A review of recent progress in the studies of molecular and microstructure of coupling agents and their functions in composites, coatings and adhesive joints

Abstract Recent progress in the studies of molecular and microstructure of interfaces and interphases in composites, coatings, and adhesive joints is reviewed. Remarkable progress has been made in elucidating the structure of silane coupling agents and their function with respect to dry and wet strengths of multiphase systems. Aminosilanes attracted major effort in the past. It is now understood that the structure of partially cured hydrolyzate is complicated. When adsorbed from a natural pH solution and dried in air at room temperature, approximately half of the amine groups form amine bicarbonate salt with the CO 2 in air. The rest of the amine groups are either intra‐ and intermolecularly hydrogen bonded to neighboring silanol groups or free from hydrogen bonding. There exists chemical bonding at the glass/silane or metal/silane interfaces. The surface characteristics, including acidity, topology and homogeneity, influence the structure of the coupling agent. The coupling agent interphase shows a gradient in various properties. Silanes tend to be ordered in the interphase and the degree of organization depends largely on the organofunctionality. The orientation and organization of the silane affects the reinforcement mechanism. There are chemisorbed and physisorbed silanes in the interphase. The coupling agent/matrix interface is a diffuse boundary where intermixing takes place due to penetration of the matrix resin into the chemisorbed silane layers and the migration of the physisorbed silane molecules into the matrix phase. With proper selection of the organofunctionality and the curing conditions, silanes can chemically react with the matrix to form copolymers. The existence of the matrix interphase is now well accepted and the effect of the interphase on the mechanical properties has been studied. It has been recognized that modification of the matrix interphase, such as a coating applied on the fiber using a similar resin as the matrix, has a complex effect on the mechanical performance. It is noteworthy that attempts to synthesize new coupling agents and to utilize the existing coupling agents more effectively still continue. Based on the molecular understanding, new concepts in the reinforcement mechanism have appeared which recognize the importance of interpenetrating networks, the structure of silane in the treating solution, and the microheterogeneity of the glass surfaces. The knowledge obtained through the studies of composites can be applied to organic coatings and adhesive joints provided that the geometrical factors are taken into consideration.