Effect of limonene on the frontal ring opening metathesis polymerization of dicyclopentadiene

A Mechanism-Based Reaction-Diffusion Model for Accelerated Discovery of Thermoset Resins Frontally Polymerized by Olefin Metathesis

Frontal ring-opening metathesis polymerization (FROMP) involves a self-perpetuating exothermic reaction, which enables the rapid and energy-efficient manufacturing of thermoset polymers and composites. Current state-of-the-art reaction-diffusion FROMP models rely on a phenomenological description of the olefin metathesis kinetics, limiting their ability to model the governing thermo-chemical FROMP processes. Furthermore, the existing models are unable to predict the variations in FROMP kinetics with changes in the resin composition and as a result are of limited utility toward accelerated discovery of new resin formulations. In this work, we formulate a chemically meaningful model grounded in the established mechanism of ring-opening metathesis polymerization (ROMP). Our study aims to validate the hypothesis that the ROMP mechanism, applicable to monomer-initiator solutions below 100 °C, remains valid under the nonideal conditions encountered in FROMP, including ambient to >200 °C temperatures, sharp temperature gradients, and neat monomer environments. Through extensive simulations, we demonstrate that our mechanism-based model accurately predicts the FROMP behavior across various resin compositions, including polymerization front velocities and thermal characteristics (e.g., Tmax). Additionally, we introduce a semi-inverse workflow that predicts FROMP behavior from a single experimental data point. Notably, the physiochemical parameters utilized in our model can be obtained through DFT calculations and minimal experiments, highlighting the model's potential for rapid screening of new FROMP chemistries in pursuit of thermoset polymers with superior thermo-chemo-mechanical properties.

Numerical Simulation of Polyacrylamide Hydrogel Prepared via Thermally Initiated Frontal Polymerization

Traditional polymer curing techniques present challenges such as a slow processing speed, high energy consumption, and considerable initial investment. Frontal polymerization (FP), a novel approach, transforms monomers into fully cured polymers through a self-sustaining exothermic reaction, which enhances speed, efficiency, and safety. This study focuses on acrylamide hydrogels, synthesized via FP, which hold significant potential for biomedical applications and 3D printing. Heat conduction is critical in FP, particularly due to its influence on the temperature distribution and reaction rate mechanisms, which affect the final properties of polymers. Therefore, a comprehensive analysis of heat conduction and chemical reactions during FP is presented through the establishment of mathematical models and numerical methods. Existing research on FP hydrogel synthesis primarily explores chemical modifications, with limited studies on numerical modeling. By utilizing Differential Scanning Calorimetry (DSC) data on the curing kinetics of polymerizable deep eutectic solvents (DES), this paper employs Malek's model selection method to establish an autocatalytic reaction model for FP synthesis. In addition, the finite element method is used to solve the reaction-diffusion model, examining the temperature evolution and curing degree during synthesis. The results affirm the nth-order autocatalytic model's accuracy in studying acrylamide monomer curing kinetics. Additionally, factors such as trigger temperature and solution initial temperature were found to influence the FP reaction's frontal propagation speed. The model's predictions on acrylamide hydrogel synthesis align with experimental data, filling the gap in numerical modeling for hydrogel FP synthesis and offering insights for future research on numerical models and temperature control in the FP synthesis of high-performance hydrogels.

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.

Polymer Hydrogels and Frontal Polymerization: A Winning Coupling

Polymer hydrogels are 3D networks consisting of hydrophilic crosslinked macromolecular chains, allowing them to swell and retain water. Since their invention in the 1960s, they have become an outstanding pillar in the design, development, and application of engineered polymer systems suitable for biomedical and pharmaceutical applications (such as drug or cell delivery, the regeneration of hard and soft tissues, wound healing, and bleeding prevention, among others). Despite several well-established synthetic routes for developing polymer hydrogels based on batch polymerization techniques, about fifteen years ago, researchers started to look for alternative methods involving simpler reaction paths, shorter reaction times, and lower energy consumption. In this context, frontal polymerization (FP) has undoubtedly become an alternative and efficient reaction model that allows for the conversion of monomers into polymers via a localized and propagating reaction-by means of exploiting the formation and propagation of a "hot" polymerization front-able to self-sustain and propagate throughout the monomeric mixture. Therefore, the present work aims to summarize the main research outcomes achieved during the last few years concerning the design, preparation, and application of FP-derived polymeric hydrogels, demonstrating the feasibility of this technique for the obtainment of functional 3D networks and providing the reader with some perspectives for the forthcoming years.

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.

