Toughening by nanostructure

Effect of Block Copolymer Self-Assembly on Phase Separation in Photopolymerizable Epoxy Blends

Directing self-assembly of photopolymerizable systems is advantageous for controlling polymer nanostructure and material properties, but developing techniques for inducing ordered structure remains challenging. In this work, well-defined diblock or random copolymers were incorporated into cationic photopolymerizable epoxy systems to investigate the impact of copolymer architecture on self-assembly and phase separated nanostructures. Copolymers consisting of poly(hydroxyethyl acrylate)-x-(butyl acrylate) were prepared using photoiniferter polymerization to control functional group placement and molecular weight/polydispersity. Prepolymer configuration and concentration induced distinctly different effects on the resin flow and photopolymerization kinetics. The diblock copolymer self-assembled into nanostructured phases within the resin matrix, whereas the random copolymer formed an isotropic mixture. Rapid photopolymerization and ambient temperature conditions during cure facilitated retention of the self-assembled phases, leading to considerably different composite morphology and thermomechanical behavior. Increased loading of the diblock copolymer induced long-range ordered cocontinuous structures. Even with nearly identical prepolymer composition, controlled nanophase separation resulted in significantly enhanced tensile properties relative to those of the isotropic system. This work demonstrates that controlling phase separation with a block copolymer architecture allows access to nanostructured photopolymers with unique and enhanced properties.

Reaction-induced morphological transitions in a blend of diblock copolymers and reactive monomers: dissipative particle dynamics simulation

The dissipative particle dynamics (DPD) method is applied to the morphological transitions of microphase-separated domains in a mixture of symmetric AB-diblock copolymers and reactive C-monomers, where polymerization and cross-linking reactions take place among C-monomers. The initial structure for the DPD simulation is an equilibrated cylindrical domain structure prepared by the density-biased Monte Carlo method with density profiles obtained from the self-consistent field theory. By introducing a cross-linking reaction among reactive C-monomers, we confirmed that the DPD simulation reproduces the morphological transitions observed in experiments, where the domain morphology changes due to segregation between A-blocks of diblock copolymers and cross-linking networks of C-monomers. When the cross-linking reaction of C-monomers is sufficiently fast compared to the deformation of the domains, the initial cylindrical domains are preserved, while the distance between the domains increases. On the other hand, when the formation of the cross-linking network is slow, the domains can deform and reconnect with each other in the developing cross-linking network. In this case, we observe morphological transitions from the initial domain morphology with a large-curvature interface to another domain morphology with a smaller-curvature interface, such as the transition from the cylindrical phase to the lamellar phase. We calculated the spatial correlations in the microphase-separated domains and found that such correlations are affected by the speed of the formation of the cross-linking network depending on whether the bridging between microphase-separated domains occurs in a nucleation and growth process or in a spinodal decomposition process.

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.

Polymerization Induced Microphase Separation for the Fabrication of Nanostructured Materials

Polymerization induced microphase separation (PIMS) is a strategy used to develop unique nanostructures with highly useful morphologies through the microphase separation of emergent block copolymers during polymerization. In this process, nanostructures are formed with at least two chemically independent domains, where at least one domain is composed of a robust crosslinked polymer. Crucially, this synthetically simple method is readily used to develop nanostructured materials with the highly coveted co-continuous morphology, which can also be converted into mesoporous materials by selective etching of one domain. As PIMS exploits a block copolymer microphase separation mechanism, the size of each domain can be tightly controlled by modifying the size of block copolymer precursors, thus providing unparalleled control over nanostructure and resultant mesopore sizes. Since its inception 11 years ago, PIMS has been used to develop a vast inventory of advanced materials for an extensive range of applications including biomedical devices, ion exchange membranes, lithium-ion batteries, catalysis, 3D printing, and fluorescence-based sensors, among many others. In this review, we provide a comprehensive overview of the PIMS process, summarize latest developments in PIMS chemistry, and discuss its utility in a wide variety of relevant applications.

Influence of Block-Copolymers' Composition as Compatibilizers for Epoxy/Silicone Blends

The objective of this study was to prepare crosslinked epoxy networks containing liquid silicone particles in order to improve their mechanical properties and obtain less brittle materials. Different copolymers were used as compatibilizers. These copolymers vary in their chemical composition and structure. All of the copolymers contain hydrophobic (PDMS sequences) and hydrophilic groups. The effect of their chemical structure and architecture on the morphology of the dispersed phase, and on the final physico-chemical and flexural characteristics of epoxy/silicone blends, was explored. The morphology of crosslinked formulations was studied by scanning electron microscopy (SEM), and the thermal characteristics (glass transition temperature, Tg, and curing exothermic peak) were determined by differential scanning calorimetry (DSC). The experimental results have shown that the average diameter and particle size distribution of silicone particles depend on the chemical structure and architecture of the compatibilizers. One copolymer has been identified as the best compatibilizer, allowing a lower mean diameter and particle size distribution in addition to the best mechanical properties of the final network (less brittle character). This study has consequently evidenced the possibility of creating in situ silicone capsules inside an epoxy network by adding tailored compatibilizers to epoxy/silicone formulations.

