Reaction-Induced Microphase Separation in Epoxy Thermosets Containing Block Copolymers Composed of Polystyrene and Poly(ε-caprolactone): Influence of Copolymer Architectures on Formation of Nanophases

Modeling the competition between phase separation and polymerization under explicit polydispersity

The dynamics of phase separation for polymer blends is important in determining the final morphology and properties of polymer materials; in practical applications, this phase separation can be controlled by coupling to polymerization reaction kinetics via a process called 'polymerization-induced phase separation'. We develop a phase-field model for a polymer melt blend using a polymerizing Cahn-Hilliard (pCH) formalism to understand the fundamental processes underlying phase separation behavior of a mixture of two species independently undergoing linear step-growth polymerization. In our method, we explicitly model polydispersity in these systems to consider different molecular-weight components that will diffuse at different rates. We first show that this pCH model predicts results consistent with the Carothers predictions for step-growth polymerization kinetics, the Flory-Huggins theory of polymer mixing, and the classical predictions of spinodal decomposition in symmetric polymer blends. The model is then used to characterize (i) the competition between phase separation dynamics and polymerization kinetics, and (ii) the effect of unequal reaction rates between species. For large incompatibility between the species (i.e. high χ), our pCH model demonstrates that the strength for phase separation directly corresponds to the kinetics of phase separation. We find that increasing the reaction rate k̃, first induces faster phase separation but this trend reverses as we further increase k̃ due to the competition between molecular diffusion and polymerization. In this case, phase separation is delayed for faster polymerization rates due to the rapid accumulation of slow-moving, high molecular weight components.

Tuneable phase behaviour and glass transition via polymerization-induced phase separation in crosslinked step-growth polymers

Once limited to chain-growth polymerizations, fine control over polymerization-induced phase separation (PIPS) has recently been demonstrated in rubber-toughened thermoset materials formed through step-growth polymerizations. The domain length scales of these thermoset materials can be elegantly tuned by utilizing a binary mixture of curing agents (CAs) that individually yield disparate morphologies. Importantly, varying the composition of the binary mixture affects characteristics of the materials such as glass transition temperature and tensile behavior. Here, we establish a full phase diagram of PIPS in a rubber-toughened epoxy system tuned by a binary CA mixture to provide a robust framework of phase behaviour. X-Ray scattering in situ and post-PIPS is employed to elucidate the PIPS mechanism whereby an initial polymerization-induced compositional fluctuation causes nanoscale phase separation of rubber and epoxy components prior to local chain crosslinking and potential macrophase separation. We further demonstrate the universality of this approach by alternatively employing binary epoxy or binary rubber mixtures to achieve broad variations in morphology and glass transitions.

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.

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.

Toward simultaneous toughening and reinforcing of trifunctional epoxies by low loading flexible reactive triblock copolymers

Flexible reactive poly(glycidyl methacrylate)-b-poly(propylene glycol)-b-poly(glycidyl methacrylate) (GPG) and nonreactive poly(ethylene glycol)-b-poly(propylene glycol)-b-poly(ethylene glycol) (EPE80) were utilized to toughen a trifunctional epoxy (diglycidyl 4, 5-epoxycyclohexane-1, 2-dicarboxylate, TDE-85). In comparison with the nonreactive EPE80 and reactive GPG92 with long reactive blocks (L_reactive), the incorporation of reactive GPG83 with short L_reactive improved the comprehensive mechanical properties of the epoxy. Upon an optimal GPG83 loading of 2.5 wt%, the tensile strength, elongation at break and critical strain energy release rate (G_1c) increased by ca. 31%, 45.9% and 130.8%, respectively, without sacrificing the modulus and thermal stability. Morphology characterization evidenced that micro-scale domains and nanosized vesical micelles coexisted in the nonreactive EPE80 toughened systems. However, homogeneous morphologies were formed in reactive GPG83 and GPG92 toughened systems. Fracture morphology analysis suggested that GPG can toughen epoxy thermosets by incorporating flexible PPG blocks into the epoxy network, thereby enabling an energy dissipation mechanism. The good balance between the mobility of flexible PPG and degree of cross-link density leads to the simultaneous toughening and reinforcing effect of GPG83 toward the trifunctional epoxy.

A high performance trifunctional epoxy thermoset was toughened and reinforced by a low loading of GPG with an appropriate reactive block length, which presented a homogeneous morphology.

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.

Enhancing mechanical performance of epoxy thermosets via designing a block copolymer to self-organize into “core–shell” nanostructure

A rigid-flexible amphiphilic pentablock copolymer, polystyrene-block-poly(ε-caprolactone)-block-polydimethylsiloxane-block-poly(ε-caprolactone)-block-polystyrene (PS-PCL-PDMS-PCL-PS, SLDLS), was designed.

Simultaneously enhanced tensile strength and fracture toughness of epoxy resins by a poly(ethylene oxide)-block-carboxyl terminated butadiene-acrylonitrile rubber dilock copolymer

PEG-b-CTBN diblock copolymer was synthesized by the esterification reaction and then used to modify epoxy via the formation of nanostructure.