materials Article Epoxy Resins Toughened with Surface Modified Epoxidized Natural Rubber Fibers by One-Step Electrospinning Joo Ran Kim 1 and Jung J. Kim 2, * 1 2 * Fiber Science, Cornell University, Ithaca, NY 14853, USA; [email protected] Department of Civil Engineering, Kyungnam University, Changwon-si 51767, Korea Correspondence: [email protected]; Tel.: +82-55-249-6421 Academic Editor: Nicole Zander Received: 4 April 2017; Accepted: 25 April 2017; Published: 27 April 2017 Abstract: Epoxidized natural rubber fibers (ERFs) are developed through one-step electrospinning and directly deposited into epoxy resins without collecting and distributing of fibers. The shape of ERFs shows rough surface due to different evaporation rate of solvent mixture consisting of chloroform and dichloromethane and the average diameter of ERFs is 6.2 µm. The increase of ERFs loading from 0 to 20 wt % into the epoxy resin increases the fracture strain significantly from 1.2% to 13% and toughness from 0.3 MPa to 1.9 MPa by a factor of 7. However, the tensile strength and Young’s modulus decrease about 34% from 58 MPa to 34 MPa and from 1.4 GPa to 0.9 GPa, respectively. Due to the crosslinking reactions between oxirane groups of ERFs and amine groups in the resin, surface roughness and the high aspect ratio of ERFs, ERFs result in more effective toughening effect with the minimum loss of tensile properties in epoxy resins. Keywords: natural rubber fibers; epoxy resin; toughening; surface modification 1. Introduction Electrospinning as an efficient and versatile technology has been developed for generating ultrafine fibers in a variety of materials, such as polymers, inorganic materials, and hybrid materials [1]. These fibers or non-woven fibrous membranes exhibit diameters ranging from a few nanometers to a few micrometers and have advantages of large surface area-to-volume ratios and various morphological modifications [2]. Electrospinning system typically consists of three basic components: a high voltage supply, a Taylor cone and a metal collector [3]. The electrodes contain a high voltage supply, with one connected to the polymer solution being metered and the other connected to the collector. As electrostatic repulsion counteracts the surface tension on the Taylor cone, the polymer solution is stretched to draw threads [4]. This stretched polymer solution evaporates the solvent to form solid fibers before fibers reach to the collector [5]. During electrospinning, the morphology or mechanical properties can be easily modified by tuning many parameters such as polymer concentration, distance between a Taylor cone and a collector, applied voltage, syringe feeding rate, etc. depending on applications such as biomaterials, reinforcement, barrier textiles and toughening [6–9]. Among these applications, brittle thermoset resins have been studied to increase the material toughness using electrospinning technique [7]. Epoxy resins toughened with electrospun polysulfone nanofibers showed an increase in fracture toughness (GIC ) of 158%, 261% and 281% at 1, 3 and 5 wt % of fiber loadings, respectively [10]. The epoxy reinforced with carbon fibers composite showed 100% improvement in fracture toughness as 20% polycaprolactone nanofiber was incorporated into the epoxy composites to increase the interlaminar fracture toughness [11]. Electrospun poly(vinyl pyrrolidone)/tetraethyl orthosilicate/silica nanoparticle nanofibers (2% loading) improved the Materials 2017, 10, 464; doi:10.3390/ma10050464 www.mdpi.com/journal/materials Materials 2017, 10, 464 2 of 13 fracture toughness by 1.9 times that of neat polypropylene resin [12]. Nanofibers composed of styrene-butadiene-styrene (SBS) block copolymer as a rubbery core and polyacrylonitrile (PAN) as a hard sheath have been produced via coaxial electrospinning, and can be used to improve the toughness of epoxy matrix increased impact energy up to 150% [13]. Many studies have investigated improving toughness of epoxy resin using synthetic copolymers and metal derivatives as toughening agents such as carboxyl-terminated acrylonitrile butadiene, synthetic ductile polymers such as the acrylic rubber, hydroxy-terminated butadiene or acrylonitrile butadiene, epoxy-terminated acrylonitrile butadiensbse, epoxy-terminated butadiene and amine-terminated acrylonitrile butadiene [14–17]. However, little research has been conducted on eco-friendly toughening agents to improve brittle epoxy resins. For example, epoxy resins with 60% functionalized green halloysite nanotubes resulted in increased impact strength to about 5.8 kJ m−2 , 1.5 times that of neat epoxy resin even metal conductivity of 0.85 W m−1 K−1 [18]. After adding 10% hyperbranched polyurethane into epoxy resins, the impact strength was increased to triple the amount of neat epoxy [19]. In another example, silicone skeleton was used as a toughening agent added into the epoxy resin, showing increased impact, flexural and tensile strength of epoxy resin by about 92.5%, 36.0% and 88.6%, respectively, compared to neat epoxy resin [20]. The problem in ductile toughening