Relief of Residual Stress in Bulk Thermosets in the Glassy State by Local Bond Exchange

The covalently cross-linked network gives thermosets superior thermal, mechanical, and electrical properties, which, however, squarely makes the large residual stress that is inevitably induced during preparation hardly relieved in the glassy state. In this work, an incredible reduction in residual stress is successfully achieved in bulk thermosets in the glassy state through introducing highly dynamic thiocarbamate bonds by "click" reactions of thiols and isocyanates. Due to the excellent dynamic behaviors of thiocarbamate bonds, local network rearrangement is achieved through thermal stimulation, while the strong 3D cross-linked network is well maintained. Ultimately, a decrease by 44% in residual stress is detected by simply annealing samples at 30 °C below glass transition temperature (Tg), during which they could well maintain more than 98.4% of the storage modulus. After the annealing, more uniform residual stress distribution is also observed, showing a 32% decline in sample standard deviation. However, the residual stress of epoxy resin, a typical thermoset as a reference, changes little even after annealing at Tg. The results prove it a feasible strategy to reduce residual stress in bulk thermosets in the glassy state by introducing proper dynamic covalent bonds.

Conversion of Contaminated Post-Consumer Polyethylene Terephthalate into a Thermoset Alkyd Coating Using Biosourced Monomers

The synthesis of a high-performance oxidative cross-linked thermoset alkyd coating is described that utilizes a novel recycling strategy from contaminated postconsumer waste polyethylene terephthalate (wPET). A single-stage "depolymerization-repolymerization" process has been developed that allows the exploitation of a waste stream from a commercial PET recycling process with 95% efficiency, which, when copolymerized with glycerol and tall oil fatty acid, delivers a sustainable fatty acid-functional polyester suitable for use in thermoset alkyd coatings. Physical drying challenges have been tackled via the development of a convergent polymer formulation strategy from a single source of wPET and the formulation of the resulting fatty acid-functional polymers with commercial alkyd driers, delivering a thermoset alkyd coating suitable for industrial applications.

Strategies towards Fully Recyclable Commercial Epoxy Resins: Diels-Alder Structures in Sustainable Composites

The Diels-Alder equilibrium is a widely known process in chemistry that can be used to provide a thermoset structure with recyclability and reprocessability mechanisms. In this study, a commercial epoxy resin is modified through the integration of functional groups into the network structure to provide superior performance. The present study has demonstrated that it is possible to adapt the curing process to efficiently incorporate these moieties in the final structure of commercial epoxy-based resins. It also evaluates the impact that they have on the final properties of the cured composites. In addition, different approaches have been studied for the incorporation of the functional group, adjusting and adapting the stoichiometry of the system components due to the differences in reactivity caused by the presence of the incorporated reactive groups, with the objective of maintaining comparable ratios of epoxy/amine groups in the formulation. Finally, it has been demonstrated that although the Diels-Alder equilibrium responds under external conditions, such as temperature, different sets of parameters and behaviors are to be expected as the structures are integrated into the thermoset, generating new equilibrium temperatures. In this way, the present research has explored sustainable strategies to enable the recyclability of commercial thermoset systems through crosslinking control and its modification.

A Preliminary Study of Thermosets from Epoxy Resins Made Using Low-Toxicity Furan-Based Diols

Glycidyl ethers are prepared from a series of furan-based diols and cured with a diamine to form thermosets. The furan diols demonstrate lower toxicity than bisphenol-A in a prior study. The diglycidyl ethers show improved thermal stability compared to the parent diols. Cured thermosets are prepared at elevated temperature using isophorone diamine (IPDA). Glass transition temperatures are in the range of 30-54 °C and depend on the structure of the furan diol. Coatings are prepared on steel substrates and show very high hardness, good adhesion, and a range of flexibility. Properties compare favorably with a control based on a bisphenol-A epoxy resin. The study demonstrates that epoxy resins based on furan diols, which have been shown to have lower toxicity than bisphenol-A, can form thermosets having properties comparable to a standard epoxy resin system; and thus, are viable as replacements for bisphenol-A epoxy resins.

Effect of Fiber Sizing Levels on the Mechanical Properties of Carbon Fiber-Reinforced Thermoset Composites

Fiber sizing is one of the most important components in manufacturing composites by affecting mechanical properties, including strength and stiffness. The sizing of manmade fibers offers many advantages, such as improving fiber/matrix adhesion and bonding properties, protecting fiber surfaces from damage during the processing and weaving stages, and enhancing the surface wettability of polymer matrices. In this work, the influence of fiber sizing levels on carbon fibers' (CFs) mechanical properties is reported at room temperature using single fiber tensile testing (Favimat+), single fiber pullout testing (SFPO), and interfacial elemental analysis by X-ray photoelectron spectroscopy (XPS). Standard modulus CFs (7 ± 0.2 μm in diameter) were sized using two commercially available Michelman sizing formulations. The average solid content for each sizing formulation was 26.3 ± 0.2% and 34.1 ± 0.2%, respectively. HEXION RIMR 135 with curing agent RIMH 137 was used as a model thermoset epoxy matrix during SFPO measurements. A predictive engineering fiber sizing methodology was also developed. Sizing amounts of 0.5, 1, and 2 wt.% on the fiber surface were achieved for both sizing formulations. For each fiber size level, 50 single-fiber tensile testing experiments and 20 single-fiber pull-out tests were conducted. The ultimate tensile strength (σult) of the carbon fibers and the interfacial shear strength (τapp) of the single fiber composite were analyzed. The sizing levels' effect on interfacial shear stress and the O/C (Oxygen/Carbon) surface composition ratio was investigated. Based on our experimental findings, an increase of 6% in fiber performance was recorded for ultimate tensile and interfacial shear strengths. As a result, generalized fiber sizing and characterization methods were established. These developed methods can be used to characterize the strength and interfacial shear strength of manmade fibers with different sizing formulations and solid contents irrespective of the matrix, i.e., thermoset or thermoplastic.

Exploring Gel-Point Identification in Epoxy Resin Using Rheology and Unsupervised Learning

Any thermoset resin's processing properties and end-use performance are heavily influenced by the gel time. The complicated viscosity of resin as a function of temperature is investigated in this work, with a particular emphasis on identifying the gel point and comprehending polymerization. Rheology studies carried out using a plate-plate controlled stress rheometer under isothermal conditions were used to compare three experimental techniques for figuring out an epoxy resin's gel point. We also look at the basic modifications that take place during polymerization. We verify the reliability of the three strategies by including Principal Component Analysis (PCA), an unsupervised machine learning methodology. PCA assists in uncovering hidden connections between these methods and various affecting factors. PCA serves a dual role in our study, confirming method validity and identifying patterns. It sheds light on the intricate relationships between experimental techniques and material properties. This concise study expands our understanding of resin behavior and provides insights that are essential for optimizing resin-based processes in a variety of industrial applications.

