Redox two-component initiated free radical and cationic polymerizations: Concepts, reactions and applications

Silicon-photonics-enabled chip-based 3D printer

Imagine if it were possible to create 3D objects in the palm of your hand within seconds using only a single photonic chip. Although 3D printing has revolutionized the way we create in nearly every aspect of modern society, current 3D printers rely on large and complex mechanical systems to enable layer-by-layer addition of material. This limits print speed, resolution, portability, form factor, and material complexity. Although there have been recent efforts in developing novel photocuring-based 3D printers that utilize light to transform matter from liquid resins to solid objects using advanced methods, they remain reliant on bulky and complex mechanical systems. To address these limitations, we combine the fields of silicon photonics and photochemistry to propose the first chip-based 3D printer. The proposed system consists of only a single millimeter-scale photonic chip without any moving parts that emits reconfigurable visible-light holograms up into a simple stationary resin well to enable non-mechanical 3D printing. Furthermore, we experimentally demonstrate a stereolithography-inspired proof-of-concept version of the chip-based 3D printer using a visible-light beam-steering integrated optical phased array and visible-light-curable resin, showing 3D printing using a chip-based system for the first time. This work demonstrates the first steps towards a highly-compact, portable, and low-cost solution for the next generation of 3D printers.

Recent Advances in Monocomponent Visible Light Photoinitiating Systems Based on Sulfonium Salts

During the last decades, multicomponent photoinitiating systems have been the focus of intense research efforts, especially for the design of visible light photoinitiating systems. Although highly reactive three-component and even four-component photoinitiating systems have been designed, the complexity to elaborate such mixtures has incited researchers to design monocomponent Type II photoinitiators. Using this approach, the photosensitizer and the radical/cation generator can be combined within a unique molecule, greatly simplifying the elaboration of the photocurable resins. In this field, sulfonium salts are remarkable photoinitiators but these structures lack absorption in the visible range. Over the years, various structural modifications have been carried out in order to redshift their absorptions in the visible region. In this work, an overview of the different sulfonium salts activable under visible light and reported to date is proposed.

Redox cationic frontal polymerization: a new strategy towards fast and efficient curing of defect-free fiber reinforced polymer composites

Frontal polymerization of epoxy-based thermosets is a promising curing technique for the production of carbon fiber reinforced composites (CFRCs). It exploits the exothermicity of polymerization reactions to convert liquid monomers to a solid 3D network. A self-sustaining curing reaction is triggered by heat or UV-radiation, resulting in a localized thermal reaction zone that propagates through the resin formulation. To date, frontal polymerization is limited to CFRCs with a low fiber volume percent as heat losses compromise on the propagation of the heat front, which is crucial for this autocatalytic curing mechanism. In addition, the choice of suitable epoxy monomers and thermal radical initiators is limited, as highly reactive cycloaliphatic epoxies as well as peroxides decarboxylate during radical induced cationic frontal polymerization. The resulting networks suffer from high defect rates and inferior mechanical properties. Herein, we overcome these shortcomings by introducing redox cationic frontal polymerization (RCFP) as a new frontal curing concept. In the first part of this study, the influence of stannous octoate (reducing agent) was studied on a frontally cured bisphenol A diglycidyl ether resin and mechanical and thermal properties were compared to a conventional anhydride cured counterpart. In a subsequent step, a quasi-isotropic CFRC with a fiber volume of >50 vol%, was successfully cured via RCFP. The composite exhibited a glass transition temperature > 100 °C and a low number of defects. Finally, it was demonstrated that the redox agent effectively prevents decarboxylation during frontal polymerization of a cycloaliphatic epoxy, demonstrating the versatility of RCFP in future applications.

Synthesis of a Room-Temperature Curable Acrylic-Urethane Polymer Binder for Road Markings with High Transmittance

Triol acrylic-urethane (t-AU) was synthesized from an addition reaction using trimethylolpropane, hexamethylene diisocyanate, and 2-hydroxyethyl methacrylate. The novel acrylic-urethane polymer was applied to a high-performance binder to prepare a reliable road marking paint. Acrylic-urethane polymer binder formulations were designed to optimize the effect of t-AU on the physical properties. The t-AU content in the formulation affected the adhesion and optical properties. The improvement in the adhesive performance and transparency ability for road markings was attributed to the optimal chemical structure or design of the acrylic-urethane polymer. The synthesis of t-AU was confirmed by Fourier transform infrared spectroscopy, and molecular weight and polydispersity index (PDI; PDI = M_w/M_n) measurements. The tensile and shear strength, hardness, gel fraction, crosslink density, contact angle, and transmittance of the acrylic-urethane polymer binder (AUP) were evaluated by curing at room temperature using a redox initiator system. An optimized AUP by adding 5 wt.% t-AU provides a viable alternative to high-performance binders in road marking paints.

