Synthesis and characterization of functionally gradient materials obtained by frontal 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.

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.

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.

One-Pot Synthesis of Robust Fluorescent Nanocomposite Gel via Frontal Polymerization

Fluorescent nanocomposite gels have attracted increasing attention due to their excellent optical properties, as well as enhanced mechanical strength originating from the nanoparticles. At present, two-step methods are usually employed, where fluorescent nanoparticles are firstly prepared, followed by mixing with gel precursor to achieve the final products after gelation, which suffer from the disadvantages of a tedious and time-consuming process. Thus, the development of a facile strategy is highly desirable, which still remains an obstacle. Herein, a new one-pot synthesis method towards robust fluorescent nanocomposite gels via frontal polymerization (FP) is proposed, where small molecular precursors (citric acid (CA) and urea, or L-cysteine) and gel precursor (vinyl monomers) are mixed together as co-reactants. During the FP process, a lot of heat release gives rise to the generation of carbonized polymer dots (CPDs). Thus, companying with the propagating of the polymerization, the production of fluorescent CPDs/gel composite is completed. In addition, as a nanofiller, CPDs dramatically enhance the mechanical property of the CPDs/gel composite. This work proposes a new fast and efficient one-pot strategy for the production of CPDs/gel composite, which will guide the development of high-performance polymer nanocomposites through an in situ synchronous reaction fashion.

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.

Switching Frontal Polymerization Mechanisms: FROMP and FRaP

Two frontal polymerization (FP) mechanisms, frontal ring-opening metathesis polymerization (FROMP) of dicyclopentadiene and frontal radical polymerization (FRaP) of benzyl acrylate and hexanediol diacrylate, were combined for rapid manufacturing of welded thermoset materials. Leveraging the immiscibility of the two different FP resins, welded thermosets and gradient foams of varying composition were achieved by switching of FP mechanisms. The adhesion strength of the welded thermoset materials differed depending on the originating mechanism. Finally, welded thermoset foams of varying porosity and homogeneity were generated through initiation from the bottom of the two resins.

Quantum Dots-Loaded Self-Healing Gels for Versatile Fluorescent Assembly

From the perspective of applied science, methods that allow the simple construction of versatile quantum dots (QDs)-loaded gels are highly desirable. In this work, we report the self-healing assembly methods for various fluorescent QDs-loaded gels. Firstly, we employed horizontal frontal polymerization (FP) to fabricate self-healing gels within several minutes using a rapid and energy-saving means of preparation. The as-prepared gels showed pH sensitivity, satisfactory mechanical properties and excellent self-healing properties and the healing efficiency reached 90%. The integration of the QDs with the gels allowed the generation of fluorescent composites, which were successfully applied to an LED device. In addition, by using the self-healing QDs-loaded gels as building blocks, the self-healing assembly method was used to construct complex structures with different fluorescence, which could then be used for sensing and encoding. This work offers a new perspective on constructing various fluorescent assemblies by self-healing assembly, and it might stimulate the future application of self-healing gels in a self-healing assembly fashion.

Anisotropic frontal polymerization in a model resin-copper composite

This work investigates experimentally and numerically frontal polymerization in a thermally anisotropic system with parallel copper strips embedded in 1,6-hexanediol diacrylate resin. Both experiments and multiphysics finite element analyses reveal that the front propagation in the thermally anisotropic system is orientation-dependent, leading to variations in the front shape and the front velocity due to the different front-metal strip interaction mechanisms along and across the metal strips. The parameters entering the cure kinetics model used in this work are chosen to capture the key characteristics of the polymerization front, i.e., the front temperature and velocity. Numerical parametric analyses demonstrate that the front velocity in the directions parallel and perpendicular to the metal strips increases as the system size decreases and approaches the analytical prediction for homogenized systems. A two-dimensional homogenized model for anisotropic frontal polymerization in the metal-resin system is proposed.

Controllable Frontal Polymerization and Spontaneous Patterning Enabled by Phase-Changing Particles

Frontal polymerization provides a rapid, economic, and environmentally friendly methodology to manufacture thermoset polymers and composites. Despite its efficiency and reduced environmental impact, the manufacturing method is underutilized due to the limited fundamental understanding of its dynamic control. This work reports the control and patterning of the front propagation in a dicyclopentadiene resin by immersion of phase-changing polycaprolactone particles. Predictive and designed patterning is enabled by multiphysical numerical analyses, which reveal that the interplay between endothermic phase transition, exothermic chemical reaction, and heat exchange govern the temperature, velocity, and propagation path of the front via two different interaction regimes. To pattern the front, one can vary the size and spacing between the particles and increase the number of propagating fronts, resulting in tunable physical patterns formed due to front separation and merging near the particles. Both single- and double-frontal polymerization experiments in an open mold are performed. The results confirm the front-particle interaction mechanisms and the shapes of the patterns explored numerically. The present study offers a fundamental understanding of frontal polymerization in the presence of heat-absorbing second-phase materials and proposes a potential one-step manufacturing method for precisely patterned polymeric and composite materials without masks, molds, or printers.

