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Chapter 2

Catalytic Accelerated Polymerization


of Benzoxazines and Their Mechanistic
Considerations
C. Liu1 and Q.-Y. Chen
Shanghai Institute of Organic Chemistry, Chinese Academy of Sciences, Shanghai, China
1
Corresponding author: e-mail: chaoliu@sioc.ac.cn

Chapter Outline
1 Introduction 9 4 Catalyst Effects on Polymerization Mechanism
2 Benzoxazine Polymerization Mechanism Consideration 9 and Network Structures 16
3 Catalysts for Accelerated Benzoxazine Polymerization 12 4.1 Pure Benzoxazines 16
3.1 Acidic Catalysts 13 4.2 Benzoxazine-Epoxy Blends 19
3.2 Basic Catalysts 15 5 Conclusion 20

1 INTRODUCTION industrial applications because of the high cost of preparing


the benzoxazine monomer itself. As a result, use of an added
Benzoxazine resins have gained much interest and attention catalyst to accelerate the polymerization of benzoxazines
because of their many useful properties associated with con- becomes a good alternative.
ventional phenolics, such as excellent heat and chemical Much effort has been devoted to developing convenient
resistance, flame retardance, low dielectric constant, good and efficient catalysts to accelerate the benzoxazine poly-
dynamic mechanical properties, and relatively inexpensive merization at lower temperatures and reduced reaction time,
cost. They also possess other desirable properties including but has met with limited success. To develop a good catalyst, it
near-zero shrinkage cure, low water absorption, good is important to understand the benzoxazine polymerization
dimensional stability, excellent FST (fire, smoke, toxicity) mechanism. This chapter focuses on the understanding of
properties, and super molecule-design flexibility [1]. These benzoxazine polymerization mechanism and the catalysts
properties offer high potential to substitute epoxy, bisma- reported for accelerating polymerization rate of benzoxazines.
leiimide, phenolics, or other thermosetting resins in many The influence of an added catalyst on the polymerization
important applications. For example, commercial benzoxa- mechanism and the network structure of the resulting polymer
zines are good candidates for formulating prepregs used for is discussed as well.
aerospace compositions, and are currently utilized fre-
quently in the aerospace industry. It is estimated that 30%
weight savings may be obtained by replacing metal with 2 BENZOXAZINE POLYMERIZATION
benzoxazine composites, which results in reduced fuel con-
MECHANISM CONSIDERATION
sumption, and emissions. However, the high temperature
(typically > 180°C) and relatively long reaction time The fundamental understanding of the benzoxazine poly-
(typically > 2 h) required for the complete polymerization merization mechanism is an important foundation to learn
of benzoxazines indicates their poor reactivity, which is how a catalyst influences and may influence the progress
one of the main drawbacks and has been a problem in their and mechanism of benzoxazine polymerization, including
practical applications. Although some novel benzoxazine the development of networks and the final structure units
monomers with special functional groups exhibit good reac- of polybenzoxazines. This only favors a good molecular
tivity and can polymerize at lower temperatures, it is gen- understanding of the structure-property relationships because
erally not practical and economical to use them for it is well known that the development of networks and the

Advanced and Emerging Polybenzoxazine Science and Technology. http://dx.doi.org/10.1016/B978-0-12-804170-3.00002-0


Copyright © 2017 Elsevier Inc. All rights reserved. 9
10 PART I Synthesis and Properties of Benzoxazine Resins

