Cross-Linking Agents for Enhanced Performance of Thermosets Prepared via Frontal Ring-Opening Metathesis Polymerization

Reactive Processing of Furan-Based Monomers via Frontal Ring-Opening Metathesis Polymerization for High Performance Materials

Frontal ring-opening metathesis polymerization (FROMP) presents an energy-efficient approach to produce high-performance polymers, typically utilizing norbornene derivatives from Diels-Alder reactions. This study broadens the monomer repertoire for FROMP, incorporating the cycloaddition product of biosourced furan compounds and benzyne, namely 1,4-dihydro-1,4-epoxynaphthalene (HEN) derivatives. A computational screening of Diels-Alder products is conducted, selecting products with resistance to retro-Diels-Alder but also sufficient ring strain to facilitate FROMP. The experiments reveal that varying substituents both modulate the FROMP kinetics and enable the creation of thermoplastic materials characterized by different thermomechanical properties. Moreover, HEN-based crosslinkers are designed to enhance the resulting thermomechanical properties at high temperatures (>200 °C). The versatility of such materials is demonstrated through direct ink writing (DIW) to rapidly produce 3D structures without the need for printed supports. This research significantly extends the range of monomers suitable for FROMP, furthering efficient production of high-performance polymeric materials.

Reprocessability in Engineering Thermosets Achieved Through Frontal Ring-Opening Metathesis Polymerization

While valued for their durability and exceptional performance, crosslinked thermosets are challenging to recycle and reuse. Here, inherent reprocessability in industrially relevant polyolefin thermosets is unveiled. Unlike prior methods, this approach eliminates the need to introduce exchangeable functionality to regenerate the material, relying instead on preserving the activity of the metathesis catalyst employed in the curing reaction. Frontal ring-opening metathesis polymerization (FROMP) proves critical to preserving this activity. Conditions controlling catalytic viability are explored to successfully reclaim performance across multiple generations of material, thus demonstrating long-term reprocessability. This straightforward and scalable remolding strategy is poised for widespread adoption. Given the anticipated growth in polyolefin thermosets, these findings represent an important conceptual advance in the pursuit of a fully circular lifecycle for thermoset polymers.

Degree of Cure, Microstructures, and Properties of Carbon/Epoxy Composites Processed via Frontal Polymerization

The frontal polymerization (FP) of carbon/epoxy (C/Ep) composites is investigated, considering FP as a viable route for the additive manufacturing (AM) of thermoset composites. Neat epoxy (Ep) resin-, short carbon fiber (SCF)-, and continuous carbon fiber (CCF)-reinforced composites are considered in this study. The evolution of the exothermic reaction temperature, polymerization frontal velocity, degree of cure, microstructures, effects of fiber concentration, fracture surface, and thermal and mechanical properties are investigated. The results show that exothermic reaction temperatures range between 110 °C and 153 °C, while the initial excitation temperatures range from 150 °C to 270 °C. It is observed that a higher fiber content increases cure time and decreases average frontal velocity, particularly in low SCF concentrations. This occurs because resin content, which predominantly drives the exothermic reaction, decreases with increased fiber content. The FP velocities of neat Ep resin- and SCF-reinforced composites are seen to be 0.58 and 0.50 mm/s, respectively. The maximum FP velocity (0.64 mm/s) is observed in CCF/Ep composites. The degree of cure (αc) is observed to be in the range of 70% to 85% in FP-processed composites. Such a range of αc is significantly low in comparison to traditional composites processed through a long cure cycle. The glass transition temperature (Tg) of neat epoxy resin is seen to be approximately 154 °C, and it reduces slightly to a lower value (149 °C) for SCF-reinforced composites. The microstructures show significantly high void contents (12%) and large internal cracks. These internal cracks are initiated due to high thermal residual stress developed during curing for non-uniform temperature distribution. The tensile properties of FP-cured samples are seen to be inferior in comparison to autoclave-processed neat epoxy. This occurs mostly due to the presence of large void contents, internal cracks, and a poor degree of cure. Finally, a highly efficient and controlled FP method is desirable to achieve a defect-free microstructure with improved mechanical and thermal properties.

Cross-Linked Polyolefins through Tandem ROMP/Hydrogenation

Cross-linked polyolefins have important advantages over their thermoplastic analogues, particularly improved impact strength and abrasion resistance, as well as increased chemical and thermal stability; however, most strategies for their production involve postpolymerization cross-linking of polyolefin chains. Here, a tandem ring-opening metathesis polymerization (ROMP)/hydrogenation approach is presented. Cyclooctene (COE)-co-dicyclopentadiene (DCPD) networks are first synthesized using ROMP, after which the dispersed Ru metathesis catalyst is activated for hydrogenation through the addition of hydrogen gas. The reaction temperature for hydrogenation must be sufficiently high to allow mobility within the system, as dictated by thermal transitions (i.e., glass and melting transitions) of the polymeric matrix. COE-rich materials exhibit branched-polyethylene-like crystallinity (25% crystallinity) and melting points (Tm = 107 °C), as well as excellent ductility (>750% extension), while majority DCPD materials are glassy (Tg = 84 °C) and much stiffer (E = 710 MPa); all materials exhibit high tensile toughness. Importantly, hydrogenation of olefins in these cross-linked materials leads to notable improvements in oxidative stability, as saturated networks do not experience the same substantial degradation of mechanical performance as their unsaturated counterparts upon prolonged exposure to air.

