Vanillin-derived epoxy resin as a high fracture toughness high stiffness matrix for carbon fibre reinforced structural composites

Abstract

The following study cements vanillin’s position as a leading replacement for BPA-based epoxy resins in high performance epoxy–amine composite applications. Diglycidyl ether of vanillyl alcohol (DGEVA) is cured with a high-performance aerospace grade crystalline diamine hardener 4,4 diaminodiphenyl sulfone (4,4-DDS) yielding a resin with a Tg of 140 °C according to DMA, high bending stiffness of 3.84 ± 0.02 GPa, and high mode I fracture toughness of 1.33 ± 0.23 MPa m1/2, as evidenced by ASTM standard tests. Initial kinetic and rheological evaluation of DGEVA–DDS highlights its potential to act as a drop-in epoxy system for many industrial composite manufacturing processes with minor processing adjustments. Resin is characterized by means of cure kinetics, thermomechanical properties and physical properties deciphering a route for carbon fibre reinforced composite manufacturing. The results show superior performance of the neat DGEVA–DDS system in mechanical tests including up to 38% greater strength, 60% stiffness, 160% fracture toughness, and minor increases when translated to composite materials as compared to BADGE–DDS.

Graphical abstract: Vanillin-derived epoxy resin as a high fracture toughness high stiffness matrix for carbon fibre reinforced structural composites

Supplementary files

Article information

Article type
Paper
Submitted
21 Mar 2025
Accepted
03 Sep 2025
First published
10 Sep 2025
This article is Open Access
Creative Commons BY license

RSC Sustainability, 2025, Advance Article

Vanillin-derived epoxy resin as a high fracture toughness high stiffness matrix for carbon fibre reinforced structural composites

B. Kaushik, W. E. Dyer, N. Lorenz and B. Kumru, RSC Sustainability, 2025, Advance Article , DOI: 10.1039/D5SU00205B

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