final structure units of polybenzoxazines to a great degree and the oxygen-protonated species is more reactive. In the
determine their various properties. This understanding can final polybenzoxazine structure, the phenolic structure unit
also guide us to develop good catalysts to efficiently accel- is less stable than the methylene bridge structure unit.
erate the benzoxazine polymerization and tailor the desired Yagci et al. investigated the photoinitiated cationic poly-
structure for various practical applications. Although merization of benzoxazines at room temperature and found
impressive progress has been achieved, the polymerization that the structure of the polybenzoxazines was very compli-
mechanism of benzoxazines remains elusive and is still under cated because of different ring-opening polymerization pro-
investigation. cesses of the protonated oxygen or nitrogen species [10].
In 1965, Burke’s group reported the ring-opening Ueda and colleagues proposed some possible polymeri-
reaction of benzoxazine with various phenols [2]. It was zation pathways at the initial stage based on the study of
found that the aminoalkylation reaction occurred preferen- acid-initiated model condensation reactions of benzoxa-
tially at the ortho position of phenols with both free ortho zines with phenols [11].
and para positions. McDongh and Smith in 1968 investi- On the basis of the literature mentioned previously and
gated the ring-chain tautomerism phenomenon of benzoxa- the detailed NMR study of ring-opening polymerization
zines by nuclear magnetic resonance (NMR) analysis and behavior of a model p-cresol-aniline-based benzoxazine,
proposed that the protonated benzoxazine prefers to produce Sebastián, Marquet, and coworkers proposed an improved
iminium ions in strong acidic conditions [3]. Riess et al. pro- mechanistic scheme to explain various observed experi-
posed in 1985 two mechanistic pathways for the reaction of mental results, as shown in Scheme 2 [12]. The polymeri-
benzoxazine with various kinds of phenols [4]. They sug- zation mechanism of benzoxazines is considered to
gested that the formation of an intermolecular hydrogen include three main steps: coordination ring-opening of
bond of phenolic hydroxyl group with oxygen atoms of oxazine ring, electrophilic attack, and rearrangement. First,
oxazine ring resulted in the ortho reaction. The para reaction the catalyst coordinates with an oxygen or nitrogen atom of
resulted from the reaction of iminium species derived from benzoxazine, and ring opening occurs to generate three pos-
the ring opening of benzoxazine via protonation by the sible cationic intermediates: A, B, and C, by different het-
phenol. erolysis patterns. The following electrophilic reactions of
Ishida and coworkers have devoted great effort to the each intermediate may involve O-attack, N-attack, and
study of polymerization mechanism of benzoxazines. They Aryl-attack at another benzoxazine molecule, resulting in
propose that the polymerization of benzoxazines proceeds the polymerization chain propagation. It is worth noticing
through a cationic ring-opening mechanism based on the that the Aryl-attack of the active intermediates may occur
detailed study of various reaction catalysts [5]. The for- at various sites of benzene ring of benzoxazine including
mation of the iminium ion intermediate by protonation of the arylamine ring of benzoxazine with varying degrees
oxygen atom of benzoxazine with a strong acid followed of reactivity, resulting in a more complex polymerization
by aromatic electrophilic substitution on another benzox- mechanism [13–17]. The inner structure of the polymer
azine molecule may induce the ring-opening polymeri- formed may contain various phenoxy structures and phe-
zation of benzoxazines [6]. Alternatively, both the oxygen nolic structures. Upon further heating at an elevated temper-
and the nitrogen atom of benzoxazine can act as the ature or extended reaction time, phenoxy structures can
potential initiation sites. Their coordination with a cationic rearrange to corresponding phenolic structures.
catalyst results in the formation of a cyclic tertiary oxonium Because the signals of CH2 units of the polybenzoxazine
or nitronium ion. The subsequent insertion of the benzox- in 1H NMR spectra are most characteristic and easily recog-
azine monomers through the reaction of the oxygen, nized, the NMR analysis of various CH2 units in polyben-
nitrogen, or the unoccupied benzene ortho position of ben- zoxazine structure was performed to learn more about the
zoxazine finishes the polymerization process, producing polymerization mechanism of benzoxazines. It should be
phenolic or phenoxy (N,O-acetal) structure repeat units mentioned that using deuterated dimethyl sulfoxide
depending on the polymerization conditions used [7] (DMSO) instead of deuterated chloroform as the NMR
(Scheme 1). The phenoxy structure can rearrange into the solvent allows better resolution of signals in the 1H NMR
corresponding phenolic structure upon further heating [8]. spectra. During the ring-opening polymerization of benzox-
Ishida et al. recently investigated further the ring-opening azines, six different types of CH2 units can be formed:
polymerization mechanism by the detailed and systematic ArO-CH2-OAr (a), -(Ph)N-CH2-N(Ph)- (b), ArO-CH2-N
analysis of the crude products of various model benzoxazine (Ph)- (c), ArO-CH2-Ar (d), -(Ph)N-CH2-Ar (e) and
dimerization reaction with a large number of pure-model Ar-CH2-Ar (f) (Scheme 2). CH2(a–d) and CH2(e–f) are
compounds prepared based on the hypothesized initiation phenoxy CH2 units and phenolic CH2 units, respectively.
mechanism [9]. It was found that the protonation initiation Although it is very difficult to exactly distinguish the con-
can occur both on the oxygen and the nitrogen atom, but the tribution of every type of CH2 units on the signals in the 1H
corresponding nitrogen-protonated species is more stable, NMR spectrum, the possible chemical shift ranges of
Catalytic Accelerated Polymerization of Benzoxazines Chapter 2 11

(I)
O
(II) R
O N
N
δ+ M δ+ (III) (I,II)
δ+ δ+ R
R R R M δ– R
O N n
Δ O N O N δ– O N
δ– M Phenoxy structure
δ+ Electrophilic
Ring-opening δ+
substitution OH
M = Catalyst (III)
With reletively lower reactivity N
Active intermediates R
n
Phenolic structure
SCHEME 1 Proposed mechanism by Ishida and coworkers for benzoxazine ring-opening polymerization.

