Dean C. Webster

High Biobased Content Epoxy–Anhydride Thermosets from Epoxidized Sucrose Esters of Fatty Acids

Novel highly functional biobased epoxy compounds, epoxidized sucrose esters of fatty acids (ESEFAs), were cross-linked with a liquid cycloaliphatic anhydride to prepare polyester thermosets. The degree of cure or conversion was studied using differential scanning calorimetry (DSC), and the sol content of the thermosets was determined using solvent extraction. The mechanical properties were studied using tensile testing to determine Youngs modulus, tensile stress, and elongation at break. Dynamic mechanical analysis (DMA) was used to determine glass-transition temperature, storage modulus, and cross-link density. The nanomechanical properties of the surfaces were studied using nanoindentation to determine reduced modulus and indentation hardness. The properties of coatings on steel substrates were studied to determine coating hardness, adhesion, solvent resistance, and mechanical durability. Compared with the control, epoxidized soybean oil, the anhydride-cured ESEFAs have high modulus and are hard and ductile, high-performance thermoset materials while maintaining a high biobased content (71-77% in theory). The exceptional performance of the ESEFAs is attributed to the unique structure of these macromolecules: well-defined compact structures with high epoxide functionality. These biobased thermosets have potential uses in applications such as composites, adhesives, and coatings.

A preliminary study on the properties and fouling-release performance of siloxane-polyurethane coatings prepared from poly(dimethylsiloxane) (PDMS) macromers.

Siloxane–polyurethane fouling-release (FR) coatings based on aminopropyl terminated poly(dimethylsiloxane) (PDMS) macromers were prepared and characterized for FR performance via laboratory biological assays. These systems rely on self-stratification, resulting in a coating with a siloxane-rich surface and polyurethane bulk. Previously, these coating systems have used PDMS with multiple functional groups which react into the polyurethane bulk. Here, aminopropyl terminated PDMS macromers were prepared, where a single amine group anchors the PDMS in the coating. Coatings were prepared with four molecular weights (1000, 5000, 10,000, and 15,000 g mol−1) and two levels of PDMS (5% and 10%). High water contact angles and low surface energies were observed for the coatings before and after water immersion, along with low pseudobarnacle removal forces. Laboratory bioassays showed reduced biofilm retention of marine bacteria, good removal of diatoms from coatings with low molecular weight PDMS, high removal of algal sporelings (young plants), and low removal forces of live barnacles.

Cyclic carbonate functional polymers and their applications

Polymers containing five-membered cyclic carbonate groups show promise in a number of different applications. Polymers containing cyclic carbonate groups can be synthesized by the free radical copolymerization of a cyclic carbonate containing unsaturated monomer. A number of cyclic carbonate containing monomers have been explored including propylene carbonate methacrylate and acrylate, vinylene carbonate, glycerin carbonate vinyl ether, and vinyl ethylene carbonate. Another synthesis route involves the conversion of oxirane groups on epoxy resins to cyclic carbonate groups by reaction with CO 2 . Research has focused on the reaction of the cyclic carbonate group with amines to form hydroxyurethanes. Difunctional cyclic carbonates reacted with diamines result in linear thermoplastic polyurethanes, while multifunctional cyclic carbonates reacted with multifunctional amines result in cross-linked polyurethanes. Other uses of cyclic carbonate functional polymers include the immobilization of enzymes and the coordination of lithium ions in solid polymer batteries.

New biobased high functionality polyols and their use in polyurethane coatings.

