Nanocavitation in Self-Assembled Amphiphilic Block Copolymer-Modified Epoxy

Design, Manufacturing, and Evaluation of Race and Automotive Prototypal Components Fabricated with Modified Carbon Fibres and Resin

This study explores the enhancement of Carbon Fibre Reinforced Polymers (CFRPs) for automotive applications through the integration of modified carbon fibres (CF) and epoxy matrices. The research emphasizes the use of block copolymers (BCPs) and electropolymerisation techniques to improve mechanical properties and interfacial adhesion. Incorporating 2.5 wt.% D51N BCPs in the epoxy matrix led to a 64% increase in tensile strength and a 51.4% improvement in interlaminar fracture toughness. The electropolymerisation of CFs further enhanced interlaminar shear strength by 23.2%, reflecting a substantial enhancement in fibre-matrix interaction. A novel out-of-autoclave manufacturing process for an energy absorber prototype was developed, achieving significant reductions in production time and cost while maintaining performance. Compression tests demonstrated that the modified materials attained an energy absorption rate of 93.3 J/mm, comparable to traditional materials. These results suggest that the advanced materials and manufacturing processes presented in this study are promising for the development of lightweight, high-strength automotive components, meeting rigorous performance and safety standards. This research highlights the potential of these innovations to contribute significantly to the advancement of materials used in the automotive industry.

Revealing Deformation Mechanisms in Polymer-Grafted Thermoplastic Elastomers via In Situ Small-Angle X-ray Scattering

The tunable properties of thermoplastic elastomers (TPEs), through polymer chemistry manipulations, enable these technologically critical materials to be employed in a broad range of applications. The need to "dial-in" the mechanical properties and responses of TPEs generally requires the design and synthesis of new macromolecules. In these designs, TPEs with nonlinear macromolecular architectures outperform the mechanical properties of their linear copolymer counterparts, but the differences in the deformation mechanism providing enhanced performance are unknown. Here, in situ small-angle X-ray scattering (SAXS) measurements during uniaxial extension reveal distinct deformation mechanisms between a commercially available linear poly(styrene)-poly(butadiene)-poly(styrene) (SBS) triblock copolymer and the grafted SBS version containing grafted poly(styrene) (PS) chains from the poly(butadiene) (PBD) midblock. The neat SBS (φSBS = 100%) sample deforms congruently with the macroscopic dimensions, with the domain spacing between spheres increasing and decreasing along and transverse to the stretch direction, respectively. At high extensions, end segment pullout from the PS-rich domains is detected, which is indicated by a disordering of SBS. Conversely, the PS-grafted SBS that is 30 vol % SBS and 70% styrene (φSBS = 30%) exhibits a lamellar morphology, and in situ SAXS measurements reveal an unexpected deformation mechanism. During deformation, there are two simultaneous processes: significant lamellar domain rearrangement to preferentially orient the lamellae planes parallel to the stretch direction and crazing. The samples whiten at high strains as expected for crazing, which corresponds with the emergence of features in the 2D SAXS pattern during stretching consistent with fibril-like structures that bridge the voids in crazes. The significant domain rearrangement in the grafted copolymers is attributed to the new junctions formed across multiple PS domains by the grafting of a single chain. The in situ SAXS measurements provide insights into the enhanced mechanical properties of grafted copolymers that arise through improved physical cross-linking that leads to nanostructure domain reorientation for self-reinforcement and craze formation where fibrils help to strengthen the polymer.

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.

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.

Effect of MWNT Functionalization with Tunable-Length Block Copolymers on Dispersity of MWNTs and Mechanical Properties of Epoxy/MWNT Composites

