Synthesis and evaluation of novel urethane macromonomers for the formulation of fracture tough 3D printable dental materials

3D printing of materials which combine fracture toughness, high modulus and high strength is quite challenging. Most commercially available 3D printing resins contain a mixture of multifunctional (meth)acrylates. The resulting 3D printed materials are therefore brittle and not adapted for the preparation of denture bases. For this reason, this article focuses on toughening by incorporation of triblock copolymers in methacrylate-based materials. In a first step, three urethane dimethacrylates with various alkyl spacer length were synthesized in a one-pot two-step synthesis. Each monomer was combined with 2-phenoxyethyl methacrylate as a monofunctional monomer and a polycaprolactone-polydimethylsiloxane-polycaprolactone triblock copolymer was added as toughener. The formation of nanostructures via self-assembly was proven by small angle X-ray scattering (SAXS) and transmission electron microscopy (TEM). The addition of the triblock copolymer resulted in a strong increase in fracture toughness for all mixtures. The nature of the urethane dimethacrylate had a significant impact on fracture toughness and flexural strength and modulus of the cured materials. Most promising systems were also investigated via dynamic fatigue propagation da/dN measurements, confirming that the toughening also works under dynamic load. By carefully selecting the length of the urethane dimethacrylate spacer and the amount of block copolymer, materials with the desired physical properties could be efficiently formulated. Especially the formulation containing the medium alkyl spacer length (DMA2/PEMA) and 5 wt% BCP1 (block copolymer), exhibits excellent mechanical properties and high fracture toughness.

Toughening of epoxy thermosets by self-assembled nanostructures of amphiphilic comb-like random copolymers

Amphiphilic comb-like random copolymers synthesized from poly(ethylene glycol) methyl ether methacrylate (PEGMMA) and stearyl methacrylate (SMA) with PEGMMA contents ranging between 30 wt% and 25 wt% were demonstrated to self-assemble into various well-defined nanostructures, including spherical micelles, wormlike micelles, and vesicle-like nanodomains, in anhydride-cured epoxy thermosets. In addition, the polymer blends of the comb-like random copolymer and poly(stearyl methacrylate) were prepared and incorporated into epoxy thermosets to form irregularly shaped nanodomains. Our research findings indicate that both the comb-like random copolymers and polymer blends are suitable as toughening modifiers for epoxy. When added at a concentration of 5 wt%, both types of modifiers lead to substantial improvements in the tensile toughness (>289%) and fracture toughness of epoxy thermosets, with minor reductions in their elastic modulus (<16%) and glass transition temperature (<6.1 °C). The fracture toughness evaluated in terms of the critical stress intensity factor (KIC) and the strain energy release rate (GIC) increased by more than 67% and 131% for the modified epoxy thermosets containing comb-like random copolymers.

Nanostructuring Biobased Epoxy Resin with PEO-PPO-PEO Block Copolymer

A biobased diglycidyl ether of vanillin (DGEVA) epoxy resin was nanostructured by poly(ethylene oxide-b-propylene oxide-b-ethylene oxide) (PEO-PPO-PEO) triblock copolymer. Due to the miscibility/immiscibility properties of the triblock copolymer in DGEVA resin, different morphologies were obtained depending on the triblock copolymer amount. A hexagonally packed cylinder morphology was kept until reaching 30 wt% of PEO-PPO-PEO content, while a more complex three-phase morphology was obtained for 50 wt%, in which large worm-like PPO domains appear surrounded by two different phases, one of them rich in PEO and another phase rich in cured DGEVA. UV-vis measurements show that the transmittance is reduced with the increase in triblock copolymer content, especially at 50 wt%, probably due to the presence of PEO crystals detected by calorimetry.