Highly Toughened Nanostructured Self-Assembled Epoxy-Based Material—Correlation Study between Nanostructured Morphology and Fracture Toughness—Impact Characteristics

We present an efficient and effective method for preparing a novel self-assembled nanostructured material with high toughness and impact strength from a blend of di-glycidyl ether of bisphenol-A (DGEBA) and epoxidized poly(styrene-block-butadiene-block-styrene) (eSBS55) tri-block copolymer. The field emission scanning electron microscopy and transmission electron microscope results show the nanostructured morphological characteristics of the blends. This study achieved the highest fracture toughness, with a fracture toughness in the form of critical stress intensity factors (KIC) value of 2.54 MPa m1/2, in epoxy/block copolymer blends compared to previous works in the field. The impact strength also increased by 116% compared to neat epoxy. This is a major advancement in epoxy toughening due to the use of a single secondary phase. The resulting highly tough and impact-resistant material is a promising candidate for coating applications in industries such as flooring, building, aerospace, and automobiles.

Enhancement of Epoxy Thermosets with Hyperbranched and Multiarm Star Polymers: A Review

Hyperbranched polymers and multiarm star polymers are a type of dendritic polymers which have attracted substantial interest during the last 30 years because of their unique properties. They can be used to modify epoxy thermosets to increase their toughness and flexibility but without adversely affecting other properties such as reactivity or thermal properties. In addition, the final properties of materials can be tailored by modifying the structure, molecular weight, or type of functional end-groups of the hyperbranched and multiarm star polymers. In this review, we focus on the modification of epoxy-based thermosets with hyperbranched and multiarm star polymers in terms of the effect on the curing process of epoxy formulations, thermal, mechanical, and rheological properties, and their advantages in fire retardancy on the final thermosets.

Epoxidized Block and Statistical Copolymers Reinforced by Organophosphorus-Titanium-Silicon Hybrid Nanoparticles: Morphology and Thermal and Mechanical Properties

Glycidyl methacrylate (GMA) and a mixture of alkyl methacrylates (average chain length of 13 carbons; termed C13MA; derived from vegetable oils) were copolymerized by nitroxide-mediated polymerization to form epoxidized statistical and block copolymers with similar compositions (F GMA ∼0.8), which were further cross-linked by a bio-based diamine. Hybrid plate-like nanoparticles containing organophosphorus-titanium-silicon (PTS) with an average size of ∼130 nm and high decomposition temperature (485 °C) were synthesized via a hydrothermal reaction to serve as additives to simultaneously enhance the thermal and mechanical properties of the blend. Nanocomposites filled with PTS were prepared at different filler-loading levels (0.5, 2, 4 wt %). Transmission electron microscopy (TEM) of the cured block copolymer displayed reaction-induced macrophase-separated domains. TEM also showed an effective dispersion of PTS hybrids in the matrix without intense agglomeration. Thermogravimetric analysis at different heating rates revealed the activation energy of poly (GMA-stat-C13MA) at maximum decomposition increased from 143.5 to 327.2 kJ mol-1 with 4 wt % PTS. Decomposition temperature and char residue improved 12 °C and ∼7 wt %, respectively, and T g increased 12 °C by adding 4 wt % PTS. Targeting various PTS concentrations enabled tuning of the tensile modulus (up to 75%), tensile strength (up to 46%), and storage modulus in both glassy state (up to 59%) and rubbery plateau regions (up to 88%). Oscillatory frequency sweeps indicated that PTS makes the storage modulus frequency dependent, suggesting that the inclusion of the nanoparticles alters the relaxation of the surrounding matrix polymer.

Long PEO-based nanoribbons generated in a polystyrene matrix through reaction-induced microphase separation followed by a fast crystallization process

A dispersion of elongated nanostructures with a high aspect ratio in polymer matrices has been reported to provide a material with valuable properties such as mechanical strength, barrier effect and shape memory, among others. In this study, we show the procedure to achieve a distribution of elongated crystalline nanodomains in a PS matrix employing the self-assembly of amphiphilic block copolymers (BCP). The selected BCP was polystyrene-block-polyethylene oxide (PS-b-PEO). It was dissolved at 10 wt% in a styrene (St) monomer and the blend was slowly photopolymerized over four days at room temperature, until the reaction was arrested by vitrification. This blend was initially homogeneous and nanostructuration took place in an early stage of the polymerization as a result of the microphase separation (MS) of PEO blocks. Due to its high tendency to crystallize, demixed PEO blocks crystallized almost concomitantly with MS triggering the growing of the nanostructures. Thus, the time window between the onset of crystallization and the vitrification of the matrix was almost four days, allowing all micelles to have the opportunity to couple to a growing nanostructure. As a result, a population of nanoribbons with average lengths surpassing 10 μm dispersed in a PS matrix was obtained. It was demonstrated that these ribbon-like nanostructures are preserved as long as the heating temperature is located below the Tg of the matrix. If the material is heated above this temperature, softening of the matrix allows the breakup of the molten PEO nanoribbons due to Plateau-Rayleigh instability.

