Yang Chen,
Cheng Zhou,
Jin Chang,
Huawei Zou* and
Mei Liang*
State Key Laboratory of Polymer Materials Engineering, Polymer Research Institute of Sichuan University, Sichuan University, Chengdu 610065, China. E-mail: hwzou@163.com; liangmeiww@163.com; Fax: +86-28-85402465; Tel: +86-28-85408288
First published on 24th October 2014
In this research, a bisphenol-A type epoxy resin (DGEBA) was modified with epoxy-block-silicone copolymers and hydroxyl-terminated silicone oligomers by physical blending and a chemical reaction, respectively. The chemical structure of the siloxane-bridged epoxy resin terminated by –OHs was characterized by Fourier transform infrared spectroscopy (FTIR), 1H-NMR and an epoxy equivalent weight (EEW) test. Both the samples showed better elongation at break and impact strength than neat resin. The TGA-FTIR results revealed that the residue of the modified epoxy resin at 600 °C increased with the increase in siloxane content, but the thermal stability was slightly reduced compared with that of the neat epoxy resin. Morphology studies indicate that the increase in izod notched impact strength is due to the suitable diameter of silicone phases because of the silicone toughening effect. Therefore, it is believed that the modified epoxy resin, with good toughness and high thermal residual weight, will have potential applications in anti-corrosion coatings and structure bonding materials.
In light of this problem, researchers have incorporated carbon nanotubes,3,4 liquid crystalline polymers,5,6 rubber,7–9 and polyurethane10,11 to improve the toughness of cured epoxy resins. Of all these methods, the most successful one is the modification with reactive liquid rubbers, such as carboxyl-terminated butadiene acrylonitrile (CTBN),12,13 hydroxyl-terminated butadiene acrylonitrile (HTBN)14,15 and amine terminated butadiene acrylonitrile (ATBN).16,17 However, the presence of an unsaturated structure in liquid rubbers brings about thermal instability and low oxidation resistance into the epoxy matrix. Hence, such modified resins are not suitable for applications at high temperatures. In contrast, the modification of epoxy resin with organosilicone polymers can improve the toughness of cured epoxy without damaging its thermal resistance.18,19 However, polysiloxanes have poor compatibility with the epoxy resin due to their varied solubility parameters, which results in the formation of a finely phase-separated structure and a considerable sacrifice in the glass transition temperatures (Tg) in thermosets.20,21 Therefore, much attention has been paid to improving the compatibility between epoxy and silicone resins. For example, the introduction of an aramid–silicone block copolymer22,23 as a compatibilizer, preparation of silicon- and carbon-based block copolymers,24 and synthesis of polysiloxane copolymer which contains epoxide groups on the side chains19 have been proved to be effective. Studies for enhancing the toughness of epoxy resins evaluated in terms of the measurement of impact strength18,24–26 and critical stress intensity factor22,23,27 are reported. So far there have been few reports in the literature focused on the elongation at break aspects of silicone oligomer modified epoxy resins.
In this study, a commercial grade epoxy-block-silicone copolymer and hydroxyl-terminated silicone oligomers of different mass ratios were employed in epoxy resin by physical blending and a chemical reaction process, respectively. The mechanical and thermal properties and morphology of these modified epoxy resins were studied. The results indicate that the modified epoxy resin exhibits high elongation at break, good impact strength and advanced thermal stability compared to neat epoxy resin. Therefore, a high temperature filler could be introduced to the modified epoxy resins in order to prepare anti-corrosive coatings, electronic packaging and structural adhesive.