SCHEME 2 Improved mechanism for the ring-opening polymerization of benzoxazines. (Reproduced with permission from C. Liu, D. Shen,

R.M. Sebastián, J. Marquet, R. Schonfeld, Mechanistic studies on ring-opening polymerization of benzoxazines: A mechanistically based catalyst design,
Macromolcules 44 (2011) 4616–4622. Copyright (2010) American Chemical Society)

various CH2 units are estimated and indicated in Scheme 2 deuterated DMSO (Fig. 1). As can be seen in Fig. 1b, 1H
by using the chemical shifts of similar CH2 units in the NMR spectrum of polymer P15min presents four main
analogous known compound as the reference. signals caused by different types of CH2 units at d 5.5–
The structural changes during benzoxazine polymeri- 5.3, 4.7–4.5 parts per million (ppm) (I); 4.7–4.4 ppm (II);
zation presented in Scheme 2 are further supported by the 4.4–4.0 ppm (III); 4.0–3.5 ppm (IV). Signal I, apart from
1
H NMR spectra of a thermally cured mixture of model the peaks at 5.4 and 4.6 ppm caused by the starting
p-cresol-aniline-based benzoxazine with 1 mol% lithium p-cresol-aniline-based benzoxazine, may be ascribed to
iodide (LiI) at 150°C or 200°C for different time in the residual oxazine rings in the structures formed by
12 PART I Synthesis and Properties of Benzoxazine Resins

FIG. 1 1H NMR spectra in deuterated DMSO of p-cresol-aniline-based benzoxazine monomer and various polymers obtained under different conditions.
The polymer P15min, P0.5h, P1h and P5h were obtained by heating p-cresol-aniline-based benzoxazine in the presence of 1 mol% LiI at 150°C for 15 min,
0.5 h, 1 h, and 5 h, respectively. The polymer P200 was obtained by heating polymer P5h at 200°C for 2 h. Note: Signal I ¼ CH2 (residual oxazine rings of
the structure formed by Aryl-attack of various intermediates, Scheme 2), Signal II ¼ CH2(a,b), Signal III ¼ CH2(c,d), Signal IV ¼ CH2(e,f). (Reproduced

with permission from C. Liu, D. Shen, R.M. Sebastián, J. Marquet, R. Schonfeld, Mechanistic studies on ring-opening polymerization of benzoxazines: A
mechanistically based catalyst design, Macromolcules 44 (2011) 4616–4622. Copyright (2010) American Chemical Society.)

Aryl-attack of intermediates A, B, or C (Scheme 2). Signal occurs easily in benzoxazine polymerization process, and
II can be the result of phenoxy CH2 units CH2(a,b). Signal that rearrangement in labile phenoxy structure units to the
III probably indicates the presence of phenoxy CH2 units final stable phenolic structure units is relatively difficult.
CH2 (c,d). Signal IV may be the result of phenolic CH2
units CH2 (e,f). The coordination ring-opening step is indi-
cated by the disappearance of signal (I) (Fig. 1b and c). 3 CATALYSTS FOR ACCELERATED
After complete ring opening and the following electrophilic
attack steps, various CH2 units in the polybenzoxazine are
BENZOXAZINE POLYMERIZATION
formed, which is shown by signals (II, III, and IV) in In light of this understanding of the benzoxazine polymer-
Fig. 1c. The rearrangement of phenoxy CH2 units CH2(a,b) ization mechanism, a catalyst accelerates the benzoxazine
into phenoxy CH2 units CH2(d) and phenolic CH2 units polymerization by inducing fast ring opening of benzox-
CH2(e), respectively, and the transformation of phenoxy azine monomer. The benzoxazine polymerization is an
CH2 units CH2 (c,d) into phenolic CH2 units CH2(e,f) by autocatalyzed reaction until vitrification is reached and dif-
rearrangement are demonstrated by the gradual disap- fusion begins to control the curing process afterwards
pearance of signals (II and III) in Fig. 1d, e, and f. These [18–20]. A good catalyst should be able to effectively coor-
results suggest that coordination of ring-opening steps dinate with oxygen or nitrogen atoms to produce active
Catalytic Accelerated Polymerization of Benzoxazines Chapter 2 13

δ+ δ+ Benxoazine
A δ– R Cationic OA
monomer
Acidic catalysts [A] O N ring-opening + Polybenzoxazine
N
R R
O N
δ–

B Benxoazine
O
R Nucleophilic monomer
Basic catalysts [B] δ– O ring-opening +
Polybenzoxazine
δ+ N N B
R

SCHEME 3 Proposed two types of ring-opening patterns with different catalysts.