agents is that most resins experience a decline in their tensile properties with the addition of ductile materials. Hence, good interfacial bonding via chemical reactions between the matrix and the toughening agent has been an active research area in order to improve the toughness without loss of tensile properties in the matrix. For example, as 0.5 wt % dodecane functionalized tannic acid incorporated into epoxy resin as the toughening agent increased the impact strength by up to 196% compared to that of neat epoxy [21]. This tendency was due to good interfacial bonding between terminal hydroxyl groups of dodecane functionalized tannic acid and the epoxy matrix [21]. Glycerol (10 wt %) was used to improve toughness of poly(lactic acid) (PLA) matrix, resulting in strain at break of up to 93% and fracture stress of 48 MPa compared to neat PLA matrix with strain at break of 2.3% and fracture stress of 64 MPa. Again, this trend is due to esterification reaction occurring at the interface between the hydroxyl groups of glycerol and the carboxylic groups of PLA [22]. Eco-friendly natural toughening agents such as epoxidized natural rubber (ENR) and liquid natural rubber have been found to be effective in improving the toughness in brittle resins because of functional groups such as oxirane groups or hydroxyl groups [23–25]. One explanation is that the oxirane groups of ENR are able to react with carboxyl, amine, glycidyl and hydroxyl groups of matrices, crosslinking with ENR to offer good interfacial bonding in the matrix [26]. One example is biodegradable PLA matrix and ENR blend via chemical reactions between oxirane groups and carboxylic groups, resulting in improved toughness and tensile properties [27,28]. The primary objectives of this study were to develop micro-sized green elastic ENR fibers (ERFs) with surface modification through one-step electrospinning. Figure 1 shows the one-step electrospinning system developed in this study for the ERFs production and concurrently distribution of ERFs with epoxy resin. ERF loading was varied at 5, 10, 15 and 20 wt % into epoxy resins (E-ERF 5, E-ERF 10, E-ERF 15 and E-ERF 20, respectively) and its effect on toughness and other mechanical properties was analyzed. Materials 2017, Materials 2017, 10, 10, 464 464 Materials 2017, 10, 464 of 13 13 33 of 3 of 13 Figure 1. One-step electrospinning to prepare ERFs into epoxy resins. Figure Figure 1. 1. One-step One-step electrospinning electrospinning to to prepare prepare ERFs into epoxy resins. 2. Results and Discussion 2. 2. Results Results and and Discussion Discussion Figure 2 shows the morphology of ERFs produced using 1% ENR polymer concentration. Figure shows morphology of produced using 1% ENR polymer concentration. Figureof22 diameter shows the the of ERFs ERFs produced using polymer concentration. The range of morphology ERFs varied from 1.6 µm to 13 µm and1% theENR average diameter of ERFs is The range of diameter of ERFs varied from 1.6 µm to 13 µm and the average diameter of of ERFs is The of diameter from 1.6 µm to 13displays µm and bumpy the average diameter ERFs aboutrange 6.2 µm as shown of in ERFs Figurevaried 2a. The surface of ERFs (spines-like) and rough about 6.2 µm as shown in Figure 2a. The surface of ERFs displays bumpy (spines-like) and rough is about µm as 2a. The surface of ERFs bumpy (spines-like) and rough edges as 6.2 shown in shown Figure in 2b.Figure This morphology is related to displays a rapid evaporation of the solvent while edges as shown shown in inFigure Figure2b. 2b.This Thismorphology morphologyisisrelated related to a rapid evaporation of the solvent while edges as to a rapid evaporation of the solvent the fibrous jet is accelerated to the metal collector. Megelski et al. [29] have studied the while effectthe of the fibrous jet is accelerated tometal the metal collector. Megelski et al. [29] have studied the effect of fibrous jet is accelerated to the collector. Megelski et al. [29] have studied the effect of different different solvents such as acetone, chloroform, tetrahydrofuran and their mixtures on the morphology different solvents such as chloroform, acetone, chloroform, tetrahydrofuran and their mixtures on the morphology solvents as polyethylene acetone, tetrahydrofuran and their mixtures on the morphology of fibers. of fibers.such When glycol (PEO) was spun from chloroform displayed rougher surface of of fibers. When polyethylene glycol (PEO) was spun from chloroform displayed rougher surface of When polyethylene glycol (PEO) spun [29]. fromSimilar chloroform displayed fibers than fibers than other fibers used otherwas solvents studies showedrougher that thesurface boilingof temperature fibers than other fibers other solvents [29]. Similar studies showed that the boiling temperature other fibers used other used solvents [29]. Similar studies that the[30]. boiling temperature ofshowed solvent of solvent was associated with surface roughness andshowed diameter size Electrospun fibers of solvent was associated with surface roughness andsize diameter size [30]. Electrospun fibers showed was