heat and wear. In this work, zirconium oxide-impregnated HNTs (Zr/HNTs) were added to epoxy resins to obtain epoxy composites with improved mechanical and thermal properties. Zr/HNTs were characterized by field-emission transmission electron microscopy, transmission electron microscopy with energy-dispersive X-ray spectroscopy, X-ray diffraction, and X-ray photoelectron spectroscopy. Changes in the thermal properties of the epoxy composites were characterized by thermo mechanical analysis and differential scanning calorimetry. Furthermore, flexural properties of the composites were analyzed using a universal testing machine.

Effect of monomer chemical structures on the cell structures and properties of cyanate ester foams

Cyanate ester (CE) foams with different chemical structures were prepared using bisphenol A dicyanate ester (BADCy), bisphenol E dicyanate ester (BECy), and tetramethyl bisphenol F dicyanate ester (TBFDCy) as monomers, through a two-step process. Rheological tests were performed to investigate the optimal conditions for the preparation of these foams. The results of morphology by scanning electron microscopy showed that cells are in the form of nearly spherical shape in foams from TBFDCy and BADCy and oval in foam from BECy. The thermal properties of the three CE foams were studied by methods of dynamic mechanical analysis (DMA), differential scanning calorimetry (DSC), and thermogravimetry/differential thermogravimetry analysis. The glass transition temperature ( Tg) obtained from DMA tests are 274, 264, and 241°C for the foams from TBFDCy, BADCy, and BECy, respectively, which are apparently higher than that tested by DSC method. The Tg, compressive properties, and thermal stabilities of the foams are improved after the introduction of the alkyl-substituent groups to the same aromatic ring of –OCN functionality, and the chemical structure–properties relationships are explained according to the monomer chemical structures.

One-Pack Epoxy Foaming with CO2 as Latent Blowing Agent

In this work, we have successfully developed a novel approach to epoxy foaming using CO₂ as the latent blowing agent. The active amine groups of a commercially available curing agent for epoxy resin are blocked by CO₂ to obtain ammonium carbamate. The prepared ammonium carbamate can be decomposed by heating. Above 100 °C, CO₂ is released from the amine groups and acts as the blowing agent, while the amine compound is used as the curing agent and cures the epoxy resin. The ammonium carbamate combines the functionalities of latent blowing agent and curing agent. The one-pack epoxy foaming formulation has good storage stability under ambient conditions. The thermoset epoxy foams prepared from the one-pack formulation have low density, good mechanical properties, and thermal stability, competitive with the epoxy foams prepared by other methods. This novel approach is simple, environmentally benign, and cost-effective, which represents a promising direction in the development of epoxy foaming technologies.