Radical photoinduced cationic frontal polymerization in porous media

Polymer Patterning by Laser-Induced Multipoint Initiation of Frontal Polymerization

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.

Review on Frontal Polymerization Behavior for Thermosetting Resins: Materials, Modeling and Application

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.

Frontal Polymerizations: From Chemical Perspectives to Macroscopic Properties and Applications

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.

Rapid Fabrication of Patterned Gels via Microchannel-Conformal Frontal Polymerization

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.

Photoinitiating systems and kinetics of frontal photopolymerization processes – the prospects for efficient preparation of composites and thick 3D structures

The frontal photopolymerisation combining a versatile interest in many applications and economic efficiency is destined to occupy a growing polymer economy.