Modeling the Optimal Conditions for Improved Efficacy and Crosslink Depth of Photo-Initiated Polymerization

Efficacy analysis of new copper complex for visible light (455, 530 nm) radical/cationic photopolymerization: The synergic effects and catalytic cycle

The kinetics and the conversion features of two 3-component systems (A/B/N), based on the proposed new kinetic schemes of Mokbel and Mau et al, in which a visible LED is used to excite a copper complex to its excited triplet state (G*). The coupling of G* with iodonium salt and ethyl 4-(dimethylamino)benzoate (EDB) produces both free radical polymerization (FRP) of acrylates and the free radical promoted cationic polymerization (CP) of epoxides using various new copper complex as the initiator. Higher FRP and CP conversion can be achieved by co-additive of [B] and N, via the dual function of (i) regeneration [A], and (ii) generation of extra radicals. The interpenetrated polymer network (IPN) capable of initiating both FRP and CP in a blend of TMPTA and EPOX. The synergic effects due to CP include: (i) CP can increase viscosity limiting the diffusional oxygen replenishment; (ii) the cation also acts as a diluting agent for the IPN network, and (iii) the exothermic property of the CP. The catalytic cycle, synergic effects, and the oxygen inhibition are theoretically confirmed to support the experimental hypothesis. The measured results of Mokbel and Mau et al are well analyzed and matching the predicted features of our modeling.

A Review on Modeling Cure Kinetics and Mechanisms of Photopolymerization

Photopolymerizations, in which the initiation of a chemical-physical reaction occurs by the exposure of photosensitive monomers to a high-intensity light source, have become a well-accepted technology for manufacturing polymers. Providing significant advantages over thermal-initiated polymerizations, including fast and controllable reaction rates, as well as spatial and temporal control over the formation of material, this technology has found a large variety of industrial applications. The reaction mechanisms and kinetics are quite complex as the system moves quickly from a liquid monomer mixture to a solid polymer. Therefore, the study of curing kinetics is of utmost importance for industrial applications, providing both the understanding of the process development and the improvement of the quality of parts manufactured via photopolymerization. Consequently, this review aims at presenting the materials and curing chemistry of such ultrafast crosslinking polymerization reactions as well as the research efforts on theoretical models to reproduce cure kinetics and mechanisms for free-radical and cationic photopolymerizations including diffusion-controlled phenomena and oxygen inhibition reactions in free-radical systems.

Efficacy Analysis of In Situ Synthesis of Nanogold via Copper/Iodonium/Amine/Gold System under a Visible Light

This article presents, for the first time, the kinetics and the general features of a photopolymerization system (under visible light), copper-complex/Iodonium/triethylamine/gold-chloride (orA/B/N/G), with initial concentrations of A0, B0, N0 and G0, based on the proposed mechanism of Tar et al. Analytic formulas were developed to explore the new features, including: (i) both free radical photopolymerization (FRP) efficacy and the production of nanogold (NG), which are proportional to the relative concentration ratios of (A0 + B0 + N0)/G0 and may be optimized for maximum efficacy; (ii) the two competing procedures of NG production and the efficacy of FRP, which can be tailored for an optimal system with nanogold in the polymer matrix; (iii) the FRP efficacy, which is contributed by three components given by the excited state of copper complex (T), and the radicals (R and S) produced by iodonium and amine, respectively; (iv) NG production, which is contributed by the coupling of T and radical (S) with gold ion; and (v) NG production, which has a transient state proportional to the light intensity and the concentration ratio A0/G0) + (N0/(K'M0), but also a steady-state independent of the light intensity.