associated with surface roughness and diameter [30]. Electrospun fibers showed an increase an increase in surface roughness and pores with increasing boiling point of the solvent mixture since an increaseroughness in surface and roughness and increasing pores withboiling increasing boiling of the solvent mixture since in surface pores with point of [30]. thepoint solvent mixture since thein boiling the boiling temperature is related to volatility of solvents As ENR is dissolved only the boiling temperature is related to volatility of solvents [30]. As ENR is dissolved in only temperature is related to volatility of solvents [30]. As ENR is dissolved in only dichloromethane dichloromethane while keeping other parameters constant, ERFs display smooth surface. As the dichloromethane while keepingconstant, other parameters constant, ERFs display smooth surface. As the while keeping other parameters ERFs display smooth surface. As for the mixture of chloroform mixture of chloroform and dichloromethane was used as the solvent ENR, the mixture of mixture of chloroform and dichloromethane was used as the solvent for ENR, the mixture of and dichloromethane usedroughness as the solvent forstudy. ENR, the mixture of solvents solvents influences thewas surface in this Since ERFs are directly influences deposited the intosurface epoxy ◦ solvents influences the surface roughness in this study. Since ERFs are directly deposited into epoxy roughness in this study. Since ERFs are directly deposited into resins heated at 40 C boiling during resins heated at 40 °C during electrospinning, the mixture ofepoxy two solvents has different resins heated at 40 °C during electrospinning, the mixture of two solvents has different boiling electrospinning, of two different (T boiling temperature (Tboiling rate b ) and volatility temperature (Tb)the andmixture volatility ratesolvents becausehas chloroform b: 61 °C) has higher temperature ◦ C) has ◦ C) [29]. temperature (Tb) and(Tvolatility ratehigher because chloroform (Tb: 61than °C) dichloromethane has higher boiling temperature because chloroform : 61 boiling temperature (T : 39 b b than dichloromethane (Tb: 39 °C) [29]. than dichloromethane (Tb: 39 °C) [29]. Figure 2. The morphology of micro-sized ERFs produced using 1% ENR polymer concentration. Figure 2. 2. The The morphology morphology of of micro-sized micro-sized ERFs ERFs produced produced using using 1% 1% ENR ENR polymer polymer concentration. concentration. Figure The internal structures of ERFs are shown in Figure 3. Left images are all brightfield images, The internal structures of ERFs are shown in Figure 3. Left images are all brightfield images, whereas right images are fluorescent images that indicate the presence of ENR stained with a whereas right images are fluorescent images that indicate the presence of ENR stained with a Materials 2017, 10, 464 4 of 13 The internal structures of ERFs are shown in Figure 3. Left images are all brightfield images, Materials 2017, 10, 464 4 of 13 whereas right images are fluorescent images that indicate the presence of ENR stained with a fluorescent The ERFs ERFs produced produced using fluorescent dye, dye, appearing appearing green green colored. colored. The using 1% 1% polymer polymer concentration concentration have long rod, non-porous, and rough surface, as shown in Figure 3a,c. A close examination have long rod, non-porous, and rough surface, as shown in Figures 3a,c. A close examination of of the the white square area in Figure 3a,b demonstrates the rough surface at the edges of the ERFs. Their white square area in Figures 3a,b demonstrates the rough surface at the edges of the ERFs. green Their color that thethat ERFs areERFs composed of ENR and have rough edges as shown 3b,d. greenindicates color indicates the are composed of ENR and have rough edgesinasFigure shown in The weak green signal indicates ERFs have smaller diameter or thinner region of ENR (less ENR Figures 3b,d. The weak green signal indicates ERFs have smaller diameter or thinner region of ENR concentration); however, the strongthe green signal indicates larger diameter or thickerorarea of ERFs. (less ENR concentration); however, strong green signal indicates larger diameter thicker area The results from a Confocal laser scanning microscopy (CLSM) images confirm the morphology of of ERFs. The results from a Confocal laser scanning microscopy (CLSM) images confirm the ERFs as shown in SEM results in Figure 2. morphology of ERFs as shown in SEM results in Figure 2. Figure 3. 