N-heterocyclic Carbene Gold Complexes Active in Hydroamination and Hydration of Alkynes

Until the year 2000, gold compounds were considered catalytically inert. Subsequently, it was found that they are able to promote the nucleophilic attack on unsaturated substrates by forming an Au–π-system. The main limitation in the use of these catalytic systems is the ease with which they decompose, which is avoided by stabilization with an ancillary ligand. N-heterocyclic carbenes (NHCs), having interesting s-donor capacities, are able to stabilize the gold complexes (Au (I/III) NHC), favoring the exploration of their catalytic activity. This review reports the state of the art (years 2007–2022) in the nucleophilic addition of amines (hydroamination) and water (hydration) to the terminal and internal alkynes catalyzed by N-heterocyclic carbene gold (I/III) complexes. These reactions are particularly interesting both because they are environmentally sustainable and because they lead to the production of important intermediates in the chemical and pharmaceutical industry. In fact, they have an atom economy of 100%, and lead to the formation of imines and enamines, as well as the formation of ketones and enols, all important scaffolds in the synthesis of bioactive molecules, drugs, heterocycles, polymers, and bulk and fine chemicals.

Photoredox-Initiated Frontal Ring-Opening Metathesis Polymerization

Herein, we report the development of a photoredox-initiated frontal ring-opening metathesis polymerization (FROMP) chemical system. We found that a ruthenium-based, bis-N-heterocyclic carbene metathesis precatalyst was activated with 9-mesityl-10-phenylacridindium tetrafluoroborate, copper(II) triflate, and a 455 nm light source. This chemistry was used to initiate the FROMP of dicyclopentadiene; once initiated, the heat released from the polymerization sustained a well-controlled reaction front. Variation in copper or metathesis precatalyst loading yielded front speeds ranging from 0.15 to 0.43 mm s^-1 and front temperatures ranging from 140 to 205 °C. While the glass transition temperatures of the resultant polymers are lower than those derived with Grubbs' second-generation catalyst, this chemical system provides extended pot life.

3D Printing of Short-Carbon-Fiber-Reinforced Thermoset Polymer Composites via Frontal Polymerization

3D printing of fiber-reinforced thermoset composites is desirable for rapid fabrication of 3D composite objects with minimal tooling. One of the main issues in 3D printing of thermoset composites is the low cure rates of matrix resins, which prevents rapid curing and rigidization of composite materials during the printing process and capturing the desired print geometry. Here, we demonstrate a new technique for in situ printing and curing of carbon-fiber-reinforced thermoset composites without any postcuring or postprocessing steps. Upon extrusion and deposition of the composite ink from a printing nozzle, the ink is cured via frontal polymerization, leading to rapid printing of high-quality composites. Tailoring the processing conditions allows for freeform or rapid, supported printing of 3D composite objects with zero void content and highly oriented carbon fiber reinforcements.

Rapid Synthesis of Elastomers and Thermosets with Tunable Thermomechanical Properties

Rapid, solvent-free synthesis of poly(1,4-butadiene) in ambient conditions is demonstrated by frontal ring-opening metathesis polymerization (FROMP) of 1,5-cyclooctadiene (COD). Furthermore, cross-linked copolymers with a wide range of tunable properties are readily prepared by FROMP of mixtures of COD and dicyclopentadiene (DCPD). Specifically, glass transition temperature and tensile modulus are varied from -90 to 114 °C and 3.1 MPa to 1.9 GPa, respectively, by controlling the comonomer ratio. Copolymers with subambient glass transition temperature exhibit robust elastomeric behavior, with the ability to repeatedly recover from large elastic deformations. As a demonstration of the capability of this manufacturing strategy, gradient materials are fabricated in less than a minute with spatially controlled properties for multistage shape memory actuation. This simple yet powerful manufacturing strategy enables rapid synthesis of copolymers ranging from elastomers to thermosets with precise control over thermomechanical properties.

Frontal Ring-Opening Metathesis Polymerization of Exo-Dicyclopentadiene for Low Catalyst Loadings

Polydicyclopentadiene (PDCPD) is a polymer of growing importance in industrial applications. Frontal ring-opening metathesis polymerization (FROMP) offers a means to rapidly cure PDCPD with minimal input energy owing to a propagating reaction wave sustained by the exothermic polymerization. Previous examples of FROMP have required the use of relatively high concentrations of costly ruthenium catalyst, negating many of the benefits of FROMP synthesis. In this contribution, we demonstrate that by using the highly reactive exo-dicyclopentadiene isomer for FROMP the concentration of catalyst is reduced over 3-fold, while maintaining a high frontal velocity. Reducing the amount of ruthenium required for FROMP makes this technique attractive for the production of large PDCPD structural components.