Synthesis and Properties of Cardanol-Based Epoxidized Novolac Resins Modified with Carboxyl-Terminated Butadiene-Acrylonitrile Copolymer

Cardanol-based, novolac-type phenolic resins were synthesized with a cardanol-to-formaldehyde molar ratio of 1 : 0.7 with different dicarboxylic acid catalysts, including oxalic and succinic acids. These novolac resins were epoxidized with a molar excess of epichlorohydrin at 120 degrees C in a basic medium. The epoxidized novolac resins were separately blended with different weight ratios of carboxyl-terminated butadiene-acrylonitrile copolymer (CTBN) ranging between 0 and 20 wt % with an interval of 5 wt %. All of the blends were cured at 120 degrees C with a stoichiometric amount of polyamine. The formation of various products during the synthesis of the cardanol-based novolac resin and epoxidized novolac resin and the blending of the epoxidized novolac resin with CTBN was studied by Fourier transform infrared spectroscopy analysis. Furthermore, the products were also confirmed by proton nuclear magnetic resonance and matrix-assisted laser desorption/ionization time-of-flight mass spectroscopy analysis. The molecular weights of the prepared novolacs and their epoxidized novolac resins were determined by gel permeation chromatography analysis. The blend samples, in both cases, with 15 wt % CTBN concentrations showed the minimum cure times. These blend samples were also the most thermally stable systems. The blend morphology, studied by scanning electron microscopy analysis, was, finally, correlated with the structural and property changes in the blends. (C) 2009 Wiley Periodicals, Inc. J Appl Polym Sci 114: 1670-1681, 2009