Preparation and Characterization of Body-Temperature-Responsive Thermoset Shape Memory Polyurethane for Medical Applications

Shape memory polymers (SMPs) are currently one of the most attractive smart materials expected to replace traditional shape memory alloys and ceramics (SMAs and SMCs, respectively) in some fields because of their unique properties of high deformability, low density, easy processing, and low cost. As one of the most popular SMPs, shape memory polyurethane (SMPU) has received extensive attention in the fields of biomedicine and smart textiles due to its biocompatibility and adjustable thermal transition temperature. However, its laborious synthesis, limitation to thermal response, poor conductivity, and low modulus limit its wider application. In this work, biocompatible poly(ε-caprolactone) diol (PCL-2OH) is used as the soft segment, isophorone diisocyanate (IPDI) is used as the hard segment, and glycerol (GL) is used as the crosslinking agent to prepare thermoset SMPU with a thermal transition temperature close to body temperature for convenient medical applications. The effects of different soft-chain molecular weights and crosslinking densities on the SMPU's properties are studied. It is determined that the SMPU has the best comprehensive performance when the molar ratio of IPDI:PCL-2OH:GL is 2:1.5:0.33, which can trigger shape memory recovery at body temperature and maintain 450% recoverable strain. Such materials are excellent candidates for medical devices and can make great contributions to human health.

An Overview of Angle Deviations of Fiber-Reinforced Polymer Composite Angular Laminates

After manufacturing, fiber-reinforced polymer composite laminates may have residual stresses, resulting in warpage in flat structures and angle changes in angular sections. These shape distortions may cause fitting mismatch problems under high-level assembly, and extra efforts to fix these problems may be needed. The present paper only makes an overview of the angle deviation of angular composite laminates made of either thermoset matrix with autoclave curing or thermoplastic matrix with thermoforming. Depending on the positive or negative angle deviation, spring-back or spring-in behavior is observed. There are many parameters, including intrinsic and extrinsic parameters, that could affect the angle deviation. In the first part of this review paper, experimental results concerning the effects of the part angle, part thickness, lay-up sequence, corner angle, flange size, tool material, tool surface, and cure cycle are summarized. Spring-in angles are generally obtained in this part. In the second part, several prediction methods, such as simple equations and finite element methods, are compared to indicate the considered parameters. Some have good agreement and some have larger errors. The crucial differences may be dependent on the micromechanical theories and the input properties of the composite and the constituents.

Effect of Fiber Misalignment and Environmental Temperature on the Compressive Behavior of Fiber Composites

This experimental study investigated how defects, in particular fiber misalignment, affect the mechanical behavior of glass fiber composites (GFRP) under compressive loading. GFRP cross-plies with three different types of fiber misalignment, namely a fold, a wave, and an in-plane undulation, were fabricated using the resin transfer molding process. The compressive tests were performed at four different temperatures, in order to investigate the role of a change in the matrix properties on the strength of the composite. The experiments showed that the defects, especially at lower temperatures, had a significant impact on the mechanical properties of the composite, exceeding the proportion of the defects inside the composite. With increasing temperature, the damage mechanism changed from fiber-dominated to matrix-dominated and, in doing so, decreased the significance of fiber misalignment for the mechanical behavior.

Method of Manufacturing Structural, Optically Transparent Glass Fiber-Reinforced Polymers (tGFRP) Using Infusion Techniques with Epoxy Resin Systems and E-Glass Fabrics

Recently, fiber-reinforced, epoxy-based, optically transparent composites were successfully produced using resin transfer molding (RTM) techniques. Generally, the production of structural, optically transparent composites is challenging since it requires the combination of a very smooth mold surface with a sufficient control of resin flow that leads to no visible voids. Furthermore, it requires a minimum deviation of the refractive indices (RIs) of the matrix polymer and the reinforcement fibers. Here, a new mold design is described and three plates of optically transparent glass fiber-reinforced polymers (tGFRP) with reproducible properties as well as high fiber volume fractions were produced using the RTM process and in situ polymerization of an epoxy resin system enclosing E-glass fiber textiles. Their mechanical (flexural), microstructural (fiber volume fraction, surface roughness, etc.), thermal (DSC, TGA, etc.), and optical (dispersion curves of glass fibers and polymer as well as transmission over visible spectra curves of the tGFRP at varying tempering states) properties were evaluated. The research showed improved surface quality and good transmission data for samples manufactured by a new Optical-RTM setup compared to a standard RTM mold. The maximum transmission was reported to be ≈74%. In addition, no detectable voids were found in these samples. Furthermore, a flexural modulus of 23.49 ± 0.64 GPa was achieved for the Optical-RTM samples having a fiber volume fraction of ≈42%.

Experimental and Simulative Analysis of the Pressure Development in a Closed Injection Pultrusion Process with Multiple Chamber Geometries

The use of innovative higher-performance highly reactive resin systems requires an enhancement of the established method of fiber impregnation (open bath) towards closed resin-injection pultrusion (CIP), due to the short pot life of the resin systems. The result is that the open bath is developed into a closed injection and impregnation chamber ("ii-chamber"). In this study, three parameters-resin viscosity, opening angle and opening factor at the injection point on the ii-chamber-are varied, each in three stages. For each set of parameters, a pultrusion trial is conducted and the process pressures in the ii-chamber and pultrusion die measured. This enables direct feedback via the process conditions of the as yet uncured composite. The data obtained are used to validate a newly developed simulation model. The model is based on Darcy's law, which has been extended to take fiber movement into account and thus represent the resulting pressure increase in the die. The flexible ii-chamber and die concept enhance our understanding of the processes taking place in the die system. The sensitivity of the process pressures can be shown for the three influencing variables. The experiment shows that of the three influencing variables investigated, viscosity has the greatest sensitivity to pressure development. In general, it can be said that over the length of the pultrusion die system, the pressure level increases across the three measuring points.

Improving the Integrated Fabrication of Insulation Systems in Electric Drives by Injection Molding of Thermosets Due to Processing Conditions and Slot Design

The expanding demand for electro mobility in general and specifically for electrified vehicles requires the expansion of electro mobility technology with respect to variations in the requirements of the process and the application. Within the stator, the electrical insulation system has a high impact on the application properties. So far, limitations, such as the identification of suitable materials for the stator insulation or high costs in the processes, have hindered the implementation of new applications. Therefore, a new technology that allows integrated fabrication via the injection molding of thermosets is founded in order to expand the applications of stators. The possibility of the integrated fabrication of insulation systems to meet the demands of the application can be improved by the processing conditions and the slot design. Within this paper, two epoxy (EP) types with different fillers are investigated to show the impact of the fabrication process in terms of different parameters; these include the holding pressure or the temperature setup, as well as the slot design and with that the flow conditions. To evaluate the improvement in the insulation system of electric drives, a single slot sample, consisting of two parallel copper wires, was used. Then, the two parameters of the average partial discharge (PD) and the partial discharge extinction voltage (PDEV), as well as the full encapsulation detected by microscopy images, were analyzed. It was shown that both characteristics (electric properties-PD and PDEV; full encapsulation) could be improved in terms of an increase in the holding pressure (up to 600 bar) or a reduction in the heating time (around 40 s), as well as the injection speed (down to 15 mm/s). Further, an improvement in the properties can be reached by increasing the space between the wires, as well as the wire and the stack, due to a higher slot depth or by implementing flow-improving grooves that have a positive effect on the flow conditions. With that, the optimization of the integrated fabrication of insulation systems in electric drives via the injection molding of thermosets was enabled with respect to the process conditions and the slot design.

