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Fully bio-based composites composed of polybenzox- In Industrial applications the use of natural products is
azine resins obtained from renewable natural resour- increasing because of concerns over environmental issues,
ces (such as cardanol, furfurylamine, and stearylamine)
and bio-fiber such as jute fiber were prepared. The
waste disposal, and depletion of nonrenewable resources.
purity of the isolated cardanol was determined by Gas On the other hand, the development of new polymer espe-
Chromatography. The structure of cardanol and its cially those based on renewable organic raw materials
benzoxazine monomers were characterized by FT-IR, using alternative sustainable process deserves the atten-
1
H-NMR, 13C-NMR, and Mass spectroscopic analysis tion of both academic and industrial research. Among dif-
and its polymerization process was monitored by Dif-
ferential scanning calorimetry analysis. The compo-
ferent renewable resources, cashew nut shell liquid
sites’ tensile and flexural strengths were measured by (CNSL), an agricultural by-product abundantly available
UTM and its impact strength was measured by IZOD in tropical countries such as India, is one of the major
impact tester respectively. The bio composite (PCF- and economical resources of naturally occurring phenols.
Bzo/Jute fiber) shows superior thermal and mechanical CNSL can be regarded as a versatile and valuable raw
(from thermogravimetric analysis and dynamic
mechanical analysis) properties when compared with
material for wide applications in the form of brake lin-
stearylamine-based composite (PCS-Bzo/Jute fiber). ings, surface coating paints, as well as in polymer produc-
The surface morphologies of the fractured composites tion [5–7]. CNSL is indeed a mixture of anacardic acid,
were analyzed by Scanning Electron Microscopy. cardanol, and traces of cardol and 2-methyl cardol. The
POLYM. COMPOS., 00:000–000, 2014. V
C 2014 Society of Plas-
alkyl side chain (R) of each of them may be saturated
tics Engineers
mono-olefinic 8 or di-olefinic 8, 11, or tri-olefinic 8, 11,
14 with a high percentage of the components having one
or two double bonds per molecule [8–10].
INTRODUCTION
CNSL as well as cardanol can be considered as a sus-
Phenol-formaldehyde resins were the first fully syn- tainable low cost and largely available natural resource by-
thetic commercial polymer resins which were first product of the cashew industry. Therefore, CNSL as well as
described over 100 years ago. Because of their relatively cardanol and its derivatives are becoming important starting
low cost and their dimensional stability, the resole type materials having possible industrial utilization such as addi-
resins are still largely used in the industry of polymeric tives for lubricants, diesel engine fuels, antioxidants, stabil-
materials. More recently, the development of izers, flame retardants, resins, inks, hydro-repellents as well
benzoxazine-based family of phenolic resins has attracted as fine chemicals, and intermediates [11, 12]. Furfurylamine
significant attention. Polybenzoxazines are a novel ther- is synthesized from furfural which is a green platform prod-
mosetting phenolic resin that has been developed to over- uct derived from a variety of agricultural by-products such
come the shortcomings associated with traditional as corncobs and wheat bran like other fatty amines contain-
phenolic resins such as releasing condensation by prod- ing a long hydrocarbon chain. Stearylamine can be pro-
ucts and using strong acids as catalysts, while retaining duced from vegetable oils. Nowadays high quality bio-
good thermal properties and flame retardancy of phenolic methanol can be produced on a large industrial scale from
resins. Benzoxazines are readily synthesized either in diverse biomass resources. The bio-methanol can be con-
solution or by melt-state reaction using a combination of verted into formaldehyde via a catalytic oxidation and fur-
phenol derivatives, paraformaldehyde, and a primary ther to paraformaldehyde by a condensation reaction.
amine [1–4]. Recently, a novel cardanol-based monofunctional ben-
zoxazine monomer has been reported by the reaction of
cardanol with ammonia and formaldehyde [10], showing
Correspondence to: M. Sarojadevi; e-mail: msrde2000@yahoo.com
DOI 10.1002/pc.23214
a glass transition temperature (Tg) of only 36 C. And so,
Published online in Wiley Online Library (wileyonlinelibrary.com). there is a need to improve the thermal and mechanical
C 2014 Society of Plastics Engineers
V properties of these resins for composite applications. In
POLYMER COMPOSITES—2014
ried out on the UTM machine (Model H10K-S Tinius
Olsen) with cross head speed of 5 mm/min according to
the ASTM, D3039/D3039M-08 and ASTM, D790-10
standards. The impact test was carried out on the Izod
impact tester according to the ASTM, D256-10 standard.
Isolation of Cardanol
Cardanol was isolated from CNSL by adopting vac-
uum distillation method according to Ref. [13].