3. The ENR concentration concentration by by Figure The internal internal structures structures of of micro-sized micro-sized ERFs ERFs produced produced using using 1% 1% ENR CLSM: (a) the brightfield image of ERFs; (b) the fluorescent image of ERFs at low magnification; CLSM: (a) the brightfield image of ERFs; (b) the fluorescent image of ERFs at low magnification; (c) the the brightfield brightfield image image of of the the white white square square area; area; (d) (d) the the fluorescent fluorescent image image of of the the white white square square area area (c) (green color corresponds to ENR stained with fluorescent dye). (green color corresponds to ENR stained with fluorescent dye). Figure 4 shows attenuated total reflection Fourier transform infrared spectroscopy (ATR-FTIR) Figure 4 shows attenuated total reflection Fourier transform infrared spectroscopy (ATR-FTIR) spectra of neat ERFs, neat epoxy and all E-ERF resins. Neat epoxy specimen shows transmittance spectra of neat ERFs, neat epoxy and all E-ERF resins. Neat epoxy specimen shows transmittance peaks at 860 cm−1 (epoxy C–O–C ring deformation) [31], 1020–1250 cm−−11 range (C–N stretching), peaks at−1860 cm−1 (epoxy C–O–C ring deformation) [31], 1020–1250 cm range (C–N stretching), −1 (CH and CH2 deformation), 1528 cm−1 (NH stretching) and 2862–2937 cm−1 1375 cm−1 and 1494 cm− 1 1375 cm and 1494 cm (CH and CH2 deformation), 1528 cm−1 (NH stretching) and−12862–2937 cm−1 range (CH and CH3 asymmetric stretching) [32]. The broad peak around 1600 cm corresponds to range (CH and CH3 asymmetric stretching) [32]. The broad peak around 1600 cm−1 corresponds to NH2 bending of excess amine group from the curing agent in the epoxy resin. Neat ERFs NH2 bending of excess amine group from the curing agent in−1the epoxy resin. Neat ERFs transmittance transmittance peaks at 751 cm−1, 852 cm−1 and 1246 cm corresponding to the oxirane groups − 1 − 1 peaks at 751 cm , 852 cm and 1246 cm−1 corresponding to the oxirane groups appeared in the appeared in the spectra [24]. spectra [24]. The E-ERF resins show additional peak at 3000–3600 cm−1 range to indicate the presence of hydroxyl groups (–OH) produced by crosslinking reaction between oxirane groups of epoxy resin or ENFs and amine of the curing agent, as shown in Figure 4b. The oxirane group is shown to open up during curing process and the reaction product is secondary amines with hydroxyl groups [33]. Two hydroxyl groups of secondary amines can react further to form ether linkages [33]. In Figure 4a, the Materials 2017, 10, 464 5 of 13 The E-ERF resins show additional peak at 3000–3600 cm−1 range to indicate the presence of hydroxyl groups (–OH) produced by crosslinking reaction between oxirane groups of epoxy resin or ENFs and amine of the curing agent, as shown in Figure 4b. The oxirane group is shown to open Materials 2017, 10, 464process and the reaction product is secondary amines with hydroxyl groups [33]. 5 of 13 up during curing Two hydroxyl groups of secondary amines can react further to form ether linkages [33]. In Figure 4a, reaction between oxirane groups of ERFs or epoxy resinresin and and excess amine of theofcuring agentagent shows the reaction between oxirane groups of ERFs or epoxy excess amine the curing −1 range − 1 peak at 1020–1250 cm corresponding to C–N linkages [34]. The increase of ERFs loading into shows peak at 1020–1250 cm range corresponding to C–N linkages [34]. The increase of ERFs loading −1 −1 range), epoxy resin shows C–N (1020–1250 (1020–1250cm cm range), C–O–C C–O–C(ether (etherstretching stretching into epoxy resin showsincrease increaseininpeaks peaks of of C–N −1) and –OH (3000–3600 cm −1), as shown in Figure 4a. The increased transmittance − 1 − 1 vibration at 945 cm vibration at 945 cm ) and –OH (3000–3600 cm ), as shown in Figure 4a. The increased transmittance peaks demonstrate that E-ERF resins show additional crosslinking reactions between oxirane group peaks demonstrate that E-ERF resins show additional crosslinking reactions between oxirane group of of ERFs and excess amine or hydroxyl group in epoxy resins [35]. ERFs and excess amine or hydroxyl group in epoxy resins [35]. Figure4. 4.(a) (a)ATR-FTIR ATR-FTIRspectra spectraofofneat neatepoxy epoxyresin, resin,neat neatERFs ERFsand andallallE-ERF E-ERFresins; resins;(b) (b)possible possible Figure reactions between oxirane group amine to form the secondary amines with hydroxyl reactions between oxirane group andand amine to form the secondary amines with hydroxyl groupsgroups and and two secondary amines form ether linkages in epoxy resin. two secondary amines form ether linkages in epoxy resin. Figure 5 presents differential scanning calorimetry (DSC) thermograms of neat epoxy, neat Figure 5 presents differential scanning calorimetry (DSC) thermograms of neat epoxy, neat ERFs, ERFs, and all E-ERF resins at different loading of ERFs scanned from −50◦ to 200 °C. In the present and all E-ERF resins at different loading of ERFs scanned from −50 to 200 C. In the present study, study, neat ERFs show Tg1 (glass transition temperature of ENR) at −25 °C, whereas neat epoxy neat ERFs show Tg1 (glass transition temperature of ENR) at −25 ◦ C, whereas neat epoxy matrix matrix shows Tg2 (glass transition temperature of epoxy resin) at 55 °C. E-ERF resins, however, show shows Tg2 (glass transition temperature of epoxy resin) at 55 ◦ C. E-ERF resins, however, show little little change in Tg1 from −28 to −25 °C but significant change in Tg2 from 55 to 65 °C as ERFs loading change in Tg1 from −28 to −25 ◦ C but significant change in Tg2 from 55 to 65 ◦ C as ERFs loading increases from 0 to 20 wt %. At 5 wt % loading of ERFs in epoxy resin, there is little increase in Tg2. increases from 0 to 20 wt %. At 5 wt % loading of ERFs in epoxy resin, there is little increase in Tg2 . However, with the 10% addition of ERFs, Tg2 increases by 7 °C. This increasing trend continues with However, with the 10% addition of ERFs, Tg2 increases by 7 ◦ C. This increasing trend continues with ERFs loading of 15 and 20 wt % in epoxy resins to 63 and 65 °C, respectively. This trend is attributed ERFs loading of 15 and 20 wt % in epoxy resins to 63 and 65 ◦ C, respectively. This trend is attributed to cross-linking reactions between oxirane group of ERFs and excess amine or hydroxyl group in to cross-linking reactions between oxirane group of ERFs and excess amine or hydroxyl group in epoxy resins to create a 3D cross-linking structure. These cross-links increase the chain length and epoxy resins to create a 3D cross-linking structure. These cross-links increase the chain length and interactions between chains, resulting in limited freedom to rotate about the bonds and interactions between chains, resulting in limited freedom to rotate about the bonds and consequently, consequently, increases the Tg2 temperature of E-ERF resins [36,37]. The finding is in line with the increases the Tg2 temperature of E-ERF resins [36,37]. The finding is in line with the observations observations made by Thomas et al. [38] for epoxy resin toughened with liquid natural rubber. Other made by Thomas et al. [38] for epoxy resin toughened with liquid natural rubber. Other researchers researchers showed this shift of Tg with increasing loading concentrations of liquid rubber [39]. They showed this shift of Tg with increasing loading concentrations of liquid rubber [39]. They explained explained that the addition of liquid natural rubber into the epoxy resin increased the curing that the addition of liquid natural rubber into the epoxy resin increased the curing temperature by temperature by allowing crosslinking reactions to occur between the epoxy resin and hydroxyl or allowing crosslinking reactions to occur between the epoxy resin and hydroxyl or carboxylic groups carboxylic groups of rubber [40]. of rubber [40]. Materials 10, 464 Materials 2017,2017, 10, 464 Materials 2017, 10, 464 66ofof1313 6 of 13 Figure 5. DSC thermograms of neat ERFs, neat epoxy and all E-ERF resins. Figure 5. DSC thermograms neatERFs, ERFs,neat neatepoxy epoxyand andall all E-ERF E-ERF resins. Figure 5. DSC thermograms ofof neat Figure 6 presents dynamic mechanical analysis (DMA) plots of E-ERF resins scanned from −50 to Figure 6 presents dynamic mechanical analysis (DMA) plots of E-ERF resins scanned from −50 to 100 °C. storagedynamic modulusmechanical (E′) of E-ERFanalysis resins is plotted a function of temperature in Figure 6a.−50 to Figure 6The presents (DMA)asplots of E-ERF resins scanned from 100 °C.storage The storage modulus (E′) of resin E-ERF resins is plotted aswhereas a function of resins temperature in Figure 6a. ◦ 0 The modulus of neat epoxy shows nearly 5 GPa, E-ERF display around 100 C. The storage modulus (E ) of E-ERF resins is plotted as a function of temperature in Figure 6a. The of neat resins, epoxyas resin shows nearly 5 GPa, whereas E-ERF resins display around 4.5storage GPa.modulus In modulus the caseofofneat E-ERF the temperature there is aE-ERF sharp decrease in storage The storage epoxy resin shows nearlyincreases, 5 GPa, whereas resins display around 4.5modulus GPa. In starting the casearound of E-ERF as the temperature there is a sharp decrease storage −28resins, °C, corresponding to Tg1 of increases, ENR. The E′ for neat ENR resin showsinthe 4.5 GPa. In the case ofaround E-ERF−28 resins, as the temperature increases, there is aneat sharp decrease in storage modulus starting corresponding to Tg1E-ERF of ENR. The E′ for ENR resin shows final storage modulus close to°C, 0 MPa at 60 °C, whereas resins show E′ values above 4 GPa at the ◦ C, corresponding to T of ENR. The E0 for neat ENR resin shows the modulus starting around − 28 g1 final storage modulus close to 0 MPa at 60 °C, whereas E-ERF resins show E′ values above 4 GPa at 60 °C. ◦ 0 ◦ final60 storage °C. modulus close to 0 MPa at 60 C, whereas E-ERF resins show E values above 4 GPa at 60 C. Figure 6. DMA plots of neat epoxy resin, neat ENR sheet, and E-ERF resins at different loading of ERFs in the temperature range of −50 to 100 °C: (a) the storage modulus; and (b) the tan δ curves. Figure 6. DMA of neat epoxy sheet, and E-ERF resins at different loading of Figure 6. DMA plotsplots of neat epoxy resin,resin, neat neat ENRENR sheet, and E-ERF resins at different loading of ERFs ◦ ERFs in the temperature range of −50 to 100 °C: (a) the storage modulus; and (b) the tan δ curves. in the temperature range of −50 to 100 C: (a) the storage modulus; and (b) the tan δ curves. Materials 2017, 10, 464 7 of 13 Materials 2017, 10, 464 7 of 13 The mechanical factor (tan (tan δ) plots E-ERF areresins shownare in Figure 6b.in TheFigure intermolecular The mechanicalloss loss factor δ) for plots forresins E-ERF shown 6b. The interactions