Toughening of Epoxies with Block Copolymer Micelles of Wormlike Morphology

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.

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.

Insights into Mechanical Dynamics of Nanoscale Interfaces in Epoxy Composites Using Nanorheology Atomic Force Microscopy

Interfacial polymer layers with nanoscale size play critical roles in dissipating the strain energy around cracks and defects in structural nanocomposites, thereby enhancing the material's fracture toughness. However, understanding how the intrinsic mechanical dynamics of the interfacial layer determine the toughening and reinforcement mechanisms in various polymer nanocomposites remains a major challenge. Here, by means of a recently developed nanorheology atomic force microscopy method, also known as nanoscale dynamic mechanical analysis (nDMA), we report direct mapping of dynamic mechanical responses at the interface of a model epoxy nanocomposite under the transition from a glassy to a rubbery state. We demonstrate a significant deviation in the dynamic moduli of the interface from matrix behavior. Interestingly, the sign of the deviation is observed to be reversed when the polymer changes from a glassy to a rubbery state, which provides an excellent explanation for the difference in the modulus reinforcement between glassy and rubbery epoxy nanocomposites. More importantly, nDMA loss tangent images unambiguously show an enhanced viscoelastic response at the interface compared to the bulk matrix in the glassy state. This observation can therefore provide important insights into the nanoscale toughening mechanism that occurs in epoxy nanocomposites due to viscoelastic energy dissipation at the interface.

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.

Nanostructuring Biobased Epoxy Resin with PEO-PPO-PEO Block Copolymer

A biobased diglycidyl ether of vanillin (DGEVA) epoxy resin was nanostructured by poly(ethylene oxide-b-propylene oxide-b-ethylene oxide) (PEO-PPO-PEO) triblock copolymer. Due to the miscibility/immiscibility properties of the triblock copolymer in DGEVA resin, different morphologies were obtained depending on the triblock copolymer amount. A hexagonally packed cylinder morphology was kept until reaching 30 wt% of PEO-PPO-PEO content, while a more complex three-phase morphology was obtained for 50 wt%, in which large worm-like PPO domains appear surrounded by two different phases, one of them rich in PEO and another phase rich in cured DGEVA. UV-vis measurements show that the transmittance is reduced with the increase in triblock copolymer content, especially at 50 wt%, probably due to the presence of PEO crystals detected by calorimetry.

Cavitation-Mediated Fracture Energy Dissipation in Polylactide at Rubbery Soybean Oil-Based Block Copolymer Interfaces Formed via Reactive Extrusion

Here, we spearhead a new approach to biopolymer impact modification that demonstrates superior performance while maintaining greater than 99% compostability. Using soybean-based monomers, a virtually untapped resource in terms of commercial volume and overall cost, a series of hyperbranched block copolymers were synthesized and melt-processed with poly(l-lactide) (PLA) to yield impact resistant all-polymer composites. Although PLA impact modification has been treated extensively, to date, the only practical solutions have relied on non-compostable petroleum-based rubbers. This study illustrates the activity of energy dissipation mechanisms such as cavitation, classically relegated to well-entangled petroleum-based rubbers, in poorly entangled hyperbranched soybean-based rubbers. Furthermore, we present a complete study of the mechanical performance and morphology of these impact modified PLA composites. The significance of combining deformation theory with a scalable green alternative to petroleum-based rubbers opens up a potential avenue for cheap compostable engineering thermoplastics.

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.

Designing Nanostructured 3D Printed Materials by Controlling Macromolecular Architecture

Nanostructured polymeric materials play important roles in many advanced applications, however, controlling the morphologies of polymeric thermosets remains a challenge. This work uses multi-arm macroCTAs to mediate polymerization-induced microphase separation (PIMS) and prepare nanostructured materials via photoinduced 3D printing. The characteristic length scale of microphase-separated domains is determined by the macroCTA arm length, while nanoscale morphologies are controlled by the macroCTA architecture. Specifically, using 2- and 4- arm macroCTAs provides materials with different morphologies compared to analogous monofunctional linear macroCTAs at similar compositions. The mechanical properties of these nanostructured thermosets can also be tuned while maintaining the desired morphologies. Using multi-arm macroCTAs can thus broaden the scope of accessible nanostructures for extended applications, including the fabrication of actuators and potential drug delivery devices.