Embedded 3D Printing of Thermally-Cured Thermoset Elastomers and the Interdependence of Rheology and Machine Pathing

Thermoset elastomers are widely used high-performance materials due to their thermal stability, chemical resistance, and mechanical properties. However, established casting and molding techniques limit the overall 3D complexity of parts that can be fabricated. Advanced manufacturing methods such as 3D printing have improved design flexibility and reduced development time but have proved challenging using thermally-cured thermosets due to their viscosity, slow gelation kinetics and high surface tension. To address this, freeform reversible embedding (FRE) 3D printing extrudes thermosets such as polydimethylsiloxane (PDMS) elastomer within a carbomer support bath, but due to the liquid-like state of the prepolymer during extrusion has been limited to hollow structures. Here, we have significantly improved FRE printing through rheological modification of PDMS with a thixotropic additive (1.0-10.0 wt%) that imparts a yield stress (30-120 Pa) to help control filament morphology. Further, to minimize the interaction of the nozzle with previously printed PDMS we implemented print process controls consisting of region-specific slicing, filament retraction, and non-print travel moves outside of the print. The combined result is the FRE printing of PDMS in complex 3D parts with high fidelity, establishing a 3D printing methodology that can be used broadly with thermally-cured thermoset elastomers and related polymers.

Flame-Retardant and Recyclable Soybean Oil-Based Thermosets Enabled by the Dynamic Phosphate Ester and Tannic Acid

The demands of safety and sustainability have driven the development of intrinsic flame-retardant biobased polymers from renewable materials. Herein, a mechanically robust, good flame-retardant, and recyclable thermoset was developed from renewable epoxidized soybean oil (ESO) by using 2-hydroxyethyl methacrylate phosphate (HEMAP) as the reactive flame retardant and tannic acid (TA) as the charring agent. The flame resistance of the obtained ESO-based thermoset achieved the highest UL-94 of V-0 rating and a limited oxygen index value of 26.7% due to the synergistic flame-retardant effect of phosphate and TA. The flame-retardant mechanisms of the gaseous phase and condensed phase were fully investigated by thermogravimetric infrared, scanning electron microscopy-energy-dispersive spectrometry, X-ray photoelectron spectroscopy, and Raman spectra. It is confirmed that the incorporation of phosphate and TA could effectively promote the formation of dense carbon layers and delay the pyrolysis of long aliphatic chains. The ternary crosslinking of ESO, HEMAP, and TA via free-radical polymerization and epoxy-ring opening reaction resulted in a rigid network with a high crosslink density, bestowing the thermoset with superior tensile strength (20.0 MPa), flexural strength (36.3 MPa), and bonding strength (16.7 MPa on steel). Moreover, the ESO-based thermoset exhibited a fast stress relaxation behavior due to the transesterification of dynamic β-hydroxyl phosphate esters, which enables the network with thermal-healing ability and recyclability. This study explores a feasible method to prepare an intrinsic flame-retardant polymer from commercially available and renewable vegetable oils and natural polyphenols.

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.

Possibilities of Integrated Fabrication of Insulation Systems in Electric Drives by Injection Molding of Thermosets

Due to the increasing demand for electro mobility and specifically for electrified vehicles, the demand for electric drive technology is expanding significantly with changing requirements in terms of the process and the application. The electrical insulation system of the stator is an essential part of the fabrication process with a high impact on the application properties. Due to limitations-for example, in terms of suitable materials for the stator insulation-a new technology of integrated fabrication by injection molding of thermosets has been founded. In this study, two epoxy (EP) types with different fillers were investigated to prove their suitability in terms of the material properties in the fabrication process and the application. A general realization of the integrated fabrication of insulation systems in electrical engineering by injection molding was proved. Further, the differences regarding the suitability of the two materials are portrayed. It was demonstrated that mainly the filler material influences the fabrication process and the properties in the application, leading to differing suitability in terms of the EP 3162 EMG within the fabrication process and in terms of XW 6640-1 within the application properties of the thermal conductivity and the thermal linear expansion. It was further shown that the filler within the material system is required to increase the thermal conductivity needed for the application. The inclusion of the filler influences the reaction kinetics and the viscosity behavior. A fabrication of the material with fillers is however still possible.

Magnetically Actuated Shape Memory Polymers for On-Demand Drug Delivery

Repeated use of intravenous infusions to deliver drugs can cause nerve damage, pain, and infection. There is an unmet need for a drug delivery method that administers drugs on demand for prolonged use. Here, we developed magnetically responsive shape memory polymers (SMPs) to enhance control over drug release. Iron oxide magnetic nanoparticles (mnps) were synthesized and incorporated into previously developed SMPs to enable magnetically induced shape memory effects that can be activated remotely via the application of an alternating magnetic field. These materials were tested for their shape memory properties (dynamic mechanical analysis), cytocompatibility (3T3 fibroblast viability), and tunable drug delivery rates (UV−VIS to evaluate the release of incorporated doxorubicin, 6-mercaptopurine, and/or rhodamine). All polymer composites had >75% cytocompatibility over 72 h. Altering the polymer chemistry and mnp content provided methods to tune drug release. Namely, linear polymers with higher mnp content had faster drug release. Highly cross-linked polymer networks with lower mnp content slowed drug release. Shape memory properties and polymer/drug interactions provided additional variables to tune drug delivery rates. Polymers that were fixed in a strained secondary shape had a slower release rate compared with unstrained polymers, and hydrophobic drugs were released more slowly than hydrophilic drugs. Using these design principles, a single material with gradient chemistry and dual drug loading was synthesized, which provided a unique mechanism to deliver two drugs from a single scaffold with distinct delivery profiles. This system could be employed in future work to provide controlled release of selected drug combinations with enhanced control over release as compared with previous approaches.

