A Sustainable Bio-Based Epoxy Thermoset as a High-Performance Alternative to BPA-Based Resins

Area of Science:

• Materials Science
• Polymer Chemistry
• Sustainable Chemistry

Background:

• Conventional bisphenol A (BPA)-based epoxy resins face limitations including toxicity, brittleness, poor recyclability, and high carbon footprint.
• There is a growing need for sustainable alternatives in structural composites, coatings, and adhesives.

Purpose of the Study:

• To develop a novel, high-performance, bio-based epoxy thermoset.
• To improve component compatibility and introduce pH-responsive degradation.
• To provide a sustainable alternative to BPA-based epoxies.

Main Methods:

• Coupling epoxidized soybean oil (ESO), lignin, and malic acid via maleic anhydride bridging.
• Characterization of mechanical properties (shear strength, tensile strength, flexural strain).
• Evaluation of thermal and chemical resistance.
• Life cycle assessment (LCA) and techno-economic analysis (TEA).

Main Results:

• The bio-based thermoset demonstrated 22.08 MPa shear strength (adhesive) and 314.57 MPa tensile strength (composites).
• Achieved ≈250% increase in flexural strain compared to BPA epoxy.
• Exhibited robust performance across temperatures (-196 to 200°C) and aggressive media.
• LCA and TEA confirmed environmental friendliness and cost-effectiveness.

Conclusions:

• A rigid-flexible bio-based network design offers a sustainable alternative to BPA epoxies.
• The developed thermoset provides a unique combination of strength, ductility, and resilience.
• This work accelerates the transition towards a circular bio-economy for high-performance materials.