Effective Industry-Academia Collaboration Driving Polymer Innovation

Polymer science is one of the few fundamental research fields where the results can be transferred into real-life products almost immediately. Industries need collaborations with the best researchers (universities or national laboratories) to elevate the field and favor the development of new materials, which will boost the chemical and materials business economy and ensure that innovative and sustainable polymer products are constantly being brought to the market. The mechanisms to ensure a seamless and fruitful collaboration are numerous, but few approaches really manage to incorporate the full range of polymer research from a molecular understanding to a macroscopic control of properties. We review some of the main components of standard industry-academia collaborations and propose to develop polymer open centers that put the business development objective as the starting point of the collaboration and allow those to gather and focus on different scientific fields toward a common objective.

Droplet-Based Microfluidic Tool to Quantify Viscosity of Concentrating Protein Solutions

PURPOSE

Measurement of the viscosity of concentrated protein solutions is vital for the manufacture and delivery of protein therapeutics. Conventional methods for viscosity measurements require large solution volumes, creating a severe limitation during the early stage of protein development. The goal of this work is to develop a robust technique that requires minimal sample.

METHODS

In this work, a droplet-based microfluidic device is developed to quantify the viscosity of protein solutions while concentrating in micrometer-scale droplets. The technique requires only microliters of sample. The corresponding viscosity is characterized by multiple particle tracking microrheology (MPT).

RESULTS

We show that the viscosities quantified in the microfluidic device are consistent with macroscopic results measured by a conventional rheometer for poly(ethylene) glycol (PEG) solutions. The technique was further applied to quantify viscosities of well-studied lysozyme and bovine serum albumin (BSA) solutions. Comparison to both macroscopic measurements and models (Krieger-Dougherty model) demonstrate the validity of the approach.

CONCLUSION

The droplet-based microfluidic device provides accurate quantitative values of viscosity over a range of concentrations for protein solutions with small sample volumes (~ μL) and high compositional resolution. This device will be extended to study the effect of different excipients and other additives on the viscosity of protein solutions.

Synergy between Phenoxy and CSR Tougheners on the Fracture Toughness of Highly Cross-Linked Epoxy-Based Composites

A remarkable synergistic increase in fracture toughness by 130% is demonstrated for a CFRP high performance epoxy composite when adding an equal weight combination of phenoxy thermoplastic and core-shell rubber (CSR) toughening agents, as compared to a single toughener at a comparable total concentration of around 10 wt%. The dual-toughened matrix exhibits an unusual morphological arrangement of the two toughener agents. The interlaminar shear strength of the composites is also synergistically improved by about 75% as compared to the reference while the compression modulus reduction and viscosity increase are significantly smaller than for the single phenoxy toughened system. A partial filtering of the CSR particles by the dense CF fabric during pre-pregging leads to a less than optimum CSR dispersion in the composites, showing that the synergy can be further optimized, possibly to the same level as the unreinforced systems.

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.

Tuning the vesicle-to-worm transition for thermoresponsive block copolymer vesicles prepared via polymerisation-induced self-assembly

Does statistical copolymerization of n-butyl methacrylate with benzyl methacrylate lower the critical temperature required for vesicle-to-worm and worm-to-sphere transitions for diblock copolymer nano-objects in mineral oil?

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.

Supramacromolecular injectable hydrogels by crystallization-driven self-assembly of carbohydrate-conjugated poly(2-isopropyloxazoline)s for biomedical applications

An approach for the preparation of self-healing and injectable hydrogels based on the crystallization-driven self-assembly of carbohydrate-conjugated poly(2-isopropyloxazoline)s is reported. Hydrogelation does not require any organic solvents, as the polymers dissolve in water below their lower critical solution temperatures. The transplanted hydrogels cause no significant foreign-body response. Considering the simplicity of the method and the biocompatibility of the resulting injectable hydrogels, crystallization-driven hydrogelation of poly(oxazoline)-based polymers may potentially be used in a wide range of biomedical applications.

RAFT dispersion polymerization of benzyl methacrylate in non-polar media using hydrogenated polybutadiene as a steric stabilizer block

Well-defined spheres, worms or vesicles are prepared via RAFT dispersion polymerization of benzyl methacrylate in n-dodecane at 90 °C using hydrogenated polybutadiene as a macro-RAFT agent.

