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Cook A, Dearborn MA, Anderberg TM, Vaidya K, Jureller JE, Esser-Kahn AP, Squires AH. Polymer Patterning by Laser-Induced Multipoint Initiation of Frontal Polymerization. ACS APPLIED MATERIALS & INTERFACES 2024; 16:17973-17980. [PMID: 38418392 PMCID: PMC11009908 DOI: 10.1021/acsami.4c00216] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 01/04/2024] [Revised: 02/12/2024] [Accepted: 02/16/2024] [Indexed: 03/01/2024]
Abstract
Frontal polymerization (FP) is an approach for thermosetting plastics at a lower energy cost than an autoclave. The potential to generate simultaneous propagation of multiple polymerization fronts has been discussed as an exciting possibility. However, FP initiated at more than two points simultaneously has not been demonstrated. Multipoint initiation could enable both large-scale material fabrication and unique pattern generation. Here, the authors present laser-patterned photothermal heating as a method for simultaneous initiation of FP at multiple locations in a 2-D sample. Carbon black particles are mixed into liquid resin (dicyclopentadiene) to enhance absorption of light from a Ti:sapphire laser (800 nm) focused on a sample. The laser is time-shared by rapid steering among initiation points, generating polymerization using up to seven simultaneous points of initiation. This process results in the formation of both symmetric and asymmetric seam patterns resulting from the collision of fronts. The authors also present and validate a theoretical framework for predicting the seam patterns formed by front collisions. This framework allows the design of novel patterns via an inverse solution for determining the initiation points required to form a desired pattern. Future applications of this approach could enable rapid, energy-efficient manufacturing of novel composite-like patterned materials.
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Affiliation(s)
- Andrés
L. Cook
- Department
of Physics, University of Chicago, Chicago, Illinois 60637, United States
| | - Mason A. Dearborn
- Pritzker
School of Molecular Engineering, University
of Chicago, Chicago, Illinois 60637, United States
| | - Trevor M. Anderberg
- Department
of Physics, University of Chicago, Chicago, Illinois 60637, United States
| | - Kavya Vaidya
- Pritzker
School of Molecular Engineering, University
of Chicago, Chicago, Illinois 60637, United States
| | - Justin E. Jureller
- James
Franck Institute, University of Chicago, Chicago, Illinois 60637, United States
| | - Aaron P. Esser-Kahn
- Pritzker
School of Molecular Engineering, University
of Chicago, Chicago, Illinois 60637, United States
- Institute
for Biophysical Dynamics, University of
Chicago, Chicago, Illinois 60637, United States
| | - Allison H. Squires
- Pritzker
School of Molecular Engineering, University
of Chicago, Chicago, Illinois 60637, United States
- Institute
for Biophysical Dynamics, University of
Chicago, Chicago, Illinois 60637, United States
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2
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Luo T, Ma Y, Cui X. Review on Frontal Polymerization Behavior for Thermosetting Resins: Materials, Modeling and Application. Polymers (Basel) 2024; 16:185. [PMID: 38256983 PMCID: PMC10818476 DOI: 10.3390/polym16020185] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/14/2023] [Revised: 01/05/2024] [Accepted: 01/05/2024] [Indexed: 01/24/2024] Open
Abstract
The traditional curing methods for thermosetting resins are energy-inefficient and environmentally unfriendly. Frontal polymerization (FP) is a self-sustaining process relying on the exothermic heat of polymerization. During FP, the external energy input (such as UV light input or heating) is only required at the initial stage to trigger a localized reaction front. FP is regarded as the rapid and energy-efficient manufacturing of polymers. The precise control of FP is essential for several manufacturing technologies, such as 3D printing, depending on the materials and the coupling of thermal transfer and polymerization. In this review, recent progress on the materials, modeling, and application of FP for thermosetting resins are presented. First, the effects of resin formulations and mixed fillers on FP behavior are discussed. Then, the basic mathematical model and reaction-thermal transfer model of FP are introduced. After that, recent developments in FP-based manufacturing applications are introduced in detail. Finally, this review outlines a roadmap for future research in this field.
