Reaction-induced phase separation mechanisms in modified thermosets

The reaction-induced phase separation in amorphous thermoplastic-modified epoxy systems was observed in situ using methods of different observation windows: small angle X-ray scattering (SAXS), light transmission (LT) and light scattering (LS). The transmission electron microscopy (TEM) technique was concurrently used to get direct representations of morphologies at different levels of the phase separation process. The selected systems were bisphenol-A diglycidylether cured with either 4,4'-diaminodiphenylsulfone or 4,4'-methylenebis[3-chloro,2,6-diethylaniline] in the presence of polyetherimide. The phase separation mechanisms involved were found to be greatly dependent on the initial modifier concentration and on the ratio of the phase separation rate with respect to the polymerization rate. Experimental results showed that, for modifier concentrations close to the critical fraction, the system was directly thrown into the unstable region, even at a low polymerization rate, and phase separation proceeded by spinodal demixing. On the other hand, for off-critical compositions the homogeneous solution demixed slowly via the nucleation and growth mechanism. In spite of the evolution of the phase diagram with reaction extent, the system remains in the metastable stare whatever the cure temperature. The cure temperature has a strong effect on the extent of phase separation, since sooner or later vitrification of the thermoplastic-rich phase occurs and stops the evolution of morphologies. A post-cure allows the phase separation process to go further and sub-particles can be generated depending on the precure and post-cure temperatures. (C) 1998 Elsevier Science Ltd. All rights reserved.