iminium cation intermediates and greatly promote the rear- exhibits good catalytic activity, which might be to the result
rangement step to obtain higher percentage of stable phe- of the formation of free protons derived from the reaction of
nolic structure, especially Mannich phenolic structure. BF3 with more basic water [21]. Recently, it was demon-
As shown in Scheme 3, most reported effective catalysts strated by Ronda and coworkers that BF3 Et2O in combi-
are acidic compounds and prefer to accelerate the benzox- nation with alcoholic solvents is an efficient catalyst
azine polymerization by a typical cationic ring-opening system for the benzoxazine polymerization in solution
pattern. However, basic compounds are also able to accel- under mild conditions [22]. It was proposed that the benzox-
erate the benzoxazine polymerization by a nucleophilic azine polymerization proceeds through an intermediate
ring-opening pattern, although they are not much studied. hemiaminal ether that leads mainly to the formation of diphe-
It should be mentioned that in many cases the two types nylmethane bridges, and not only the classic Mannich-type
of ring-opening patterns may exist simultaneously. In other bridges. All these results suggest that exploring a wide range
words, the cationic part of a catalyst coordinates with of metallic compounds would be a good way to develop
oxygen or nitrogen atoms of benzoxazine to accelerate highly efficient catalyst for accelerated rate benzoxazine
ring-opening of benzoxazine, and the anionic part may play ring-opening polymerization. Moreover, it is also advanta-
a nucleophilic role meanwhile, more or less to facilitate the geous that the catalytic activity of a metallic compound can
ring-opening step. It is expected that a highly effective cat- be conveniently tuned by combination of center metals with
alyst would consist of a cationic part with a high affinity appropriate ligands. Various phenolic structures derived
towards oxygen and/or nitrogen atoms and an anionic part from the ring-opening of the oxazine ring or dimers and
with both strong nucleophilic ability and good leaving- higher oligomers in the benzoxazine monomers can actually
group properties. act as catalysts for further ring-opening polymerization
reactions, resulting in the autocatalyzed nature of benzox-
azine polymerization [20]. Some phenols have been shown
3.1 Acidic Catalysts to exhibit a good catalytic effect on the benzoxazine poly-
The majority of effective catalysts reported for accelerating merization (Fig. 2). Benzoxazine polymerization with a
benzoxazine polymerization rate are acidic catalysts, proba- strong carboxylic acid such as trifluoroacetic acid as the cat-
bly because of the nature of cationic ring-opening polymeri- alyst was found to proceed with no lag between the ring-
zation. Some representative acidic catalysts presented in the opening and aromatic electrophilic substitution steps by
literature are shown in Fig. 2. an iminium cation intermediate. [6] By comparison, amino-
Ishida et al. investigated in detail the effect of many methyl ester species are initially generated when a weak car-
potential catalysts on benzoxazine polymerization. On the boxylic acid, such as adipic acid, is used as catalyst for the
basis of comprehensive survey and studies of various cat- benzoxazine polymerization. While the dielectic constant
ionic, anionic, and radical catalysts, they proposed a cationic increases, they are transformed into the iminium ion form
ring-opening mechanism for benzoxazine polymerization of the reactive intermediate and the following electrophilic
[5]. In general, an acidic catalyst is more effective. Many attack reactions occur. In general, weak carboxylic acids
Lewis acids, such as PCl5, PCl3, POCl3, TiCl4, AlCl3, and show better performance on the benzoxazine polymeri-
MeOTf were shown to be effective for the benzoxazine zation (Fig. 2).
polymerization at moderate temperatures. Interestingly, it Yagci’s group studied the photoinitiated ring-opening cat-
was found that the BF3 Et2O complex was not an effective ionic polymerization of a monofunctional benzoxazine with
catalyst for the polymerization reaction of benzoxazine in onium salts such as diphenyliodonium hexafluorophosphate
methylene chloride solution, while BF3 2H2O complex (Ph2I+PF6-) and triphenylsulfonium hexafluorophosphate
14 PART I Synthesis and Properties of Benzoxazine Resins

FIG. 2 Representative acidic catalysts used for accelerated benzoxazine polymerization.