Sample code | E-51 | PSG1 | PSG2 | PSG3 | PSG4 |
---|---|---|---|---|---|
Z-6018 (g) | 0 | 10 | 20 | 30 | 40 |
DGEBA (g) | 80 | 70 | 60 | 50 | 40 |
Sample code | E-51 (g) | Z-6018 (g) | SH023 (g) | DER732 (g) | EC-301 (g) |
---|---|---|---|---|---|
a The total weight of the modified epoxy resins is 100 percent except curing agent. | |||||
EG | 80.00 | 0 | 0 | 20.00 | 30.38 |
PSDG1 | 70.00 | 10.00 | 0 | 20.00 | 24.52 |
PSDG2 | 60.00 | 20.00 | 0 | 20.00 | 23.16 |
PSDG3 | 50.00 | 30.00 | 0 | 20.00 | 20.08 |
PSDG4 | 40.00 | 40.00 | 0 | 20.00 | 16.12 |
PSHG1 | 70.00 | 0 | 10.00 | 20.00 | 27.38 |
PSHG2 | 60.00 | 0 | 20.00 | 20.00 | 24.39 |
PSHG3 | 50.00 | 0 | 30.00 | 20.00 | 21.40 |
PSHG4 | 40.00 | 0 | 40.00 | 20.00 | 18.40 |
Epoxide equivalent weights (EEWs) of the PSG systems were determined according to a GB 1677-81 standard. The analyses were performed in duplicate. The samples weighed 0.5–1.0 g, which were sufficient to determine the EEW values.
1H-NMR spectra were recorded on a DRX-400 spectrometer (Bruker Company, Germany) with CDCl3 solvent.
The tensile strength and breaking elongation of the cured specimens were conducted with the help of a Universal tensile instrument (INSTRON 5567) according to GB/T 2567-2008. The test was performed at a rate of 10 mm min−1 at room temperature.
The izod notched impact strength of the cured specimens was tested with an Izod Impact Tester (MTS Co.) according to GB/T 2567-2008. The size of the tested specimen was 4 mm × 10 mm × 80 mm. All mechanical property values were obtained by averaging the five experimental values.
The morphology of the impact fracture surfaces was observed using a scanning electron microscope (SEM:JSM-5900, JEOL Co., Ltd.) at an accelerating voltage of 10 kV. Prior to the examination, the fractured surfaces were coated with gold in order to enhance conductivity and prevent charging.
The thermal stability was studied by means of thermogravimetric analysis (TGA:Q500, TA Co, Ltd., USA) coupled with a FTIR spectrometer (Nicolet Magna 570, Nicolet Co, Ltd., USA). The sample weights ranged from 5–10 mg and were heated from 50 to 600 °C at a rate of 10 °C min in a dry nitrogen atmosphere. The flow rate of gases into the cell for the TGA/FTIR experiments was 100 mL min−1. The solid weight loss, together with other process variables such as temperature and gaseous species were detected using the FTIR spectrometer throughout the measurements.
Pure epoxy resin (1H-NMR, CDCl3), δ (ppm): 7.14–6.8 (aromatic ring protons), 4.17 (–CH2–O-Ar), 3.33–3.30 (–CH, oxirane), 2.9–2.7 (–CH2, oxirane), 1.8–1.6 (–CH3). The 1H-NMR of PSG1 is shown in Fig. 2. The presence of characteristics peaks in the 1H-NMR spectra (δ, ppm, 2.2 (CH–O–Si)) of PSG1 is attributed to the reaction between Si–O–H and C–O–H of the epoxy resin and Z-6018 (Scheme 2).32 The results further support the formation of the PSG copolymer.
The EEW values of the synthesized PSG copolymer are listed in Table 3. The calculated values, based on the weight ratios, agree well with the experimental data of the PSG copolymer. The opening rate of the epoxy ring remains almost unchanged. This further confirms that few epoxy groups are involve in the ring opening reaction. These results are consistent with the theoretical assumptions, 1H-NMR and FTIR results.
