High Temperature Epoxy Foam: Optimization of Process Parameters

Development of Sustainable High Performance Epoxy Thermosets for Aerospace and Space Applications

There is an imperative need to find sustainable ways to produce bisphenol A free, high performance thermosets for specific applications such as the space or aerospace areas. In this study, an aromatic tris epoxide, the tris(4-hydroxyphenyl)methane triglycidyl ether (THPMTGE), was selected to generate high crosslinked networks by its copolymerization with anhydrides. Indeed, the prepared thermosets show a gel content (GC) ~99.9% and glass transition values ranged between 167-196 °C. The thermo-mechanical properties examined by DMA analyses reveal the development of very hard materials with E' ~3-3.5 GPa. The thermosets' rigidity was confirmed by Young's moduli values which ranged between 1.25-1.31 GPa, an elongation at break of about 4-5%, and a tensile stress of ~35-45 MPa. The TGA analyses highlight a very good thermal stability, superior to 340 °C. The Limit Oxygen Index (LOI) parameter was also evaluated, showing the development of new materials with good flame retardancy properties.

Novel Expandable Epoxy Beads and Epoxy Particle Foam

Expanded polymeric beads offer the advantage of being able to produce parts with complex geometries through a consolidation process. However, established polymeric beads are made of thermoplastics, deform and melt beyond their temperature services. In this manuscript, a new technique is proposed to fabricate expandable epoxy beads (EEBs), then expand and fuse them to produce epoxy particle foams (EPFs). This technique is called solid-state carbamate foaming technique. For production of EEBs, a mixture of epoxy, carbamate and hardener is prepared and poured into a 10 mL syringe. The mixture is manually extruded into 60 °C water to obtain a cylindric shape. The extrudate is then further cured to obtain an epoxy oligomer behaving rheological tan delta 3 and 2 at 60 °C. The extrudate is cut into pellets to obtain EEBs. The EEBs are then loaded into an aluminum mold and placed in an oven at 160 °C to expand, fuse to obtain EPFs of 212 kg/m³ and 258 kg/m³. The obtained EPFs provide a T_g of 150–154 °C. The fusion boundaries in EPFs are well formed. Thus, the produced EPFs exhibit a compressive modulus of 50–70 MPa, with a torsion storage modulus at 30 °C of 34–56 MPa.

Mechanical Performances of Phenolic Modified Epoxy Resins at Room and High Temperatures

Epoxy is an important resin matrix and has been widely applied in laminated composites as a coating or adhesive material. In this article, the phenolic was applied to modify the mechanical properties of epoxy resin. The phenolic modified epoxy resins with various phenolic content were prepared via a polytetrafluoroethylene mould, and the phenolic modified epoxy-based plain woven laminated composites (PWLCs) were manufactured via vacuum assisted resin transfer method for further study of phenolic modified epoxy resins’ mechanical properties. The compression tests were performed perpendicularly to thickness at 2 mm/min to investigate the mechanical performances of phenolic modified epoxy resins and epoxy-based PWLCs. The results showed that the addition of phenolic into epoxy could improve the mechanical performances of epoxy resins and epoxy-based composites at room temperature, and the phenolic influenced epoxy-based PWLC more than epoxy matrix at room temperature. However, at high temperatures, the addition of phenolic decreased the mechanical performances of epoxy resins and epoxy-based composites, and the adverse effect of phenolic became more serious with the increase of phenolic content at high temperature. In addition, the thermogravimetric analyses were also conducted from 30 °C to 800 °C on phenolic modified epoxy resins and the results showed that the phenolic modified epoxy resin had an earlier loss in weight than unmodified epoxy resin. The earlier loss in weight meant that the addition of phenolic into epoxy resin led to the formation of unstable molecules at high temperature.

Towards Transient Electronics through Heat Triggered Shattering of Off-the-Shelf Electronic Chips

With most of the critical data being stored in silicon (Si) based electronic devices, there is a need to develop such devices with a transient nature. Here, we have focused on developing a programmable and controllable heat triggered shattering transience mechanism for any off-the-shelf (OTS) Si microchip as a means to develop transient electronics which can then be safely and rapidly disabled on trigger when desired. This transience mechanism is based on irreversible and spontaneous propagation of cracks that are patterned on the back of the OTS chip in the form of grooves and then filled with thermally expandable (TE) material. Two types of TE materials were used in this study, commercially available microsphere particles and a developed elastomeric material. These materials expand >100 times their original volume on the application of heat which applies wedging stress of the groove boundaries and induces crack propagation resulting in the complete shattering of the OTS Si chip into tiny silicon pieces. Transience was controlled by temperature and can be triggered at ~160–190 °C. We also demonstrated the programmability of critical parameters such as transience time (0.35–12 s) and transience efficiency (5–60%) without the knowledge of material properties by modeling the swelling behavior using linear viscoelastic models.

Recent Trends of Foaming in Polymer Processing: A Review

Polymer foams have low density, good heat insulation, good sound insulation effects, high specific strength, and high corrosion resistance, and are widely used in civil and industrial applications. In this paper, the classification of polymer foams, principles of the foaming process, types of blowing agents, and raw materials of polymer foams are reviewed. The research progress of various foaming methods and the current problems and possible solutions are discussed in detail.

Effect of Resin and Blocked/Unblocked Hardener Mixture on the Production of Epoxy Foams with CO2 Blocked Hardener in Batch Foaming Process

The present study focuses on the processing and properties of epoxy foams by the use of CO2 blocked hardener N-aminoethylpiperazine (B-AEP) and different resins. Although some studies described the foaming with carbamates, little attention has been given to the interaction of resin properties (such as viscosity) on the foaming performance. Therefore, two resins, diglycidyl ether of bisphenol-A (DGEBA) and epoxy novolac (EN), as well as their 50:50 blend, were foamed with B-AEP and unblocked/blocked AEP hardener mixtures in a batch foaming process. Furthermore, the commercially available chemical blowing agent para-toluenesulfonyl hydrazide (TSH) was used as a benchmark for commonly used chemical blowing agents. The lowest density in this study was reached by the DGEBA+B-AEP system in the range of 215 kg/m3 with the drawback of an inhomogeneous cell structure and high cell size distribution. The best cell morphology and lowest cell size distribution was reached with the EN+15:85% unblocked:blocked hardener mixture, resulting in a density in the range of 394 kg/m3. A syntactic foam was achieved by a DGEBA+50:50% unblocked:blocked hardener mixture with a density of around 496 kg/m3. It was found that a higher viscosity of the resin lead to an increase in the density and a decrease in the cell size distribution range as a result of a closer expansion time window.

Thermosetting polyester foams by infiltration in soluble preforms

Rigid thermosetting foams are produced by infiltration of an unsaturated polyester resin into a soluble preform. In the experimentation, preforms were made of carbamide particles which were compacted at different values of pressure to change the foam structure and properties. After resin polymerization, carbamide particles are evacuated by immersion in water, leaving pores into the samples. Foams with porosity ranging from 52% to 77% were obtained as a function of the preform density. Quasi-static and cyclic compression tests were performed to evaluate foam properties. By increasing porosity, the foam strength reduces as well as the energy adsorbed at failure, and the energy lost in each single loading–unloading cycle.