Closed-Loop Recyclable Fully Bio-Based Epoxy Vitrimers from Ferulic Acid-Derived Hyperbranched Epoxy Resin

Closed-loop recycling of tough epoxy supramolecular thermosets constructed with hyperbranched topological structure

The regulation of topological structure of covalent adaptable networks (CANs) remains a challenge for epoxy CANs. Here, we report a strategy to develop strong and tough epoxy supramolecular thermosets with rapid reprocessability and room-temperature closed-loop recyclability. These thermosets were constructed from vanillin-based hyperbranched epoxy resin (VanEHBP) through the introduction of intermolecular hydrogen bonds and dual dynamic covalent bonds, as well as the formation of intramolecular and intermolecular cavities. The supramolecular structures confer remarkable energy dissipation capability of thermosets, leading to high toughness and strength. Due to the dynamic imine exchange and reversible noncovalent crosslinks, the thermosets can be rapidly and effectively reprocessed at 120 °C within 30 s. Importantly, the thermosets can be efficiently depolymerized at room temperature, and the recovered materials retain the structural integrity and mechanical properties of the original samples. This strategy may be employed to design tough, closed-loop recyclable epoxy thermosets for practical applications.

Supported Ionic Liquid-Phase Materials (SILP) as a Multifunctional Group of Highly Stable Modifiers and Hardeners for Carbon and Flax Epoxy Composites

This paper introduces a novel approach to enhance epoxy resin formulations by using SILP materials as multifunctional hardeners and fillers in composite structures reinforced with carbon and flax fibers. This study explores the integration of ionic liquids (ILs) onto a silica support structure, presenting various permutations involving silica selection, ionic liquid choice, and concentration. The focus of this study was to elucidate the influence of SILP on resin curing ability and the mechanical properties of the resulting composites. Detailed research was conducted, including Brunauer-Emmett-Teller analysis (BET) for SILP materials and curing characterization for epoxy resin formulations with different SILP materials. Furthermore, the mechanical properties of the obtained composites were determined by Scanning Electron Microscopy analysis (SEM) (the force at break, the maximum elongation at break, tensile strength, and modulus of elasticity). Through SILP incorporation, the mechanical properties of composites, including the modulus of elasticity and tensile strength, are substantially improved, a phenomenon akin to traditional filler effects. The findings highlight SILP materials as prospective candidates for concurrent hardening and filling roles within composites (through a single-step procedure, with prolonged storage stability and controlled processing conditions), particularly pertinent as the composite industry veers toward epoxy bioresins necessitating liquefaction via temperature application.

Closed-loop recyclability of a biomass-derived epoxy-amine thermoset by methanolysis

Epoxy resin thermosets (ERTs) are an important class of polymeric materials. However, owing to their highly cross-linked nature, they suffer from poor recyclability, which contributes to an unacceptable level of environmental pollution. There is a clear need for the design of inherently recyclable ERTs that are based on renewable resources. We present the synthesis and closed-loop recycling of a fully lignocellulose-derivable epoxy resin (DGF/MBCA), prepared from dimethyl ester of 2,5-furandicarboxylic acid (DMFD), 4,4'-methylenebis(cyclohexylamine) (MBCA), and glycidol, which displays excellent thermomechanical properties (a glass transition temperature of 170°C, and a storage modulus at 25°C of 1.2 gigapascals). Notably, the material undergoes methanolysis in the absence of any catalyst, regenerating 90% of the original DMFD. The diamine MBCA and glycidol can subsequently be reformed by acetolysis. Application and recycling of DGF/MBCA in glass and plant fiber composites are demonstrated.

Bio-Based Thermosetting Resins: From Molecular Engineering to Intrinsically Multifunctional Customization

Recent years have witnessed a growing interest in bio-based thermosetting resins in terms of environmental concerns and the desire for sustainable industrial practices. Beyond sustainability, utilizing the structural diversity of renewable feedstock to craft bio-based thermosets with customized functionalities is very worthy of expectation. There exist many bio-based compounds with inherently unique chemical structures and functions, some of which are even difficult to synthesize artificially. Over the past decade, great efforts are devoted to discovering/designing functional properties of bio-based thermosets, and notable progress have been made in antibacterial, antifouling, flame retardancy, serving as carbon precursors, and stimuli responsiveness, among others, largely expanding their application potential and future prospects. In this review, recent advances in the field of functional bio-based thermosets are presented, with a particular focus on molecular structures and design strategies for discovering functional properties. Examples are highlighted wherein functionalities are facilitated by the inherent structures of bio-based feedstock. Perspectives on issues regarding further advances in this field are proposed at the end.