Recycling of Thermoset Materials and Thermoset-Based Composites: Challenge and Opportunity

Thermoset materials and their composites are characterized by a long life cycle with their main applications in aircrafts, wind turbines and constructions as insulating materials. Considering the importance of recovery and valorization of these materials at their end-of-life, avoiding landfilling, the interest concerning their recycling grows continuously. The thermoset materials and their composites, to be successfully recovered and valorized, must degrade their three-dimensional structures and recover the mono-oligomers and/or fillers. The thermoset materials could successfully degrade through thermal treatment at different temperatures (for example, above 1000 °C for incineration, ca. 500 °C for oxidation/combustion of organic constituents, etc.), chemical degradation by catalyst, irradiation with or without the presence of water, alcohol, etc., and mechanical recycling, obtaining fine particles that are useful as filler and/or reinforcement additives. Among these recycling methods, this mini-review focuses on the formulation and recovery method of innovative thermoset with in-build recyclability, i.e., materials having chemical links that could be degraded on-demand or containing dynamic covalent bonds to have re-processable and/or recyclable thermoset. This issue could be considered the future perspective in developing novel thermoset materials. The aim of this review is to get an overview of the state of the art in thermoset recycling and of the most commonly used thermoset composites, recovering valuable reinforcing fibers. Additionally, in this work, we also report not only known recycling routes for thermoset and thermoset-based composites, but also new and novel formulating strategies for producing thermosets with built-in recyclability, i.e., containing chemical-triggered on-demand links. This mini-review is also a valuable guide for educational purposes for students and specialized technicians in polymer production and recycling.

Incremental Numerical Approach for Modeling the Macroscopic Viscoelastic Behavior of Fiber-Reinforced Composites Using a Representative Volume Element

The objective of this study is to describe the stress relaxation behavior of an epoxy-based fiber-reinforced material. An existing incremental formulation of an orthotropic linear viscoelastic material behavior was adapted to Voigt notation and to the special case of an isotropic material. Virtual relaxation tests on a representative volume element were performed, and the behavior of individual components of the relaxation tensor of the transversely isotropic composite material was determined. The study demonstrated that in the case of only one viscoelastic material, each component of the relaxation tensor can be described in terms of a scalar form factor and the behavior of the neat resin. The developed method was implemented in an incremental finite element model (FEM) analysis to calculate the stress relaxation on the macroscopic ply level. A validation of the approach has shown a promising agreement up to a limit below the glass transition temperature of 15 °C in longitudinal and 35 °C in transverse direction. This study therefore demonstrates a novel way to incrementally describe the macroscopic viscoelastic behavior of materials with a single viscoelastic component with good controllability for engineering purposes.

Network Formation and Physical Properties of Epoxy Resins for Future Practical Applications

Epoxy resins are used in various fields in a wide range of applications such as coatings, adhesives, modeling compounds, impregnation materials, high-performance composites, insulating materials, and encapsulating and packaging materials for electronic devices. To achieve the desired properties, it is necessary to obtain a better understanding of how the network formation and physical state change involved in the curing reaction affect the resultant network architecture and physical properties. However, this is not necessarily easy because of their infusibility at higher temperatures and insolubility in organic solvents. In this paper, we summarize the knowledge related to these issues which has been gathered using various experimental techniques in conjunction with molecular dynamics simulations. This should provide useful ideas for researchers who aim to design and construct various thermosetting polymer systems including currently popular materials such as vitrimers over epoxy resins.

Off-Axis and On-Axis Performance of Novel Acrylic Thermoplastic (Elium®) 3D Fibre-Reinforced Composites under Flexure Load

The flexure response of novel thermoplastic (Elium^®) 3D fibre-reinforced composites (FRC) was evaluated and compared with a conventional thermoset (Epolam^®)-based 3D-FRC. Ten different types of sample 3D-FRC were prepared by varying fibre orientations, i.e., 0°, 30°, 45°, 60° and 90°, and resin system, i.e., thermoplastic and thermoset. The bending characteristics and failure mechanisms were determined by conducting a three-point bend test. Results elucidate that the on-axis specimens show linear response and brittle failure; in contrast, the off-axis specimens depicted highly nonlinear response and ductile failure. The thermoplastic on-axis specimen exhibited almost similar flexure strength; in comparison, the off-axis specimens show ~17% lower flexure strength compared to thermoset 3D-FRC. Thermoplastic 3D-FRC shows ~40% higher energy absorption, ~23% lower flexure modulus and ~27% higher flexure strains as compared to its thermoset counterpart.

Recycled (Bio)Plastics and (Bio)Plastic Composites: A Trade Opportunity in a Green Future

Today’s world is at the point where almost everyone realizes the usefulness of going green. Due to so-called global warming, there is an urgent need to find solutions to help the Earth and move towards a green future. Many worldwide events are focusing on the global technologies in plastics, bioplastic production, the recycling industry, and waste management where the goal is to turn plastic waste into a trade opportunity among the industrialists and manufacturers. The present work aims to review the recycling process via analyzing the recycling of thermoplastic, thermoset polymers, biopolymers, and their complex composite systems, such as fiber-reinforced polymers and nanocomposites. Moreover, it will be highlighted how the frame of the waste management, increasing the materials specificity, cleanliness, and a low level of collected material contamination will increase the potential recycling of plastics and bioplastics-based materials. At the same time, to have a real and approachable trade opportunity in recycling, it needs to implement an integrated single market for secondary raw materials.

Low Formaldehyde Binders for Mineral Wool Insulation: A Review

Insulating materials are ubiquitous in a built environment and play a critical role in reducing the energy consumed to maintain habitable indoor environments. Mineral wool insulation (MWI) products, including glass, stone, and slag variants, are the most widely used class of insulating materials in Europe and account for more than 50% of the total market by volume. MWI typically consists of two key components: a mesh of inorganic fibers that are several micrometers in diameter, and an organic thermosetting adhesive commonly referred to as the "binder." Traditional phenol-formaldehyde-urea (PFU) binders used in the manufacture of MWI are increasingly being scrutinized for the formaldehyde released during their manufacture and service lifetime. The recent classification of formaldehyde as a carcinogen by various safety organizations has accelerated a paradigm shift within the industry toward alternative binder technologies that minimize or indeed eliminate formaldehyde emissions. This review examines more recent strategies for achieving low- or zero-added formaldehyde binders for MWI, with a particular focus on the patent literature. The chemistry underpinning traditional PFU binders is presented and compared to new strategies involving scavenging molecules that decrease formaldehyde emissions, as well as zero-added formaldehyde binder technologies such as polyester, Maillard, and epoxide thermosets.

Hydrolyzable Poly(β-Thioether Ester Ketal) Thermosets via Acyclic Ketal Monomers

Hydrolytically degradable poly(β-thioether ester ketal) thermosets are synthesized via radical-mediated thiol-ene photopolymerization using three novel dialkene acyclic ketal monomers and a mercaptopropionate based tetrafunctional thiol. For all thermoset compositions investigated, degradation behavior is highly tunable based on the structure of the incorporated ketal and pH. Complete degradation of the thermosets is observed upon exposure to acidic and neutral pH, and under high humidity conditions. Polymer networks comprised of crosslink junctions based on acyclic dimethyl ketals degrade the quickest, whereas networks containing acyclic cyclohexyl ketals undergo hydrolytic degradation on a longer timescale. Thermomechanical analysis revealed low glass transition temperatures and moduli typical of thioether-based thermosets. This article is protected by copyright. All rights reserved.

