A thermoplastic/thermoset blend exhibiting thermal mending and reversible adhesion

Regulation of the Phase Structure in the Crystallizing Curing System PCL-DGEBA

Qualitative and quantitative aspects of the formation of various types of phase structures, sizes and compositions were considered. For the studied polycaprolactone-epoxy resin/4,4'-diaminediphenylsulfone system, a phase diagram characterized by amorphous separation with a lower critical solution temperature was constructed and its evolution was traced with increasing conversion degree of epoxy groups. A method is proposed for determining the temperature-concentration parameters that determine the type of phase structure of composite materials, based on the optical interferometry method. All types of phase structures and features of structure formation in the phase reversal region and at its boundaries have been studied using optical and scanning electron microscopy methods. The dimensions of the structural elements were determined and their correlation with the temperature and concentration regimes of the system's curing was established. The composition of phases in cured compositions was studied using FTIR spectroscopy, DSC and scanning electron microscopy. It is shown that by varying the temperature-concentration parameters of curing reactive thermoplastic systems, it is possible to specifically regulate the type of phase structure, phase sizes and their composition, which determine the operational properties of the material.

Dynamic Thermosetting Resins with Synergistic Enhanced Strength and Toughness through Combination with Rigid and Soft Microdomains

Preparation of materials that possess highly strong and tough properties simultaneously is a great challenge. Thermosetting resins as a type of widely used polymeric materials without synergistic strength and toughness limit their applications in some special fields. In this report, an effective strategy to prepare thermosetting resins with synergistic strength and toughness, is presented. In this method, the soft and rigid microspheres with dynamic hemiaminal bonds are fabricated first, followed by hot-pressing to crosslink at the interfaces. Specifically, the rigid or soft microspheres are prepared via precipitation polymerization. After hot-pressing, the resulting rigid-soft blending materials exhibit superior strength and toughness, simultaneously. As compared with the precursor rigid or soft materials, the toughness of the rigid-soft blending films (RSBFs) is improved to 240% and 2100%, respectively, while the strength is comparable to the rigid precursor. As compared with the traditional crushing, blending, and hot-pressing of rigid or soft materials to get the nonuniform materials, the strength and toughness of the RSBFs are improved to 168% and 255%, respectively. This approach holds significant promise for the fabrication of polymer thermosets with a unique combination of strength and toughness.

Blending to Make Nonhealable Polymers Healable: Nanophase Separation Observed by CP/MAS 13 C NMR Analysis

Can commodity polymers are made to be healable just by blending with self-healable polymers? Here we report the first study on the fundamental aspect of this practically challenging issue. Poly(ether thiourea) (PTUEG₃ ; T_g =27 °C) reported in 2018 is extraordinary in that it is mechanically robust but can self-heal even at 12 °C. In contrast, poly(octamethylene thiourea) (PTUC₈ ; T_g =50 °C), an analogue of PTUEG₃ , cannot heal below 92 °C. We found that their polymer blend self-healed in a temperature range above 32 °C even when its PTUEG₃ content was only 20 mol %. Unlike PTUEG₃ alone, this polymer blend, upon exposure to high humidity, barely plasticized, keeping its excellent mechanical properties due to the non-hygroscopic nature of the PTUC₈ component. CP/MAS ¹³ C NMR analysis revealed that the polymer blend was nanophase-separated, which possibly accounts for why such a small amount of PTUEG₃ provided the polymer blend with humidity-tolerant self-healable properties.

An Analysis of the Effect of Activation Temperature and Crack Geometry on the Healing Efficiency of Polycaprolactone (PCL)/Epoxy Blends

Self-healing materials have attracted great interest in recent years. Particularly, the use of thermoset/thermoplastics blends has emerged as a good option with relatively low activation temperatures and potential infinite healing cycles. Nevertheless, a methodical study of healing conditions and evaluation is still required for further industrial development. The effect of activation temperature and crack morphology in polycaprolactone (PCL)/epoxy blends are explored. For this purpose, PCL content was varied (5, 10, and 15 wt %) with contents lower than critical composition. Therefore, the morphology of all studied blends is the epoxy matrix with a separated PCL phase. In this sense, an increase in PCL content leads to a reduction in the Tg, due to the partial PCL miscibility, and the presence of larger PCL domains. It was observed that a higher temperature (150 °C) and PCL content led to a more efficient self-healing process because of both the lower viscosity of the melted PCL at higher temperatures and the presence of larger PCL reservoirs when increasing the PCL content. Crack morphology influence was studied by inducing cracks with different tools: a custom crack machine with a cutting blade, a scalpel, and a pin. The results show that the recovery was better when the cracks were smaller and shallower, that is, with the pin. In addition, the healing efficiency by means of both parameters, crack volume and depth change, showed more similar results in slimmer cracks, due to a lower crack width-to-depth ratio.