(Ph3S+ PF6-) [10]. Irradiation of the catalyst results in the for- possible mechanism may involve the thermal dissociation of
mation of protons. The subsequent protonation of benzoxazine these sulfonate to afford the real active species alkyl cations
can possibly occur either at oxygen or nitrogen atoms. The and/or p-toluene sulfonic acid (PTS). It is worth noticing that
structure of the polymers formed is complex and suggests a Ishida’s group reported in 1999 that TsOCH showed good
complicated polymerization mechanism. catalytic activity on cationic ring-opening polymerization of
Endo and coworkers developed several active catalyst benzoxazines [26]. (4) It was further found that more efficient
systems for accelerating benzoxazine polymerization. ring-opening polymerization of benzoxazine was achieved by
(1) Electron-deficient hexafluoroacetylacetonato (F6-acac) using a dual system composed of 2-ethyl-4-methylimidazole
complexes of manganese and iron were found to be highly (EMI) and PTS [8], which can also be considered a latent cat-
active catalysts for benzoxazine polymerization, which are alyst system, with PTS providing active protons to coordinate
moisture tolerant and harmless to the thermal stability of with oxygen or nitrogen atoms of benzoxazine, and EMI as the
the resulting polybenzoxazine [23]. (2) They first reported nucleophile to facilitate the ring opening and the following
the use of metal free and neutral aromatic urethanes rearrangement steps. (5) Recently, they demonstrated the
derived from the phenolic compounds such as resorcinol ability of simple thiophenols as catalysts for the ring-opening
and phenyl isocyanate as efficient catalysts for the poly- polymerization of benzoxazines, which was designed based
merization of benzoxazines in [24]; the possible catalytic on the reversible nature of the reaction of benzoxazines with
mechanism is presented in Scheme 4. Thermal dissociation thiols (Scheme 5) [27]. It should be noted that Gorodisher
of these urethanes may result in the formation of real active and coworkers reported in 2011 the detailed study on the reac-
species, resorcinol and phenyl isocyanate, which facilitate tions of various thiols with benzoxazines [28].
the rapid induction of the ring-opening polymerization of ben- Based on the NMR study on the ring-opening polymer-
zoxazine and finally are incorporated into the resulting poly- ization behavior of a model p-cresol-aniline-based benzox-
benzoxazine. (3) Cyclohexyl p-toluenesulfonate (TsOCH) azine under various conditions, Sebastián, Marquet, and
and neophenyl p-toluenesulfonate (TsONP) were estimated coworkers further examined the mechanistic process of ben-
as metal free and highly efficient thermally latent catalysts zoxazine polymerization and designed and studied several
for the benzoxazine ring-opening polymerization [25]. They bifunctional catalysts. Lil was found to be an extremely
do not catalyze the polymerization below 100°C while active and effective catalyst [12]. To our knowledge, it is
inducing the polymerization at elevated temperatures. The one of the most effective catalysts yet reported for the
Catalytic Accelerated Polymerization of Benzoxazines Chapter 2 15

H H
N HO OH O
Ph O O N C
Ph
+ Ph N
O O
Me Me
O N O N

Me Me

+ O
H Me C
O N +
Ph N –
Me

O N
O OH

Me
Me

O

OH OH N O
+
N Ph
N
Me Me
HO
Me Me
SCHEME 4 Plausible mechanism for the catalytic effect of urethanes on the benzoxazine polymerization.

SCHEME 5 Reversible reaction of benzoxa- –


zines with thiols. RS
+
Ph H Ph
O N O N OH OH
+
R-SH –
N SR N
RS
Me Me

Me Me Me Me

ring-opening polymerization of benzoxazines. They further DSC analysis. The corresponding mixtures of p-cresol-
established the catalytic activities of a number of different aniline-based benzoxazine with various basic catalysts were
catalysts and their effects on the structure of the final placed in a DSC and heated with a rate of 10°C/min. Fig. 3
polymer by dynamic differential scanning calorimetry shows the plots and data obtained by the DSC. Pure p-
(DSC) and NMR analysis [29]. cresol-aniline-based benzoxazine reacts with an onset tem-
perature of 261°C and a maximum temperature of 268°C,
showing its poor reactivity. All of the basic catalysts studied
3.2 Basic Catalysts exhibit catalytic effects, more or less. In cases of DBU,
Compared with numerous acidic catalysts reported for accel- PBu3, and DMAP, the heat-evolution profiles are signifi-
erating benzoxazine polymerization rate, basic catalysts have cantly shifted toward a low temperature field, and the cor-
not drawn much attention, although some amines and imid- responding onset and maximum temperatures decrease by
azoles were demonstrated to show good catalytic effect 61°C and 44°C, respectively, demonstrating their obvious
onbenzoxazine polymerization in some Japanese patents catalytic effects. By comparison, EMI shows lower catalytic
[30,31]. activity with onset and maximum temperatures at 221°C
We chose several typical basic catalysts including and 237°C, respectively. When PPh3 is used, the onset
EMI, 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), 4- and maximum temperatures are just slightly lower than that
dimethylaminopyridine (DMAP), triphenylphosphine observed with pure p-cresol-aniline-based benzoxazine,
(PPh3), and tributylphosphane (PBu3) to investigate and which might be the result of its lower nucleophilic ability.
compare their catalytic activities on ring-opening polymer- These results also suggest that basic catalysts are not as effi-
ization of the model p-cresol-aniline-based benzoxazine by cient as acidic catalysts. However, considering the different
16 PART I Synthesis and Properties of Benzoxazine Resins

6 FIG. 3 DSC plots and data of pure p-cresol-


Catalysts Tonset (°C) Tmax (°C) ΔH (KJ/mol) Exo Up
Pure monomer aniline-based benzoxazine and its mixtures
No catalyst 261 268 345 with 5 mol% of various basic catalysts.
EMI 221 237 321
4 DBU 200 226 355 PPh3
DMAP 212 224 353
PPh3 257 265 301
Heat flow (W/g)