between ENR and epoxy resin brought about different altering trends of T ENR g because intermolecular interactions between ENR and epoxy resin brought about different altering trends of ◦C is at elastic state whereas rigid epoxy resin stays at glassy state. The tan δ peak at around − 25 Tg because ENR is at elastic state whereas rigid epoxy resin stays at glassy state. The tan δ peak at represents of therelaxation neat ENR.ofAs ERFs increases from 0 increases to 20 wt %, the 0Tg1 of around −25relaxation °C represents the neatloading ENR. As ERFs loading from to values 20 wt %, ◦ C; however, T values of E-ERF resins increase from E-ERF resins decrease slightly from − 28 to − 25 g2 °C; however, Tg2 values of E-ERF the Tg1 values of E-ERF resins decrease slightly from −28 to −25 ◦ C. The reason is that the chemical crosslinking reactions between oxirane groups of ENR 51 to 65 resins increase from 51 to 65 °C. The reason is that the chemical crosslinking reactions between and excess crosslinking epoxycrosslinking resin occur and result long molecular chain offerinhigher oxirane groups of ENRagent andinexcess agent in in epoxy resin occur andand result long than intermolecular hydrogen bonding. Therefore, free motion of epoxy molecular chain segments molecular chain and offer higher than intermolecular hydrogen bonding. Therefore, free motionare of restrained, whichchain results in an increase of Tg2 [41,42]. epoxy molecular segments are restrained, which results in an increase of Tg2 [41,42]. Figure 7. SEM images of fracture surface in tensile mode: (a) the fracture surface of neat epoxy resin; Figure 7. SEM images of fracture surface in tensile mode: (a) the fracture surface of neat epoxy resin; (b) the fracture surface of E-ERF 10 resins; (c,d) the top surface of E-ERF 10 resin; (e) bridging zone of (b) the fracture surface of E-ERF 10 resins; (c,d) the top surface of E-ERF 10 resin; (e) bridging zone of E-ERF 10 resin; (f) nanoweb formation in bridging zone. E-ERF 10 resin; (f) nanoweb formation in bridging zone. Figure 7 shows the tensile fracture surfaces of E-ERF 10 resins. For neat epoxy resin, many Figure 7 shows or thesharp tensilecracks fracturecan surfaces of E-ERF 10 resins. For neat epoxy have resin, reported many layered layered structures be seen in Figure 7a. Many studies this structures or sharp cracks can be seen in Figure 7a. Many studies have reported this appearance be appearance to be the distinctive brittle fracture surface of thermoset resins [43,44]. However, to after the distinctive brittle fracture surface of thermoset resins [43,44]. However, after adding ERFs to epoxy adding ERFs to epoxy resins, the resins decrease in brittle features and sharp crests on the fracture resins, theAs resins in brittle featuresinto andepoxy sharp resins crests on the fracture surfaces. As the loading surfaces. the decrease loading of ERFs added increase, the fracture surfaces display of ERFs added into epoxy resins increase, the fracture surfaces display rougher and glossier rougher and glossier features without the formation of cracks along the fiber directionfeatures which without formation cracks along of theweak fiber direction which indicates the primary characteristic of indicatesthe the primaryofcharacteristic interfacial bonding between fibers and resins [45]. Figure 7b shows the tensile fracture surface of E-ERF 10 resin, clearly demonstrating that ERFs are seen protruding long fibers from the epoxy resin. The ERFs show good dispersion with the wide Materials 2017, 10, 464 8 of 13 weak interfacial bonding between fibers and resins [45]. Figure 7b shows the tensile fracture surface of E-ERF 10 resin, clearly demonstrating that ERFs are seen protruding long fibers from the epoxy resin. The ERFs show good dispersion with the wide range of diameter sizes in in E-ERF 10 resin. The interface between ERFs and epoxy resin displays little fiber pullout, delamination or interface failure induced from weak interfacial bonding between fibers and resins. The strong interfacial bonding occurs by means of crosslinking reaction between oxirane groups of ERFs and amine groups of excess curing agent, increasing the load transfer of ERFs to the epoxy resin. Chemical reactions such as epoxy-amine reaction in the interface play a critical role for interfacial adhesion, specifically the oxirane group opening in the interface and the formation of covalent bonds with ERFs [46]. Figure 7c shows the top surface of the E-ERF 10 resin. ERFs display circular or entangled fibers on the surface; however, they still maintain their rough surface to help ERFs to bond physically to epoxy resin, as shown in Figure 7d. Figure 7e shows the bridging zone of the E-ERF 10 resin. It demonstrates an effective toughening mechanism through the addition of ductile materials such as rubber materials. ERFs effectively connect or bridge two fracture surfaces of the E-ERF 10 resins. Because of inherent toughness and high aspect ratio of ERFs, cracks larger than 500 µm are stopped from propagating into larger cracks. These results show that the adhesion between