Thiophenium Salts as New Oxidant for Redox Polymerization under Mild- and Low-Toxicity Conditions

In mild conditions (under air, room temperature, no monomer purification and without any energy activation), redox free radical polymerization (RFRP) is considered as one of the most effective methods to polymerize (meth)acrylate monomers. In the past several years, there has been a growing interest in research on the development of new redox initiating systems (RISs), thanks mainly to the evolution of toxicity labeling and the stability issue of the current RIS based on peroxide and aromatic amine. In this study, a new, low-toxicity RIS based on thiophenium salt as the oxidant species is presented with various reductive species. The reactivity and the stability of the proposed RISs are investigated and the synthesis of new thiophenium salts reported.

A critical review on biochar-assisted free radicals mediated redox reactions influencing transformation of potentially toxic metals: Occurrence, formation, and environmental applications

Potentially toxic metals have become a viable threat to the ecosystem due to their carcinogenic nature. Biochar has gained substantial interest due to its redox-mediated processes and redox-active metals. Biochar has the capacity to directly adsorb the pollutants from contaminated environments through several mechanisms such as coprecipitation, complexation, ion exchange, and electrostatic interaction. Biochar's electron-mediating potential may be influenced by the cyclic transition of surface moieties and conjugated carbon structures. Thus, pyrolysis configuration, biomass material, retention time, oxygen flow, and heating time also affect biochar's redox properties. Generally, reactive oxygen species (ROS) exist as free radicals (FRs) in radical and non-radical forms, i.e., hydroxyl radical, superoxide, nitric oxide, hydrogen peroxide, and singlet oxygen. Heavy metals are involved in the production of FRs during redox-mediated reactions, which may contribute to ROS formation. This review aims to critically evaluate the redox-mediated characteristics of biochar produced from various biomass feedstocks under different pyrolysis conditions. In addition, we assessed the impact of biochar-assisted FRs redox-mediated processes on heavy metal immobilization and mobility. We also revealed new insights into the function of FRs in biochar and its potential uses for environment-friendly remediation and reducing the dependency on fossil-based materials, utilizing local residual biomass as a raw material in terms of sustainability.

Efficacy analysis of new copper complex for visible light (455, 530 nm) radical/cationic photopolymerization: The synergic effects and catalytic cycle

The kinetics and the conversion features of two 3-component systems (A/B/N), based on the proposed new kinetic schemes of Mokbel and Mau et al, in which a visible LED is used to excite a copper complex to its excited triplet state (G*). The coupling of G* with iodonium salt and ethyl 4-(dimethylamino)benzoate (EDB) produces both free radical polymerization (FRP) of acrylates and the free radical promoted cationic polymerization (CP) of epoxides using various new copper complex as the initiator. Higher FRP and CP conversion can be achieved by co-additive of [B] and N, via the dual function of (i) regeneration [A], and (ii) generation of extra radicals. The interpenetrated polymer network (IPN) capable of initiating both FRP and CP in a blend of TMPTA and EPOX. The synergic effects due to CP include: (i) CP can increase viscosity limiting the diffusional oxygen replenishment; (ii) the cation also acts as a diluting agent for the IPN network, and (iii) the exothermic property of the CP. The catalytic cycle, synergic effects, and the oxygen inhibition are theoretically confirmed to support the experimental hypothesis. The measured results of Mokbel and Mau et al are well analyzed and matching the predicted features of our modeling.