Sample code | E-51 | PSG1 | PSG2 | PSG3 | PSG4 |
---|---|---|---|---|---|
a The EEW of E-51 is given by the product introduction of DGEBA.b The EEWs of PSG1, PSG2, PSG3, PSG4 are calculated based on the epoxy equivalent weight and the weight ratios of DGEBA. | |||||
EEW (calculated value) (g mol−1) | 185–192a | 212b | 247b | 296b | 370b |
EEW (experimental value) (g mol−1) | 185 | 238 | 255 | 304 | 378 |
The rate of opening of the epoxy ring (%) | 0% | 11% | 3% | 2.6% | 2% |
Fig. 3 SEM micrographs of the fracture surfaces of epoxy resin modified with silicone: (a) EG, (b) PSHG1, (c) PSHG2, (d) PSHG4, (e) PSDG1, (f) PSDG2, (g) PSDG4. |
Fig. 3(e)–(g) show the morphology of the systems with Z-6018, which had silicone contents of about 10 wt%, 20 wt% and 40 wt%, respectively. A bi-phase separation structure was obviously observed through SEM. However, the SEM photographs show that better silicone phases could be uniformly dispersed in the epoxy matrix at the Z-6018 addition of 10 wt%, compared with the modified systems with 20 wt% and 40 wt% Z-6018. In particular, the diameter of the dispersed phases reached 2.8 μm in the system with 40 wt% Z-6018.
Fig. 4 Tensile strength (a) and elongation at break (b) of the PSHG systems as a function of SH023 content. |
The values of tensile strength and elongation at break of the PSDG systems are illustrated in Fig. 5(a) and (b), respectively. The decline in tensile strength with an increase of Z-6018 is due to the presence of flexible siloxane linkages, free rotation of the Si–O–Si bonds, and weak interface boundaries between the siloxane and epoxy resin. The elongation at break showed few fluctuations until the Z-6018 content reached 40 wt% of the modified epoxy resins. Due to the bad compatibility between epoxy and silicone resins in PSDG systems, when a small amount of silicone is added, the –Si–O–Si– chains are not enough to change the network of epoxy resin, and therefore, the elongation at break remains unchanged.
Fig. 5 Tensile strength (a) and elongation at break (b) of the PSDG systems as a function of Z-6018 content. |
Fig. 6 shows the impact strength of the PSHG systems as a function of SH023 content. As observed, the impact strength values of the systems are significantly raised with increasing SH023 content. When the content of SH023 reaches 40 wt%, the impact strength of the systems increased nearly three times higher than that of the pure epoxy resins. This result can be interpreted in terms of increased energy dissipation induced by addition of a siloxane segment into the epoxy network.34,35 Siloxane chains act as obstacles in the crack path, and more energy is required for crack propagation.
Fig. 7 shows the impact strength values of the PSDG systems as a function of Z-6018 content. It was found that the impact strength of the modified systems has a maximum value when the Z-6018 content is 10 wt%. It can be explained that Z-6018 (10 wt%) has a good compatibility with epoxy resin. The silicone segment of Z-6018 is flexible enough to enhance the impact strength by increasing energy dissipation. When the Z-6018 content increased to more than 10 wt%, the compatibility of the epoxy resins and Z-6018 decreased. In addition, the diameter of the silicone phases became larger, thus resulting in poorer impact strength of the blends.
It has been reported that the fracture toughness of a brittle epoxy is related to the size of the dispersion phase.36 The impact strength will initially increase with the increasing size of the dispersion phase to a maximum value and after that, fall with the further increasing of the second phase. Comparisons made between the SEM micro-graphs of the PSHG and PSDG systems reveal that, in the same dispersed phase content, the dispersed particle sizes for the PSDG systems are larger than those observed for the PSHG systems. Thus, the impact strength values of the PSHG systems are significantly increased with increasing SH023 content, while addition of Z-6018 increased first and then decreased.