PBu3 209 227 372 DMAP EMI


2
PBu3

DBU
0

–2

–4
0 50 100 150 200 250 300
Temperatures (°C)

catalytic patterns (Scheme 3), basic catalysts might have degree [18–20]. In the middle to later stages, the catalyst-
unique catalytic effects and result in special and valuable acceleration effect is decelerated significantly, which might
inner structures in the final polymer. Moreover, they may be caused by decreased freedom in motion of the polymer in
be used in combination with an acidic catalyst to form a dual solid state in part caused by the development of a hydrogen-
catalyst system to facilitate the accelerated benzoxazine bonding network. On the other hand, the inherently difficult
polymerization. transformation of a relatively labile phenoxy structure into a
final stable phenolic structure by rearrangement may be
another reason (Fig. 1) [8,12]. However, the nature of the
4 CATALYST EFFECTS ON catalyst has a profound influence on the progress and termi-
POLYMERIZATION MECHANISM nation mechanism of the benzoxazine polymerization. As a
AND NETWORK STRUCTURES result, different final network structures and cross-link
density may be generated with different catalysts, which
4.1 Pure Benzoxazines may allow, in principle, the tailoring of a particular structure
Benzoxazines, especially with high purity, have compara- and, therefore, the final properties of the polymer.
tively poor reactivity in the absence of catalysts, which A dual catalyst system composed of PTS and EMI was
may hinder their widespread applications. The catalyst proposed for efficient catalysis of ring-opening polymeri-
has the greatest impact on the ring-opening step and induces zation of benzoxazines (Scheme 6) [8]. PTS is advantageous
a faster benzoxazine polymerization, but it does not affect for C-O dissociation of benzoxazines, and EMI serves as a
the later processes associated with cross-linking to the same nucleophile to facilitate the C-O dissociation and to prevent

SCHEME 6 Proposed catalytic rearrangement model of the dual catalyst system comprising of PTS and EMI.
Catalytic Accelerated Polymerization of Benzoxazines Chapter 2 17

its recombination. This dual catalyst system is particularly the other hand, the coordination of Fe3+ with the oxygen
efficient for successful main-chain rearrangement of and nitrogen atom in the polybenzoxazine may increase
phenoxy into phenolic structure, because it significantly sup- the cross-link density and anchor the potentially weak moi-
presses the recombination of the iminium species into the eties, therefore improving the thermal properties of the
original phenoxy structure. This process allows the iminium polymer.
species time to move to the position for the Mannich reaction Recently, the catalytic effect on the ring-opening poly-
with the ortho position of the phenol moiety. merization of benzoxazines was compared in detail using
LiI was designed and found to be a highly active difunc- two representative acidic catalysts, 3,30 -thiodiphenol
tional catalyst for the ring-opening polymerization of (TDP) and 3,3’-thiodipropionic acid (TDA), at a variety
benzoxazines (Scheme 7). Lithium cation effectively coor- of loadings [32]. The nature of the catalyst has an obvious
dinates with oxygen or nitrogen atoms and accelerates ring- influence on the progress and termination mechanism of the
opening of benzoxazines. Iodide ion is the nucleophilic polymerization reaction and therefore the network archi-
anionic part with good leaving ability and can react with tecture and final properties of the polybenzoxazines. It
the ring-opened iminium intermediates to prevent its rapid was found that TDA better reduces the onset of polymeri-
recombination with the phenolate (Scheme 7) [12]. This zation and improves cross-link density and thermal prop-
synergistic effect is also highly efficient for the rearran- erties (Tg and thermal stability) of the polybenzoxazine.
gement of phenoxy into phenolic structures. Because TDA (pKa ¼ 4.1) is a stronger acid than TDP
The effect of various catalysts on the ring-opening poly- (pKa ¼ 6.6), it is reasonable that TDA shows higher catalytic
merization and structure of a simple-model p-cresol-aniline- activity on the benzoxazine polymerization and induces a
based benzoxazine was further investigated by qualitatively faster ring opening of benzoxazine. On the basis of vibra-
analyzing the shape of signal at 4.0–3.5 ppm in 1H NMR tional spectroscopic analysis, the thermal polymerization
spectra caused by phenolic CH2 units of the final polymer and TDP-catalyzed polymerization of benzoxazines
[29]. Several typical catalysts were chosen to study how a conform to a similar polymerization mechanism, and the
catalyst can affect the structure of the final polymer resulting polymer network has similar cross-link density
structure. The polymerization of p-cresol-aniline-based and glass transition temperatures. By comparison, the
benzoxazine were carried out in the presence of 1 mol% ring-opening polymerization of benzoxazine with TDA pro-
of various catalysts at 180°C for 2 h, and the structure of gresses via a different mechanism. After faster ring opening
the phenolic polymer was compared by analyzing their 1H of more benzoxazine monomers, the chain propagation is
NMR spectra in DMSO-d6. As can been seen in Fig. 4, more cluster-like (less linear) before cross-linking, leading
except for the Mannich phenolic CH2 units, more complex to more reaction sites and a higher cross-link density and a
types of phenolic CH2 units such as arylamine Mannich phe- subsequently higher Tg. In addition, we propose that the
nolic CH2 units, general phenolic CH2 units, and arylamine higher acidity of TDA might result in deactivation of the
general phenolic CH2 units, may exist with different cata- phenol ring of benzoxazine toward active cationic interme-
lysts. As a result, the amounts and type of phenolic CH2 diates and, consequently, more reactions of the active inter-
units might be adjusted by using an appropriate catalyst. mediates on the arylamine ring of benzoxazine. This change
It was reported in 2012 that in the presence of FeCl3, of reaction path further increases the cross-link density and,
ring-opening polymerization of benzoxazines proceeds therefore, the thermal properties of the polybenzoxazine.
effectively to generate the arylamine Mannich phenolic The effect of catalyst loading is initially really obvious
structure in the polybenzoxazine because the coordination but reaches on apparent plateau at 10–15 mol%, and the
of Fe3+ with the oxygen atom decreases reactivity of phenol addition of >15 mol% of catalyst had a negative effect on
ring and makes the cross-linking reactions occur on the the cross-link density, Tg and thermal stability of the
paraposition of aniline [17]. This arylamine Mannich polymer. Although the conclusion was made on the basis
structure can delay degradation of the aniline moiety and of the experimental results without any plausible expla-
improve the thermal properties of polybenzoxazine. On nation, we suppose that the catalyst added may act, in part,

