Abstract
A novel method based on phase inversion and inter-boundary reaction in a reactive system comprising a thermoplastic phenoxy and a thermosetting epoxy has been proposed to design micro epoxy particles with a thermoplastic polymer shell. Due to the hydroxyl group in phenoxy, inter-domain reactions were found to lead to a chemical link between the polymer and the epoxy network. As cure progressed, the phenoxy component was first expelled out of the epoxy spheres at initial stages of cure and a phase-separated morphology was set. Subsequently, the pendant -OH groups in the phenoxy shells were grafted onto the outer surfaces of the epoxy core particles (3–4 μm) at high enough temperatures (187°C or higher) during later stages of cure. This paper describes the mechanisms and fundamental phenomenon under which this unique method of preparing polymer/epoxy spheres (epoxy cores/phenoxy shell) of controlled sizes can be realized. Several factors have been found to affect the geometry of the epoxy spheres and the chemical bondings between the polymer and epoxy.
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