The dispersion level of carbon nanotubes (CNTs) and interface design are two of the most crucial roles in developing the superior mechanical performance of polymer/CNT nanocomposites. In this work, a series of azide-terminated poly(glycidyl methacrylate)-block-poly(hexyl methacrylate) (PGMA-b-PHMA) copolymers with different PHMA chain lengths and similar PGMA chain lengths were grafted on the surface of multiwall carbon nanotubes (MWNTs). PHMA length changes significantly impact the grafting density and solubility in organic solvents of as-prepared block copolymer functionalized MWNTs(bc@fMWNTs). Then, the bc@fMWNTs were introduced to epoxy, and the resulted epoxy/bc@fMWNT composites show better mechanical properties than neat epoxy and epoxy/p-MWNT composites. The results suggest that longer PHMA chains cause the two competitive and opposing effects on the dispersion state and soft interface. On the one hand, the longer PHMA chains on the surface of MWNTs would afford higher deformation for the matrix and enhanced mobility for MWNTs because of the soft and flexible nature of PHMA, enhancing the energy dissipation during strain. On the other hand, as the length of PHMA extends, the dispersion level of bc@fMWNTs in epoxy declines, which is harmful to the composite’s mechanical properties. Hence, epoxy/bc@fMWNTs composites with relatively short PHMA chains show the best tensile and fracture properties.

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.

Fracture Behavior of Polyrotaxane-Toughened Poly(Methyl Methacrylate)

The fracture behavior of polyrotaxane (PR)-modified poly(methyl methacrylate) (PMMA) was investigated. PR is a supramolecule with rings threaded onto a linear backbone chain, which is capped by bulky end groups to prevent the rings from de-threading. The ring structure is α-cyclodextrin (CD), and it can be functionalized to enhance its affinity with the hosting polymer matrix. Adding only 1 wt % of PR containing methacrylate functional groups (mPR) at the terminal of some of the polycaprolactone-grafted chains on CD promotes massive crazing, resulting in a significant improvement in fracture toughness while maintaining the modulus and transparency of the PMMA matrix. Dynamic mechanical analysis and atomic force microscopy studies reveal that mPR strongly interact with PMMA, leading to higher molecular mobility and enhanced molecular cooperativity during deformation. This molecular cooperativity may be responsible for the formation of massive crazing in a PMMA matrix, which leads to greatly improved fracture toughness.

Manipulation of Fracture Behavior of Poly(methyl methacrylate) Nanocomposites by Interfacial Design of a Metal-Organic-Framework Nanoparticle Toughener

The interfacial region between nanoparticles and polymer matrix plays a critical role in influencing the mechanical behavior of polymer nanocomposites. In this work, a set of model systems based on poly(methyl methacrylate) (PMMA) matrix containing poly(alkyl glycidyl ether) brushes grafted on 50 nm metal-organic-framework (MOF) nanoparticles were synthesized and investigated. By systematically increasing the polymer brush length and graft density on the MOF nanoparticles, the fracture behavior of PMMA/MOF nanocomposite changes from forming only a few large crazes to generating massive crazing and to undergoing shear banding, which results in significant improvement in fracture toughness. The implication of the present finding for the interfacial design of the nanoparticles for the development of high-performance, multifunctional polymer nanocomposites is discussed.

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.

Linking Nanoscale Chemical Changes to Bulk Material Properties in IEPM Polymer Composites Subject to Impact Dynamics

A synthesizable interfacial epoxy-polyurea-hybridized matrix (IEPM), composed of chemical bonded nanostructures across an interface width ranging between 2 and 50 μm, is a candidate for dialing-in molecular vibrational properties and providing high-impact dynamics resistance to conventional fiber(x)-reinforced epoxy (F/E), engendering an x-hybrid polymeric matrix composite system (x-IEPM- t_c). Atomic force microscopy and scanning electron microscopy elucidate the interfacial nanoscale morphology and chemical structure via reaction kinetics of curing epoxy (as a function of time, t_c) and fast-reacting (prepolymerized) polyurea. Nano-infrared spectroscopy (nano-IR) spectra, per non-negative matrix factorization analysis, reveal that simultaneous presence of characteristic epoxy and polyurea vibrational modes, within a nanoscale region, along with unique IEPM characteristics and properties following thermomechanical analysis and dynamic mechanical analysis (DMA), indicate chemical bonding, enabling IEPM reaction kinetics, as a function of  t_c, to control natural bond vibrations and type/distribution of interfacial chemical bonds and physical mixtures, likely due to the bond mechanism between -NCO in polyurea and epoxide and -NH₂ in epoxy hardener (corresponding to characteristic absorption peaks in nano-IR results), leading to enhanced IEPM quality (fewer defects/voids). Test results of ballistic-resistant panels, integrated with thin intermediate layers of x-IEPM-b- t_c, confirm that lower t_c significantly enhances loss modulus (∝ material damping and per DMA) in impact dynamics environments.

