Neutron reflectometry study on the interfacial layer of epoxy resin to improve adhesion strength

Liu, Y.*; 宮田 登*; 宮崎 司*; 春藤 淳臣*; 川口 大輔*; 田中 敬二*; 青木 裕之  

Liu, Y.*; Miyata, Noboru*; Miyazaki, Tsukasa*; Shundo, Atsuomi*; Kawaguchi, Daisuke*; Tanaka, Keiji*; Aoki, Hiroyuki

The performance of structural adhesives is strongly influenced by the interfacial structure between the adhesive and adherend. In this study, we developed a nanometric stable interfacial layer derived from an epoxy resin system containing excess hardener. This layer, formed on solid substrates, exhibited excellent structural stability, even after extensive solvent washing. Neutron reflectometry (NR) was employed to investigate its structure under both dry and humid conditions, revealing a robust and well-defined interface that suppressed moisture accumulation at the adherend interface. FT-IR spectroscopy confirmed an excess of unreacted amino groups in the adsorbed layer, enabling further curing reactions with freshly applied epoxy resin. Re-coating experiments demonstrated that the adsorbed layer remained intact after thermal curing, suggesting strong interfacial compatibility. Notably, the presence of the adsorbed layer led to a significant enhancement in adhesive performance. Lap shear tests showed that the adhesion strength of the epoxy resin nearly doubled when the adsorbed layer was introduced at the interface. This approach does not rely on external coupling agents or primers, but instead utilizes a homologous material system to tailor interfacial properties through molecular-level design. The strategy presented here offers a practical and scalable method for improving adhesion in epoxy systems. By directly engineering the adhesive interface using components intrinsic to the epoxy formulation, this method enables reliable and enhanced bonding performance without altering the bulk material.