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Affiliation(s)
| | | | - Xiaoyu Cui
- School of Aerospace Engineering and Applied Mechanics, Tongji University, Shanghai 200092, China; (T.L.); (Y.M.)
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Suslick BA, Hemmer J, Groce BR, Stawiasz KJ, Geubelle PH, Malucelli G, Mariani A, Moore JS, Pojman JA, Sottos NR. Frontal Polymerizations: From Chemical Perspectives to Macroscopic Properties and Applications. Chem Rev 2023; 123:3237-3298. [PMID: 36827528 PMCID: PMC10037337 DOI: 10.1021/acs.chemrev.2c00686] [Citation(s) in RCA: 11] [Impact Index Per Article: 11.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/26/2023]
Abstract
The synthesis and processing of most thermoplastics and thermoset polymeric materials rely on energy-inefficient and environmentally burdensome manufacturing methods. Frontal polymerization is an attractive, scalable alternative due to its exploitation of polymerization heat that is generally wasted and unutilized. The only external energy needed for frontal polymerization is an initial thermal (or photo) stimulus that locally ignites the reaction. The subsequent reaction exothermicity provides local heating; the transport of this thermal energy to neighboring monomers in either a liquid or gel-like state results in a self-perpetuating reaction zone that provides fully cured thermosets and thermoplastics. Propagation of this polymerization front continues through the unreacted monomer media until either all reactants are consumed or sufficient heat loss stalls further reaction. Several different polymerization mechanisms support frontal processes, including free-radical, cat- or anionic, amine-cure epoxides, and ring-opening metathesis polymerization. The choice of monomer, initiator/catalyst, and additives dictates how fast the polymer front traverses the reactant medium, as well as the maximum temperature achievable. Numerous applications of frontally generated materials exist, ranging from porous substrate reinforcement to fabrication of patterned composites. In this review, we examine in detail the physical and chemical phenomena that govern frontal polymerization, as well as outline the existing applications.
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Affiliation(s)
- Benjamin A Suslick
- Beckman Institute for Advanced Science and Technology, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
- Department of Chemistry, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
| | - Julie Hemmer
- Beckman Institute for Advanced Science and Technology, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
| | - Brecklyn R Groce
- Department of Chemistry, Louisiana State University, Baton Rouge, Louisiana 70803 United States
| | - Katherine J Stawiasz
- Beckman Institute for Advanced Science and Technology, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
- Department of Chemistry, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
| | - Philippe H Geubelle
- Beckman Institute for Advanced Science and Technology, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
- Department of Aerospace Engineering, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
| | - Giulio Malucelli
- Department of Applied Science and Technology, Politecnico di Torino, 15121 Alessandria, Italy
| | - Alberto Mariani
- Department of Chemical, Physical, Mathematical and Natural Sciences, University of Sassari, 07100 Sassari, Italy
- National Interuniversity Consortium of Materials Science and Technology, 50121 Firenze, Italy
| | - Jeffrey S Moore
- Beckman Institute for Advanced Science and Technology, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
- Department of Chemistry, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
| | - John A Pojman
- Department of Chemistry, Louisiana State University, Baton Rouge, Louisiana 70803 United States
| | - Nancy R Sottos
- Beckman Institute for Advanced Science and Technology, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
- Department of Materials Science and Engineering, University of Illinois at Urbana-Champaign, Urbana, Illinois 61801, United States
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Shen H, Wang HP, Wang CF, Zhu L, Li Q, Chen S. Rapid Fabrication of Patterned Gels via Microchannel-Conformal Frontal Polymerization. Macromol Rapid Commun 2021; 42:e2100421. [PMID: 34347322 DOI: 10.1002/marc.202100421] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 07/05/2021] [Revised: 07/28/2021] [Indexed: 11/10/2022]
Abstract
From the perspective of both fundamental and applied science, it is extremely advisable to develop a facile and feasible strategy for fabricating gels with defined structures. Herein, the authors report the rapid synthesis of patterned gels by conducting frontal polymerization (FP) at millimeter-scale (2 mm), where a series of microchannels, including linear-, parallel-, divergent-, snakelike-, circular- and concentric circular channels, were used. They have investigated the effect of various factors (monomer mass ratio, channel size, initiator concentration, and solvent content) on FP at millimeter-scale, along with the propagating rule of the front during FP in these microchannels. In addition, we developed a new microfluidic-assisted FP (MFP) strategy by combining the FP and microfluidic technique. Interestingly, the MFP can realize the production of hollow-structured gel in a rapid and continuous fashion, which have never been reported. Our work not only offers an effective pathway towards patterned gels by the microchannel-conformal FP, but also gives new insight into the continuous production of hollow-structured materials. Such a method will be beneficial for fabricating vessel and scaffold materials in a flexible, easy-to-perform, time and energy saving way.