Nucleophile
I
δ+
R Li δ– δ+ R OLi Benzoxazine
O N O N monomer
LiI Polybenzoxazine
Coordination N I
R
Leaving group
SCHEME 7 Possible mechanism for LiI-catalyzed ring-opening polymerization of benzoxazines.
18 PART I Synthesis and Properties of Benzoxazine Resins

OH OH
I
N

Me Me I : Mannich phenolic CH2 units


OH
IV II II: Arylamine Mannich phenolic CH2 units
N
III: General phenolic CH2 units
OH IV: Arylamine general phenolic CH2 units
Me III
Me
OH

Me

CH2(I,II)
(a) Standarda

(b) PTS

(c) EMI
CH2(III,IV)
(d) LiI
CH2(III,IV)
(e) LiBr
CH2(III,IV)
(f) LiOTf
CH2(III,IV)
(g) Al(OTf)3

(h) NH4I

(i) ZnCl2

9 8 7 6 5 4 3 2 PPM
FIG. 4 1H NMR spectra in DMSO-d6 of thermally cured mixtures of p-cresol-aniline-based benzoxazine with 1 mol% various catalysts at 180°C for 2 h.
a
Polymer obtained by thermal polymerization of p-cresol-aniline-based benzoxazine at 20°C for 4 h. (Reproduced with permission from C. Liu, D. Shen,

R.M. Sebastián, J. Marquet, R. Schonfeld, Catalyst effects on the ring-opening polymerization of 1,3-benzoxazine and on the polymer structure, Polymer
54 (2013) 2873–2878.

as a terminator by its own reaction with the active interme- different inner structure and poor properties. As shown in
diates. When its loading is too high (>15 mol%) in the Scheme 8, (1) the ring-opening polymerization of benzoxa-
system, the chain propagation process may be disturbed zines performed at lower temperatures (typically < 160°C)
or even prevented, which decreases the cross-link density under a catalyst provides polybenzoxazine with more
and consequently reduces the Tg and thermal stability of complex inner structures because at lower temperatures
the resulting polymer. Moreover, too much loading amount and in the presence of a catalyst, more ring-opening patterns
of the catalyst may result in the polymer degradation issue. seem to be available, resulting in three main intermediates:
Decreasing the benzoxazine polymerization temperature A, B and C. The following aromatic electrophilic substi-
is highly desirable and, by using various catalysts, different tution reactions of these active intermediates operate by
degrees of success have been achieved. However, in view of O-attack, N-attack, and Aryl-attack patterns with low selec-
the previous discussion, polymerization temperature is still tivity, affording various phenoxy or phenolic structures. The
an important factor for obtaining polybenzoxazine with polybenzoxazine obtained commonly possesses relatively
good properties. Although benzoxazines can polymerize poor properties because of less Mannich phenolic structure
under lower temperatures with extended reaction time by units generated, which is thought to account for many
using a catalyst, the corresponding polymers may possess unusual properties of polybenzoxazine by forming the very
Catalytic Accelerated Polymerization of Benzoxazines Chapter 2 19