High-functionality polyols for application in polyurethanes (PUs) were prepared by epoxide ring-opening reactions from epoxidized sucrose esters of soybean oil-epoxidized sucrose soyates-in which secondary hydroxyl groups were generated from epoxides on fatty acid chains. Ester polyols were prepared by using a base-catalyzed acid-epoxy reaction with carboxylic acids (e.g., acetic acid); ether polyols were prepared by using an acid-catalyzed alcohol-epoxy reaction with monoalcohols (e.g., methanol). The polyols were characterized by using gel permeation chromatography, FTIR spectroscopy, (1)H NMR spectroscopy, differential scanning calorimetry (DSC), and viscosity measurements. PU thermosets were prepared by using aliphatic polyisocyanates based on isophorone diisocyanate and hexamethylene diisocyanate. The properties of the PUs were studied by performing tensile testing, dynamic mechanical analysis, DSC, and thermogravimetric analysis. The properties of PU coatings on steel substrates were evaluated by using ASTM methods to determine coating hardness, adhesion, solvent resistance, and ductility. Compared to a soy triglyceride polyol, sucrose soyate polyols provide greater hardness and range of cross-link density to PU thermosets because of the unique structure of these macromolecules: well-defined compact structures with a rigid sucrose core coupled with high hydroxyl group functionality.

Novel biobased epoxy compounds: epoxidized sucrose esters of fatty acids

Novel biobased high functionality epoxy resins were synthesized by the epoxidation of sucrose ester resins of vegetable oil fatty acids (SEFA). A series of sucrose esters of fatty acids were epoxidized by peracetic acid generated in situ from hydrogen peroxide and acetic acid in the presence of an ion exchange resin catalyst to produce the epoxidized sucrose esters of fatty acids (ESEFA). The conversion of double bonds to epoxides was greater than 99%. The products were characterized by matrix-assisted laser desorption and ionization time-of-flight (MALDI-TOF) mass spectrometry, Fourier-transform infrared (FTIR) spectroscopy, and nuclear magnetic resonance (NMR) spectroscopy. The physical properties were characterized using bulk viscosity, intrinsic viscosity, and density measurements. The thermal properties were characterized by differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Since sucrose esters consist of a sucrose core fully substituted with eight vegetable oil fatty acids, both SEFAs and ESEFAs possess well-defined compact macromolecular structures. As novel biobased epoxy compounds, ESEFAs possess high epoxy functionality (8–15 per molecule), high density, and a compact molecular structure. Thus, ESEFAs are very promising in a number of uses from the formation of biobased thermosets by crosslinking of the epoxy groups, to further derivatization by reaction of the epoxy groups.

Combinatorial materials research applied to the development of new surface coatings IV. A high-throughput bacterial biofilm retention and retraction assay for screening fouling-release performance of coatings

Abstract A high-throughput bacterial biofilm retention screening method has been augmented to facilitate the rapid analysis and down-selection of fouling-release coatings for identification of promising candidates. Coatings were cast in modified 24-well tissue culture plates and inoculated with the marine bacterium Cytophaga lytica for attachment and biofilm growth. Biofilms retained after rinsing with deionised water were dried at ambient laboratory conditions. During the drying process, retained biofilms retracted through a surface de-wetting phenomenon on the hydrophobic silicone surfaces. The retracted biofilms were stained with crystal violet, imaged, and analysed for percentage coverage. Two sets of experimental fouling-release coatings were analysed with the high-throughput biofilm retention and retraction assay (HTBRRA). The first set consisted of a series of model polysiloxane coatings that were systematically varied with respect to ratios of low and high MW silanol-terminated PDMS, level of cross-linker, and amount of silicone oil. The second set consisted of cross-linked PDMS-polyurethane coatings varied with respect to the MW of the PDMS and end group functionality. For the model polysiloxane coatings, HTBRRA results were compared to data obtained from field immersion testing at the Indian River Lagoon at the Florida Institute of Technology. The percentage coverage calculations of retracted biofilms correlated well to barnacle adhesion strength in the field (R2 = 0.82) and accurately identified the best and poorest performing coating compositions. For the cross-linked PDMS-polyurethane coatings, the HTBRRA results were compared to combinatorial pseudobarnacle pull-off adhesion data and good agreement in performance was observed. Details of the developed assay and its implications in the rapid discovery of new fouling-release coatings are discussed.

