Solid epoxy resin is highly desired in adhesives, electronic materials and coatings due to the attractive characteristics of solvent-free, highly efficient utilization and convenient storage and transportation. However, the challenges remain in fabricating high-toughness solid epoxy resin through a facile and efficient way. Here, a high-performance environment-friendly solid epoxy resin was fabricated by employing maleic anhydride grafted ethylene-vinyl acetate copolymer (EVA-g-MAH) as the flexibilizer via one-step banburying method. The results showed that the modified epoxy resin maintained a high glass transition temperature (T g) and thermal stability, while its impact strength, tensile toughness and flexural toughness were significantly increased compared with the neat epoxy resin. The impact strength, tensile toughness and flexural toughness of R-EM10 are improved 138%, 195% and 149%, respectively. The EVA-g-MAH was introduced in the epoxy matrix as a separate phase to increase toughness via transfer stress and dissipated energy. The attractive properties of this facile fabrication process and the high-toughness, as well as the environment-friendly performance make this solid epoxy highly promising for large-scale industrial application.
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