SCHEME 8 Proposed polymerization temperature and catalyst effect on benzoxazine polymerization mechanism and inner structure of polybenzoxazine.

stable six-membered hydrogen bond [33,34]. More impor- physical cross-link points. To further improve the pro-
tantly, the chain propagation process possibly faces more cessing and properties of polybenzoxazine, it has been
difficulty at lower temperatures because of the competing reported that copolymerization of benzoxazines with
intramolecular six-membered ring hydrogen bonding for- epoxies may improve the cross-link density and inner
mation [35,36]. Monofunctional benzoxazines cannot structure of polybenzoxazines by the reaction of the phe-
provide a large molecular-weight linear polybenzoxazine. nolic hydroxyl groups from the ring opening of benzoxazine
(2) However, when the benzoxazine polymerization is monomers with epoxy groups, and therefore enhance
carried out at higher temperatures (typically > 180°C), thermal and mechanical properties [37]. Investigation of
O-CH2 bonds of the benzoxazine monomers may be in com- the polymerization behavior of a benzoxazine-epoxy blend
plete or partial dissociation state, and ring opening of the suggests that the copolymerization of benzoxazine and
benzoxazines selectively generates the thermodynamically epoxy resins occurs at high temperatures after the polymer-
more stable intermediate A. The following aromatic electro- ization reaction of benzoxazines [38]. Thus it is valuable for
philic substitution reactions of intermediate A mainly are O- practical applications to use catalysts to accelerate the copo-
attack or Aryl-attack type electrophilic reactions, providing lymerization reaction rate at lower temperatures and reduce
only Mannich phenoxy and Mannich phenolic structures. the copolymerization time. Notably, the catalysts effective
The subsequent fast rearrangement of Mannich phenoxy for the benzoxazine polymerization, especially acidic cata-
structure into Mannich phenolic structure proceeds at higher lysts, commonly show weakened catalytic effects on the
temperatures. Moreover, the chain propagation process goes benzoxazine-epoxy blend, because they may be deactivated
smoothly at higher temperatures as well. As a result, the final because of their coordination with epoxy groups.
polybenzoxazine has larger amounts of Mannich phenolic During the polymerization of a benzoxazine-epoxy
structure with better network development and therefore blend in the presence of a catalyst, three types of reactions
might possess better properties. Notably, too high polymeri- may occur including benzoxazine homopolymerization,
zation temperature may destroy the inner hydrogen-bonding epoxy homopolymerization ,and benzoxazine-epoxy copo-
interaction and lead to polymer degradation. In brief, when lymerization (Scheme 9). Different catalysts can be used to
conducting the polymerization of benzoxazines in practical selectively polymerize the blend components, to control the
applications, we should appropriately choose the polymeri- polymerization kinetics of the individual components in the
zation temperature, polymerization time, and catalyst to benzoxazine-epoxy blend to a degree by choosing the appro-
achieve the best cost/performance ratio. priate catalyst. Depending on the catalyst and the blend com-
position, the inner structure of the resulting polymer can be
varied, and a predominantly interpenetrating network of
4.2 Benzoxazine-Epoxy Blends
homopolymers or grafted copolymer structure may be gen-
Despite their excellent properties, polybenzoxazines possess erated, which allows the final properties to be tailored as
surprisingly low chemical cross-link density in comparison desired [39].
with the ordinary thermosetting resins, and the molecular The copolymerization of a bisphenol A-based
origin of their unusual properties originate from large benzoxazine-epoxy blend in the presence of a thermolatent
amounts of complex hydrogen bonds [33,34] that act as catalyst (the salts of p-toluenesulfonic acid and amines) was
20 PART I Synthesis and Properties of Benzoxazine Resins

R SCHEME 9 Three types of polymerization


OH
O N reactions in a benzoxazine-epoxy blend in the
Δ or Catalyst N presence of a catalyst.
n
(1) R
Benzoxazine homopolymerization

O Catalyst O H
n
(2) CH2R H
CH2R
m
Epoxy homopolymerization
O CH2R

R
OH O
O N
Δ or Catalyst N
Epoxy
N
(3) n Δ or Catalyst n
R R
Benzoxazine-epoxy copolymerization

found to occur more rapidly and led to a resulting polymer of benzoxazines and how a catalyst influences the devel-
with superior mechanical properties than those from opment of networks and inner structure of the resulting
benzoxazine-epoxy blend without a catalyst. This was the polymer. This understanding will help to find desired cata-
result of a higher cross-link density [40]. Nevertheless, lysts that can provide polybenzoxazines with good prop-
study of the copolymerization of benzoxazine-epoxy blend erties at lower temperatures and reduced reaction time.
in the presence of EMI suggests that EMI-catalyzed homo-
polymerization of the epoxy occurs at lower temperatures,
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