Ionic Liquid-Cured Epoxy/PCL Blends with Improved Toughness and Adhesive Properties

In this work, ionic liquid (IL)-cured epoxy resins were modified by adding poly(ε-caprolactone) (PCL). Three different ILs were used in order to study how (a) the chemical structure of the ILs and (b) the PCL content affect the phase behaviour, microstructure, mechanical and adhesive properties. Regardless of the IL used or the PCL content, the obtained materials showed a single phase. The addition of PCL to the epoxy resin resulted in plasticizing of the network blends, lower glass transition temperatures (Tg), and crosslinking densities (νe). Low PCL contents did not have a significant impact on the mechanical properties. However, the adhesive properties improved significantly at low PCL contents. Higher PCL contents led to a significant increase in toughness, especially in the case of the imidazolium-based IL. The balance achieved between the mechanical and adhesive properties of these IL-cured epoxy/PCL blends constitutes an important step towards sustainability. This is because a biodegradable polymer (PCL) was used to substitute part of the epoxy resin, and the ILs-which are non-volatile and cure effectively at much lower contents-were used instead of conventional curing agents. Given the wide use of this kind of materials in the adhesive industry, the practical significance of these results must be emphasised.

Progress and Roadmap for Intelligent Self-Healing Materials in Autonomous Robotics

Robots are increasingly assisting humans in performing various tasks. Like special agents with elite skills, they can venture to distant locations and adverse environments, such as the deep sea and outer space. Micro/nanobots can also act as intrabody agents for healthcare applications. Self-healing materials that can autonomously perform repair functions are useful to address the unpredictability of the environment and the increasing drive toward the autonomous operation. Having self-healable robotic materials can potentially reduce costs, electronic wastes, and improve a robot endowed with such materials longevity. This review aims to serve as a roadmap driven by past advances and inspire future cross-disciplinary research in robotic materials and electronics. By first charting the history of self-healing materials, new avenues are provided to classify the various self-healing materials proposed over several decades. The materials and strategies for self-healing in robotics and stretchable electronics are also reviewed and discussed. It is believed that this article encourages further innovation in this exciting and emerging branch in robotics interfacing with material science and electronics.

Intrinsic Self-Healing Epoxies in Polymer Matrix Composites (PMCs) for Aerospace Applications

This article reviews some of the intrinsic self-healing epoxy materials that have been investigated throughout the course of the last twenty years. Emphasis is placed on those formulations suitable for the design of high-performance composites to be employed in the aerospace field. A brief introduction is given on the advantages of intrinsic self-healing polymers over extrinsic counterparts and of epoxies over other thermosetting systems. After a general description of the testing procedures adopted for the evaluation of the healing efficiency and the required features for a smooth implementation of such materials in the industry, different self-healing mechanisms, arising from either physical or chemical interactions, are detailed. The presented formulations are critically reviewed, comparing major strengths and weaknesses of their healing mechanisms, underlining the inherent structural polymer properties that may affect the healing phenomena. As many self-healing chemistries already provide the fundamental aspects for recyclability and reprocessability of thermosets, which have been historically thought as a critical issue, perspective trends of a circular economy for self-healing polymers are discussed along with their possible advances and challenges. This may open up the opportunity for a totally reconfigured landscape in composite manufacturing, with the net benefits of overall cost reduction and less waste. Some general drawbacks are also laid out along with some potential countermeasures to overcome or limit their impact. Finally, present and future applications in the aviation and space fields are portrayed.

