Yuya Tachibanaab,
Junko Toriia,
Ken-ichi Kasuya*a,
Masahiro Funabashic and
Masao Kuniokac
aDivision of Molecular Science, Faculty of Science and Technology, Gunma University, 1-5-1 Tenjin, Kiryu, Gunma 376-8515, Japan. E-mail: kkasuya@gunma-u.ac.jp
bJapan Science and Technology Agency (JST), PRESTO, 4-1-8 Honcho, Kawaguchi, Saitama 332-0012, Japan
cNational Institute of Advanced Industrial Science and Technology (AIST), Higashi 1-1-1, Tsukuba, Ibaraki 305-8565, Japan
First published on 21st October 2014
The development of bio-based plastics is an important research area because of its contribution to environmental preservation. Herein, we evaluated the properties of a bio-based epoxy resin synthesised using 2,2-bis(4-glycidyloxyphenyl)propane as the epoxy monomer and oxabicyclodicarboxylic anhydride (OBCA) as a bio-based hardener derived from furfural. The major hardening process of the resin at 130 °C, manifested in an exponential increase in the storage modulus, was complete within an hour, which was longer than that for a commercially available petroleum-based epoxy resin hardened using cis-cyclohexane dicarboxylic anhydride (CDCA). This indicated that OBCA was less reactive than CDCA, which has a similar structure. The bio-based epoxy resin showed excellent transparency in the visible light region and was thermally stable, with 5% weight loss at temperatures exceeding 270 °C. Glass transition temperatures were above 100 °C, and mechanical properties were moderately better than those of the commercially available epoxy resin. Moreover, the bio-based carbon content ranged from 21% to 53%, depending on the amount of OBCA added. Thus, the bio-based OBCA is a good hardener for a bio-based epoxy resin that can be used as a value-added material in industrial applications.
Epoxy resin is one of the most important thermosetting resins for industrial applications such as coating material for automobiles, ships, and bridges to prevent corrosion, sealant for electrical devices for protection from air and moisture, and adhesive for buildings, automobiles, aircrafts, and sporting goods.8,9 Epoxy resins comprise monomers that contain at least two epoxide groups and can react with polyfunctional hardeners like amines, acid, alcohols, thiols, and anhydrides to give high-performance cross-linked resins. A mixture of an epoxy monomer and hardener is usually cured by external stimulation such as UV irradiation or heating to give epoxy resin, and the properties of the cured resin can be controlled by the hardener and cure time. Compared to other commercially available polymers, some epoxy resins are expensive. However, these are widely used in manufacturing because of their high performance and availability, which give added value to the cost of material. Although the additional cost of production usually precludes the utilization of bio-based epoxy resins in manufacturing, this can be outweighed by superior properties of these resins.
A few bio-based epoxy resins have been synthesised from bio-based epoxy monomers and bio-based hardeners.10,11 Epichlorohydrin, which is generally used as an epoxy monomer, was synthesised from glycerol derived from natural fat, which is a by-product of bio-diesel and a surfactant.12 The hydroxyl groups of lignin derivatives react with epichlorohydrin to give epoxy monomers.13 Recently, the conversion and curing of itaconic acid was reported.14 Vegetable oil containing an unsaturated fatty acid moiety was also converted to an epoxy monomer through epoxidation of the double bond.15 Bio-based polyfunctional compounds like vegetable oil,16 polysaccharide,17 and polylysine18 were converted to hardeners with thiol or amino groups. Cyclic acid anhydrides are usually used as a hardener in manufacturing, and bio-based acid anhydrides can be obtained from abietic acid or maleopimarate.19
The bio-based carbon content, defined as the ratio of carbons derived from biomass to the total carbon of the material, has been established in ASTM, CEN, and ISO,20 and is thus an objective standard to evaluate bio-based materials. The amount of hardener in an epoxy resin is substantial, usually over 30%. Therefore, the bio-based carbon content of an epoxy resin is sufficient for a bio-based polymer, even if only the hardener is derived from biomass.
We have focused on furan derivatives produced from cellulose and hemicellulose as biomass resources to produce polymers. Furan derivatives, such as 5-hydroxymethylfurfural (HMF), furfural, furfuryl alcohol, and furan, are produced from biomass resources and used industrially as organic solvents or resins.21–24 The U.S. Department of Energy has stated that these are the most value-added chemicals derived from biomass.25 Therefore, considerable effort has been expended in their efficient conversion from biomass resources.26–28
Furfural was previously converted to oxabicyclodicarboxylic anhydride (OBCA) through the synthetic route shown in Scheme 1. OBCA is known as norcantharidin, which is an anti-cancer drug.29 Its polymerization with diols leads to formation of bio-based polyoxabicyclates (POBCs) that can replace commercially available transparent elastic polymers.30 The properties of POBCs depend on the rigidity, bulkiness, and reactivity of OBCA, which is an oxo-bridged cyclohexane dicarboxylic anhydride.