General-Purpose Coarse-Grained Toughened Thermoset Model for 44DDS/DGEBA/PES

The objective of this work is to predict the morphology and material properties of crosslinking polymers used in aerospace applications. We extend the open-source dybond plugin for HOOMD-Blue to implement a new coarse-grained model of reacting epoxy thermosets and use the 44DDS/DGEBA/PES system as a case study for calibration and validation. We parameterize the coarse-grained model from atomistic solubility data, calibrate reaction dynamics against experiments, and check for size-dependent artifacts. We validate model predictions by comparing glass transition temperatures measurements at arbitrary degree of cure, gel-points, and morphology predictions against experiments. We demonstrate for the first time in molecular simulations the cure-path dependence of toughened thermoset morphologies.

Morphological evolution and mechanical properties of an “anchor chain” nanodomain structure of a reactive amphiphilic triblock copolymer in epoxy resin

A epoxy-reactive poly(3,4-epoxycyclohexylmethyl methacrylate)-block-poly(dimethylsiloxane)-block-poly(3,4-epoxycyclohexylmethyl methacrylate) (PMETHB-b-PDMS-b-PMETHB) triblock can self-assemble in epoxy resin to form “anchor-chain” nanodomains.

Investigation of Azobenzene Photoisomerization Effect on Morphologies and Properties of Nanostructured Thermosets Involving Epoxy and a Diblock Copolymer

This work highlights the effect of azobenzene photoisomerization on the morphologies and properties of the nanostructured thermosets involving epoxy and a diblock copolymer. First, a diblock copolymer composed of poly(ethylene oxide) (PEO) and poly(6-(4-(4-cyanophenylazo)phenoxy)hexyl methacrylate) (PCPHM) was synthesized, and this diblock copolymer was composed of an epoxy-philic block (i.e., PEO) and an azobenzene moiety-beating block (viz., PCPHM). This diblock copolymer was introduced into epoxy to obtain the nanostructured thermosets via reaction-induced microphase separation approach. To control the configuration of azobenzene moieties of the PCPHM block, the curing reactions were performed in the absence and/or presence of ultraviolet (UV) irradiation, respectively. It was found that, without UV irradiation, the PCPHM microdomains were generated with the trans isomers of azobenzene. Under UV irradiation, however, the PCPHM microdomains were formed with the cis configuration of azobenzene moieties. The ultraviolet-visible light (UV-vis) spectroscopy showed that the trans and cis configurations of azobenzene moieties were significantly fixed with the occurrence of curing reactions. The photoluminescent measurements showed that the nanostructured thermosets with trans-azobenzene moieties can emit fluorescence, which was in sharp contrast to those with cis-azobenzene moieties. The results of small-angle X-ray and atomic force microscopy showed that the nanostructured thermosets with trans and cis isomers of azobenzene moieties had quite different morphologies. It was found that the sizes of the PCPHM microdomains with cis configuration of azobenzene moieties were significantly larger than those with trans configuration. The difference in configuration of azobenzene moieties also resulted in the difference in glass-transition temperatures and dielectric properties of the materials. The results suggest a new approach to modulate the morphologies and physical properties of the nanostructured thermosets by means of photoisomerization of azobenzene moieties.

Fluorescence Enhancement Induced by Curing Reaction in Nanostructured Epoxy Thermosets Containing a Diblock Copolymer

In this work, a novel curing-induced fluorescence (FL) enhancement phenomenon in the nanostructuring process of epoxy thermosets was investigated. Toward this end, a diblock copolymer composed of poly(ethylene oxide) and poly(((4-vinylphenyl)ethene-1,1,2-triyl)tribenzene) (PTPEE) blocks was introduced into epoxy thermosets. Before curing reaction, the mixtures of epoxy precursors with the diblock copolymer only emitted feeble FL under ultra-visible (UV) irradiation. However, photoluminescence was significantly enhanced after the curing reaction was carried out. It was found that the novel FL enhancement phenomenon resulted from the aggregation-induced emission behavior of PTPEE blocks, which was triggered by curing reaction. In the nanostructured thermosets, the fluorophore blocks (viz. PTPEE) of this diblock copolymer were segregated into aggregates, that is, a reaction-induced microphase separation occurred. Owing to the generation of PTPEE microdomains, the epoxy nanocomposites significantly displayed the enhanced dielectric constants due to the promoted contribution from electron polarizations via π-π conjugation in the materials.