Generation of One-Dimensional Fibrous Polyethylene Nanocrystals in Epoxy Thermosets

The one-dimensional (1D) polyethylene (PE) nanocrystals were generated in epoxy thermosets via crystallization-driven self-assembly. Toward this end, an ABA triblock copolymer composed of PE midblock and poly(ε-caprolactone) (PCL) endblocks was synthesized via the ring opening metathesis polymerization followed by hydrogenation approach. The nanostructured thermosets were obtained via a two-step curing approach, i.e., the samples were cured first at 80 °C and then at 150 °C. Under this condition, the one-dimensional (1D) fibrous PE microdomains with the lengths up to a couple of micrometers were created in epoxy thermosets. In contrast, only the spherical PE microdomains were generated while the thermosets were cured via a one-step curing at 150 °C. By the use of the triblock copolymer, the generation of 1D fibrous PE nanocrystals is attributable to crystallization-driven self-assembly mechanism whereas that of the spherical PE microdomains follows traditional self-assembly mechanism. Compared to the thermosets containing the spherical PE microdomains, the thermosets containing the 1D fibrous PE nanocrystals displayed quite different thermal and mechanical properties. More importantly, the nanostructured thermosets containing the 1D fibrous PE nanocrystals displayed the fracture toughness much higher than those only containing the spherical PE nanocrystals; the K_IC value was even three times as that of control epoxy.

Block Copolymer Modified Nanonetwork Epoxy Resin for Superior Energy Dissipation

Herein, this work aims to fabricate well-ordered nanonetwork epoxy resin modified with poly(butyl acrylate)-b-poly(methyl methacrylate) (PBA-b-PMMA) block copolymer (BCP) for enhanced energy dissipation using a self-assembled diblock copolymer of polystyrene-b-poly(dimethylsiloxane) (PS-b-PDMS) with gyroid and diamond structures as templates. A systematic study of mechanical properties using nanoindentation of epoxy resin with gyroid- and diamond-structures after modification revealed significant enhancement in energy dissipation, with the values of 0.36 ± 0.02 nJ (gyroid) and 0.43 ± 0.03 nJ (diamond), respectively, when compared to intrinsic epoxy resin (approximately 0.02 ± 0.002 nJ) with brittle characteristics. This enhanced property is attributed to the synergic effect of the deliberate structure with well-ordered nanonetwork texture and the toughening of BCP-based modifiers at the molecular level. In addition to the deliberate structural effect from the nanonetwork texture, the BCP modifier composed of epoxy-philic hard segment and epoxy-phobic soft segment led to dispersed soft-segment domains in the nanonetwork-structured epoxy matrix with superior interfacial strength for the enhancement of applied energy dissipation.

Reaction-induced phase transitions with block copolymers in solution and bulk

Reaction-induced phase transitions use chemical reactions to drive macromolecular organisation and self-assembly. This review highlights significant and recent advancements in this burgeoning field.

Polystyrene-block-Polydimethylsiloxane as a Potential Silica Substitute for Polysiloxane Reinforcement

Here we report microphase-separated poly(styrene-block-dimethylsiloxane) (PS-b-PDMS) as a reinforcing filler in PDMS thermosets that overcomes the long-standing problem of aging in the processing of silica-reinforced silicone. Surprisingly, PS-b-PDMS reinforced composites display comparable mechanical performance to silica-modified analogs, even though the modulus of PS is much smaller than that of silica and there is no evidence of percolation with respect to the rigid PS domains. We have found that a few unique characteristics contribute to the reinforcing performance of PS-b-PDMS. The strong self-assembly behavior promotes batch-to-batch repeatability by having well-dispersed fillers. The structure and size of the fillers depend on the loading and characteristics of both filler and matrix, along with the shear effect. The reinforcing effect of PS-b-PDMS is mostly brought by the entanglements between the corona layer of the filler and the matrix, rather than the hydrodynamic reinforcement of the PS phase.

Improving the toughness of thermosetting epoxy resins via blending triblock copolymers

In this study, the triblock copolymer poly(methyl methacrylate)-b-poly(butyl acrylate)-b-poly(methyl methacrylate) (MAM) was used to modify bisphenol A epoxy resin to improve its toughness. The effects of MAM on the curing behaviors, mechanical properties, fracture morphology and thermal properties of epoxy were carefully studied. The results of dissolution experiments show that MAM has good compatibility with epoxy resin under certain conditions. FT-IR and DSC analyses show that adding MAM to epoxy hinders the curing reaction of epoxy resin, without participating in the curing reaction and changing the curing mechanism. The mechanical properties indicated by K_IC and impact strength with an MAM content of 10 phr for the toughened system increase by 91.5% and 83.5%, respectively, compared to the situation without MAM, which may ascribed to the nanoparticles formed during the process of MAM/epoxy blending. In the curing process of an epoxy resin, the typical phase structure that occurs through the self-assembly process can be clearly observed in the MAM/epoxy blends. As the MAM content increases, the amount of nanoparticles gradually increases. This work further confirms that the toughness of the composite material was enhanced to a large extent without significantly decreasing the glass transition temperature of the blends.