"Invisible" Digital Light Processing 3D Printing with Near Infrared Light

The ability to 3D print structures with low-intensity, long-wavelength light will broaden the materials scope to facilitate inclusion of biological components and nanoparticles. Current materials limitations arise from the pervasive absorption, scattering, and/or degradation that occurs upon exposure to high-intensity, short-wavelength (ultraviolet) light, which is the present-day standard used in light-based 3D printers. State-of-the-art techniques have recently extended printability to orange/red light. However, as the wavelength of light increases, so do the inherent challenges to match the speed and resolution of traditional UV light-induced solidification processes (i.e., photocuring). Herein, a photosystem is demonstrated to enable low-intensity (<5 mW/cm2), long-wavelength (∼850 nm) near-infrared (NIR) light-driven 3D printing, "invisible" to the human eye. The combination of a NIR absorbing cyanine dye with electron-rich and -deficient redox pairs was required for rapid photocuring in a catalytic manner. The rate of polymerization and time to solidification upon exposure to NIR light were characterized via in situ spectroscopic and rheological monitoring. Translation to NIR digital light processing (projection-based) 3D printing was accomplished through rigorous optimization of resin composition and printing parameters to balance the speed (<60 s/layer) and resolution (<300 μm features). As a proof-of-concept, composite 3D printing with nanoparticle-infused resins was accomplished. Preliminary analysis showed improved feature fidelity for structures produced with NIR relative to UV light. The present report provides key insight that will inform next-generation light-based photocuring technology, such as wavelength-selective multimaterial 3D bio- and composite-printing.

Relocation and reinforcement of the adhesive/composite interface with spontaneous amine-peroxide interfacial polymerization

OBJECTIVES

This study demonstrates a spontaneous redox polymerization process located at the adhesive-composite interface that precedes photocure of the composite with the intent to improve bonding.

METHODS

An aromatic amine and benzoyl peroxide redox initiator system was partitioned between BAPO-photoinitiated BisGMA/HEMA adhesive and BisGMA/TEGDMA resin-composites. The composite was placed on the photocured adhesive layer with a brief delay before photopolymerization of the composite layer. Micro-tensile bond strength between the adhesive and composite was assessed in comparison with the non-redox active control materials.

RESULTS

The presence of amine or peroxide in these resins without the redox initiation contribution enhanced both the rate and the final conversion of the BAPO-based photopolymerizations. Control formulations using redox-only initiation showed active polymer formation starting at approximately 30 s when physical mixing of the redox components was involved; however, simply by waiting 60 s between composite placement and photocure provided adequate time for passive interfacial diffusion of benzoyl peroxide from the pre-cured adhesive into the overlaid aromatic amine-containing composite such that a sufficient degree of redox initiated interfacial polymerization occurred prior to the composite photocure. The result was a significant increase in the adhesive to composite micro-tensile bond strength with the failure site moved away from the mainly interfacial failure noted for the control.

SIGNIFICANCE

The stress-free autonomous pre-conversion of a redox-initiated thin film of composite that then provides a compositionally homogeneous interface for composite photopolymerization offers a means to enhance at least short-term bond strength between the adhesive and composite phases during restorative placement.

Efficacy Analysis of In Situ Synthesis of Nanogold via Copper/Iodonium/Amine/Gold System under a Visible Light

This article presents, for the first time, the kinetics and the general features of a photopolymerization system (under visible light), copper-complex/Iodonium/triethylamine/gold-chloride (orA/B/N/G), with initial concentrations of A0, B0, N0 and G0, based on the proposed mechanism of Tar et al. Analytic formulas were developed to explore the new features, including: (i) both free radical photopolymerization (FRP) efficacy and the production of nanogold (NG), which are proportional to the relative concentration ratios of (A0 + B0 + N0)/G0 and may be optimized for maximum efficacy; (ii) the two competing procedures of NG production and the efficacy of FRP, which can be tailored for an optimal system with nanogold in the polymer matrix; (iii) the FRP efficacy, which is contributed by three components given by the excited state of copper complex (T), and the radicals (R and S) produced by iodonium and amine, respectively; (iv) NG production, which is contributed by the coupling of T and radical (S) with gold ion; and (v) NG production, which has a transient state proportional to the light intensity and the concentration ratio A0/G0) + (N0/(K'M0), but also a steady-state independent of the light intensity.

