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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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Park J, Kwak SY. Frontal polymerization-triggered simultaneous ring-opening metathesis polymerization and cross metathesis affords anisotropic macroporous dicyclopentadiene cellulose nanocrystal foam. Commun Chem 2022; 5:119. [PMID: 36697913 PMCID: PMC9814902 DOI: 10.1038/s42004-022-00740-1] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 03/31/2022] [Accepted: 09/22/2022] [Indexed: 01/28/2023] Open
Abstract
Multifunctionality and effectiveness of macroporous solid foams in extreme environments have captivated the attention of both academia and industries. The most recent rapid, energy-efficient strategy to manufacture solid foams with directionality is the frontal polymerization (FP) of dicyclopentadiene (DCPD). However, there still remains the need for a time efficient one-pot approach to induce anisotropic macroporosity in DCPD foams. Here we show a rapid production of cellular solids by frontally polymerizing a mixture of DCPD monomer and allyl-functionalized cellulose nanocrystals (ACs). Our results demonstrate a clear correlation between increasing % allylation and AC wt%, and the formed pore architectures. Especially, we show enhanced front velocity (vf) and reduced reaction initiation time (tinit) by introducing an optimal amount of 2 wt% AC. Conclusively, the small- and wide-angle X-ray scattering (SAXS, WAXS) analyses reveal that the incorporation of 2 wt% AC affects the crystal structure of FP-mediated DCPD/AC foams and enhances their oxidation resistance.
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Affiliation(s)
- Jinsu Park
- grid.31501.360000 0004 0470 5905Department of Materials Science and Engineering, Seoul National University, 1 Gwanak-ro, Gwanak-gu, Seoul, 08826 South Korea
| | - Seung-Yeop Kwak
- grid.31501.360000 0004 0470 5905Department of Materials Science and Engineering, Seoul National University, 1 Gwanak-ro, Gwanak-gu, Seoul, 08826 South Korea ,grid.31501.360000 0004 0470 5905Research Institute of Advanced Materials (RIAM), Seoul National University, 1 Gwanak-ro, Gwanak-gu, Seoul, 08826 South Korea ,grid.31501.360000 0004 0470 5905Institute of Engineering Research, Seoul National University, 1 Gwanak-ro, Gwanak-gu, Seoul, 08826 South Korea
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Bhowmik PK, Principe RCG, Chen SL, King D, Han H, Jubair A, Kartazaev V, Gayen SK. Synthesis, optical spectroscopy and laser potential of 2,4,6-triphenylpyrylium chloride. Chem Phys Lett 2022. [DOI: 10.1016/j.cplett.2022.139927] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/03/2022]
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Taschner R, Liska R, Knaack P. Evaluation of suitable onium tetrafluoroborates for cationic polymerization of epoxides. POLYM INT 2021. [DOI: 10.1002/pi.6330] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
Affiliation(s)
- Roland Taschner
- Department of Polymer Chemistry and Technology, Institute of Applied Synthetic Chemistry, TU Wien Vienna Austria
| | - Robert Liska
- Department of Polymer Chemistry and Technology, Institute of Applied Synthetic Chemistry, TU Wien Vienna Austria
| | - Patrick Knaack
- Department of Polymer Chemistry and Technology, Institute of Applied Synthetic Chemistry, TU Wien Vienna Austria
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