Ultrastrong and High-Tough Thermoset Epoxy Resins from Hyperbranched Topological Structure and Subnanoscaled Free Volume

The strength and toughness of thermoset epoxy resins are generally mutually exclusive, as are the high performance and rapid recyclability. Experimentally determined mechanical strength values are usually much lower than their theoretical values. The preparation of thermoset epoxy resins with high modulus, high toughness, ultrastrong strength, and highly efficient recyclability is still a challenge. Here, novel hyperbranched epoxy resins (Bn, n = 6, 12, 24) with imide structures by a thiol-ene click reaction. Bn shows an excellent comprehensive function in simultaneously improving the strength, modulus, toughness, low-temperature resistance, and degradability of diglycidyl ether of bisphenol-A (DGEBA). All the mechanical properties first increase and then decrease with minimization of the free volume properties. The improvement is attributable to uniform molecular holes or free volume by a molecular mixture of linear and hyperbranched topological structures. The precise measurement and controllability of the molecular free volume properties of epoxy resins is first discovered, as well as the imide structure degradation of crosslinked epoxy resins. The two conflicts are successfully resolved between strength and toughness and between high performance during service and high efficiency during degradation. These findings provide a route for designing ultrastrong, tough, and recyclable thermoset epoxy resins.

Low viscosity and low temperature curing reactive POSS/epoxy hybrid resin with enhanced toughness and comprehensive thermal performance

The mechanical and high-temperature resistance properties of epoxy resins cured at low temperatures (Tcuring ≤ 100 °C) are often inferior, and the most toughening modification methods for epoxy resins tend to compromise thermal resistance, which significantly limit the practical applications of it. Therefore, this work reported a low viscosity and low-temperature curing epoxy hybrid resin system (OPEP), adopting E-51 as a resin matrix, liquid anhydride (MHHPA) as a curing agent, tertiary amine (DMBA) as a curing accelerator, and reactive octa-epoxy terminated polyhedral oligomeric silsesquioxane (OG-POSS) as a toughening modifier. Results demonstrated that the OPEP system has excellent processability with low viscosity and long processing window period and satisfies the practical requirements of low-temperature curing. The OG-POSS exhibits superior compatibility and reactivity with the resin matrix, and its addition slightly reduces the Eα of the curing reaction and has a certain promotive effect on the curing of epoxy resin. In addition, the curing reaction rate of the OPEP resin complies with the Šesták-Berggren autocatalytic kinetics model. The impact strength, flexural strength, tensile strength, and elongation at break of the OPEP resin reached a maximum of 15.55 kJ m-2, 121.65 MPa, 90.36 MPa, and 2.48%, representing increases of 55.97%, 3.1%, 64.68%, and 26.51% compared to those of the pure resin, respectively. Notably, due to the heat-resistant inorganic silicon cage structure of OG-POSS, the thermal decomposition temperature (Td5), glass transition temperature (Tg), and heat distortion temperature (THDT) of the OPEP0.02 resin were 313.2 °C, 123.7 °C, and 102.0 °C, showing increases of 13.0 °C, 2.3 °C, and 6.8 °C compared to the pure resin, respectively, which is difficult to achieve for the general thermosetting resin toughening modification method. This research utilized organic-inorganic nanohybrid materials (POSS) to optimize the toughness and thermal stability of the resin in a coordinated manner, providing guidance for the preparation of high-performance epoxy resins that cure at low temperatures.

Bio-based hyperbranched epoxy resins: synthesis and recycling

Epoxy resins (EPs), accounting for about 70% of the thermosetting resin market, have been recognized as the most widely used thermosetting resins in the world. Nowadays, 90% of the world's EPs are obtained from the bisphenol A (BPA)-based epoxide prepolymer. However, certain limitations severely impede further applications of this advanced material, such as limited fossil-based resources, skyrocketing oil prices, nondegradability, and a "seesaw" between toughness and strength. In recent years, more and more research has been devoted to the preparation of novel epoxy materials to overcome the compromise between toughness and strength and solve plastic waste problems. Among them, the development of bio-based hyperbranched epoxy resins (HERs) is unique and attractive. Bio-based HERs synthesized from bio-derived monomers can be used as a matrix resin or a toughener resulting in partially or fully bio-based epoxy thermosets. The introduction of a hyperbranched structure can balance the strength and toughness of epoxy thermosets. Here, we especially focused on the recent progress in the development of bio-based HERs, including the monomer design, synthesis approaches, mechanical properties, degradation, and recycling strategies. In addition, we advance the challenges and perspectives to engineering application of bio-based HERs in the future. Overall, this review presents an up-to-date overview of bio-based HERs and guidance for emerging research on the sustainable development of EPs in versatile high-tech fields.