Enhancing mode I and II interlaminar fracture toughness of carbon fiber-filled epoxy-based composites using both rice husk silica and silk fibroin electrospun nanofibers

In this study, we used both silk fibroin nanofibers (nSFs) and rice husk silica nanoparticles as epoxy (EP) resin reinforcement materials to improve the modes I and II interlaminar fracture toughness of EP-filled carbon fiber-based (CF/EP) composites. The nSFs were obtained by electrospinning, while the rice husk silica nanoparticles were obtained via acidic and thermal treatments. The results showed that the interfacial shear strength, GIC, and GIIC of the CF/EP composites improved by 25, 36, and 30%, respectively, by adding 0.2 wt% nSF and 20 wt% silica nanoparticles.

Recent Advances in High Performance Polymers—Tribological Aspects

High-performance polymer (HPP)-based engineering materials in tribological applications have been under continuous research over the last few decades. This paper reviewed the recent studies on the sliding wear properties of HPPs and their nanocomposites, which are associated with the intrinsic and extrinsic parameters. In particular, the effects of the intrinsic properties of polymer composites (e.g., mechanical properties of the materials and the types of fillers) and external environmental conditions (e.g., service temperature and lubrication medium) on the formation of transfer layers (TLs) were discussed. The latter would govern the overall friction and wear of polymeric materials in sliding against metallic counterparts. In addition, correlations between the basic mechanical properties of HPPs and their sliding wear behavior were also explored.

Characteristics of water absorption in amine-cured epoxy networks: a molecular simulation and experimental study

Moisture corrosion of cured epoxy resins seriously affects the durability of epoxy products and has been a serious issue in scientific and engineering fields. In this study, a series of cured epoxy resins with different structures were prepared by tuning their curing conversion in both experimental and simulation methods. In experiments, the equilibrium water content and the diffusion coefficient of amine-cured epoxy resins were measured by gravimetric measurement. The interaction between water molecules and epoxy network was investigated by time-resolved FTIR, difference spectroscopy and 2D correlation spectroscopy. In simulation, the hydrogen bonds, the mobility of hydroxypropyl ether groups and water molecules, and the free volume with its distributions were analyzed. Five types of water molecules were intuitively observed in this study; free volume had a stronger influence on equilibrium water content than polarity in the bifunctional epoxy/amine system, and the increase in the diffusion coefficient was considered as the result of reduction in motion resistance and an increase in channels for the motion of water molecules.

Photonic Resins: Designing Optical Appearance via Block Copolymer Self-Assembly

Despite a huge variety of methodologies having been proposed to produce photonic structures by self-assembly, the lack of an effective fabrication approach has hindered their practical uses. These approaches are typically limited by the poor control in both optical and mechanical properties. Here we report photonic thermosetting polymeric resins obtained through brush block copolymer (BBCP) self-assembly. We demonstrate that the control of the interplay between order and disorder in the obtained photonic structure offers a powerful tool box for designing the optical appearance of the polymer resins in terms of reflected wavelength and scattering properties. The obtained materials exhibit excellent mechanical properties with hardness up to 172 MPa and Young's modulus over 2.9 GPa, indicating great potential for practical uses as photonic coatings on a variety of surfaces.

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.

Flame retardancy and toughening properties of epoxy composites containing ammonium polyphosphate microcapsules and expanded graphite

