We
report a robust, 100% atom-efficiency strategy for preparing
waste polycarbonate (WPC)-derived epoxy resin. To demonstrate the
preparation process, we perform a pyridine-catalyzed model reaction
between diphenyl carbonate (DPC) and diglycidyl ether of bisphenol
A (DGEBA) in a molar ratio of 1:2. After epoxy-equivalent titration
and two-dimensional nuclear magnetic resonance (2D-NMR) analysis,
we confirm that the product is bis(1-(4-(2-(4-(oxiran-2-ylmethoxy)phenyl)propan-2-yl)phenoxy)-3-phenoxypropan-2-yl)
carbonate (DPC-EP2). Based on the model reaction, three WPC-based
epoxy resins (WPC-EPX, X = 2, 3, and 4) were prepared by the reaction
of WPC with DGEBA in a molar ratio of 1:2, 1:3, and 1:4 in the presence
of pyridine. The WPC-EPX epoxy resins were cured with WPC, phenol
novolac (PN), diamino diphenylmethane (DDM), and dicyandiamide (DICY).
The mechanical and thermal properties of the thermosets were discussed.
We also prepared epoxy/carbon fiber composites and investigated the
degradation of epoxy thermosets and the recycling of the carbon fiber.
When the WPC-EP2 epoxy resin was cured with WPC, it can be successfully
degraded to a phenoxy resin and 1,3-dihyexylurea through a catalyst-free
aminolysis process. Undamaged carbon fibers have been recycled, according
to the scanning electron microscopy–energy-dispersive X-ray
spectroscopy (SEM–EDS) and tensile stress–strain data.
The transformation of WPC to WPC-EPX, the aminolysis of WPC-EP2/WPC
to a phenoxy resin and 1,3-dihexylurea, and the recycling of carbon
fiber in the composite have been successfully demonstrated. Therefore,
we believe that this work contributes greatly to the field of “sustainable
approaches in waste utilization.”