Development of sustainable carbon fiber composites using dual dynamic epoxy vitrimers: a synergy of stiffness, flexibility, and recyclability

The increasing demand of carbon fiber-reinforced polymer (CFRP) composites in sectors such as aerospace and wind energy underscores the need for sustainable end-of-life solutions. In this work, a dual dynamic bio-based epoxy consisting of covalent adaptable networks (vitrimers) was developed by blending diglycidyl ether of bisphenol-A (DGEBA) with acrylated epoxidized soybean oil (AESO) in varying ratios, cured with 2,2'-dithiodibenzoic acid (DTBA), and transesterification catalyzed by tin(ii) 2-ethylhexanoate (Sn(Oct)₂). Among the formulations, D70B30 and D50B50 vitrimers exhibited a synergistic balance between mechanical stiffness and flexibility, owing to the aromatic rigidity of DGEBA and the aliphatic softness of AESO. Both vitrimers demonstrated excellent thermal stability (<i>T</i> _d5% = 342 °C and 325 °C, respectively), high gel content (>99%), and outstanding self-healing efficiencies (∼92% for D70B30, ∼90% for D50B50) due to dynamic transesterification and disulfide bond exchange mechanisms. They also exhibited rapid stress relaxation and efficient degradability, confirming their vitrimeric behavior. These optimized matrices were used to fabricate CFRP laminates <i>via</i> vacuum-assisted resin infusion molding (VARIM), resulting in composites with remarkable mechanical performance. D70B30-CF showed superior tensile strength (281 MPa) and flexural strength (600 MPa), while D50B50-CF exhibited a more rigid response with higher flexural modulus (58.7 GPa). Additionally, the vitrimer matrix allowed for efficient chemical recycling in EG/DMF at 70 °C, enabling complete matrix dissolution and full recovery of undamaged carbon fibers within 4 hours. Structural and morphological integrity of the recycled fibers was confirmed through FTIR, XRD, and SEM analysis. This study presents a viable strategy for developing high-performance, reprocessable, and recyclable CFRPs using sustainable covalent adaptable networks.