Synthesis of 3-(Furyan-2-Yl)-5-(Pentadeca-8,11-Dienyl)3,4-
Dihydro-2h-1,3-Benzoxazine [CF-Bzo]. Cardanol-furfuryl-
amine-based benzoxazine was synthesized by solvent-less
process [Scheme 1]. Freshly distilled cardanol (9 g, 0.03 mol),
SCH. 1. Synthesis of benzoxazine monomers (CF-Bzo and CS-Bzo). furfurylamine (3 ml, 0.03 mol), and paraformaldehyde (1.5 g,
0.06 mol) were added to a round bottomed flask and placed
over a magnetic stirrer. The mixture was heated to 80–90 C,
the present research a fully bio-based polybenzoxazine and stirred at this temperature for half an hour until the mix-
with suitable properties have been synthesized using car- ture becomes homogenous with dark maroon color. Then the
danol, furfurylamine, stearylamine, and paraformaldehyde temperature was further raised to 120–130 C and refluxed for
as raw materials. another 2 h. After which, the reaction mixture was cooled to
room temperature and concentrated under reduced pressure to
MATERIALS yield CF-Bzo as red brown oil. Yield, 92%
whereas the protons of the branch chain appear at 5.3, NMR Spectroscopy of the Synthesized Monomers
0.8, 2.4, and 1.5 ppm because of the presence of vinyl, The 1H-NMR spectra shown in Fig. 6 confirm the struc-
methyl, and methylene groups, respectively. The aromatic ture of the benzoxazine monomers, CF-Bzo, and CS-Bzo.
protons appear as multiplets between 6.5 and 7.5 ppm, The oxazine ring protons (Ar-CH2-N and O-CH2-N) for
respectively. The aromatic carbon which is attached to both the monomers gave resonance peaks at 3.9 and 4.8
the phenolic moiety appears at 157 ppm. All the other ppm for both CF-Bzo and CS-Bzo, respectively. For CF-
aromatic carbons gave peaks inbetween 110 and 150 Bzo, the protons of the furan ring gave peaks at 6.2, 6.3,
ppm. Whereas, the carbons of the long alkyl side chain and 7.4 ppm; whereas the methylene group connecting the
(which is attached to the aromatic ring) gave peaks oxazine ring and the furan ring resonate at 3.9 ppm. The
between 10 and 40 ppm, respectively [15]. aromatic ring protons appear as multiplets between 6.5 and
The mass spectrum of cardanol is shown in Fig. 3, 7.5 ppm. The long chain alkyl protons attached with the
which shows the molecular ion peak at 300 for cardanol. benzene ring (from the cardanol group) gave peaks at 5.3
And the purity of cardanol is confirmed by Gas Chromatog- ppm for vinyl protons, at 0.8 ppm for methyl protons and
raphy analysis as shown in Fig. 4 showing 96% of cardanol at 2.4 and 1.5 ppm for methylene proton, respectively. In a
and the remaining corresponds to isomers of cardanol. similar way, the side chain alkyl protons (arising from
both stearylamine and cardanol) gave characteristic peaks
between 2.7 and 0.8 ppm, respectively [19, 20].
FT-IR Spectroscopy of the Synthesized Monomers
The 13C-NMR spectra in Fig. 7 further confirm the
The structure of the novel benzoxazine monomers were structure of the benzoxazines, CF-Bzo, and CS-Bzo. The
supported by the FT-IR spectra as shown in Fig. 5. The oxazine ring carbons (Ar-CH2-N and O-CH2-N) appear as
characteristic absorptions of benzoxazine ring structure for two singlets at 48.1 and 82.3 ppm for CF-Bzo and at 58.1
and 82.4 ppm for CS-Bzo, respectively. In CF-Bzo the benzoxazine ring gets opened up by the cleavage of C-O
carbons of the furan ring gave characteristic peaks bond in it, upon which its ring structure gets transformed
between 150 and 100 ppm and the methylene carbon in- to a linear open chain structure. As a result of this trans-
between oxazine and furan ring appeared at 49.9 ppm. formation, the trisubstituted benzene ring becomes tetra-
Moreover, the carbons of CS-Bzo show peaks in two substituted leading to the formation of polybenzoxazine.
regions. The one between 110 and 160 ppm arise because Both the benzoxazine monomers (CF-Bzo and CS-
of the aromatic carbons. And the other between 10 and Bzo) show two exothermic peaks. The first one is associ-
35 ppm arise from the long alkyl side chain of both the ated with curing of the benzoxazine monomers, which
stearylamine and cardanol groups, respectively [19]. was observed from 214 C to 265 C with a peak maxi-
The mass spectrum of CF-Bzo and CS-Bzo is shown mum of 237 C for CF-Bzo and from 219 C to 248 C
in Fig. 8, which shows the molecular ion peak at with a peak maximum of 274 C for CS-Bzo, respectively.
m/e 5 421.4 for CF-Bzo and at m/e 5 594.5 for CS-Bzo. And the second one is associated with the degradation of
the aliphatic chain around 348 C for both the monomers.