Cross-Linking and Evaluation of the Thermo-Mechanical Behavior of Epoxy Based Poly(ionic Liquid) Thermosets

Poly(ionic liquids) (PILs) and ionenes are polymers containing ionic groups in their repeating units. The unique properties of these polymers render them as interesting candidates for a variety of applications, such as gas separation membranes and polyelectrolytes. Due to the vast number of possible structures, numerous synthesis protocols to produce monomers with different functional groups for task-specific PILs are reported in literature. A difunctional epoxy-IL resin was synthesized and cured with multifunctional amine and anhydride hardeners and the thermal and thermomechanical properties of the networks were assessed via differential scanning calorimetry and dynamic mechanical analysis. By the selection of suitable hardeners, the glass transition onset temperature (Tg,onset) of the resulting networks was varied between 18 °C and 99 °C. Copolymerization of epoxy-IL with diglycidyl ether of bisphenol A (DGEBA) led to a further increase of the Tg,onset. The results demonstrate the potential of epoxy chemistry for tailorable PIL networks, where the hardener takes the place of the ligands without requiring an additional synthesis step and can be chosen from a broad range of commercially available compounds.

Dry Fibre Placement: The Influence of Process Parameters on Mechanical Laminate Properties and Infusion Behaviour

Within the dry fibre placement (DFP) process, spread and pre-bindered carbon fibre rovings are automatically processed into dry textile preforms using 2-D and 3-D laying systems. The aim was to automate existing hand lay-up processes, reducing the complexity, increasing robustness, and facilitating the handling of the DFP technology. Process reliability, low waste rates, and flexible production are demonstrated. In this publication, the influences of the process parameters, 2 mm wide gaps and the percentage of 90° plies in the laminate, are investigated with regard to the mechanical properties, the permeability, and the infusion times in the preform z-direction (thickness). The effects on stiffness and strength are compared for several use cases. An approach to determine the infusion times as a function of the laminate thickness, the ply structure, and 2 mm wide gaps is demonstrated and analysed using vacuum-assisted process (VAP) infusion tests. The investigations are performed with carbon fibre tows (24 k), a reactive epoxy-based binder system, and a thermoset infusion resin system.

Transparent Fiber-Reinforced Composites Based on a Thermoset Resin Using Liquid Composite Molding (LCM) Techniques

In this study, optically transparent glass fiber-reinforced polymers (tGFRPs) were produced using a thermoset matrix and an E-glass fabric. In situ polymerization was combined with liquid composite molding (LCM) techniques both in a resin transfer molding (RTM) mold and a lite-RTM (L-RTM) setup between two glass plates. The RTM specimens were used for mechanical characterization while the L-RTM samples were used for transmittance measurements. Optimization in terms of the number of glass fabric layers, the overall degree of transparency of the composite, and the mechanical properties was carried out and allowed for the realization of high mechanical strength and high-transparency tGFRPs. An outstanding degree of infiltration was achieved maintaining up to 75% transmittance even when using 29 layers of E-glass fabric, corresponding to 50 v.% fiber, using an L-RTM setup. RTM specimens with 44 v.% fiber yielded a tensile strength of 435.2 ± 17.6 MPa, and an E-Modulus of 24.3 ± 0.7 GPa.

Structural Variation and Chemical Performance-A Study of the Effects of Chemical Structure upon Epoxy Network Chemical Performance

Epoxy resins are used widely as protective coatings, in a wide range of harsh chemical environments. This work explores the influence of subtle structural variation in both epoxy and amine monomers upon chemical performance of cured networks, whether changing molecular geometry, the nature of the chemistry, or the mass between cross-linking reactive groups. To achieve this, four industrially relevant epoxy resins (two based on bisphenol A-Epikote 828 (E828) and Dow Epoxy Resin 332 (DER 332)-and two based on bisphenol F-Dow Epoxy Resin 354 (DER 354) and Araldite PY306 (PY306)) and the isomerically pure para-para-diglycidyl ether of bisphenol F (ppDGEBF) were used to explore variation caused by epoxy monomer variation. Four similar amines (meta-xylylenediamine (MXDA), para-xylylenediamine (PXDA), 1,3-bis(aminomethyl)cyclohexane (1,3-BAC), 1,4-bis(aminomethyl)cyclohexane (1,4-BAC)) were used to explore any variations caused by regioisomerism and aromaticity. Bisphenol F-based resins were found to outperform bisphenol A-based analogues, and chain extension within the epoxy component was found to be detrimental to performance. For amines, 1,3-substitution (vs 1,4) and aromaticity were both found to be beneficial to chemical performance.

Effect of Thermal Ageing on the Mechanical Strength of Carbon Fibre Reinforced Epoxy Composites

Applications of Carbon Fibre Reinforced Polymers (CFRP) at temperatures over 150-200 °C are becoming common in aerospace and automotive applications. Exposure of CFRP to these temperatures can lead to permanent changes in their mechanical properties. In this work, we investigated the effect of thermal ageing in air on the strength of carbon fabric/epoxy composites. To this end, accelerated artificial ageing at different temperatures was performed on carbon fabric/epoxy specimens. The flexural and interlaminar shear strengths of the aged specimens were assessed by three-point bending and short beam shear tests, respectively, and compared to those of unaged samples. For ageing at temperatures below the glass transition temperature of the resin, Tg, a moderate reduction of strength was found, with a maximum decrease of 25% for 2160 h at 75% Tg. On the other hand, a rapid strength decrease was observed for ageing temperatures above Tg. This was attributed to degradation of the epoxy matrix and of the fibre/epoxy interface. In particular, a 30% strength decrease was found for less than 6 h at 145% Tg. Therefore, it was concluded that even a short exposure to operating temperatures above Tg could substantially impair the load-carrying capability of CFRP components.

Novel Repair Procedure for CFRP Components Instead of EOL

Today, numerous carbon fiber (CF) reinforced plastic (CFRP) components are in continuous usage under harsh environmental conditions. New components often replace damaged structural parts in safety-critical applications. In addition to this, there is also no effective repair method to initially restore the mechanics of these structures using dry fiber material. The high costs of CFRP components are not in proportion to their lifetime. The research project IGF-19946 BR "CFRP-Repair" addresses this specific challenge. By using an oxide semiconductor that is activated by ultraviolet (UV) irradiation, the thermoset matrix can be depolymerized and thus locally removed from the damaged CFRP component. Afterward, the harmed fibers can be physically removed from the laminate in this certain area. A load-adjusted tailored fiber reinforcement patch is subsequently applied and consolidated by local thermoset re-infiltrating. Using this procedure, the structure can be locally repaired with new CF. As a result, repaired CFRP structures can be obtained with reduced mechanics and an approximately original surface. This article gives an insight into the developed repair procedure of CFRP components in an innovative and more efficient way than the state-of-the-art.