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.

Remolding and Deconstruction of Industrial Thermosets via Carboxylic Acid-Catalyzed Bifunctional Silyl Ether Exchange

Convenient strategies for the deconstruction and reprocessing of thermosets could improve the circularity of these materials, but most approaches developed to date do not involve established, high-performance engineering materials. Here, we show that bifunctional silyl ether, i.e., R'O-SiR₂-OR'', (BSE)-based comonomers generate covalent adaptable network analogues of the industrial thermoset polydicyclopentadiene (pDCPD) through a novel BSE exchange process facilitated by the low-cost food-safe catalyst octanoic acid. Experimental studies and density functional theory calculations suggest an exchange mechanism involving silyl ester intermediates with formation rates that strongly depend on the Si-R₂ substituents. As a result, pDCPD thermosets manufactured with BSE comonomers display temperature- and time-dependent stress relaxation as a function of their substituents. Moreover, bulk remolding of pDCPD thermosets is enabled for the first time. Altogether, this work presents a new approach toward the installation of exchangeable bonds into commercial thermosets and establishes acid-catalyzed BSE exchange as a versatile addition to the toolbox of dynamic covalent chemistry.

Buoyancy-Induced Convection Driven by Frontal Polymerization

In this Letter, we study the interaction between a self-sustaining exothermic reaction front propagating in a direction perpendicular to that of gravity and the buoyancy-driven convective flow during frontal polymerization (FP) of a low-viscosity monomer resin. As the polymerization front transforms the liquid monomer into the solid polymer, the large thermal gradients associated with the propagating front sustain a natural convection of the fluid ahead of the front. The fluid convection in turn affects the reaction-diffusion (RD) dynamics and the shape of the front. Detailed multiphysics numerical analyses and particle image velocimetry experiments reveal this coupling between natural convection and frontal polymerization. The frontal Rayleigh (Ra) number affects the magnitude of the velocity field and the inclination of the front. A higher Ra number drives instability during FP, leading to the observation of thermal-chemical patterns with tunable wavelengths and magnitudes.

Additive Manufacturing of Degradable Materials via Ring-Opening Metathesis Polymerization (ROMP)

Thermoset materials comprise a significant proportion of high-performance plastics due to their shape permanence and excellent thermal and mechanical properties. However, these properties come at the expense of degradability. Here, we show for the first time that the industrial thermoset polydicyclopentadiene (PDCPD) can be additively manufactured (AM) with degradable 2,3-dihydrofuran (DHF) linkages using a photochemical approach. Treatment of the manufactured objects with acid results in rapid degradation to soluble byproducts. This work highlights the potential of ring-opening metathesis polymerization (ROMP) chemistry to create degradable materials amenable to advanced manufacturing processes.

Frontal polymerization-triggered simultaneous ring-opening metathesis polymerization and cross metathesis affords anisotropic macroporous dicyclopentadiene cellulose nanocrystal foam

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 (v_f) and reduced reaction initiation time (t_init) 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.

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.

Crosslink density and mechanical property evolution during the curing of polyurethane-urea/sodium silicate hybrid composites

In order to understand the evolution of the structure–property relationship between the crosslink density and mechanical properties of polyurethane-urea/sodium silicate (PU/SS) hybrid composites, a series of PU/SS composites with 2.5 wt% organofunctional silanes and pure PU/SS composites are investigated at different curing time. Mechanical properties, the fracture surface morphology, and thermo-mechanical properties of these PU/SS composites are characterized by electron omnipotence experiment machine, scanning electron microscope, and dynamic mechanical analysis (DMA), respectively. The mechanical test results show the strength and fracture toughness of the PU/SS composites first increase and then stabilize during cure, and the modification leads to PU/SS composites with significantly higher mechanical properties. Further, the morphology of fractured samples also reveals that the longer curing time and the modification of the PU/SS composites means a higher curing degree. Moreover, the increase in the crosslink density calculated from the DMA tests quantitatively confirmed the positive influence of the curing time and the modification in enhancing mechanical properties. In addition, it is also found that the mechanical properties of the PU/SS composites not only depend on the crosslink density but also on the well-dispersed hybrid PU/SS system.

Molecularly Designed Additives for Chemically Deconstructable Thermosets without Compromised Thermomechanical Properties

"Drop-in" additives that introduce chemically cleavable bonds into thermosets without compromising thermomechanical properties could enable triggered material deconstruction and enhanced sustainability. While the installation of cleavable bonds into the strands of the commercial thermoset polydicyclopentadiene (pDCPD) using comonomers facilitates chemical deconstruction, these additives can lower the material's glass transition temperature (T_g). By contrast, the installation of cleavable crosslinkers into pDCPD can maintain or potentially increase T_g but does not facilitate chemical deconstruction. Here, we introduce "strand-cleaving crosslinker" (SCC) additives that provide cleavable pDCPD network junctions. Notably, pDCPD samples featuring 10% v/v of SCCs can be deconstructed under mild conditions to yield soluble products and display a 48 °C higher T_g than analogous decontructable pDCPD made using cleavable comonomers and an equivalent T_g to virgin pDCPD. The SCC concept could offer a general strategy for the design of chemically deconstructable thermoset materials without compromise on thermomechanical performance.