the ERFs and the epoxy resin are reasonably strong with the absence of breakage or pullout features [47]. The enlarged image (Figure 7f) shows the nanoweb (fishnet-like) formation in the bridging zone. These nanoweb formations have been explained by Liu et al. [48]. The solvent remained in electrospun fibers caused by the incomplete solvent evaporation led to form the connected fibers or nanoweb [48,49]. After curing, neat epoxy resin and all E-ERF resins are tested for their tensile properties. Figure 8 shows typical tensile stress–strain plots of neat epoxy resin and all E-ERF resins and their tensile properties are summarized in Table 1. The increase in ERFs loading in the epoxy resin from 0 to 20 wt % increase the fracture strain significantly from 1.2% to 12.8% and the toughness at break increase seven times from 0.3 to 1.9 MPa. Remarkably, the tensile strength and Young’s modulus show only a minimal decline of 34% from 58 to 34 MPa and from 1.4 GPa to 0.9 GPa, respectively. The neat epoxy specimens are broken in a brittle manner with no apparent yielding, revealing the typical characteristic of a thermoset resin. The tensile strength decreases with an increase in ERFs loading since the ERFs act as stress concentrators, causing a decrease in facture strength and Young’s modulus [50]. E-ERF 5 and E-ERF 10 show about 1.2 GPa and 1.1 GPa of modulus, and 52 MPa and 47 MPa of fracture strength, respectively, compared to that of neat epoxy resin having modulus of 1.4 GPa and tensile strength of 58 MPa. Compared to other studies, epoxy resin containing ENR particles (not in fiber form) showed much loss in tensile properties [24,51,52]. For example, epoxy resin with 12% liquid epoxidized natural rubber (particle size 0.48 to 0.67 in diameter) increased 125% impact toughness, but decreased tensile properties by 15 MPa from 65 MPa to 50 MPa, compared to neat epoxy resin [51]. As 20% ENR was added into epoxy resin it have been reported to improve the impact strength of 2.55 J m−1 and KIC value of 1.79 MPa m1/2 but the modulus decreased to half that of neat epoxy resin [52]. However, the fiber form of ERFs results in significantly higher strain, fracture toughness, and minimal loss of tensile properties when incorporated into the epoxy resin in this study. High aspect ratio due to its fiber form contributes to better interfacial interaction, flexibility in surface functionalities, and superior mechanical performance than the particle form of ENR [53]. The minimal loss in strength and modulus can be explained by the crosslinking reactions between oxirane groups and amine which result in a very effective 3D structure that helps to maintain the tensile properties. Materials 2017, 10, 464 9 of 13 Materials 2017, 10, 464 9 of 13 Figure Figure 8. 8. Typical Typical stress–strain stress–strain plot of neat epoxy resin and all E-ERF resins. Table of all all E-ERF E-ERF resins. resins. Table 1. 1. Tensile Tensile properties properties of Type Typeofof Resins Resins E-ERF E-ERF Epoxy/ERF Composition Tensile Tensile StrengthTensile Tensile StrainToughness Toughness at BreakYoung’s Young’s Modulus Epoxy/ERF Composition Strength Strain at Break Modulus (w/w) (MPa) (%) (%) (MPa) (GPa) (w/w) (MPa) (MPa) (GPa) 100/0 100/0 95/5 95/5 90/10 90/10 85/15 85/15 80/20 80/20 58 (1.6) 1.2 (0.1) 0.3 (0.03) 58 (1.6) * * 1.2 (0.1) 0.3 (0.03) 52 (1.2) 4.4 (0.3) 0.8 (0.1) 52 (1.2) 4.4 (0.3) 0.8 (0.1) 47 (1.0) 7.5 (0.5) 1.4 (0.1) 47 (1.0) 7.5 (0.5) 1.4 (0.1) 39 (0.8) 10.2 (0.4) 1.8 (0.2) 39 (0.8) 1.8 (0.2) 34 (1.1) 12.8 10.2 (0.8)(0.4) 1.9 (0.1) 34 (1.1) 12.8 (0.8) 1.9 (0.1) * The values in parentheses are standard deviation. (0.09) 1.4 1.4 (0.09) 1.2 1.2 (0.05) (0.05) 1.1 (0.05) 1.1 (0.05) 1.0 (0.04) (0.04) 0.9 1.0 (0.05) 0.9 (0.05) * The values in parentheses are standard deviation. 3. Experimental Section 3. Experimental Section 3.1. Materials 3.1. Materials Araldite® GY 6010 (MW: 11,000–14,000, unmodified DGEBA liquid) was purchased from ® ® 956-2 (modified Araldite 11,000–14,000, unmodified DGEBA liquid)amines) was purchased from Huntsman Co. GY (Salt6010 Lake (MW: City, UT, USA). Aradur aliphatic was purchased ® 956-2 (modified aliphatic amines) was purchased Huntsman Co. (Salt Lake City, UT, USA). Aradur from Krayden Inc. (Denver, CO, USA). Epoxidized natural rubber (ENR, 50 mol % conversion) from Krayden by Inc.Malaysian (Denver, CO, USA).Board. Epoxidized natural rubber (ENR, 50 mol % dye, conversion) was was donated Rubber Adirondack green 520 fluorescent chloroform, donated by Malaysian Rubber from Board. Adirondack green Co. 520 (St. fluorescent chloroform, dichloromethane were purchased Sigma Aldrich Chemical Louis, MO,dye, USA). dichloromethane were purchased from Sigma Aldrich Chemical Co. (St. Louis, MO, USA). 