Free-Radical Frontal Polymerization with a Microencapsulated Initiator: Characterization of Microcapsules and Their Effect on Pot Life, Front Velocity, and 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.

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.

Preparation of Microcapsules Containing Benzoyl Peroxide Initiator with Gelatin-Gum Arabic/Polyurea-Formaldehyde Shell and Evaluating Their Storage Stability

This work involves the optimized preparation and characterization of microcapsules which contain benzoyl peroxide (BPO) dispersed in dibutyl phthalate (DBP) with gelatin-gum arabic (Gel-GA)/polyurea-formaldehyde (PUF) shell. The microcapsules were prepared in two steps using complex coacervation and in situ polymerization techniques, respectively, at various mixing speeds and different core:shell ratios. The scanning electron microscopy (SEM), optical microscopy, and Fourier transform infrared (FTIR) spectroscopy were used for characterization of prepared microcapsules. The resultant microcapsules were spherical with average diameters about 120-200 μm, had no intercapsule bonding, and had thicknesses of 0.7-1.5 μm. The results revealed high core content loading, 82-89 wt % for microcapsules prepared at various mixing speeds. The differential scanning calorimetry analysis (DSC) indicated that the encapsulated BPO was not influenced by the encapsulation process and maintained its activity. Moreover, with a compact and double Gel-GA/PUF shell, the microcapsules were stable, and no leakage of core material in an acrylate-based resin and toluene as an organic solvent was recorded. The resultant microcapsules have the potential of usage in industries such as self-healing systems and structural adhesives where the impermeability of microcapsules is an important factor.

Mechanistic approach to a photochemical/thermal dual-cure initiating system based on pyrylium salt–hydroperoxide for epoxide cationic polymerization

An initiating system based on pyrylium salts and the hydroperoxide group is a promising method to perform a dual-cure of epoxides via cationic polymerization.

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.