Effect of Different Types of Block Copolymers on Morphology, Mechanical Properties, and Fracture Mechanisms of Bisphenol-F Based Epoxy System

The effect of adding different types of soft block copolymer on the tensile properties, fracture mechanic properties, and thermo-mechanical properties of bisphenol F based epoxy resin were studied. Two different self-assembling block copolymers, (a) constituting of a center block of poly (butyl acrylate) and two side blocks of poly (methyl) methacrylate-co-polar co-monomer (BCP 1) and (b) poly(ethylene oxide)-b-poly(butylene oxide) (PEO-PBO) diblock copolymer (BCP 2), were used with an epoxy-hardener system. The maximum fracture toughness and fracture energy were measured as KIc = 2.75 MPa·m1/2 and GIc = 2.37 kJ/m2 for the 10 wt % of BCP 1 modified system, which were 366% and 2270% higher in comparison to reference epoxy system, and a 63% reduction in tensile strength was also observed. Similarly, for BCP2 modified systems, the maximum value of KIc = 1.65 MPa·m1/2 and GIc = 1.10 kJ/m2 was obtained for epoxy modified with 12 wt % of BCP2 and a reduction of 32% in tensile strength. The fracture toughness and fracture energy were co-related to the plastic zone size for all the modified systems. Finally, the analysis of the fracture surfaces revealed the toughening micro-mechanisms of the nanocomposites.

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.

From Tunable DNA/Polymer Self-Assembly to Tailorable and Morphologically Pure Core-Shell Nanofibers

In reported experimental studies, DNA/polymer self-assemblies are usually kinetically trapped, leading to the encapsulation and irregular collapse of DNA chains within the resultant assemblies. In striking contrast, eukaryotic cells use tetrasome-to-nucleosome pathways to escape possible kinetic trapping for the formation of well-defined 10 nm chromatin fibers. Here, we report a novel pathway for DNA and amphiphilic diblock copolymer self-assembly inspired by the tetrasome pathway with highly controllable kinetics. The polymer is an A- b-B diblock copolymer with a hydrophilic and noninteractive block A and a hydrophobic and interactive block B. Below the critical water content for the micellization, B blocks wrap the backbone of a DNA chain by weak electrostatic interactions to form a linear DNA/polymer complex. With a gradual increase in the water content, the diblock copolymer unimers in the bulk solution tend to aggregate on the linear DNA/polymer complex, which induces the originally wrapped DNA chain, to change its conformation to wrap around the polymer aggregate, guiding and tailoring the self-assembly. Highly controllable kinetics is achieved via the reduced DNA/polymer electrostatic interactions and the high dynamics of the polymer chains in the system. DNA/polymer self-assembly leads to tailorable and morphologically pure core-shell nanofibers. Compared to the DNA/micelle self-assembly pathway described in our previous study, the present self-assembly pathway exhibits advantages for the fabrication of flexible nanofibers with lengths in micrometers and the potential for unique applications in preparing not only 2D networks at extremely low percolation thresholds but also chemiresistors with large on/off current ratios.

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.

Energy Landscape in Supramolecular Coassembly of Platinum(II) Complexes and Polymers: Morphological Diversity, Transformation, and Dilution Stability of Nanostructures

Establishment of energy landscape has emerged as an efficient pathway for improved understanding and manipulation of both thermodynamic and kinetic behaviors of complicated supramolecular systems. Herein, we report the establishment of energy landscapes of supramolecular coassembly of platinum(II) complexes and polymers, as well as the fabrication of nanostructures with enhanced complexity and intriguing properties from the coassembly systems. In the energy landscape, coassembly at room temperature has been found to only allow the longitudinal growth of platinum(II) complexes and block copolymers into core-shell nanofibers that are the kinetically trapped products. Thermal annealing can switch on the transverse growth of platinum(II) complexes and block copolymers to produce core-shell nanobelts that are the thermodynamically stable nanostructures. The extents of the transverse growth are found to increase with thermal annealing temperatures, leading to nanobelts with larger widths. Besides, rapid quenching of a hot coassembly mixture to room temperature can capture intermediate nanobelt- block-nanofiber nanostructures that are metastable and capable of converting to nanobelts upon further incubation at room temperature. Moreover, sonication treatment has been found to couple with the energy landscape of the coassembly system and open a unique energy-driven pathway to activate the kinetically forbidden nanofiber-to-nanobelt morphological transformation. Furthermore, based on the established energy landscapes, nanosphere- block-nanobelt nanostructures with distinct segmented architectures have been fabricated by thermal annealing of the ternary mixture of platinum(II) complexes, block copolymers, and polymer brushes in a one-pot and single-step procedure. Finally, the nanobelts and nanosphere- block-nanobelt nanostructures are found to possess intriguing morphological stability against acid and dilution, exhibiting characteristics that are important for promising biomedical applications.