On a Biobased Epoxy Vitrimer from a Cardanol Derivative Prepared by a Simple Thiol-Epoxy "Click" Reaction

The development of this work lies in the relevant interest in epoxy resins, which, despite their wide use, do not meet the requirements for sustainable materials. Therefore, the proposed approach considers the need to develop environmentally friendly systems, in terms of both the starting material and the synthetic method applied as well as in terms of end-of-life. The above issues were taken into account by (i) using a monomer from renewable sources, (ii) promoting the formation of dynamic covalent bonds, allowing for material reprocessing, and (iii) evaluating the degradability of the material. Indeed, an epoxy derived from cardanol was used, which, for the first time, was applied in the development of a vitrimer system. The exploitation of a diboronic ester dithiol ([2,2'-(1,4-phenylene)-bis[4-mercaptan-1,3,2-dioxaborolane], DBEDT) as a cross-linker allowed the cross-linking reaction to be carried out without the use of solvents and catalysts through a thiol-epoxy "click" mechanism. The dynamicity of the network was demonstrated by gel fraction experiments and rheological and DMA measurements. In particular, the formation of a vitrimer was highlighted, characterized by low relaxation times (around 4 s at 70 °C) and an activation energy of ca. 48 kJ/mol. Moreover, the developed material, which is easily biodegradable in seawater, was found to show promising flame reaction behavior. Preliminary experiments demonstrated that, unlike an epoxy resin prepared from the same monomer and using a classical cross-linker, our boron-containing material exhibited no dripping under combustion conditions, a phenomenon that will allow this novel biobased system to be widely used.

Hyperbranched Dynamic Crosslinking Networks Enable Degradable, Reconfigurable, and Multifunctional Epoxy Vitrimer

Degradation and reprocessing of thermoset polymers have long been intractable challenges to meet a sustainable future. Star strategies via dynamic cross-linking hydrogen bonds and/or covalent bonds can afford reprocessable thermosets, but often at the cost of properties or even their functions. Herein, a simple strategy coined as hyperbranched dynamic crosslinking networks (HDCNs) toward in-practice engineering a petroleum-based epoxy thermoset into degradable, reconfigurable, and multifunctional vitrimer is provided. The special characteristics of HDCNs involve spatially topological crosslinks for solvent adaption and multi-dynamic linkages for reversible behaviors. The resulting vitrimer displays mild room-temperature degradation to dimethylacetamide and can realize the cycling of carbon fiber and epoxy powder from composite. Besides, they have supra toughness and high flexural modulus, high transparency as well as fire-retardancy surpassing their original thermoset. Notably, it is noted in a chance-following that ethanol molecule can induce the reconstruction of vitrimer network by ester-exchange, converting a stiff vitrimer into elastomeric feature, and such material records an ultrahigh modulus (5.45 GPa) at -150 °C for their ultralow-temperature condition uses. This is shaping up to be a potentially sustainable advanced material to address the post-consumer thermoset waste, and also provide a newly crosslinked mode for the designs of high-performance polymer.

Structure and thermal behavior of biobased vitrimer of lactic acid and epoxidized canola oil

Biobased vitrimers were obtained from epoxidized canola oil (ECO) and lactic acid (LA) using zinc acetate (ZnAc) and ZnAl-layered double hydroxide (ZnAl) in the proportions of 1 and 2 wt% as transesterification catalysts. Reactions containing ECO and LA showed an average enthalpy of cure of approximately 85 mJ mg-1 and materials cured in the presence of the catalysts showed lower enthalpies of cure and decrease in the material gel content. ECO-LA reaction generated materials with rubber-like properties with Tg ranging from -15 °C to -23 °C, where the material without a catalyst showed the higher Tg value. The presence of catalysts gave the material vitrimer properties, with the softening point associated with transesterification reactions and topology freezing temperature transition at temperatures (Tv) between 195-235 °C.