In this study, the triblock copolymer poly(methyl methacrylate)-b-poly(butyl acrylate)-b-poly(methyl methacrylate) (MAM) was used to modify bisphenol A epoxy resin to improve its toughness.

Effect of Different Types of Block Copolymers on Morphology, Mechanical Properties, and Fracture Mechanisms of Bisphenol-F Based Epoxy System

The effect of adding different types of soft block copolymer on the tensile properties, fracture mechanic properties, and thermo-mechanical properties of bisphenol F based epoxy resin were studied. Two different self-assembling block copolymers, (a) constituting of a center block of poly (butyl acrylate) and two side blocks of poly (methyl) methacrylate-co-polar co-monomer (BCP 1) and (b) poly(ethylene oxide)-b-poly(butylene oxide) (PEO-PBO) diblock copolymer (BCP 2), were used with an epoxy-hardener system. The maximum fracture toughness and fracture energy were measured as KIc = 2.75 MPa·m1/2 and GIc = 2.37 kJ/m2 for the 10 wt % of BCP 1 modified system, which were 366% and 2270% higher in comparison to reference epoxy system, and a 63% reduction in tensile strength was also observed. Similarly, for BCP2 modified systems, the maximum value of KIc = 1.65 MPa·m1/2 and GIc = 1.10 kJ/m2 was obtained for epoxy modified with 12 wt % of BCP2 and a reduction of 32% in tensile strength. The fracture toughness and fracture energy were co-related to the plastic zone size for all the modified systems. Finally, the analysis of the fracture surfaces revealed the toughening micro-mechanisms of the nanocomposites.

Tensile Properties, Fracture Mechanics Properties and Toughening Mechanisms of Epoxy Systems Modified with Soft Block Copolymers, Rigid TiO2 Nanoparticles and Their Hybrids

The effect of the hybridization of a triblock copolymer and a rigid TiO2 nanofiller on the tensile, fracture mechanics and thermo-mechanical properties of bisphenol F based epoxy resin were studied. The self-assembling block copolymer, constituted of a center block of poly (butyl acrylate) and two side blocks of poly (methyl) methacrylate-co-polar co-monomer was used as a soft filler, and TiO2 nanoparticles were employed as rigid modifiers. Toughening solely by block copolymers (BCP’s) led to the highest fracture toughness and fracture energy in the study, KIc = 2.18 MPa·m1/2 and GIc = 1.58 kJ/m2. This corresponds to a 4- and 16-fold improvement, respectively, over the neat reference epoxy system. However, a reduction of 15% of the tensile strength was observed. The hybrid nanocomposites, containing the same absolute amounts of modifiers, showed a maximum value of KIc = 1.72 MPa·m1/2 and GIc = 0.90 kJ/m2. Yet, only a minor reduction of 4% of the tensile strength was observed. The fracture toughness and fracture energy were co-related to the plastic zone size for all the modified systems. Finally, the analysis of the fracture surfaces revealed the toughening mechanisms of the nanocomposites.

Triblock Copolymer Toughening of a Carbon Fibre-Reinforced Epoxy Composite for Bonded Repair

Epoxy resins are the most widely used systems for structural composite applications; however, they lack fracture toughness, impact strength and peel strength due to high cross-linking densities. Use of conventional toughening agents to combat this can lead to reductions in mechanical, thermal and processability properties desirable for bonded composite applications. In this work, an asymmetric triblock copolymer of poly(styrene)⁻b⁻poly(butadiene)⁻b⁻poly(methylmethacrylate) was used to modify an epoxy resin system, with the materials processed using both vacuum bag and positive pressure curing techniques. Interlaminar fracture toughness testing showed improvements in initiation fracture toughness of up to 88%, accompanied by a 6 °C increase in glass transition temperature and manageable reductions in gel-time. Shear testing resulted in a 121% increase in ultimate shear strain with only an 8% reduction in shear strength. Performance improvements were attributed to nano-structuring within the toughened resin system, giving rise to matrix cavitation and dissipation of crack front strain energy upon loading.