Cyclic Olefin Copolymer Interleaves for Thermally Mendable Carbon/Epoxy Laminates

Thin cyclic olefin copolymer (COC) foils were used as intrinsic thermoplastic healing agents in carbon fiber (CF)-reinforced epoxy laminates. COC films were produced by hot pressing and were interleaved in the interlaminar regions between each EP/CF lamina, during the hand layup fabrication of the laminates. Three samples were produced, i.e., the neat EP/CF laminate without COC, and two laminates containing COC layers with a thickness of 44 μm and 77 μm, respectively. It was observed that the fiber volume fraction decreased, and the porosity increased with the introduction of COC layers, and this effect was more evident when thick films were used. These two effects, combined with the sub-optimal adhesion between COC and EP, caused a decrease in the mechanical properties (i.e., the elastic modulus, flexural strength, interlaminar shear strength and interlaminar fracture toughness) of the laminates. Specimens subjected to mode I interlaminar fracture toughness test were then thermally mended under pressure by resistive heating, through the Joule effect of conductive CFs. A temperature of approximately 190 °C was reached during the healing treatment. The healing efficiency was evaluated as the ratio of critical strain energy release rate (G_IC) of the healed and virgin specimens. Healed specimens containing COC layers of 44 μm and 77 μm exhibited a healing efficiency of 164% and 100%, respectively. As expected, the healing treatment was not beneficial for the neat EP/CF laminate without COC, which experienced a healing efficiency of only 2%. This result proved the efficacy of COC layers as a healing agent for EP/CF laminates, and the effectiveness of resistive heating as a way to activate the intrinsic healing mechanism.

Self-Healing of Electrical Damage in Polymers

Polymers are widely used as dielectric components and electrical insulations in modern electronic devices and power systems in the industrial sector, transportation, and large appliances, among others, where electrical damage of the materials is one of the major factors threatening the reliability and service lifetime. Self-healing dielectric polymers, an emerging category of materials capable of recovering dielectric and insulating properties after electrical damage, are of promise to address this issue. This paper aims at summarizing the recent progress in the design and synthesis of self-healing dielectric polymers. The current understanding to the process of electrical degradation and damage in dielectric polymers is first introduced and the critical requirements in the self-healing of electrical damage are proposed. Then the feasibility of using self-healing strategies designed for repairing mechanical damage in the healing of electrical damage is evaluated, based on which the challenges and bottleneck issues are pointed out. The emerging self-healing methods specifically designed for healing electrical damage are highlighted and some useful mechanisms for developing novel self-healing dielectric polymers are proposed. It is concluded by providing a brief outlook and some potential directions in the future development toward practical applications in electronics and the electric power industry.

Thermoplastic Blend Exhibiting Shape Memory-Assisted Self-Healing Functionality

Here, we report on a polymer blend consisting of a soft thermoplastic polyurethane (TPU) elastomer and a low melting temperature thermoplastic healing agent (polycaprolactone, PCL). In this study, polymer blends containing up to 60 wt % PCL were prepared and the resulting mechanical, thermal, shape memory, and self-healing properties were studied. These immiscible polymers exhibit two well-separated transitions attributable to the melting of PCL and TPU hard segments. This viscoelastic behavior engendered shape memory capability at moderate processing temperatures (∼90 °C) and melt processability at elevated temperatures (>160 °C). The reversible plasticity shape memory (RPSM) effect was also characterized: when subjected to 125% strain at room temperature and subsequently heated to 90 °C, the samples nearly fully recovered to their original length. Moreover, upon heating to above PCL's melting temperature, the flow of PCL into an undeformed crack was shown to fill the crack void, thus promoting self-repair. Through the action of mild heating (90 °C/30 min), fracture surfaces are brought into intimate contact through the action of the RPSM effect and subsequently healed through the redistribution of molten PCL. The shape memory-assisted self-healing efficiency was evaluated by comparing the tensile force restoration after healing of a highly deformed, notched sample to its behavior prior to notching. It was observed that blends containing up to 30 wt % PCL showed nearly complete restoration of properties. In contrast, pure TPU showed only about 5% healing efficiency because of the absence of the PCL healing agent. Blends containing 50 and 60 wt % PCL likewise did not exhibit appreciable restoration of properties, and this was attributed to their propensity to neck during crack opening and poor mechanical properties at elevated temperatures. Blends may serve as a self-healing replacement for pure TPU in existing applications (e.g., automotive and sporting goods) or as a self-healing shape memory polymer in advanced products in soft robotic, biomedical, and microelectronic applications.