Strong and Ultra-tough Ionic Hydrogel Based on Hyperbranched Macro-Cross-linker: Influence of Topological Structure on Properties

The application of hydrogels often suffers from their inherent limitation of poor mechanical properties. Here, a carboxyl-functionalized and acryloyl-terminated hyperbranched polycaprolactone (PCL) was synthesized and used as a macro-cross-linker to fabricate a super strong and ultra-tough ionic hydrogel. The terminal acryloyl groups of hyperbranched PCL are chemically incorporated into the network to form covalent cross-links, which contribute to robust networks. Meanwhile, the hydrophobic domains formed by the spontaneous aggregation of PCL chains and coordination bonds between Fe3+ and COO- groups serve as dynamic non-covalent cross-links, which enhance the energy dissipation ability. Especially, the influence of the hyperbranched topological structure of PCL on hydrogel properties has been well investigated, exhibiting superior strengthening and toughening effects compared to the linear one. Moreover, the hyperbranched PCL cross-linker also endowed the ionic hydrogel with higher sensitivity than the linear one when used as a strain sensor. As a result, this well-designed ionic hydrogel possesses high mechanical strength, superior toughness, and well ionic conductivity, exhibiting potential applications in the field of flexible strain sensors.

Hemiaminal dynamic covalent networks with rapid stress relaxation, reprocessability and degradability endowed by the synergy of disulfide and hemiaminal bonds

This work proposes a strategy to address the challenge of achieving rapid reprocessability of vitrimers at mild temperatures by introducing dynamic disulfide and hemiaminal bonds into hemiaminal dynamic covalent networks (HDCNs). The resulting HDCNs, termed HDCNs-DTDA, were prepared through a facile polycondensation between formaldehyde and 4,4'-dithiodianiline. The dual dynamic bond system in the HDCNs-DTDA enables rapid stress relaxation under mild temperature (65 °C for 54 s), which is significantly faster than that observed in HDCNs containing a single dynamic bond (HDCNs-DDM). The HDCNs-DTDA also exhibit a glass transition temperature of 96 °C, excellent solvent resistance and high recovery rates (97%) of tensile strength after reprocessing. In addition, HDCNs-DTDA can be easily degraded in HCl and thiol solutions at room temperature to enable chemical recyclability. Finally, HDCNs-DTDA demonstrates fast shape memory behaviors using thermal stimulation.

Preparation of Epoxy Resin with Disulfide-Containing Curing Agent and Its Application in Self-Healing Coating

Intrinsic self-healing polymers via dynamic covalent bonds have been attracting extensive attention because of their repeatable self-healing property. Herein, a novel self-healing epoxy resin was synthesized with disulfide-containing curing agent via the condensation of dimethyl 3,3'-dithiodipropionate (DTPA) and polyether amine (PEA). Therefore, in the structure of cured resin, flexible molecular chains and disulfide bonds were imported into the cross-linked polymer networks for triggering self-healing performance. The self-healing reaction of cracked samples was realized under a mild condition (60 °C for 6 h). The distribution of flexible polymer segments, disulfide bonds and hydrogen bonds in cross-linked networks plays a great role in the self-healing process of prepared resins. The molar ratio of PEA and DTPA strongly affects the mechanical performance and self-healing property. Especially when that molar ratio of PEA to DTPA is 2, the cured self-healing resin sample showed great ultimate elongation (795%) and excellent healing efficiency (98%). The products can be used as an organic coating, in which the crack could self-repair during a limited time. The corrosion resistance of a typical cure coating sample has been testified by an immersion experiment and electrochemistry impedance spectrum (EIS). This work provided a simple and low-cost route to prepare a self-healing coating for prolonging the service life of conventional epoxy coatings.

Manufacture of antibacterial carbon fiber-reinforced plastics (CFRP) using imine-based epoxy vitrimer for medical application

An antibacterial carbon fiber-reinforced plastics (CFRP) was manufactured based on a vitrimer containing imine groups. A liquid curing agent was prepared to include an imine group in the matrix, and was synthesized without a simple mixing reaction and any purification process. The vitrimer used as the matrix for CFRP was prepared by reacting a commercial epoxy with a synthesized curing agent. The structural and thermal properties of the vitrimer were determined by Fourier transform-infrared spectroscopy (FT-IR), differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). In addition, the temperature-dependent behavior of the vitrimer was characterized by stress relaxation, reshaping, and shape memory experiments. The mechanical properties of composites fabricated using vitrimer were fully analyzed by tensile, flexural, short-beam strength, and Izod impact tests and had mechanical properties similar to reference material. Moreover, both the vitrimer and the vitrimer composites showed excellent antibacterial activity against Staphylococcus aureus and Escherichia coil due to the imine group inside the vitrimer. Therefore, vitrimer composites have potential for applications requiring antimicrobial properties, such as medical devices.

