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.

NIR-Sensitized Cationic and Hybrid Radical/Cationic Polymerization and Crosslinking

NIR‐sensitized cationic polymerization proceeded with good efficiency, as was demonstrated with epoxides, vinyl ether, and oxetane. A heptacyanine functioned as sensitizer while iodonium salt served as coinitiator. The anion adopts a special function in a series selected from fluorinated phosphates (a: [PF₆]⁻, b: [PF₃(C₂F₅)₃]⁻, c: [PF₃(n‐C₄F₉)₃]⁻), aluminates (d: [Al(O‐t‐C₄F₉)₄]⁻, e: [Al(O(C₃F₆)CH₃)₄]⁻), and methide [C(O‐SO₂CF₃)₃]⁻ (f). Vinyl ether showed the best cationic polymerization efficiency followed by oxetanes and oxiranes. DFT calculations provided a rough pattern regarding the electrostatic potential of each anion where d showed a better reactivity than e and b. Formation of interpenetrating polymer networks (IPNs) using trimethylpropane triacrylate and epoxides proceeded in the case of NIR‐sensitized polymerization where anion d served as counter ion in the initiator system. No IPN was formed by UV‐LED initiation using the same monomers but thioxanthone/iodonium salt as photoinitiator. Exposure was carried out with new NIR‐LED devices emitting at either 805 or 870 nm.

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.

The NIR-sensitized cationic photopolymerization of oxetanes in combination with epoxide and acrylate monomers

NIR-sensitized photopolymerisation at 805 nm facilitates the cationic polymerization of oxetanes. This can additionally be combined with free-radical polymerization.

Cellulose-based polyacetals by direct and sensitized photocationic ring-opening polymerization of levoglucosenyl methyl ether

Polyacetal homopolymers and block copolymers are produced by photochemically initiated cationic ring-opening polymerization (CROP).

Ring-opening polymerization of isopropylglycidyl ether (IPGE) with new catalysts of Ti, Sn, Al-alkoxides and comparison of its reactivity

The polymerization reactions of isopropylglycidyl ether (IPGE) were carried out by various catalysts potassium hydroxide, potassium tert-butoxide, tetrafluorophthalate aluminum sec-butoxide, tetrafluorophthalate tin tert-butoxide, and tetrafluorophthalate-titanium isopropoxide complexes. Tetrafluorophthalate-aluminum, tin, and titanium have been prepared from aluminum sec-butoxide, tin tert-butoxide, and titanium isopropoxide in alcohol and tetrafluorophthalic acid. Poly-IPGE and catalysts were characterized by 1H, 13C NMR, FTIR spectroscopy, elemental analysis, and gel permeation chromatography. IPGE is less reactive toward OH- nucleophiles than 3-glycidyloxypropyltrimethoxysilane and propylene oxide.