Switching from Single to Simultaneous Free-Radical and Anionic Polymerization with Enamine-Based Organic Electron Donors

Although most monomers can polymerize through different propagation pathways, polymerization-initiating systems that can switch from one mode to another are rare. In this study, we demonstrate that enamine-based organic electron donors (OEDs) constitute the first systems able to initiate either free-radical or anionic polymerization under simple, mild, and safe conditions. While direct electron-transfer reduction of monomers by OEDs results in the initiation of anionic chain-growth polymerization, introduction of a competing oxidant with a higher reduction potential than the monomer switches the former anionic propagation to a clean radical-propagation process. The benefit of this dual-mode activator is highlighted in the synthesis of an interpenetrating polymer network through simultaneous initiation of radical and anionic propagation processes.

Recent Advances in bis-Chalcone-Based Photoinitiators of Polymerization: From Mechanistic Investigations to Applications

Over the past several decades, photopolymerization has become an active research field, and the ongoing efforts to develop new photoinitiating systems are supported by the different applications in which this polymerization technique is involved-including dentistry, 3D and 4D printing, adhesives, and laser writing. In the search for new structures, bis-chalcones that combine two chalcones' moieties within a unique structure were determined as being promising photosensitizers to initiate both the free-radical polymerization of acrylates and the cationic polymerization of epoxides. In this review, an overview of the different bis-chalcones reported to date is provided. Parallel to the mechanistic investigations aiming at elucidating the polymerization mechanisms, bis-chalcones-based photoinitiating systems were used for different applications, which are detailed in this review.

Advances, Challenges, and Opportunities of Poly(γ-butyrolactone)-Based Recyclable Polymers

The discovery and prosperous growth of synthetic polymers have presented both significant advantages and daunting challenges in the last century. To address the issues of environmental pollution and fossil consumption, recyclable, degradable, and/or biobased polymers have been given much attention in the polymer science community. This viewpoint focuses on the emerging fully chemical recyclable poly(γ-butyrolactone)-based polymers. The breakthrough from nonpolymerizable to efficient polymerization is highlighted by the benefits of the development of a series of catalysis for ring-opening polymerization of γ-butyrolactone. Subsequently, the design of γ-butyrolactone derivatives and synthesis of more recyclable polymers are summarized together with the discussions about the structure and property relationship. Finally, the remaining challenges and promising opportunities are suggested in order to provide insights into the further direction for sustainable polymers.

N-Aryl glycines as versatile initiators for various polymerizations

N-(1-Pyrenyl)glycine can act as a versatile initiator for various polymerizations.

Rapid High-Resolution Visible Light 3D Printing

Light-driven 3D printing to convert liquid resins into solid objects (i.e., photocuring) has traditionally been dominated by engineering disciplines, yielding the fastest build speeds and highest resolution of any additive manufacturing process. However, the reliance on high-energy UV/violet light limits the materials scope due to degradation and attenuation (e.g., absorption and/or scattering). Chemical innovation to shift the spectrum into more mild and tunable visible wavelengths promises to improve compatibility and expand the repertoire of accessible objects, including those containing biological compounds, nanocomposites, and multimaterial structures. Photochemistry at these longer wavelengths currently suffers from slow reaction times precluding its utility. Herein, novel panchromatic photopolymer resins were developed and applied for the first time to realize rapid high-resolution visible light 3D printing. The combination of electron-deficient and electron-rich coinitiators was critical to overcoming the speed-limited photocuring with visible light. Furthermore, azo-dyes were identified as vital resin components to confine curing to irradiation zones, improving spatial resolution. A unique screening method was used to streamline optimization (e.g., exposure time and azo-dye loading) and correlate resin composition to resolution, cure rate, and mechanical performance. Ultimately, a versatile and general visible-light-based printing method was shown to afford (1) stiff and soft objects with feature sizes <100 μm, (2) build speeds up to 45 mm/h, and (3) mechanical isotropy, rivaling modern UV-based 3D printing technology and providing a foundation from which bio- and composite-printing can emerge.

