Waterborne polyurethane sizing agent with excellent water resistance and thermal stability for improving the interfacial performance of carbon fibers/epoxy resin composites

In order to improve the water-resistance and thermal stability of waterborne polyurethane (WPU), a series of silane and maleimide co-modified waterborne polyurethane emulsions (WPU-M-S) were prepared. Because of the high bond energy of the Si-O bond in silane and the rigid ring in 4-HPM, the WPU-M-S sizing agent achieved better thermal stability. Meanwhile, the excellent hydrophobicity of silane enhances its water resistance. Then, the electrochemical anodic oxidation (EAO) treatment was used to activate the surface of the carbon fibers to introduce carboxyl and hydroxyl groups. Next, WPU-M-S was attached to the carbon fiber by the sizing process. For compound modified carbon fibers, the water contact angle increased, and the single filament tensile strength was also improved. The WPU-M-S sizing agent can react with both the active groups on the fiber surface and the amino groups in the epoxy resin system, thereby achieving a significant improvement in the composite interfacial bonding performance. The interlaminar shear strength (ILSS) of the sizing carbon fibers reinforced epoxy resin composite was promoted to 59.80 MPa, with an increase of 41.61% compared with unsized carbon fiber. [Display omitted] •A series of silane and maleimide co-modified WPU emulsions were prepared.•The WPU-M-S sizing agent achieved better water resistance and thermal stability.•Electrochemical anodic oxidation method was used to achieve surface activation of carbon fibers.•The ILSS of the sizing carbon fiber reinforced composites was promoted to 59.80 MPa (+41.61%).