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Affiliation(s)
- Haixia Shen
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Chemical Engineering, Jiangsu Key Laboratory of Fine Chemicals and Functional Polymer Materials, Nanjing Tech University, No. 5 Xin Mofan Road, Nanjing, 210009, P. R. China
| | - Hao-Peng Wang
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Chemical Engineering, Jiangsu Key Laboratory of Fine Chemicals and Functional Polymer Materials, Nanjing Tech University, No. 5 Xin Mofan Road, Nanjing, 210009, P. R. China
| | - Cai-Feng Wang
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Chemical Engineering, Jiangsu Key Laboratory of Fine Chemicals and Functional Polymer Materials, Nanjing Tech University, No. 5 Xin Mofan Road, Nanjing, 210009, P. R. China
| | - Liangliang Zhu
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Chemical Engineering, Jiangsu Key Laboratory of Fine Chemicals and Functional Polymer Materials, Nanjing Tech University, No. 5 Xin Mofan Road, Nanjing, 210009, P. R. China
| | - Qing Li
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Chemical Engineering, Jiangsu Key Laboratory of Fine Chemicals and Functional Polymer Materials, Nanjing Tech University, No. 5 Xin Mofan Road, Nanjing, 210009, P. R. China
| | - Su Chen
- State Key Laboratory of Materials-Oriented Chemical Engineering, College of Chemical Engineering, Jiangsu Key Laboratory of Fine Chemicals and Functional Polymer Materials, Nanjing Tech University, No. 5 Xin Mofan Road, Nanjing, 210009, P. R. China
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5
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Petko F, Świeży A, Ortyl J. Photoinitiating systems and kinetics of frontal photopolymerization processes – the prospects for efficient preparation of composites and thick 3D structures. Polym Chem 2021. [DOI: 10.1039/d1py00596k] [Citation(s) in RCA: 11] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 12/23/2022]
Abstract
The frontal photopolymerisation combining a versatile interest in many applications and economic efficiency is destined to occupy a growing polymer economy.
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Affiliation(s)
- Filip Petko
- Photo HiTech Ltd, Bobrzyńskiego 14, 30-348 Cracow, Poland
- Department of Biotechnology and Physical Chemistry, Faculty of Chemical Engineering and Technology, Cracow University of Technology, Warszawska 24, 30-155 Kraków, Poland
| | - Andrzej Świeży
- Photo HiTech Ltd, Bobrzyńskiego 14, 30-348 Cracow, Poland
- Department of Biotechnology and Physical Chemistry, Faculty of Chemical Engineering and Technology, Cracow University of Technology, Warszawska 24, 30-155 Kraków, Poland
| | - Joanna Ortyl
- Photo HiTech Ltd, Bobrzyńskiego 14, 30-348 Cracow, Poland
- Department of Biotechnology and Physical Chemistry, Faculty of Chemical Engineering and Technology, Cracow University of Technology, Warszawska 24, 30-155 Kraków, Poland
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