In this study, we demonstrate that OBCA can act as a bio-based hardener using 2,2-bis(4-glycidyloxyphenyl)propane (BADGE) as the epoxy monomer and tetraphenylphosphonium bromide (TPPB) as the catalyst to obtain a bio-based epoxy resin. BADGE has two epoxide groups and is formed by the condensation between bisphenol A and epichlorohydrin. It is a commercially available epoxy monomer widely used in manufacturing.31 To evaluate OBCA as a hardener, a commodity epoxy resin was also synthesised for comparison using cis-cyclohexane dicarboxylic anhydride (CDCA). The hardening process of each epoxy resin was evaluated as time-dependent properties using dynamic mechanical analysis (DMA) at the hardening temperature. The chemical structure after hardening was analysed using Fourier transform infrared (FT-IR) spectroscopy. Optical properties were evaluated using ultraviolet-visible (UV-vis) spectroscopy. Thermal stability was measured using thermal gravimetric analysis (TGA). The mechanical properties of the moulded specimens were assessed based on tensile strength and temperature-dependent DMA. The latter was also used to obtain thermal properties.
The thermal hardening process was investigated by carrying out a time-dependent dynamic mechanical analysis based on isothermal measurements at ambient temperature. The rheology of the hardening process is commonly evaluated by separately analysing the viscous liquid and solid material using a rheometer and by dynamic mechanical analysis, respectively. However, it is possible to evaluate both states using the latter with a Material Pocket made of stainless plate as done in this study. The pre-mixing viscous liquid sample was placed between the two halves of the Material Pocket and compressed carefully to avoid leakage as shown in Fig. 1. The sample was immediately heated to the hardening temperature within 5 min and the temperature was kept constant while measuring isothermal properties. The changes in E′ and tanδ (Fig. 2) showed the hardening behaviour of 1 and 2 at different hardening temperatures.
The value of E′ at the initial temperature (0 °C) was different from that at the hardening temperature; however, this did not arise from the temperature difference, but from the use of the Material Pocket to handle the sample in the DMA apparatus. The decrease in E′ of 1 during heating to the isothermal temperature indicates that the viscosity of the reaction mixture decreased with temperature. E′ exponentially increased after hardening to form the cross-linked network began (major hardening process), and almost reached a plateau when hardening was nearly complete. The major hardening process at 110, 130, 150, and 179 °C was almost done within 155, 43, 21, and 19 min, respectively; thus, as the hardening temperature increased, the corresponding time shortened. On the other hand, the E′ of 1 continued to increase gradually at all temperatures even after the initial exponential rise and the elapsed time was over 250 min, which indicates that a minor hardening process occurred even after the major one. This result coincided with those of thermal gravimetric analysis and tensile strength testing as will be discussed below.
The time-dependent hardening behaviour of 2 at 130 °C is shown in Fig. 3. The E′ of 2 exponentially increased between 5 and 16 min and then almost reached a plateau, similar to 1 (Fig. 2b), although the increase for the latter occurred between 21 and 43 min. This indicated that the hardening process of 2 at 130 °C also began immediately and was nearly complete in 16 min. However, a minor hardening process gradually continued after the major one. The change in the E′ of 1 in this plateau region was larger than that of 2. This suggests that the reactivity of OBCA with BADGE was lower than that of CDCA. The difference in reactivity can be attributed to the bulky oxabicyclic moiety of OBCA that sterically hinders the acid anhydride moiety.
Fig. 3 Time-dependent dynamic mechanical analysis. Storage modulus E′ (red open triangles) and tanδ (blue open circles) of 2 at 130 °C during isothermal analysis. |
In addition, the hardening behaviour of 1 and 2 indicates that the cross-linked network possibly formed during the major hardening process while residual functional groups, such as epoxy and carboxylic acid, possibly reacted in the cross-linked network during the minor hardening process. The change in physical properties resulting from the minor hardening process was insignificant after 60 min at all hardening temperatures; however, the change was smallest at 130 °C. Hereafter, the properties of bio-based epoxy resin 1 will be evaluated using the samples that hardened at 130 °C.
The ratio between the epoxy and hardener usually affects the properties of the epoxy resin.8 Initially, an epoxy/hardener mole ratio of 1.32/2.10 was adopted. The E′ and tanδ of 1 at a ratio of 1.32/0.94 and 1.32/3.96 are shown in Fig. 2e and f, respectively. The hardening time depended on the amount of hardener. The major hardening process of 1 was complete at 22, 43, and 75 min using 0.94, 2.10, and 3.96 mmol of OBCA, respectively. As the amount of OBCA increased, the time required for the major hardening process became longer. With a small amount of OBCA, the cross-linked network formed is low density. Therefore, the hardening process could rapidly proceed because the hardener could easily move through the low-density network. On the other hand, the hardening process became slower in proportion to the amount of OBCA as the cross-linked network became denser. Furthermore, the high flexibility of the moulded film of 1, obtained using 0.94 mmol OBCA, compared with the other films indicates the formation of a low-density cross-linked network. The physical properties of 1 obtained using 0.94 mmol OBCA are listed in Table 1.