Recent Advances on Copper Complexes as Visible Light Photoinitiators and (Photo) Redox Initiators of Polymerization

Metal complexes are used in numerous chemical and photochemical processes in organic chemistry. Metal complexes have not been excluded from the interest of polymerists to convert liquid resins into solid materials. If iridium complexes have demonstrated their remarkable photochemical reactivity in polymerization, their high costs and their attested toxicities have rapidly discarded these complexes for further developments. Conversely, copper complexes are a blooming field of research in (photo) polymerization due to their low cost, easy syntheses, long-living excited state lifetimes, and their remarkable chemical and photochemical stabilities. Copper complexes can also be synthesized in solution and by mechanochemistry, paving the way towards the synthesis of photoinitiators by Green synthetic approaches. In this review, an overview of the different copper complexes reported to date is presented. Copper complexes are versatile candidates for polymerization, as these complexes are now widely used not only in photopolymerization, but also in redox and photoassisted redox polymerization processes.

Monocomponent Photoinitiators based on Benzophenone-Carbazole Structure for LED Photoinitiating Systems and Application on 3D Printing

In this article, different substituents (benzoyl, acetyl, styryl) are introduced onto the carbazole scaffold to obtain 8 novel carbazole derivatives. Interestingly, a benzoyl substituent, connected to a carbazole group, could form a benzophenone moiety, which composes a monocomponent Type II benzophenone-carbazole photoinitiator (PI). The synergetic effect of the benzophenone moiety and the amine in the carbazole moiety is expected to produce high performance photoinitiating systems (PISs) for the free radical photopolymerization (FRP). For different substituents, clear effects on the light absorption properties are demonstrated using UV-Visible absorption spectroscopy. Benzophenone-carbazole PIs can initiate the FRP of acrylates alone (monocomponent Type II photoinitiator behavior). In addition, fast polymerization rates and high function conversions of acrylate are observed when an amine and/or an iodonium salt are added in systems. Benzophenone-carbazole PIs have good efficiencies in cationic photopolymerization (CP) upon LED @ 365 nm irradiation in the presence of iodonium salt. In contrast, other PIs without synergetic effect demonstrate unsatisfied photopolymerization profiles in the same conditions. The best PIS identified for the free radical photopolymerization were used in three-dimensional (3D) printing. Steady state photolysis and fluorescence quenching experiments were carried out to investigate the reactivity and the photochemistry and photophysical properties of PIs. The free radicals, generated from the studied PISs, are detected by the electron spin resonance - spin trapping technique. The proposed chemical mechanisms are provided and the structure/reactivity/efficiency relationships are also discussed. All the results showed that the benzophenone-carbazole PIs have a good application potential, and this work provides a rational design route for PI molecules. Remarkably, BPC2-BPC4, C6, C8 were never synthetized before; therefore, 5 of the 8 compounds are completely new.

Silane/iodonium salt as redox/thermal/photoinitiating systems in radical and cationic polymerizations for laser write and composites

Methylphenylsilane (MPS) and octadecylsilane (ODS) are originally proposed here combined with iodonium salt as a highly versatile triple initiating system for redox, photo and thermal polymerizations (both radical and cationic).

A monocomponent bifunctional benzophenone–carbazole type II photoinitiator for LED photoinitiating systems

A bifunctional benzophenone–carbazole-based photoinitiator (BPC) was designed from its molecular structure viewpoint.

Recent Advances on Visible Light Metal-Based Photocatalysts for Polymerization under Low Light Intensity

In recent years, polymerization processes activated by light have attracted a great deal of interest due to the wide range of applications in which this polymerization technique is involved. Parallel to the traditional industrial applications ranging from inks, adhesives, and coatings, the development of high-tech applications such as nanotechnology and 3D-printing have given a revival of interest to this polymerization technique known for decades. To initiate a photochemical polymerization, the key element is the molecule capable to interact with light, i.e., the photoinitiator and more generally the photoinitiating system, as a combination of several components is often required to create the reactive species responsible for the polymerization process. With the aim of reducing the photoinitiator content while optimizing the polymerization yield and/or the polymerization speed, photocatalytic systems have been developed, enabling the photosensitizer to be regenerated during the polymerization process. In this review, an overview of the photocatalytic systems developed for polymerizations carried out under a low light intensity and visible light is provided. Over the years, a wide range of organometallic photocatalysts has been proposed, addressing both the polymerization efficiency and/or the toxicity, as well as environmental issues.

Indole-based charge transfer complexes as versatile dual thermal and photochemical polymerization initiators for 3D printing and composites

Indole-based Charge Transfer Complexes (CTCs) are newly presented dual photo/thermal initiators for safe and robust polymerizations in high tech applications.