Manipulating Frontal Polymerization and Instabilities with Phase-Changing Microparticles

Recently presented as a rapid and eco-friendly manufacturing method for thermoset polymers and composites, frontal polymerization (FP) experiences thermo-chemical instabilities under certain conditions, leading to visible patterns and spatially dependent material properties. Through numerical analyses and experiments, we demonstrate how the front velocity, temperature, and instability in the frontal polymerization of cyclooctadiene are affected by the presence of poly(caprolactone) microparticles homogeneously mixed with the resin. The phase transformation associated with the melting of the microparticles absorbs some of the exothermic reaction energy generated by the FP, reduces the amplitude and order of the thermal instabilities, and suppresses the front velocity and temperatures. Experimental measurements validate predictions of the dependence of the front velocity and temperature on the microparticle volume fraction provided by the proposed homogenized reaction-diffusion model.

Starch as a reinforcement agent for poly(ionic liquid) hydrogels from deep eutectic solvent via frontal polymerization

For the first time, conductive starch/poly(ionic liquid) hydrogels from a polymerizable deep eutectic solvent (DES) by frontal polymerization (FP) were reported. The solubility and dispersibility for starch granules in the polymerizable DES was investigated. The effects of starch content on FP behaviors, mechanical properties and electrical conductivity of composite hydrogels were studied. Results showed that starch could be partially dissolved and dispersed in the DES. Comparing with the pure poly(ionic liquid) hydrogel from DES (the tensile strength was 41 K Pa), the tensile strength of composite hydrogel could increased by 3.07 times and reached 126 K Pa. When the fixed strain was 80 %, its compressive strength could increase by 6 times and reaches 16.8 MPa. The main reason was that there was a strong interfacial interaction between starch and the polymer hydrogel network. The starch/poly(ionic liquid) composite hydrogels also had good electrical conductivity. Absorption of water could increase the conductivity of the composite hydrogel significantly.

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.

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.

Microtopography-Guided Radial Gradient Circle Array Film with Nanoscale Resolution

Distribution of multimaterials at arbitrary positions with nanoscale resolution and over a large area substrate is essential to future advances in functional graded materials. Such stringent requirements are highly beyond the reach of current techniques, although newly developed 3D printing technologies are addressed. Here, a radial gradient circle array film with the distribution accuracy up to ≈18 nm is fabricated by using microtopographic substrate. A mathematical model is developed to guide the distribution of position, size, shape, and type of materials on an arbitrary section for the given morphology of substrate. The periodic electrical and mechanical properties of the radial gradient circle film are identified, which can be beneficial for further functionalization and applications, such as gradient refractive index lenses, microcoils, and microantennas.

Frontal Ring-Opening Metathesis Copolymerization: Deviation of Front Velocity from Mixing Rules

Frontal ring-opening metathesis polymerization (FROMP) of dicyclopentadiene (DCPD) shows promise for rapid, energy-efficient manufacturing of high-performance polymers and composites. Copolymerization in FROMP allows for systematic modification of materials properties while retaining the benefits of the DCPD system such as low cost of the monomer and excellent mechanical properties of the resulting polymer. While the copolymerization reactivity and copolymer properties generally exhibit monotonic dependence on monomer composition as predicted by simple, empirical mixing rules, we discovered that the frontal copolymerization behavior of DCPD with a dinorbornenyl (di-NBE) cross-linker deviates significantly from that expected relationship. As the comonomer content increases, the FROMP reaction shows a nonmonotonic increase in front velocity with intermediate compositions 40% faster than either pure component. We then studied the behavior of a series of comonomers, analyzed several factors (such as thermodynamic and kinetic properties) that might influence front velocity, and found that the nonmonotonic trend mainly results from the cross-linked structure. This copolymerization system provides a promising strategy to tune materials properties (such as glass transition temperature) and simultaneously improve the efficiency in FROMP-based materials manufacturing.

Protease-Sensitive Hydrogel Biomaterials with Tunable Modulus and Adhesion Ligand Gradients for 3D Vascular Sprouting

Biomaterial strategies focused on designing scaffolds with physiologically relevant gradients provide a promising means for elucidating 3D vascular cell responses to spatial and temporal variations in matrix properties. In this study, we present a photopolymerization approach, ascending photofrontal free-radical polymerization, to generate proteolytically degradable hydrogel scaffolds of poly(ethylene) glycol with tunable continuous gradients of (1) elastic modulus (slope of 80 Pa/mm) and uniform immobilized RGD concentration (2.06 ± 0.12 mM) and (2) immobilized concentration of the RGD cell-adhesion peptide ligand (slope of 58.8 μM/mm) and uniform elastic modulus (597 ± 22 Pa). Using a coculture model of vascular sprouting, scaffolds embedded with gradients of elastic modulus induced increases in the number of vascular sprouts in the opposing gradient direction, whereas RGD gradient scaffolds promoted increases in the length of vascular sprouts toward the gradient. Furthermore, increases in vascular sprout length were found to be prominent in regions containing higher immobilized RGD concentration.