Preparation of Naphthalene-Based Flame Retardant for High Fire Safety and Smoke Suppression of Epoxy Resin

One of the current challenges in the development of flame retardants is the preparation of an environmentally friendly multi-element synergistic flame retardant to improve the flame retardancy, mechanical performance, and thermal performance of composites. This study synthesized an organic flame retardant (APH) using (3-aminopropyl) triethoxysilane (KH-550), 1,4-phthalaadehyde, 1,5-diaminonaphthalene, and 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide (DOPO) as raw materials, through the Kabachnik-Fields reaction. Adding APH to epoxy resin (EP) composites could greatly improve their flame retardancy. For instance, UL-94 with 4 wt% APH/EP reached the V-0 rating and had an LOI as high as 31.2%. Additionally, the peak heat release rate (PHRR), average heat release rate (AvHRR), total heat release (THR), and total smoke produced (TSP) of 4% APH/EP were 34.1%, 31.8%, 15.2%, and 38.4% lower than EP, respectively. The addition of APH improved the mechanical performance and thermal performance of the composites. After adding 1% APH, the impact strength increased by 15.0%, which was attributed to the good compatibility between APH and EP. The TG and DSC analyses revealed that the APH/EP composites that incorporated rigid naphthalene ring groups had higher glass transition temperatures (Tg) and a higher amount of char residue (C₇₀₀). The pyrolysis products of APH/EP were systematically investigated, and the results revealed that flame retardancy of APH was realized by the condensed-phase mechanism. APH has good compatibility with EP, excellent thermal performance, enhanced mechanical performance and rational flame retardancy, and the combustion products of the as-prepared composites complied with the green and environmental protection standards which are also broadly applied in industry.

Biobased Transesterification Vitrimers

The rapid increase in the use of plastics and the related sustainability issues, including the depletion of global petroleum reserves, have rightly sparked interest in the use of biobased polymer feedstocks. Thermosets cannot be remolded, processed, or recycled, and hence cannot be reused because of their permanent molecular architecture. Vitrimers have emerged as a novel polymer family capable of bridging the difference between thermoplastic and thermosets. Vitrimers enable unique recycling strategies, however, it is still important to understand where the raw material feedstocks originate from. Transesterification vitrimers derived from renewable resources are a massive opportunity, however, limited research has been conducted in this specific family of vitrimers. This review article provides a comprehensive overview of transesterification vitrimers produced from biobased monomers. The focus is on the biomass structural suitability with dynamic covalent chemistry, as well as the viability of the synthetic methods.

Mechanically Robust and Chemically Recyclable Polyhydroxyurethanes from CO2-Derived Six-Membered Cyclic Carbonates

In the current context of sustainable chemistry development and new regulations, aminolysis of cyclic carbonate is one of the most promising routes to nonisocyanate polyurethanes, also called polyhydroxyurethanes (PHU). In this study, a new kind of shape memory PHU vitrimers with outstanding mechanical properties and chemical recyclability is prepared. The monomer employed for aminolysis to form the PHUs is bis(six-membered cyclic carbonate) of 4,4'-biphenol (BCC-BP), which is synthesized by bi(1,3-diol) precursors and CO₂. The synthetic strategy, isocyanate-free and employing CO₂ as a building block, is environmentally friendly and suits the concept of carbon neutrality. The thermal properties, mechanical properties, and dynamic behaviors of the PHUs are explored. The maximum breaking strength and elongation at break of the resultant PHUs reach 65 MPa and 452%, respectively, exceeding other reported PHU-based materials in combined performance. Such a PHU material can also lift up a load 4700 times heavier than its own weight by a shape recovery process. Finally, the bi(1,3-diol) can be regenerated through the alcoholysis of PHUs to realize chemical recycling. This work provides a feasibility study for a green synthetic approach and for designing a novel PHU material with outstanding properties.

Sustainable design of vanillin-based vitrimers using vinylogous urethane chemistry

A vanillin derivative containing β-hydroxy-amine functionalities was introduced into vitrimer materials using vinylogous urethane chemistry. These new materials have a high bio-based content and show fast reprocessability.