Structure-Property Relationships in Epoxy-Anhydride Systems: A Comprehensive Comparative Study of Cycloaliphatic, Novolac, and Aromatic Prepolymers.

This study provides a comprehensive quantitative comparison of three structurally distinct epoxy prepolymers-cycloaliphatic, novolac, and bis-aromatic (BADGE)-cured with a single hardener, methyl nadic anhydride (MNA), and catalyzed by 1-methylimidazole under strictly identical stoichiometric and thermal conditions. Each formulation was optimized in terms of epoxy/anhydride ratio and catalyst concentration to ensure meaningful cross-comparison under representative cure conditions. A multi-technique approach combining differential scanning calorimetry (DSC), dynamic rheometry, and thermogravimetric analysis (TGA) was employed to jointly assess cure kinetics, network build-up, and long-term thermal stability. DSC analyses provided reaction enthalpies and glass transition temperatures (Tg) ranging from 145 °C (BADGE-MNA) to 253 °C (cycloaliphatic ECy-MNA) after stabilization of the curing reaction under the chosen thermal protocol, enabling experimental fine-tuning of stoichiometry beyond the theoretical 1:1 ratio. Isothermal rheology revealed gel times of approximately 14 s for novolac, 16 s for BADGE, and 20 s for the cycloaliphatic system at 200 °C, defining a clear hierarchy of reactivity (Novolac > BADGE > ECy). Post-cure thermomechanical performance and thermal aging resistance (100 h at 250 °C) were assessed via rheometry and TGA under both dynamic and isothermal conditions. They demonstrated that the novolac-based resin retained approximately 93.7% of its initial mass, confirming its outstanding thermo-oxidative stability. The three systems exhibited distinct trade-offs between reactivity and thermal resistance: the novolac resin showed superior thermal endurance but, owing to its highly aromatic and rigid structure, limited flowability, while the cycloaliphatic resin exhibited greater molecular mobility and longer pot life but reduced stability. Overall, this work provides a comprehensive and quantitatively consistent benchmark, consolidating stoichiometric control, DSC and rheological reactivity, Tg evolution, thermomechanical stability, and degradation behavior within a single unified experimental framework. The results offer reliable reference data for modeling, formulation, and possible use of epoxy-anhydride thermosets at temperatures above 200 °C.