3.2. Electrospinning of ENR Fibers 3.2. Electrospinning of ENR Fibers ENR (1 wt %) was dissolved in the mixture of 1:2 (v/v) of dichloromethane and chloroform ENR wt %)for was the mixture of 1:2 (v/v) of dichloromethane anda chloroform and and then (1 stirred 12dissolved h at roomintemperature (RT). The solution was put into 10 mL syringe, then stirred for 12 h fibers at room temperature (RT). The solution into feeding a 10 mLrate syringe, and and electrospun into (ERFs) with a high voltage of 12 kV.was Theput syringe used was − 1 electrospun into fibers (ERFs) with a high voltage of 12 kV. The syringe feeding rate used was 30 µL 30 µL min and the distance between the syringe needle tip (diameter: 1 mm) and the collector was −1 ◦C min the distance syringe needle tip (diameter: mm) collector and the collector wasto15 15 cm.and Precured epoxy between resin wasthe placed above the bath containing1metal and heated 40cm. Precured epoxy placed thedeposited bath containing with stirred at 50resin rpm.was ERFs wereabove directly into themetal epoxycollector resin. and heated to 40 °C with stirred at 50 rpm. ERFs were directly deposited into the epoxy resin. 3.3. Fabrication Process of Epoxy Composites at Different Loadings of ERFs 3.3. Fabrication Process of Epoxy Composites®at Different Loadings of ERFs The curing agent, 35 wt % Aradur 956-2, was added into neat epoxy matrix (DGEBA) and stirred 50 rpmagent, for 3035min. ERFswas using 1 wtinto % ENR concentration Theatcuring wt %Electrospun Aradur® 956-2, added neat polymer epoxy matrix (DGEBA)were and directlyatdeposited into30 themin. epoxy resin. Then the epoxy ERFs atconcentration different loadings stirred 50 rpm for Electrospun ERFs using 1resin wt containing % ENR polymer were was poured into a into Teflon mold (127 127 mm) and precured for 3 h atERFs 40 ◦ C. The epoxy matrix directly deposited the® epoxy resin.×Then the epoxy resin containing at different loadings Materials 2017, 10, 464 10 of 13 containing ERFs was cast in the form of sheets and the epoxy sheets were then cured in the oven at 1 h for 100 ◦ C. Afterwards, all specimens were conditioned at 21 ◦ C and 65% RH for 72 h prior to their characterization. 3.4. Thermal Analysis All epoxy resins containing ERFs at 5, 10, 15 and 20 wt % (E-ERF 5, E-ERF 10, E-ERF 15, and E-ERF 20, respectively) were tested their thermal properties. E-ERF resins were scanned on differential scanning calorimeter (TA-DSC 2000, TA instruments Inc., New Castle, DE, USA) at a heating rate of 5 ◦ C min−1 from −50 to 200 ◦ C to evaluate the changes in their thermal properties under a nitrogen flow rate of 100 mL min−1 . 3.5. Tensile Properties of E-ERF Resins All E-ERF resins were cut by a laser cutter to obtain the dimensions of 50 mm × 10 mm and were characterized for their tensile properties according to ASTM D882-02 standard at a strain rate of 0.6 mm min−1 and gauge length of 30 mm. All tests were performed on Instron universal tensile tester (Instron, Model 5566, Instron Co., Canton, MA, USA) using at least ten specimens [54]. 3.6. Dynamic Mechanical Analysis of E-ERF Resins Dynamic mechanical properties of E-ERF resins were analyzed using DMA (DMA Q800, TA Instruments, New Castle, DE, USA) in 3-point bending mode. Resins were cut into the final specimen dimensions of 30 mm × 10 mm and scanned from −50 to 100 ◦ C at a ramp rate of 5 ◦ C min−1 . All tests were performed at 5 µm amplitude and sinusoidal tensile stress (frequency, 1 Hz), and conducted at least three times [55]. 3.7. Morphological and Chemical Analyses Microstructures of the tensile fracture surfaces of all E-ERF resins were analyzed using Tescan Mira3 FESEM. ATR-FTIR (Magna 560, Nicolet Instrument Technologies, Fitchburg, WI, USA) was used to confirm crosslinking reactions of E-ERF resins. Neat ENR, neat epoxy matrix and all E-ERF resins were scanned from 700 to 4000 cm−1 wavenumbers with a total of 300 scans and a resolution of 2 cm−1 . ENR solution was stained with 0.5% Adirondack green 520 fluorescent dye of ENR before electrospinning. Then, it was electrospun directly into epoxy matrix. The resins were analyzed using a confocal laser scanning microscope (CLSM; Zeiss LSM710, Thornwood, NY, USA) and 520 nm excitation filter with 25× objective lens. 4. Conclusions A convenient one-step electrospinning was developed for green elastic natural rubber fibers. ERFs were directly deposited to epoxy resins without collecting or redepositing of fibers. The surface of ERFs displayed bumpy (spines-like) and rough edges due to different volatility rate of solvents. The range of diameter of ERFs varied from 1.6 µm to 13 µm and the average diameter was approximately 6.2 µm. The increase of ERFs loading from 0 to 20 wt % into epoxy resins increased the fracture strain significantly from 1.2% to 12.8% and toughness at break from 0.3 MPa to 1.9 MPa, an increase by a factor of 7. However, Young’s modulus decreased minimally from 1.4 GPa to 0.9 GPa. E-ERF resins showed the presence of strong interfacial bonding between the ERFs and the epoxy resin without breakage or pullout of fibers. Inherent rubber toughness and high aspect ratio of fiber form of ERFs could contribute to efficient energy dissipation, since effective crosslinking reactions between the oxirane groups and amine or hydroxyl groups in epoxy resin allow the 3D structure to serve as an effective toughening agent. 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