Differential Scanning Calorimetric Analysis of the These observations clearly show that the synthesized bio-
Benzoxazine Monomers
The polymerization behavior of the individual mono-
mers CF-Bzo and CS-Bzo were studied using DSC at a
heating rate of 10 C/min under nitrogen atmosphere from
30 C to 300 C. Figure 9 shows the DSC thermograms
and the data are summarized in Table 1. On heating, the
based benzoxazines (CS-Bzo and CF-Bzo) exhibit curing the FT-IR spectra of the CF-Bzo and CS-Bzo monomers
behavior similar to that of ring-opening polymerization of after heating to 100 C, 150 C, 200 C, and 250 C for 1 h
benzoxazine in the range of 200–250 C [21, 22]. at each temperature. For the monomers (CF-Bzo and
CS-Bzo) after curing at 250 C, the dramatic decrease of
intensity of peaks around 960 (oxazine ring), 1072 (C-O-
Curing Behavior of the Benzoxazine Monomers by FT-IR C), 1242 and 1350 cm21 (-CH2- of benzene ring) and
Spectroscopy appearance of bands around 3450 cm21 (-OH) confirms
The curing reaction of the monomers was further con- that the curing of the benzoxazine ring components pro-
firmed by FT-IR analysis [Scheme 2]. Figure 10 shows ceeds via ring-opening polymerization [23]. During the
FIG. 7. 13C-NMR spectrum of benzoxazine monomers: (a) CF-Bzo and (b) CS-Bzo.
Flame Retardancy of the Polymers in many applications requiring good flame resistance. It
was found that in the prepared polymers (CF-Pbzo and
The limiting oxygen index (LOI) value, which is taken
CS-Pbzo) the LOI value increases with an increase in
as an indicator to evaluate the polymer’s flame retardancy
char yield showing values greater than 26 as expected,
was measured as shown in Table 2. LOI is defined as the
thus confirming their good flame retardant properties
minimum fraction of oxygen in a mixture of O2 and N2
[4, 26, 27].
that will support flaming combustion. The LOI values
were calculated from the char yield resulted from TGA
analysis by using Van Krevelan and Hofytzer equation as Preparation of Jute Fiber Composite
shown below,
Another part of the present work is aimed at prepara-
LOI517:5 1 0:4 ðCYÞ tion and characterization of cardanol-based benzoxazine
matrix composites reinforced by jute fibers. Fibers are an
where LOI is the Limiting oxygen index, CY the Char important alternative, offering several advantages which
yield (from TGA data). includes their abundance, bio-degradability, light-weight,
The char yield of the CF-Pbzo and CS-Pbzo was found renewability, negligible toxicity, low cost, and properties
to be high in the range of 23–34% indicating high flame comparable with those of glass, carbon and aramid fibers.
retardancy, which is expressed in terms of their LOI In this work, plain weave jute fiber cloth was used to pre-
value. In general, the LOI value of the polymer should pare composites. The jute fiber was treated with 10%
be above the threshold value of 26, to render them self- NaOH solution and neutralized with dilute acetic acid and
extinguishing property and to qualify their requirement dried for 1 h at 110 C prior to use. Jute fiber was placed
FIG. 10. FT-IR spectrum showing curing behavior of benzoxazine monomers: (a) CF-Bzo and (b) CS-Bzo.
[Color figure can be viewed in the online issue, which is available at wileyonlinelibrary.com.]
S.No. Sample Ti% T5% T10% Char yield (%) LOI values
FIG. 13. Loss modulus of (from DMA measurements): (a)CF-PBzo
1. a 329 374 403 34 31.1
and (b) CS-PBzo/Jute fiber composites. [Color figure can be viewed in
2. b 298 342 356 23 26.7
the online issue, which is available at wileyonlinelibrary.com.]
The lower value for CS-Pbzo/Jute composite may be results stearylamine, furfurylamine, cardanol, and its
attributed to the fact that because of the presence of long derivatives could be considered nowadays as a very
aliphatic chain of the stearyl group, an intermolecular attractive renewable bio resources to use in eco-friendly
hydrogen bonding occurs in this composite, which results process.
in de-bonding of the resin with the fiber. Whereas, in the
case of CF-Pbzo/Jute composite, because of the presence
of the active furan ring, there is an enhancement in bond-
ing between the resin and the fiber leading to an improve- ACKNOWLEDGMENT
ment in the cross-link density of the composite, showing The authors acknowledge the Department of Science and
high modulus than that of CS-Pbzo/Jute fiber [10]. More- Technology, New Delhi and The council of Scientific and
over, the SEM images in Fig. 14 shows that the compati- Industrial Research for funding this project. The authors
bility between the resin and the fiber is better (showing also acknowledge DST (FIST) and UGC (SAP) for the
minimum voids) in CF-Pbzo/Jute fiber composites when financial support extended to procure instrumental facilities.
compared with CS-Pbzo/Jute fiber composites (showing
more number of voids). REFERENCES