Synthesis of well-defined PCL-b-PnBA-b-PMMA ABC-type triblock copolymers: toward the construction of nanostructures in epoxy thermosets

A novel PCL-b-PnBA-b-PMMA was designed and applied to construct ordered nanostructures within epoxy thermosets.

Controlling the generation of bilayer and multilayer vesicles in block copolymer/epoxy blends by a slow photopolymerization process

Vesicles are a highly attractive morphology to achieve in micellar dispersions of block copolymers (BCP) in epoxy thermosets due to the fact that small amounts can affect a large volume fraction of the matrix, a fact that is important for toughening purposes. However, generating vesicles in epoxy matrices requires operating in a narrow range of formulations and processing conditions. In this report, we show that block-copolymer vesicles dispersed in an epoxy matrix could be obtained through a sphere-to-cylinder-to-vesicle micellar transition induced by visible-light photopolymerization at room temperature. A 10 wt% colloidal solution of poly(ethylene-co-butene)-block-poly(ethylene oxide) (PEB-b-PEO) block copolymer (BCP) in an epoxy monomer (DGEBA) self-assembled into spherical micelles as shown by small-angle X-ray scattering (SAXS). During a slow photopolymerization of the epoxy monomer carried out at room temperature, a sphere-to-cylinder-to-vesicle transition took place as revealed by in situ SAXS and TEM images. This was driven by the tendency of the system to reduce the local interfacial curvature as a response to a decrease in the miscibility of PEO blocks in the polymerizing epoxy matrix. When the BCP concentration was increased from 10 to 20 and 40 wt%, the final structure evolved from bilayer vesicles to multilayer vesicles and to lamellae, respectively. In particular, for 20 wt% PEB-b-PEO, transient structures such as partially fused multilayered vesicles were observed by TEM, giving insight into the growth mechanism of multilayer vesicles. On the contrary, when a relatively fast thermal polymerization was performed at 80 °C, the final morphology consisted of kinetically trapped spherical and cylindrical micelles. Hopefully, this study will lead to new protocols for the preparation of vesicles dispersed in epoxy matrices in a controlled way.

Toughening of an epoxy thermoset with poly[styrene-alt-(maleic acid)]-block-polystyrene-block-poly(n-butyl acrylate) reactive core–shell particles

Reactive core–shell particles for epoxy toughening were synthesized via reversible addition–fragmentation chain transfer emulsion polymerization mediated by an amphiphilic macro-RAFT agent followed by core-crosslinking to increase stability.

Curing kinetics and morphology of a nanovesicular epoxy/stearyl-block-poly(ethylene oxide) surfactant system

Brittle epoxy based thermosets can be made tougher by introducing structural inhomogeneities at the micro- or nanoscale. In that respect, nano vesicles and worm-like micelles from self-assembling blockcopolymers have been shown to be very effective. This paper describes the curing kinetics and morphology of an epoxy composed of diglycidyl ether of bisphenol A (DGEBA) and 4,4'-methylenedianiline (MDA), modified by 20% of the surfactant stearyl-block-poly(ethylene oxide). Time resolved, synchrotron small-angle X-ray scattering demonstrates that at any time during the epoxy curing process, the surfactant predominantly adopts a bilayer vesicular nano-morphology. Transmission electron microscopy on fully cured systems reveals the coexistence of spherical and worm-like micelles. Differential scanning calorimetry experiments prove that the presence of surfactant reduces the epoxy curing rate but that ultimately full curing is accomplished. The material glass transition temperature falls below that of the pure resin due to plasticization. It is suggested that favorable secondary interactions between the PEO segments and the epoxy resin are responsible for the observed phenomena.