Novel Copper Photoredox Catalysts for Polymerization: An In Situ Synthesis of Metal Nanoparticles

The copper II complex (HLCuCl) carrying 2,4 dinitrophenylhydrazone (L) is synthesized and evaluated as a new photoredox catalyst/photoinitiator in combination with triethylamine (TEA) and iodonium salt (Iod) for the radical polymerization of ethylene glycol diacrylate during exposure to visible light using a photoreactor at 419 nm. The copper complex reactivity with TEA/Iod salt/gold chloride showed a good production and stability of gold nanoparticles. Finally, the high performance of Cu (II) complex for radical photopolymerization incorporating gold nanoparticles is provided. The photochemical mechanisms for the production of initiating radicals are studied using cyclic voltammetry. Polymer nanocomposites containing gold nanoparticles (Au NPs) in situ photogenerated during the irradiation process were prepared. The formation of Au NPs inside the polymer matrix was through UV-Vis and EDS/SEM analyses.

Ultra-High Through-Cure of (Meth)Acrylate Copolymers via Photofrontal Polymerization

Photopolymerization offers substantial advantages in terms of time, temperature, energy consumption, and spatial control of the initiation. The application however is strongly limited due to the constrained penetration of light into thick films. Strategies to overcome the problem of limited curing depth, as well as to improve the curing of shadow areas, involve dual curing, frontal polymerization, and upconversion of particles. Whereas excellent results have been accomplished applying photofrontal polymerization on a theoretical level, few studies report on practical applications achieving high curing depth within short time. This study aims to investigate the potential of photofrontal polymerization, performed only with photoinitiator and light, for the fast and easy production of several-centimeter-thick (meth)acrylic layers. Monomer/ initiator systems were evaluated with respect to their optical density as well as photobleaching behavior. Moreover, depth-dependent polymerization was studied in specimens of varying monomer ratio and photoinitiator concentration. When an ideal photoinitiator concentration was selected, curing up to 52 mm in depth was accomplished within minutes.

Curing Kinetic Analysis of Acrylate Photopolymer for Additive Manufacturing by Photo-DSC

In this research, the curing degree of an acrylate-based monomer using direct UV-assisted writing technology was characterized by differential photo calorimetry (Photo-DSC) to investigate the curing behavior. Triggered by the UV light, the duo function group monomer 1,6-Hexamethylene diacrylate (HDDA), photoinitiator 1173 and photoinhibitor exhibit a fast curing process. The exothermal photopolymerization reaction was performed in the isothermal mode in order to evaluate the different thermal effects that occurred during the photopolymerization process. The influences of both UV light intensity and exposure time were studied with single-factor analysis. The results obtained by photo-DSC also allow us to perform the kinetic study of the polymerization process: The results show that, for the reaction, the higher the UV intensity, the higher the curing degree together with faster curing speed. At the same time, the effect of the heat released during the exothermic reaction is negligible for the polymerization process. When increasing the exposure time, limited improvement of curing degree was shown, and the distribution is between 65-75%. The reaction enthalpy and related curing degree work as a function of time. The Avrami theory of phase change was introduced to describe the experimental data. The functions of a curing degree with light intensity and exposure time were achieved, respectively.

Modeling the Kinetics, Curing Depth, and Efficacy of Radical-Mediated Photopolymerization: The Role of Oxygen Inhibition, Viscosity, and Dynamic Light Intensity

Kinetic equations for a modeling system with type-I radical-mediated and type-II oxygen-mediated pathways are derived and numerically solved for the photopolymerization efficacy and curing depth, under the quasi-steady state assumption, and bimolecular termination. We show that photopolymerization efficacy is an increasing function of photosensitizer (PS) concentration (C ₀) and the light dose at transient state, but it is a decreasing function of the light intensity, scaled by [C ₀/I ₀]^0.5 at steady state. The curing (or cross-link) depth is an increasing function of C ₀ and light dose (time × intensity), but it is a decreasing function of the oxygen concentration, viscosity effect, and oxygen external supply rate. Higher intensity results in a faster depletion of PS and oxygen. For optically thick polymers (>100 um), light intensity is an increasing function of time due to PS depletion, which cannot be neglected. With oxygen inhibition effect, the efficacy temporal profile has an induction time defined by the oxygen depletion rate. Efficacy is also an increasing function of the effective rate constant, K = k'/ k T 0 . 5 , defined by the radical producing rate (k') and the bimolecular termination rate (k _T). In conclusion, the curing depth has a non-linear dependence on the PS concentration, light intensity, and dose and a decreasing function of the oxygen inhibition effect. Efficacy is scaled by [C ₀/I ₀]^0.5 at steady state. Analytic formulas for the efficacy and curing depth are derived, for the first time, and utilized to analyze the measured pillar height in microfabrication. Finally, various strategies for improved efficacy and curing depth are discussed.