Ammonium polyphosphate microcapsules (BM (polybenzoxazine modified) APP) were prepared through the in situ ring-opening polymerization of allyl group containing benzoxazine monomers on the surfaces of ammonium polyphosphate (APP), and they were significantly hydrophobic than the APP. A flame retardant system of epoxy (EP) resin was prepared with BMAPP and expanded graphite (EG). Flame retardancy, the thermal degradation behavior, a mechanical property of EP and EP/BMAPP/EG composites was investigated through limited oxygen index, vertical burning test, cone calorimetry (CONE), and the thermogravimetric analysis (TGA). The flame retardancy tests indicated that the EG could improve the thermal performance, promote the charring, and enhance the char quality of EP/BMAPP. Scanning electron microscopy (SEM) and Fourier-transform infrared spectroscopy (FTIR) were employed to analyze the morphology and composition of the char residue formed during CONE testing, and to understand the mechanism of char formation. The results of TG-FTIR confirmed the possible mechanism of flame retardancy of EP/BMAPP/EG in the gas phase during combustion. The EG content effects on Young’s modulus, the tensile strength, and the fracture toughness ( KIC) of the EP/BMAPP composites were also investigated. The KIC of the composites containing 1% of EG and 10% of BMAPP increased by approximately 76% and 153%, respectively, compared to the neat matrix and EP/BMAPP-10%. The SEM images of the fractured surface indicated that the enhanced toughness of EP/BMAPP/EG composites mainly attributed to the debonding of the BMAPP and the subsequent plastic void growth of the matrix, as well as the crack deflection effect of the BMAPP/EG.

Nanovoid formation and mechanics: a comparison of poly(dicyclopentadiene) and epoxy networks from molecular dynamics simulations

Protective equipment in civilian and military applications requires the use of polymer materials that are both stiff and tough over a wide range of strain rates. However, typical structural materials, like tightly cross-linked epoxies, are very brittle. Recent experiments demonstrated that cross-linked poly(dicyclopentadiene) (pDCPD) networks can circumvent this trade-off by providing structural properties such as a high glass transition temperature and glassy modulus, while simultaneously exhibiting excellent toughness and high-rate impact resistance. The greater performance of pDCPD was attributed to more facile plastic deformation and nano-scale void formation, but the chemical and structural mechanisms underlying this response were not clear. Here, we use atomistic molecular dynamics to compare the molecular- and chain-level properties of pDCPD and epoxy networks undergoing high strain rate deformation. We quantify the tensile modulus and yield strength of the networks as well as the prevalence and characteristics of nanovoids that form during deformation. Networks of similar molecular weight between cross-links are compared. Two key molecular-level properties are identified - monomer flexibility and polar chemistry - that influence the behavior of the networks. Increasing monomer flexibility reduces the modulus and yield strength, while strong non-covalent interactions (e.g., hydrogen bonds) that accompany polar moieties provide higher modulus and yield strength. The lack of strong non-covalent interactions in pDCPD was found to account for its lower modulus and yield strength compared to the epoxies. We examine the molecular-level properties of nanovoids, such as shape, alignment, and local stress distribution, as well as the local chemical environment, finding that nanovoid formation and growth are increased by the monomer rigidity but decreased by polar chemistry. As a result, the pDCPD network, which has a stiff chain backbone with nonpolar alkane chemistry, exhibits more and larger nanovoids that grow more readily during deformation, which could account for the higher toughness and more ductile behavior observed in pDCPD.

Simultaneously toughening and strengthening cyanate ester resin with better dielectric properties by building nanostructures in its crosslinked network using polyimide-block-polysiloxane rod-coil block copolymers

The fabrication and origin of high performance cyanate ester resins by building nanostructures in its crosslinked network with polyimide-block-polysiloxane block copolymers.

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.

Wheat Gluten Blends with Maleic Anhydride-Functionalized Polyacrylate Cross-Linkers for Improved Properties

A family of polyacrylate-based cross-linkers was synthesized to maximize the toughness of high Tg, high modulus wheat gluten blends in the glassy state. Mechanical testing and damping measurements were conducted to provide an example where the work of fracture and strength of the blend substantially exceeds polystyrene while maintaining flexure stiffness in excess of 3 GPa. The new rubbery cross-linkers, polymethyl acrylate-co-maleic anhydride and polyethyl acrylate-co-maleic anhydride, improve WG mechanical properties and reduce water absorption simultaneously. MDSC, FTIR, HPLC, and NMR data confirmed the cross-linking reaction with wheat gluten. Flexural, DMA, and water absorption testing were carried out to characterize the property improvements. DMA was conducted to investigate the relationship between energy damping and mechanical property improvement. If the cross-linker damping temperature is close to the testing temperature, the entire sample exhibits high damping, toughness, and strength.