Sample code | T−5% (°C) | Tmax1 (°C) | Tmax2 (°C) | Solid residue at 600 °C (%) |
---|---|---|---|---|
EG | 332.07 | 347.04 | 377.02 | 4.47 |
PSHG2 | 329.31 | 346.85 | 361.99 | 8.64 |
PSHG4 | 316.87 | — | 351.33 | 13.17 |
PSDG2 | 328.88 | — | 344.89 | 18.44 |
PSDG4 | 323.16 | — | 351.29 | 33.54 |
However, the thermal stability decreased according to the temperature of thermal degradation. Specifically, when the proportion of epoxy resin decreased, the systems began to lose weight earlier than the unmodified epoxy resins due to the lower cross-linking density of the cured systems. On the other hand, the siloxane bond –Si–O– has a binding energy of 445 kJ mol−1, which is higher than that of the carbon–carbon bond –C–C– in the epoxy resins. Consequently, a higher activation energy is required to destroy the siloxane inorganic polymer skeleton, thus leaving a higher solid residue.
As shown in Fig. 9(a), the solid residual yield increased to 33.54%, compared with epoxy resins with 40 wt% Z-6018. From the DTA curves of the PSDG systems in Fig. 9(b), it can be detected that the thermal decomposition temperature showed a similar trend for the PSDG and PSHG systems. In addition, a reduction of mass loss rate was detected with the increase of Z-6018 loading. These results could be explained by the stability of the inorganic nature of the siloxane structure and its partial ionic nature, which stabilized the epoxy resin from the heat. While heating, the low surface energy of silicone renders it to migrate to the surface of the epoxy resin by forming a protective self-heating layer with resistance to heat and the ability to slow down the thermal degradation of the polymer. Eventually, we find that epoxy resins modified by Z-6018 show a higher residual yield than epoxy resins modified by the same addition of SH023. This is due to the proportion of silicone in Z-6018 being higher than in SH023.
Fig. 10 FTIR spectra of volatile products recorded at the indicated temperatures for the decomposition of silicone modified epoxy resins in a nitrogen atmosphere: (a) EG, (b) PSHG4, (c) PSDG4. |
During the second step of thermal degradation, the characteristic peak of water still existed until 55 min (550 °C). The resultant water could be associated with the dehydration of the two hydroxy propyl groups of the phenoxy resin. The evolved gases also show bands at 2990–3020 cm−1 and 1000–1300 cm−1 which are related to the sp2 and sp3 C–H stretching vibrations of para-disubstituted aromatic and aliphatic groups. The spectrum also revealed the presence of aldehyde-containing compounds by overlapping (CO)–H stretches (around 2700 cm−1 to 2900 cm−1 and 1724 cm−1) in the IR spectrum. The peaks that appeared at 3010 cm−1 and 1316 cm−1 are the characteristic peaks of CH4. The spectrum showed the appearance of bands at 1608 cm−1 at 340 °C and at 820 cm−1, which could be attributed to the CC stretching vibrations and the aromatic C–H stretching of para-disubstituted aromatic compounds, respectively. At 55 min (600 °C) the characteristic peaks of CO2 and N–H appeared and the thermal degradation rates of these products were very low.
As shown in Fig. 10(b) and (c), the evolved gas analysis for PSHG4 or PSDG4 exhibited characteristic bands of compounds containing an –OH group (e.g. H2O, phenol; 3500–3900 cm−1), methyl substituted compounds (CH2/CH3 stretching, 2890–3000 cm−1), CO2 (2330, 2360 cm−1), compounds containing an aromatic ring (1320–1580 cm−1, 823 cm−1), hydrocarbons (C–H stretching at 1113 cm−1, 1248 cm−1 and 1172 cm−1), and N–C (675 cm−1).
From the above results, it is noted that the main evolved gas products for EG were different from epoxy resins modified by SH023 or Z-6018. The main evolved gas products of EG were composed of small molecules, such as CO2. In another aspect, epoxy resins modified by SH023 or Z-6018 released mainly methyl-substituted, carbonyl and aromatic gas products, which have higher molecular weights compared with that of the EG gas products.
Footnote |
† Electronic supplementary information (ESI) available. See DOI: 10.1039/c4ra09230a |
This journal is © The Royal Society of Chemistry 2014 |