Frontal Polymerization with Thiol−Ene Systems

Bubble-Free Frontal Polymerization of Acrylates via Redox-Initiated Free Radical Polymerization

Thermal frontal polymerization (FP) of acrylate monomers mixed with conventional peroxide initiators leads to significant bubble formation at the polymerizing front, limiting their practical applications. Redox initiators present a promising alternative to peroxide initiators, as they prevent the formation of gaseous byproducts during initiator decomposition and lower the front temperature, thereby enabling bubble-free FP. In this study, we investigate the FP of acrylate monomers of varying functionalities, including methyl methacrylate (MMA), 1,6-hexanediol diacrylate (HDDA), and trimethylolpropane triacrylate (TMPTA), using N,N-dimethylaniline/benzoyl peroxide (DMA/BPO) redox couple at room temperature and compare their front behavior, pot life, and bubble formation with those of same resin systems mixed with a conventional peroxide initiator, Luperox 231. The use of redox couples in FP of acrylates shows promise for rapid, energy-efficient manufacturing of polyacrylates and can enable new applications such as 3D printing and composite manufacturing.

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.

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.

Frontal Polymerization of a Thin Film on a Wood Substrate

Frontal polymerization has been explored as a technique to form two-dimensional thin films (<0.5 mm) on wood. We used trimethylolpropane triacrylate with a thermal free-radical initiator. The viscosity of the resin was adjusted by incorporating fumed silica within the formulation. As filler materials, either calcium carbonate or graphene nanoplatelets was used to evaluate the effect of filler type and content on front propagation. We observed that resin viscosity and film thickness critically affected the qualitative and quantitative propagation of the thermal front resulting in the formation of the coating. A workable coating was formed at a viscosity of 0.6 Pa·s, which was obtained when 3 phr (parts per hundred resin) of fumed silica was used in the resin formulation. Wet film thickness for this resin system was also found to have a limiting value, and full propagation of the front to result in a conformal coating required at least 15 mil (1 mil = 25 μm) of wet film thickness. Filler materials affected film propagation as a function of particle size and thermal properties. While 15 phr calcium carbonate could be incorporated with the resin, only 5 phr graphene nanoplatelets could be loaded within the matrix to ensure complete propagation of the front. Interestingly, for graphene fronts, velocity and temperature reduced systematically as a function of filler content. Filler type and content affected porosity and roughness of the coating, which was quantified by computerized tomography to understand the relationship between porosity and adhesion of the coated film with the wood substrate.

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.

Generation of a carbon dots/ammonium persulfate redox initiator couple for free radical frontal polymerization

We report a new redox initiator couple of ammonium persulfate (APS)/carbon dots (CDs) with high initiation efficiency used in frontal polymerization (FP).

In vitro evaluation of thermal frontally polymerized thiol-ene composites as bone augments

Because of the large number of total knee replacement (TKR) surgeries conducted per year, and with projections of increased demand to almost a million primary TKR surgeries per year by 2030 in the United States alone, there is a need to discover more efficient working materials as alternatives to current bone cements. There is a need for surgeons and hospitals to become more efficient and better control over the operative environment. One area of inefficiency is the cement steps during TKR. Currently the surgeon has very little control over cement polymerization. This leads to an increase in time, waste, and procedural inefficiencies. There is a clear need to create an extended working time, moldable, osteoconductive, and osteoinductive bone augment as a substitution for the current clinically used bone cement where the surgeon has better control over the polymerization process. This study explored several compositions of pentaerythritol-co-trimethylolpropane tris-(3-mercaptopropionate) hydroxyapatite composite materials prepared via benzoyl peroxide-initiated thermal frontal polymerization. The 4:1 acrylate to thiol ratio containing augment material shows promise with a maximal propagation temperature of 160°C ± 10°C, with mechanical strength of 3.65 MPa, and 111% cytocompatibility, relative to the positive control. This frontally polymerized material may have application as an augment with controlled polymerization supporting cemented implants. © 2015 Wiley Periodicals, Inc. J Biomed Mater Res Part B: Appl Biomater, 104B: 1152-1160, 2016.

Synthesis and characterization of functionally gradient materials obtained by frontal polymerization

Functionally gradient materials (FGMs) with gradual and continuous changes of their properties in one or more dimensions are useful in a wide range of applications. However, obtaining such materials with accurate control of the gradient, especially when the gradient is nonlinear, is not easy. In this work, frontal polymerization (FP) was exploited to synthesize polymeric FGMs. We demonstrated that the use of ascending FP with continuous feeding of monomers with computer-controlled peristaltic pumps provided an excellent method for the preparation of functionally gradient materials with programmed gradients. To test the effectiveness of the method, copolymers made from triethylene glycol dimethacrylate/hexyl methacrylate with linear and hyperbolic gradient in composition were synthesized. Differential scanning calorimetry (DSC), Shore A hardness measurements, compression tests, and swelling studies were performed along the length of the materials to assess the relationship between the gradients and the material properties. Glass transition temperatures, determined by DSC, showed a linear dependence on the composition and were in agreement with theoretical values. The other properties showed different and specific behaviors as a function of the compositional gradient.

In situ and frontal polymerization for the consolidation of porous stones: a unilateral NMR and magnetic resonance imaging study

Consolidation treatment of porous materials was performed by in situ and frontal polymerization of acrylic monomers inside a porous stone. To study the penetration of the polymer inside the stone and its consolidating effects we used water as a contrast agent, detecting its penetration using unilateral NMR and magnetic resonance imaging. All data obtained on differently treated stones were compared with corresponding ones obtained analyzing both untreated stones and stones simply painted with a well-known polymeric protective agent. In situ polymerization of acrylic monomers inside porous stones has been demonstrated to be an extremely powerful consolidating method, whereas thermally initiated frontal polymerization seems less efficient. In both cases the optimal choice of monomers is still open and requires further study. Our data indicate that unilateral NMR represents an inexpensive and simple technique for the non-invasive observation of the water uptake and of the effect of consolidation procedures in porous materials.