Self-Healing Polymers Based on Coordination Bonds

Self-healing ability is an important survival feature in nature, with which living beings can spontaneously repair damage when wounded. Inspired by nature, people have designed and synthesized many self-healing materials by encapsulating healing agents or incorporating reversible covalent bonds or noncovalent interactions into a polymer matrix. Among the noncovalent interactions, the coordination bond is demonstrated to be effective for constructing highly efficient self-healing polymers. Moreover, with the presence of functional metal ions or ligands and dynamic metal-ligand bonds, self-healing polymers can show various functions such as dielectrics, luminescence, magnetism, catalysis, stimuli-responsiveness, and shape-memory behavior. Herein, the recent developments and achievements made in the field of self-healing polymers based on coordination bonds are presented. The advantages of coordination bonds in constructing self-healing polymers are highlighted, the various metal-ligand bonds being utilized in self-healing polymers are summarized, and examples of functional self-healing polymers originating from metal-ligand interactions are given. Finally, a perspective is included addressing the promises and challenges for the future development of self-healing polymers based on coordination bonds.

Healable Carbon Fiber-Reinforced Epoxy/Cyclic Olefin Copolymer Composites

Cyclic olefin copolymer (COC) particles were dispersed in various amounts in an epoxy matrix, and the resulting blends were used to impregnate unidirectional carbon fibers (CF) by hand lay-up. The thermal stability was not substantially modified by the presence of COC particles. The mixture of the two polymers resulted in a phase separated blend and the flexural modulus and interlaminar shear strength progressively decreased with the addition of COC particles in the laminates. Mode I fracture toughness tests were executed on double cantilever beam specimens. The opened crack was then thermally mended at 190 °C for 1 h. The laminates containing 30 wt.% of COC particles showed a healing efficiency of ~180%.

Influence of Morphology on the Healing Mechanism of PCL/Epoxy Blends

Polycaprolactone (PCL) is being researched as a self-healing agent blended with epoxy resins by several reasons: low melting point, differential expansive bleeding (DBE) of PCL, and reaction induced phase separation (RIPS) of PCL/epoxy blends. In this work, PCL/epoxy blends were prepared with different PCL ratios and two different epoxy networks, cured with aliphatic and aromatic amine hardeners. The curing kinetic affects to the blend morphology, varying its critical composition. The self-healing behavior is strongly affected by the blend morphology, reaching the maximum efficiency for co-continuous phases. Blends with dispersed PCL phase into epoxy matrix can also show high self-healing efficiency because of the low PCL domains that act as reservoir of self-healing agent. In this last case, it was confirmed that the most efficient self-healable blends are one whose area occupied by PCL phase is the largest. These blends remain the good thermal and mechanical behavior of epoxy matrix, in contrast to the worsened properties of blends with bicontinuous morphology. In this work, the self-healing mechanism of blends is studied in depth by scanning electron microscopy. Furthermore, the influence of the geometry of the initial surface damage is also evaluated, affecting to the measurement of self-healing efficiency.

Light-Switchable Self-Healing Dynamic Linear Polymers: Reversible Cycloaddition Reactions of Thymine-Containing Units

A dynamic linear polymer was formed by the [2π+2π] reversible cycloaddition reaction of a thymine-based monomer under topochemical conditions and was used in self-healing applications. The reversible polymerisation of the thymine monomer was confirmed by UV and GPC analysis. Irradiation at 302 nm resulted in polymerisation of the monomer, and irradiation with wavelengths lower than 240 nm resulted in depolymerisation and the production of oligomeric units. This leads to a reduction in the glass transition temperature, and promoted healing of surface scratches due to the increased chain mobility. The self-healing ability of scratched samples was assessed based on the visual disappearance of the damage. In addition, the mechanical properties of the polymer before and after healing were found to be similar.