Rapid energy-efficient manufacturing of polymers and composites via frontal polymerization

Thermoset polymers and composite materials are integral to today's aerospace, automotive, marine and energy industries and will be vital to the next generation of lightweight, energy-efficient structures in these enterprises, owing to their excellent specific stiffness and strength, thermal stability and chemical resistance^1-5. The manufacture of high-performance thermoset components requires the monomer to be cured at high temperatures (around 180 °C) for several hours, under a combined external pressure and internal vacuum ⁶ . Curing is generally accomplished using large autoclaves or ovens that scale in size with the component. Hence this traditional curing approach is slow, requires a large amount of energy and involves substantial capital investment^6,7. Frontal polymerization is a promising alternative curing strategy, in which a self-propagating exothermic reaction wave transforms liquid monomers to fully cured polymers. We report here the frontal polymerization of a high-performance thermoset polymer that allows the rapid fabrication of parts with microscale features, three-dimensional printed structures and carbon-fibre-reinforced polymer composites. Precise control of the polymerization kinetics at both ambient and elevated temperatures allows stable monomer solutions to transform into fully cured polymers within seconds, reducing energy requirements and cure times by several orders of magnitude compared with conventional oven or autoclave curing approaches. The resulting polymer and composite parts possess similar mechanical properties to those cured conventionally. This curing strategy greatly improves the efficiency of manufacturing of high-performance polymers and composites, and is widely applicable to many industries.

Alkyl Phosphite Inhibitors for Frontal Ring-Opening Metathesis Polymerization Greatly Increase Pot Life

Frontal ring-opening metathesis polymerization (FROMP) has potential for use in rapid fabrication of structural polymers. However, the high activity of the ruthenium catalyst used for FROMP has limited the working time to <1 h. We report the use of alkyl phosphites as inhibitors for Grubbs' type catalysts to substantially extend working time. Subtle changes in alkyl phosphite structure are shown to impact both pot life and frontal velocity. Specifically, by varying phosphite structure and concentration, we are able to control pot life between 0.25 and 30 h while still allowing FROMP to proceed at velocities between 1 and 8 cm/min to yield fully cured thermoset polymers. These results are of interest for conventional ROMP synthesis and may open the way to new FROMP-based manufacturing possibilities.

β-Cyclodextrin-based supramolecular poly(N-isopropylacrylamide) hydrogels prepared by frontal polymerization

Frontal polymerization (FP) was successfully applied to the synthesis of poly(N-isopropylacrylamide)-grafted-acryloyl-β-cyclodextrin supramolecularly crosslinked hydrogels. It was established that acryloyl-β-cyclodextrin (AβCD) allowed performing successful frontal polymerizations with N-isopropylacrylamide even in the absence of any covalent crosslinker, which is something generally required. It was found that the swelling properties of the resulting hydrogels can be tuned by varying the amount of AβCD. Namely, when little amounts of this non-covalent crosslinker were used, superabsorbent hydrogels were obtained. Hydrogels containing also a covalent crosslinker were also prepared for comparison. These latter exhibited swelling ratios that are much lower than the others.

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.

Temporal Control of Gelation and Polymerization Fronts Driven by an Autocatalytic Enzyme Reaction

Chemical systems that remain kinetically dormant until activated have numerous applications in materials science. Herein we present a method for the control of gelation that exploits an inbuilt switch: the increase in pH after an induction period in the urease-catalyzed hydrolysis of urea was used to trigger the base-catalyzed Michael addition of a water-soluble trithiol to a polyethylene glycol diacrylate. The time to gelation (minutes to hours) was either preset through the initial concentrations or the reaction was initiated locally by a base, thus resulting in polymerization fronts that converted the mixture from a liquid into a gel (ca. 0.1 mm min(-1)). The rate of hydrolytic degradation of the hydrogel depended on the initial concentrations, thus resulting in a gel lifetime of hours to months. In this way, temporal programming of gelation was possible under mild conditions by using the output of an autocatalytic enzyme reaction to drive both the polymerization and subsequent degradation of a hydrogel.

Temporal Control of Gelation and Polymerization Fronts Driven by an Autocatalytic Enzyme Reaction

Chemical systems that remain kinetically dormant until activated have numerous applications in materials science. Herein we present a method for the control of gelation that exploits an inbuilt switch: the increase in pH after an induction period in the urease-catalyzed hydrolysis of urea was used to trigger the base-catalyzed Michael addition of a water-soluble trithiol to a polyethylene glycol diacrylate. The time to gelation (minutes to hours) was either preset through the initial concentrations or the reaction was initiated locally by a base, thus resulting in polymerization fronts that converted the mixture from a liquid into a gel (ca. 0.1 mm min-1). The rate of hydrolytic degradation of the hydrogel depended on the initial concentrations, thus resulting in a gel lifetime of hours to months. In this way, temporal programming of gelation was possible under mild conditions by using the output of an autocatalytic enzyme reaction to drive both the polymerization and subsequent degradation of a hydrogel.

pH/temperature-sensitive hydrogel-based molecularly imprinted polymers (hydroMIPs) for drug delivery by frontal polymerization

Frontal polymerization was successfully utilized, for the first time, to obtain pH/temperature-sensitive hydrogel-based molecularly imprinted polymers (hydroMIPs).