Green Picosecond Laser Machining of Thermoset and Thermoplastic Carbon Fiber Reinforced Polymers

There has been an increase in demand for the development of lightweight and high-strength materials for applications in the transportation industry. Carbon fiber reinforced polymer (CFRP) is known as one of the most promising materials owing to its high strength-to-weight ratio. To apply CFRP in the automotive industry, various machining technologies have been reported because it is difficult to machine. Among these technologies, picosecond laser beam-induced machining has attracted great interest because it provides negligible heat transfer and can avoid tool wear. In this work, we conducted and compared machining of 2.15 mm-thick thermoset and 1.85 mm-thick thermoplastic CFRPs by using a green picosecond laser. The optimized experimental conditions for drilling with a diameter of 7 mm led to a small taper angle (average ~ 3.5°). The tensile strength of the laser-drilled specimens was evaluated, and the average value was 570 MPa. Our study indicates that green picosecond laser processing should be considered as a promising option for the machining of CFRP with a small taper angle.

Hot Embossing of Micro-Pyramids into Thermoset Thiol-Ene Film

This paper presents the first attempt to texturize a fully crosslinked thermoset shape memory polymer using a hot embossing technique. UV-cured thiol-ene films were successfully embossed with anisotropically-etched Si (100) stamps at a temperature of 100 °C, which is about 50 °C above the glass transition temperature of the polymer. The low storage modulus of the polymer in a rubbery state allowed us to permanently emboss random micro-pyramidal patterns onto the surface of the film with high fidelity by applying 30 MPa pressure for 1 h. Atomic force microscopy (AFM) investigation showed perfect replication of the stamp micropattern with typical height of the largest inverted pyramids close to 0.7 µm and lateral dimensions in the range of 1–2 µm. Changes in surface roughness parameters of the embossed thiol-ene films after annealing them at 100 °C for 1 h or storing for 2 months in air at standard room conditions were negligible. The achieved results open new perspectives for the simple and inexpensive hot embossing technique to be applied for the micropatterning of prepolymerized thermoset shape memory films as an alternative to micropatterning using UV casting.

Physical and dosimetric characterization of thermoset shape memory bolus developed for radiotherapy

PURPOSE

We developed a thermoset shape memory bolus (shape memory bolus) made from poly-ε-caprolactone (PCL) polymer. This study aimed to investigate whether the shape memory bolus can be applied to radiotherapy as a bolus that conformally adheres to the body surface, can be created in a short time, and can be reused.

METHODS

The shape memory bolus was developed by cross-linking tetrabranch PCL with reactive acrylate end groups. Dice similarity coefficient (DSC) was used to evaluate shape memory characterization before deformation and after restoration. In addition, the degree of adhesion to the body surface and crystallization time were calculated. Moreover, dosimetric characterization was evaluated using the water equivalent phantom and an Alderson RANDO phantom.

RESULTS

The DSC value between before deformation and after restoration was close to 1. The degree of adhesion of the shape memory bolus (1.9%) was improved compared with the conventional bolus (45.6%) and was equivalent to three-dimensional (3D) printer boluses (1.3%-3.5%). The crystallization time was approximately 1.5 min, which was clinically acceptable. The dose calculation accuracy, dose distribution, and dose index were the equivalent compared with 3D boluses.

CONCLUSION

The shape memory bolus has excellent adhesion to the body surface, can be created in a short time, and can be reused. In addition, the shape memory bolus needs can be made from low-cost materials and no quality control systems are required for individual clinical departments, and it is useful as a bolus for radiotherapy.

Epoxidation of Cardanol's Terminal Double Bond

In this investigation, the terminal double bonds of the side chain epoxidized cardanol glycidyl ether (SCECGE) molecule were further epoxidized in the presence of Oxone^® (potassium peroxomonosulfate) and fluorinated acetone. Regular methods for the double bond epoxidation are not effective on the terminal double bonds because of their reduced electronegativity with respect to internal double bonds. The terminal double bond functionality of the SCECGE was epoxidized to nearly 70%, increasing the epoxy functionality of SCECGE from 2.45 to 2.65 epoxies/molecule as measured using proton magnetic nuclear resonance (¹H-NMR). This modified material—side chain epoxidized cardanol glycidyl ether with terminal epoxies (TE-SCECGE)—was thermally cured with cycloaliphatic curing agent 4-4′-methylenebis(cyclohexanamine) (PACM) at stoichiometry, and the cured polymer properties, such as glass transition temperature (T_g) and tensile modulus, were compared with SCECGE resin cured with PACM. The T_g of the material was increased from 52 to 69 °C as obtained via a dynamic mechanical analysis (DMA) while the tensile modulus of the material increased from 0.88 to 1.24 GPa as a result of terminal double bond epoxidation. In addition to highlighting the effects of dangling side groups in an epoxy network, this modest increase in T_g and modulus could be sufficient to significantly expand the potential uses of amine-cured cardanol-based epoxies for fiber reinforced composite applications.

Influence of Epoxidized Cardanol Functionality and Reactivity on Network Formation and Properties

Cardanol is a renewable resource based on cashew nut shell liquid (CNSL), which consists of a phenol ring with a C15 long aliphatic side chain in the meta position with varying degrees of unsaturation. Cardanol glycidyl ether was chemically modified to form side-chain epoxidized cardanol glycidyl ether (SCECGE) with an average epoxy functionality of 2.45 per molecule and was cured with petroleum-based epoxy hardeners, 4-4'-methylenebis(cyclohexanamine) and diethylenetriamine, and a cardanol-based amine hardener. For comparison, cardanol-based diphenol diepoxy resin, NC514 (Cardolite), and a petroleum-based epoxy resin, diglycidyl ether of bisphenol-A (DGEBA) were also evaluated. Chemical and thermomechanical analyses showed that for SCECGE resins, incomplete cure of the secondary epoxides led to reduced cross-link density, reduced thermal stability, and reduced elongation at break when compared with difunctional resins containing only primary epoxides. However, because of functionality greater than two, amine-cured SCECGE produced a T_g very similar to that of NC514 and thus could be useful in formulating epoxy with renewable cardanol content.

Growth and arrest of topological cycles in small physical networks

The chordless cycle sizes of spatially embedded networks are demonstrated to follow an exponential growth law similar to random graphs if the number of nodes [Formula: see text] is below a critical value [Formula: see text] For covalent polymer networks, increasing the network size, as measured by the number of cross-link nodes, beyond [Formula: see text] results in a crossover to a new regime in which the characteristic size of the chordless cycles [Formula: see text] no longer increases. From this result, the onset and intensity of finite-size effects can be predicted from measurement of [Formula: see text] in large networks. Although such information is largely inaccessible with experiments, the agreement of simulation results from molecular dynamics, Metropolis Monte Carlo, and kinetic Monte Carlo suggests the crossover is a fundamental physical feature which is insensitive to the details of the network generation. These results show random graphs as a promising model to capture structural differences in confined physical networks.

Mechanical and Strain-Sensing Capabilities of Carbon Nanotube Reinforced Composites by Digital Light Processing 3D Printing Technology

Mechanical and strain sensing capabilities of carbon nanotube (CNT) reinforced composites manufactured by digital light processing (DLP) 3D printing technology have been studied. Both CNT content and a post-curing treatment effects have been analyzed. It has been observed that post-curing treatment has a significant influence on mechanical properties, with an increase of Young’s modulus and glass transition temperature whereas their effect in electrical properties is not so important. Furthermore, the strain sensing tests show a linear response of electrical resistance with applied strain, with higher values of sensitivity when decreasing CNT content due to a higher interparticle distance. Moreover, the electrical sensitivity of bending tests is significantly lower than in tensile ones due to the compression subjected face effect. Therefore, the good gauge factor values (around 2–3) and the high linear response proves the applicability of the proposed nanocomposites in structural health monitoring applications.