Reconfigurable and Reprocessable Thermoset Shape Memory Polymer with Synergetic Triple Dynamic Covalent Bonds

Degradable shape memory polymers (SMPs), especially for polyurethane-based SMPs, have shown great potential for biomedical applications. How to reasonably fabricate SMPs with the ideal combination of degradability, shape reconfigurability, and reprocessability is a critical issue and remains a challenge for medical disposable materials. Herein, a shape memory poly(urethane-urea) with synergetic triple dynamic covalent bonds is reported via embedding polycaprolactone unit into poly(urethane-urea) with the hindered urea dynamic bond. The single polymer network is biodegradable, thermadapt, and reprocessable, without sacrificing the outstanding shape memory performance. Such a shape memory network with plasticity and reprocessability is expected to have significant and positive impact on the medical device industry.

Multiple welding of long fiber epoxy vitrimer composites

Vitrimers appear as a new class of polymers that exhibit mechanical strength and are insoluble even at high temperatures, like thermosets, and yet, like thermoplastics, they are heat processable, recyclable and weldable. The question arises whether this welding property is maintained in composite materials made of more than 50 vol% of reinforcing fibers. In this paper, we quantitatively analyze the bond strength of epoxy vitrimer-based composite plates made by resin transfer molding and compare them to their non-vitrimer counterparts made of a standard thermoset epoxy. It is demonstrated that only epoxy vitrimer samples show substantial bond strength and the ability to be repeatedly welded thanks to the exchange reactions, which promote improved surface conformity and chemical bonding between the adherands at the joint interface. This opens the way towards joining composite parts without adhesives nor mechanical fasteners.

Self-healing gels based on constitutional dynamic chemistry and their potential applications

This review presents recent developments and potential applications of physical and chemical self-healing gels based on constitutional dynamic chemistry.

Reprocessing and recycling of thermosetting polymers based on bond exchange reactions

In this paper, we experimentally demonstrated the reprocessing, recycling and repairing abilities of pulverized thermoset polymer with exchangeable bonds.

Shape Memory Assisted Self-Healing Coating

In this communication, we report the preparation and characterization of new shape memory assisted self-healing (SMASH) coatings. The coatings feature a phase-separated morphology with electrospun thermoplastic poly(ε-caprolactone) (PCL) fibers randomly distributed in a shape memory epoxy matrix. Mechanical damage to the coating can be self-healed via heating, which simultaneously triggers two events: (1) the shape recovery of the matrix to bring the crack surfaces in spatial proximity, and (2) the melting and flow of the PCL fibers to rebond the crack. In controlled healing experiments, damaged coatings not only heal structurally, but also functionally by almost completely restoring the corrosion resistance. We envision the wide applicability of the SMASH concept in designing the next-generation self-healing materials.

Influence of cross-linkers on the cohesive and adhesive self-healing ability of polysulfide-based thermosets

Synthetic systems with intrinsic self-repairing or self-healing abilities have emerged during the past decade. In this work, the influence of the cross-linker and chain rigidity on the healing ability of thermoset rubbers containing disulfide bonds have been investigated. The produced materials exhibit adhesive and cohesive self-healing properties. The recovery of these two functionalities upon the thermally triggered healing events has shown to be highly dependent on the network cross-link density and chain rigidity. As a result, depending on the rubber thermoset intrinsic physical properties, the thermal mending leading to full cohesive recovery can be achieved in 20-300 min at a modest healing temperature of 65 °C. The adhesive strength ranges from 0.2 to 0.5 MPa and is fully recovered even after multiple failure events.

Healable thermoset polymer composite embedded with stimuli-responsive fibres

Severe wounds in biological systems such as human skin cannot heal themselves, unless they are first stitched together. Healing of macroscopic damage in thermoset polymer composites faces a similar challenge. Stimuli-responsive shape-changing polymeric fibres with outstanding mechanical properties embedded in polymers may be able to close macro-cracks automatically upon stimulation such as heating. Here, a stimuli-responsive fibre (SRF) with outstanding mechanical properties and supercontraction capability was fabricated for the purpose of healing macroscopic damage. The SRFs and thermoplastic particles (TPs) were incorporated into regular thermosetting epoxy for repeatedly healing macroscopic damages. The system works by mimicking self-healing of biological systems such as human skin, close (stitch) then heal, i.e. close the macroscopic crack through the thermal-induced supercontraction of the SRFs, and bond the closed crack through melting and diffusing of TPs at the crack interface. The healing efficiency determined using tapered double-cantilever beam specimens was 94 per cent. The self-healing process was reasonably repeatable.