Dual-Wavelength (UV and Blue) Controlled Photopolymerization Confinement for 3D-Printing: Modeling and Analysis of Measurements

The kinetics and modeling of dual-wavelength (UV and blue) controlled photopolymerization confinement (PC) are presented and measured data are analyzed by analytic formulas and numerical data. The UV-light initiated inhibition effect is strongly monomer-dependent due to different C=C bond rate constants and conversion efficacies. Without the UV-light, for a given blue-light intensity, higher initiator concentration (C10) and rate constant (k') lead to higher conversion, as also predicted by analytic formulas, in which the total conversion rate (RT) is an increasing function of C1 and k'R, which is proportional to k'[gB1C1]0.5. However, the coupling factor B1 plays a different role that higher B1 leads to higher conversion only in the transient regime; whereas higher B1 leads to lower steady-state conversion. For a fixed initiator concentration C10, higher inhibitor concentration (C20) leads to lower conversion due to a stronger inhibition effect. However, same conversion reduction was found for the same H-factor defined by H0 = [b1C10 - b2C20]. Conversion of blue-only are much higher than that of UV-only and UV-blue combined, in which high C20 results a strong reduction of blue-only-conversion, such that the UV-light serves as the turn-off (trigger) mechanism for the purpose of spatial confirmation within the overlap area of UV and blue light. For example, UV-light controlled methacrylate conversion of a glycidyl dimethacrylate resin is formulated with a tertiary amine co-initiator, and butyl nitrite. The system is subject to a continuous exposure of a blue light, but an on-off exposure of a UV-light. Finally, we developed a theoretical new finding for the criterion of a good material/candidate governed by a double ratio of light-intensity and concentration, [I20C20]/[I10C10].

Thiol-Ene Photopolymerization: Scaling Law and Analytical Formulas for Conversion Based on Kinetic Rate and Thiol-Ene Molar Ratio

Kinetics and analytical formulas for radical-mediated thiol-ene photopolymerization were developed in this paper. The conversion efficacy of thiol-ene systems was studied for various propagation to chain transfer kinetic rate-ratio (R_K), and thiol-ene concentration molar-ratio (R_C). Numerical data were analyzed using analytical formulas and compared with the experimental data. We demonstrated that our model for a thiol-acrylate system with homopolymerization effects, and for a thiol-norbornene system with viscosity effects, fit much better with the measured data than a previous model excluding these effects. The general features for the roles of R_K and R_C on the conversion efficacy of thiol (C_T) and ene (C_V) are: (i) for R_K = 1, C_V and C_T have the same temporal profiles, but have a reversed dependence on R_C; (ii) for R_K >> 1, C_T are almost independent of R_C; (iii) for R_K << 1, C_V and C_T have the same profiles and both are decreasing functions of the homopolymerization effects defined by k_CV; (iv) viscosity does not affect the efficacy in the case of R_K >> 1, but reduces the efficacy of C_V for other values of R_K. For a fixed light dose, higher light intensity has a higher transient efficacy but a lower steady-state conversion, resulting from a bimolecular termination. In contrast, in type II unimolecular termination, the conversion is mainly governed by the light dose rather than its intensity. For optically thick polymers, the light intensity increases with time due to photoinitiator depletion, and thus the assumption of constant photoinitiator concentration (as in most previous models) suffers an error of 5% to 20% (underestimated) of the crosslink depth and the efficacy. Scaling law for the overall reaction order, defined by [A]^m[B]ⁿ and governed by the types of ene and the rate ratio is discussed herein. The dual ratio (R_K and R_C) for various binary functional groups (thiol-vinyl, thiol-acrylate, and thiol-norbornene) may be tailored to minimize side effects for maximal monomer conversion or tunable degree of crosslinking.