A New Way of Toughening of Thermoset by Dual-Cured Thermoplastic/Thermosetting Blend

The work aims at establishing the optimum conditions for dual thermal and electron beam curing of thermosetting systems modified by styrene/butadiene (SB)-based triblock copolymers in order to develop transparent and toughened materials. The work also investigates the effects of curing procedures on the ultimate phase morphology and mechanical properties of these thermoset–SB copolymer blends. It was found that at least 46 mol% of the epoxidation degree of the SB copolymer was needed to enable the miscibility of the modified block copolymer into the epoxy resin. Hence, an electron beam curing dose of ~50 kGy was needed to ensure the formation of micro- and nanostructured transparent blends. The micro- and nanophase-separated thermosets obtained were analyzed by optical as well as scanning and transmission electron microscopy. The mechanical properties of the blends were enhanced as shown by their impact strengths, indentation, hardness, and fracture toughness analyses, whereby the toughness values were found to mainly depend on the dose. Thus, we have developed a new route for designing dual-cured toughened micro- and nanostructured transparent epoxy thermosets with enhanced fracture toughness.

Assessments of Secondary Reinforcement of Epoxy Matrix-Glass Fibre Composite Laminates through Nanosilica (SiO₂)

The principal objective of this research work was to investigate the results of impregnating epoxy matrix-glass fibre composite laminates with nanosilica as secondary reinforcement. 0.5, 0.75, 1 and 3 wt% nanosilica was used and thereafter properties of composites were assessed through tensile, three point bending, quasi static indentation tests and dynamic mechanical analysis. Scanning electron microscope examinations were done on fracture surfaces and failure modes were analyzed. The internal failures of the composite due to quasi-static indentation were evaluated through C-Scan. Among samples of different weight fractions, 0.75 wt% nanosilica reinforced composite laminates exhibited substantial increase of 42% in tensile strength and 39.46% in flexural strength. The reduction in glass transition temperature (T_g), increase in storage modulus (E'), loss modulus (E″) and damping factor (tan δ) were also observed. Quasi-static indentation assessments revealed that energy absorption property was enhanced significantly by 53.97%. Hence nanosilica up to 0.75 wt% can be used as a potential candidate for secondary reinforcement in epoxy composite laminates.

Polyether Sulfone-Based Epoxy Toughening: From Micro- to Nano-Phase Separation via PES End-Chain Modification and Process Engineering

The toughness of a high-performance thermosetting epoxy network can be greatly improved by generating polyether sulfone-based macro- to nano-scale morphologies. Two polyethersulfones (PES) which only differ by their chain-end nature have been successively investigated as potential tougheners of a high-T_g thermoset matrix based on a mixture of trifunctional and difunctional aromatic epoxies and an aromatic diamine. For a given PES content, morphologies and toughness of the resulting matrices have been tuned by changing curing conditions and put into perspective with PES chain-end nature.

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.

Improved epoxy thermosets by the use of poly(ethyleneimine) derivatives

Epoxy resins are commonly used as thermosetting materials due to their excellent mechanical properties, high adhesion to many substrates and good heat and chemical resistances. This type of thermosets is intensively used in a wide range of fields, where they act as fiber-reinforced materials, general-purpose adhesives, high-performance coatings and encapsulating materials. These materials are formed by the chemical reaction of multifunctional epoxy monomers forming a polymer network produced through an irreversible way. In this article the improvement of the characteristics of epoxy thermosets using different hyperbranched poly(ethyleneimine) (PEI) derivatives will be explained.

Isolation of Aramid Nanofibers for High Strength and Toughness Polymer Nanocomposites

The development of nanoscale reinforcements that can be used to improve the mechanical properties of a polymer remains a challenge due to the long-standing difficulties with exfoliation and dispersion of existing materials. The dissimilar chemical nature of common nanofillers (e.g., carbon nanotubes, graphene) and polymeric matrix materials is the main reason for imperfect filler dispersion and, consequently, low mechanical performance of their composites relative to theoretical predictions. Here, aramid nanofibers that are intrinsically dispersible in many polymers are prepared from commercial aramid fibers (Kevlar) and isolated through a simple, scalable, and low-cost controlled dissolution method. Integration of the aramid nanofibers in an epoxy resin results in nanocomposites with simultaneously improved elastic modulus, strength, and fracture toughness. The improvement of these two mutually exclusive properties of nanocomposites is comparable to the enhancement of widely reported carbon nanotube reinforced nanocomposites but with a cost-effective and more feasible method to achieve uniform and stable dispersion. The results indicate the potential for aramid nanofibers as a new class of reinforcements for polymers.