Impact of structure and functionality of core polyol in highly functional biobased epoxy resins.

Highly functional biobased epoxy resins were prepared using dipentaerythritol (DPE), tripentaerythritol (TPE), and sucrose as core polyols that were substituted with epoxidized soybean oil fatty acids, and the impact of structure and functionality of the core polyol on the properties of the macromolecular resins and their epoxy-anhydride thermosets was explored. The chemical structures, functional groups, molecular weights, and compositions of epoxies were characterized using nuclear magnetic resonance (NMR) spectroscopy, Fourier-transform infrared (FTIR) spectroscopy, gel permeation chromatography (GPC), and matrix-assisted laser desorption/ionization time-of-flight mass spectrometry (MALDI MS). The epoxies were also studied for their bulk viscosity, intrinsic viscosity, and density. Crosslinked with dodecenyl succinic anhydride (DDSA), epoxy-anhydride thermosets were evaluated using differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), tensile tests, and tests of coating properties. Epoxidized soybean oil (ESO) was used as a control. Overall, the sucrose-based thermosets exhibited the highest moduli, having the most rigid and ductile performance while maintaining the highest biobased content. DPE/TPE-based thermosets showed modestly better thermosetting performance than the control ESO thermoset.

Laboratory screening of coating libraries for algal adhesion.

Abstract Coatings libraries achieved through a combinatorial chemistry approach, which may generate tens to hundreds of formulations, can be deposited in an array of 12 patches, each approximately 9 cm2, on 10 × 20 cm primed aluminum panels. However, existing methods to quantify algal biomass on coatings are unsuitable for this type of array format. This paper describes an algorithm modelled on a probability distribution that quantifies the area of surface covered by a green alga from digital images. The method allows coatings with potential fouling-release properties to be down-selected for further evaluation. The use of the algorithm is illustrated by a set of eight siloxane-polyurethane coatings made using organofunctional poly(dimethylsiloxane) (PDMS) and poly(ϵ-caprolactone)-PDMS-poly(ϵ-caprolactone) (PCL-PDMS-PCL) triblock copolymers along with four PDMS standards which were deposited on one panel. Six replicate panels were seeded with Ulva zoospores which grew into sporelings (small plants) that completely covered the surface. The ease of removal of the Ulva sporeling biofilms was determined by automated water jetting at six different impact pressures. The coverage of the biofilm on the twelve individual formulations after jet washing was quantified from the green colour of digital images. The data are discussed in relation to the composition of the coatings.

Mini-review: Combinatorial approaches for the design of novel coating systems

Abstract Combinatorial and high throughput experimental methods are being applied to the design and development of novel polymers and coatings used in a number of application areas. Methods have been developed for polymer synthesis and screening and for the development of polymer thin film and coating libraries and the screening of these libraries for key properties such as surface energy and modulus. Combinatorial and high throughput methods enable the efficient exploration of a large number of compositional variables over a wide range. In the development of coatings for use in the marine environment, the key challenge is in the development of screening methods that can predict good performance. A number of assays are under development that will permit the rapid screening of the interaction of coatings with representative marine organisms.

Thermoset Coatings from Epoxidized Sucrose Soyate and Blocked, Bio-Based Dicarboxylic Acids

A new 100% bio-based thermosetting coating system was developed from epoxidized sucrose soyate crosslinked with blocked bio-based dicarboxylic acids. A solvent-free, green method was used to block the carboxylic acid groups and render the acids miscible with the epoxy resin. The thermal reversibility of this blocking allowed for the formulation of epoxy-acid thermoset coatings that are 100% bio-based. This was possible due to the volatility of the vinyl ethers under curing conditions. These systems have good adhesion to metal substrates and perform well under chemical and physical stress. Additionally, the hardness of the coating system is dependent on the chain length of the diacid used, making it tunable.