Synthesis and Properties of Thermosets from Tung Oil and Furfuryl Methacrylate

This work focuses on the development of cross-linked polymer from a highly unsaturated vegetable oil, tung oil (TO) and a bio-based acrylate, furfuryl methacrylate (FMA). The presence of a high degree of unsaturated carbon-carbon bonding in TO makes it a suitable precursor for polymer synthesis. Using this advantage of TO, in this work, we have synthesised a cross-linked polymer from TO and FMA through free radical polymerisation followed by Diels–Alder (DA) reaction. Successful incorporation of both of the raw materials and the two chemical reactions was shown using Fourier-transform infrared (FTIR) and Raman spectroscopy. The development of cross-linked structure was analysed through thermogravimetric analysis (TGA) and dynamic mechanical analysis (DMA).

Divanillin-Based Aromatic Amines: Synthesis and Use as Curing Agents for Fully Vanillin-Based Epoxy Thermosets

Bio-based aromatic diamines from vanillin substrate were successfully synthesized and characterized. These amines, i.e., methylated divanillylamine (MDVA) and 3,4-dimethoxydianiline (DMAN), were then tested as curing agents for the design of bio-based epoxy thermosets. The epoxy thermosets obtained from these novel vanillin-based amines exhibited promising thermomechanical properties in terms of glass transition temperature and char residue.

Novel Continuous Fiber Bi-Matrix Composite 3-D Printing Technology

A new paradigm in continuous fiber-reinforced polymer fused filament fabrication based on a thermoset-thermoplastic bi-matrix material system is proposed and proved. This totally new 3-D printing concept has the potential to overcome the drawbacks and to combine the advantages of separate thermoset and thermoplastic-based, fused filament fabrication methods and to advance continuous fiber-reinforced polymer 3-D printing toward higher mechanical performances of 3-D printed parts. The novel bi-matrix 3-D printing method and preliminary results related to the 3-D printed composite microstructure and performances are reported.

Synthesis of Pluri-Functional Amine Hardeners from Bio-Based Aromatic Aldehydes for Epoxy Amine Thermosets

Most of the current amine hardeners are petro-sourced and only a few studies have focused on the research of bio-based substitutes. Hence, in an eco-friendly context, our team proposed the design of bio-based amine monomers with aromatic structures. This work described the use of the reductive amination with imine intermediate in order to obtain bio-based pluri-functional amines exhibiting low viscosity. The effect of the nature of initial aldehyde reactant on the hardener properties was studied, as well as the reaction conditions. Then, these pluri-functional amines were added to petro-sourced (diglycidyl ether of bisphenol A, DGEBA) or bio-based (diglycidyl ether of vanillin alcohol, DGEVA) epoxy monomers to form thermosets by step growth polymerization. Due to their low viscosity, the epoxy-amine mixtures were easily homogenized and cured more rapidly compared to the use of more viscous hardeners (<0.6 Pa s at 22 °C). After curing, the thermo-mechanical properties of the epoxy thermosets were determined and compared. The isophthalatetetramine (IPTA) hardener, with a higher number of amine active H, led to thermosets with higher thermo-mechanical properties (glass transition temperatures (T_g and T_α) were around 95 °C for DGEBA-based thermosets against 60 °C for DGEVA-based thermosets) than materials from benzylamine (BDA) or furfurylamine (FDA) that contained less active hydrogens (T_g and T_α around 77 °C for DGEBA-based thermosets and T_g and T_α around 45 °C for DGEVA-based thermosets). By comparing to industrial hardener references, IPTA possesses six active hydrogens which obtain high cross-linked systems, similar to industrial references, and longer molecular length due to the presence of two alkyl chains, leading respectively to high mechanical strength with lower T_g.

Cardanol and Eugenol Based Flame Retardant Epoxy Monomers for Thermostable Networks

Epoxy materials have attracted attention for many applications that require fireproof performance; however, the utilization of hazardous reagents brings about potential damage to human health. Eugenol and cardanol are renewable, harmless resources (according to ECHA) that allow the achievement of synthesis of novel phosphorylated epoxy monomers to be used as reactive flame retardants. These epoxy building blocks are characterized by ¹H NMR and ³¹P NMR (nuclear magnetic resonance) and reacted with a benzylic diamine to give bio-based flame-retardant thermosets. Compared to DGEBA (Bisphenol A Diglycidyl Ether)-based material, these biobased thermosets differ by their cross-linking ratio, the nature of the phosphorylated function and the presence of an aliphatic chain. Eugenol has led to thermosets with higher glass transition temperatures due to a higher aromatic density. The flame-retardant properties were tested by thermogravimetric analyses (TGA), a pyrolysis combustion flow calorimeter (PCFC) and a cone calorimeter. These analyses demonstrated the efficiency of phosphorus by reducing significantly the peak heat release rate (pHRR), the total heat release (THR) and the effective heat of combustion (EHC). Moreover, the cone calorimeter test exhibited an intumescent phenomenon with the residues of phosphorylated eugenol thermosets. Lastly, the higher flame inhibition potential was highlighted for the phosphonate thermoset.

Robust Carbon Nitride-Based Thermoset Coatings for Surface Modification and Photochemistry

Herein, the convenient visible light-induced photografting of hydroxyl ethyl methacrylate onto graphitic carbon nitride (g-CN) is described, leading to well-dispersible g-CN-based precursor polymers that can be injected. Mixing with citric acid as the cross-linker and heating leads to stable thermoset coatings. The process is versatile and easy to perform, leading to g-CN-based coatings. Moreover, the coating can be further functionalized/modified via grafting of other polymer chains, and the resulting structure is useful as photocatalytic surface or as photoelectrode.

Radio Frequency Heating of Carbon Nanotube Composite Materials

Here, we give the first-ever report of radio frequency (RF) electromagnetic heating of polymer nanocomposite materials via direct-contact and capacitively coupled electric field applicators. Notably, RF heating allows nanocomposite materials to be resistively heated with electric fields. We highlight our novel RF heating technique for multiwalled carbon nanotube (MWCNT) thermoplastic composites and measure their broadband dielectric properties. We also demonstrate three different electric field applicator configurations and discuss their practical use in an industrial setting. We demonstrate the use of RF heating to cure an automotive-grade epoxy loaded with MWCNTs. Our results show that lap shear joints cured faster with the RF method compared with control samples cured in an oven because of the heat-transfer advantages of directly heating the epoxy composite. Finally, we implement our RF curing technique to assemble an automotive structure by locally curing an epoxy adhesive applied to a truck chassis.