Epoxy resin | Amount of hardener/mmol | Hardening time/h | Bio-based carbon content | Td5%b/°C | Tgc/°C | Young's modulusd/GPa | Tensile Strengthd/MPa | Strain at breaking pointd/% |
---|---|---|---|---|---|---|---|---|
a Hardened at 130 °C and 5 MPa.b Measured by thermal gravimetric analysis.c Measured by dynamical mechanical analysis.d Measured by tensile strength testing. | ||||||||
1 | 2.10 | 1 | 38 | 317 | 115 | 0.9 ± 0.4 | 55.8 ± 5.3 | 6.1 ± 1.6 |
2.10 | 2 | 38 | 293 | 116 | 1.3 ± 0.5 | 65.2 ± 4.3 | 6.0 ± 1.2 | |
2.10 | 3 | 38 | 328 | 116 | 1.2 ± 0.1 | 59.8 ± 5.0 | 5.3 ± 1.0 | |
0.94 | 4 | 21 | 292 | 28 | 0.37 ± 0.1 | 9.5 ± 1.3 | 69.3 ± 7.3 | |
2.10 | 4 | 38 | 310 | 115 | 1.6 ± 0.5 | 68.0 ± 11 | 5.2 ± 1.0 | |
3.94 | 4 | 53 | 287 | 146 | 2.8 ± 0.3 | 63.9 ± 25 | 3.9 ± 1.3 | |
2 | 2.10 | 1 | 0 | 322 | 83 | 1.2 ± 0.1 | 66.7 ± 5.3 | 6.3 ± 1.8 |
2.10 | 2 | 0 | 307 | 89 | 1.2 ± 0.3 | 67.8 ± 8.6 | 5.7 ± 1.2 | |
2.10 | 3 | 0 | 315 | 94 | 1.0 ± 0.2 | 63.0 ± 4.5 | 6.2 ± 1.1 | |
2.10 | 4 | 0 | 286 | 93 | 0.8 ± 0.2 | 68.0 ± 3.4 | 7.5 ± 1.8 |
The bio-based carbon contents of 1 and 2 are summarized in Table 1 as well. The bio-based carbon contents of the epoxy resin hardened using 0.94, 2.10, and 3.96 mmol OBCA were 21, 38, and 53%, respectively. This indicates that the bio-based carbon content of 1 can be easily increased by using the bio-based hardener OBCA, which derives its carbons from bio-based furfural.
Fig. 4 IR spectra of (a) BAGDE, (b) OBCA, (c) CDCA, (d) 1 (0.94 mmol OBCA), (e) 1 (2.10 mmol OBCA), (f) 1 (3.96 mmol OBCA), and g) 2. |
When the amount of OBCA used in 1 was 3.96 mmol, the peak at 1856 cm−1 due to acid anhydride was still observed 4 h from the beginning of hardening as shown in Fig. 4f. Although one BADGE molecule having two epoxide groups can theoretically react with four OBCA molecules, it was difficult to complete the hardening process with stoichiometric amounts of OBCA and BADGE owing to the high-density cross-linked network, which could interfere with the reaction between the epoxide and acid anhydride. If the reaction proceeds stoichiometrically, the epoxy resin becomes a fragile material owing to the presence of four OBCA units at the termini of bisphenol A. Therefore, residual OBCA was left from the initial 3.96 mmol after the four-hour hardening process.
As mentioned above, the hardening process did not reach completion after 4 h. We then attempted to identify the residual functional groups during the hardening of 1 with 0.94 mmol OBCA. Each sample of 1 and 2 was prepared as a 0.2 mm thick film at different hardening times (1, 2, 3, and 4 h) by the hot-pressing method at 5 MPa and 130 °C. All epoxy resin films were transparent and hard at each hardening time. However, the residual functional groups could not be identified as the difference in the hardening time was not manifested in the IR spectra.
On the other hand, the Tg of 1 increased with increasing amount of OBCA. Thus, a large amount of OBCA led to the formation of a high-density cross-linked network, resulting in a heat-resistant epoxy resin. The Tg of 1 hardened using 0.94 mmol OBCA was around room temperature; therefore, this moulded sample was more flexible than the others. In comparison, the E′ and Tg of 2 using 2.10 mmol CDCA were 3.1 GPa and 93 °C. Tg is an important parameter to consider in choosing an epoxy resin for industrial use. The Tg of 1 was above the boiling point of water (100 °C) while that of 2 was not, which makes the thermal properties of the former superior to the latter.
The mechanical properties of 1 using 0.94 mmol OBCA indicate that it is more flexible than other epoxy resins owing to its low-density cross-linked network. Conversely, 1 using 3.96 mmol OBCA was more fragile than others owing to its high-density cross-linked network.
Although BADGE was chosen as the epoxy in this study to evaluate OBCA as a hardener, other epoxies including the bio-based ones that were previously reported can also be used.10–13 A bio-based epoxy and bio-based OBCA hardener will thus give a fully bio-based epoxy resin.
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