Development of Bio-Based Thermosetting Resins from Maltodextrin-Itaconate Systems Toward Styrene-Free Unsaturated...

Area of Science:

• Polymer Chemistry
• Materials Science
• Sustainable Chemistry

Background:

• The development of sustainable thermosetting resins faces challenges balancing bio-based content with processability.
• Conventional polysaccharide-based systems often exhibit high viscosity, limiting their practical application.
• Petroleum-derived diluents like styrene are commonly used but raise environmental concerns.

Purpose of the Study:

• To develop a highly bio-based, styrene-free unsaturated polyester resin (UPR) with improved processability and performance.
• To demonstrate a novel strategy utilizing maltodextrin-derived mixed esters and dimethyl itaconate (DMI).
• To provide a sustainable alternative for industrial thermosets.

Main Methods:

• Synthesis of maltodextrin-derived mixed esters.
• Formulation of a low-viscosity prepolymer-DMI curing solution.
• Characterization of the crosslinked network using Fourier-transform infrared spectroscopy.
• Evaluation of thermal and mechanical properties of the cured resin.

Main Results:

• A low-viscosity, styrene-free curing solution was achieved using functionalized prepolymer and DMI.
• Fourier-transform infrared spectroscopy confirmed the formation of a robust crosslinked network.
• The cured resin demonstrated excellent thermal stability (T_g = 141 °C, decomposition onset ≈ 250 °C) and mechanical strength (flexural strength = 44 MPa).
• Superior dimensional stability was observed with a low linear thermal expansion coefficient (77 ppm/°C).

Conclusions:

• A highly bio-based, easily processable unsaturated polyester resin (UPR) was successfully developed.
• The novel formulation offers a sustainable and high-performance alternative to conventional thermosets.
• This work presents a design template for next-generation eco-friendly industrial thermosets.