Renewable (Bis)pyrrolidone Based Monomers as Components for Thermally Curable and Enzymatically Depolymerizable 2-Oxazoline Thermoset Resins

In this study we describe the synthesis of bis(pyrrolidone) based dicarboxylic acids from itaconic acid and their application in 2-oxazoline resins for fully renewable thermoset materials. The monomers are obtained using a bulk aza-Michael addition of a diamine and two itaconic acid molecules using a catalytic amount of water. The monomers can be isolated in high purity after recrystallization, though their yield proved to be highly dependent on the selected diamine spacer length: In general, only the dicarboxylic acids containing diamines with an even number of methylene spacers are isolated in high yields. Through NMR, GPC, and FTIR analysis we demonstrate that these bis(pyrrolidone) based dicarboxylic acids exhibit significantly enhanced curing rates in 2-oxazoline resins compared to resins containing aliphatic dicarboxylic acids such as sebacic acid. Overall, we demonstrate that the rate of 2-oxazoline ring-opening addition with carboxylic acid functionalities is determined by the used dicarboxylic acid, whereas the ring-opening addition of the 2-oxazoline functionality with amide groups is determined by the used bis(2-oxazoline) compound. The thermosets obtained after curing proved to be readily plasticized by water, opening up possibilities for enzymatic degradation.

High-Tg, Low-Dielectric Epoxy Thermosets Derived from Methacrylate-Containing Polyimides

Three methacrylate-containing polyimides (Px⁻MMA; x = 1⁻3) were prepared from the esterification of hydroxyl-containing polyimides (Px⁻OH; x = 1⁻3) with methacrylic anhydride. Px⁻MMA exhibits active ester linkages (Ph⁻O⁻C(=O)⁻) that can react with epoxy in the presence of 4-dimethylaminopyridine (DMAP), so Px⁻MMA acted as a curing agent for a dicyclopentadiene-phenol epoxy (HP7200) to prepare epoxy thermosets (Px⁻MMA/HP7200; x = 1⁻3) thermosets. For property comparisons, P1⁻OH/HP7200 thermosets were also prepared. The reaction between active ester and epoxy results in an ester linkage, which is less polar than secondary alcohol resulting from the reaction between phenolic OH and epoxy, so P1⁻MMA/HP7200 are more hydrophobic and exhibit better dielectric properties than P1⁻OH/HP7200. The double bond of methacrylate can cure at higher temperatures, leading to epoxy thermosets with a high-Tg and moderate-to-low dielectric properties.

Healable, Reconfigurable, Reprocessable Thermoset Shape Memory Polymer with Highly Tunable Topological Rearrangement Kinetics

The unique capability of topological rearrangement for dynamic covalent polymer networks has enabled various unusual properties (self-healing, solid-state plasticity, and reprocessability) that are not found in conventional thermosets. Achieving these properties in one network in a synergetic fashion can open up new opportunities for shape memory polymer. To accomplish such a goal, the freedom to tune topological rearrangement kinetics is critical. This is, however, challenging to achieve. In this work, two sets of dynamic bonds (urethane and hindered urea) are incorporated into a hybrid network for synthesizing shape memory poly(urea-urethane). By changing the bond ratio, networks with highly tunable topological rearrangement kinetics are obtained. Combining self-healing, solid-state plasticity, and reprocessability in one such shape memory network leads to unusual versatility in its shape-shifting performance.

Optimizing Polymer Infusion Process for Thin Ply Textile Composites with Novel Matrix System

For mass production of structural composites, use of different textile patterns, custom preforming, room temperature cure high performance polymers and simplistic manufacturing approaches are desired. Woven fabrics are widely used for infusion processes owing to their high permeability but their localised mechanical performance is affected due to inherent associated crimps. The current investigation deals with manufacturing low-weight textile carbon non-crimp fabrics (NCFs) composites with a room temperature cure epoxy and a novel liquid Methyl methacrylate (MMA) thermoplastic matrix, Elium^®. Vacuum assisted resin infusion (VARI) process is chosen as a cost effective manufacturing technique. Process parameters optimisation is required for thin NCFs due to intrinsic resistance it offers to the polymer flow. Cycles of repetitive manufacturing studies were carried out to optimise the NCF-thermoset (TS) and NCF with novel reactive thermoplastic (TP) resin. It was noticed that the controlled and optimised usage of flow mesh, vacuum level and flow speed during the resin infusion plays a significant part in deciding the final quality of the fabricated composites. The material selections, the challenges met during the manufacturing and the methods to overcome these are deliberated in this paper. An optimal three stage vacuum technique developed to manufacture the TP and TS composites with high fibre volume and lower void content is established and presented.

A Simple and Efficient Protocol for the Catalytic Insertion Polymerization of Functional Norbornenes

Norbornene can be polymerized by a variety of mechanisms, including insertion polymerization whereby the double bond is polymerized and the bicyclic nature of the monomer is conserved. The resulting polymer, polynorbornene, has a very high glass transition temperature, Tg, and interesting optical and electrical properties. However, the polymerization of functional norbornenes by this mechanism is complicated by the fact that the endo substituted norbornene monomer has, in general, a very low reactivity. Furthermore, the separation of the endo substituted monomer from the exo monomer is a tedious task. Here, we present a simple protocol for the polymerization of substituted norbornenes (endo:exo ca. 80:20) bearing either a carboxylic acid or a pendant double bond. The process does not require that both isomers be separated, and proceeds with low catalyst loadings (0.01 to 0.02 mol%). The polymer bearing pendant double bonds can be further transformed in high yield, to afford a polymer bearing pendant epoxy groups. These simple procedures can be applied to prepare polynorbornenes with a variety of functional groups, such as esters, alcohols, imides, double bonds, carboxylic acids, bromo-alkyls, aldehydes and anhydrides.

Smart, Sustainable, and Ecofriendly Chemical Design of Fully Bio-Based Thermally Stable Thermosets Based on Benzoxazine Chemistry

A smart synthetic chemical design incorporating furfurylamine, a natural renewable amine, into a partially bio-based coumarin-containing benzoxazine is presented. The versatility of the synthetic approach is shown to be flexible and robust enough to be successful under more ecofriendly reaction conditions by replacing toluene with ethanol as the reaction solvent and even under solventless conditions. The chemical structure of this coumarin-furfurylamine-containing benzoxazine is characterized by FTIR, (1) H NMR spectroscopy and two-dimensional (1) H-(1) H nuclear Overhauser effect spectroscopy (2D (1) H-(1) H NOESY). The thermal properties of the resin toward polymerization are characterized by differential scanning calorimetry (DSC) and the thermal stability of the resulting polymers by thermogravimetric analysis (TGA). The results reveal that the furanic moiety induces a co-operative activating effect, thus lowering the polymerization temperature and also contributes to a better thermal stability of the resulting polymers. These results, in addition to those of natural renewable benzoxazine resins reviewed herein, highlight the positive and beneficial implication of designing novel bio-based polybenzoxazine and possibly other thermosets with desirable and competitive properties.