Frontal Polymerization of a Thin Film on a Wood Substrate

Free-Standing 3D Printing of Epoxy-Vinyl Ether Structures Using Radical-Induced Cationic Frontal Polymerization

The application of frontal polymerization to additive manufacturing has advantages in energy consumption and speed of printing. Additionally, with frontal polymerization, it is possible to print free-standing structures that require no supports. A resin was developed using a mixture of epoxies and vinyl ether with an iodonium salt and peroxide initiating system that frontally polymerizes through radical-induced cationic frontal polymerization. The formulation, which was optimized for reactivity, physical properties, and rheology, allowed the printing of free-standing structures. Increasing ratios of vinyl ether and reactive cycloaliphatic epoxide were found to increase the front velocity. Addition of carbon nanofibers increased the front velocity more than the addition of milled carbon fibers. The resin filled with carbon nanofibers and fumed silica exhibited shear-thinning behavior and was suitable for extrusion-based printing at a weight fraction of 4 wt %. A desktop 3D printer was modified to control resin extrusion and deposition with a digital syringe dispenser. Flexural properties of molded and 3D-printed specimens showed that specimens printed in the transverse direction exhibited the lowest strength, likely due to the presence of voids, adhesion issues between filaments, and preferential carbon nanofiber alignment along the filaments. Finally, free-standing printing of single, angled filaments and helical geometries was successfully demonstrated by coordinating ultraviolet-based reaction initiation, low air pressure for resin extrusion, and printing speed to match front velocity.

A Self-Healing System for Polydicyclopentadiene Thermosets

Self-healing offers promise for addressing structural failures, increasing lifespan, and improving durability in polymeric materials. Implementing self-healing in thermoset polymers faces significant manufacturing challenges, especially due to the elevated temperature requirements of thermoset processing. To introduce self-healing into structural thermosets, the self-healing system must be thermally stable and compatible with the thermoset chemistry. This article demonstrates a self-healing microcapsule-based system stable to frontal polymerization (FP), a rapid and energy-efficient manufacturing process with a self-propagating exothermic reaction (≈200 °C). A thermally latent Grubbs-type complex bearing two N-heterocyclic carbene ligands addresses limitations in conventional G2-based self-healing approaches. Under FP's elevated temperatures, the catalyst remains dormant until activated by a Cu(I) co-reagent, ensuring efficient polymerization of the dicyclopentadiene (DCPD) upon damage to the polyDCPD matrix. The two-part microcapsule system consists of one capsule containing the thermally latent Grubbs-type catalyst dissolved in the solvent, and another capsule containing a Cu(I) coagent blended with liquid DCPD monomer. Using the same chemistry for both matrix fabrication and healing results in strong interfaces as demonstrated by lap-shear tests. In an optimized system, the self-healing system restores the mechanical properties of the tough polyDCPD thermoset. Self-healing efficiencies greater than 90% via tapered double cantilever beam tests are observed.

Rapid Preparation of Superabsorbent Self-Healing Hydrogels by Frontal Polymerization

Hydrogels have received increasing interest owing to their excellent physicochemical properties and wide applications. In this paper, we report the rapid fabrication of new hydrogels possessing a super water swelling capacity and self-healing ability using a fast, energy-efficient, and convenient method of frontal polymerization (FP). Self-sustained copolymerization of acrylamide (AM), 3-[Dimethyl-[2-(2-methylprop-2-enoyloxy)ethyl]azaniumyl]propane-1-sulfonate (SBMA), and acrylic acid (AA) within 10 min via FP yielded highly transparent and stretchable poly(AM-co-SBMA-co-AA) hydrogels. Thermogravimetric analysis and Fourier transform infrared spectroscopy confirmed the successful fabrication of poly(AM-co-SBMA-co-AA) hydrogels with a single copolymer composition without branched polymers. The effect of monomer ratio on FP features as well as porous morphology, swelling behavior, and self-healing performance of the hydrogels were systematically investigated, showing that the properties of the hydrogels could be tuned by adjusting the chemical composition. The resulting hydrogels were superabsorbent and sensitive to pH, exhibiting a high swelling ratio of up to 11,802% in water and 13,588% in an alkaline environment. The rheological data revealed a stable gel network. These hydrogels also had a favorable self-healing ability with a healing efficiency of up to 95%. This work contributes a simple and efficient method for the rapid preparation of superabsorbent and self-healing hydrogels.

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.

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.

Critical Role of Layer Thickness in Frontal Polymerization

Thermal frontal polymerization (FP) is a chemical process during which a cold monomer-initiator mixture is converted into a hot polymer as a polymerization front propagates in the system due to the interplay between heat diffusion and the exothermicity of the reaction. The theoretical description of FP generally focuses on one-dimensional (1D) reaction-diffusion (RD) models where the effect of heat losses is encoded into an effective parameter in the heat equation. We show here the limits of such 1D models to describe FP under nonadiabatic conditions. To do so, the propagation of a polymerization front is analyzed both analytically and numerically in a rectangular two-dimensional (2D) layer. The layer thickness is shown to control the dynamics of the front and to determine its very existence. We find that for given heat losses, a minimum thickness is required for front propagation as recently observed in FP experiments of 2D thin films on wood. Moreover, when the thickness exceeds a critical value, the front is observed to survive independently of the rate of heat losses. This result cannot be predicted with 1D models where front extinction is always possible. A scaling analysis is proposed to highlight the physical interpretation of such a front survival. The influence of dimensionality on thermal instabilities is also analyzed, with a focus on the differences with the 1D predictions.

Anisotropic Foams via Frontal Polymerization

The properties of foams, an important class of cellular solids, are most sensitive to the volume fraction and openness of its elementary compartments; size, shape, orientation, and the interconnectedness of the cells are other important design attributes. Control of these morphological traits would allow the tailored fabrication of useful materials. While approaches like ice templating have produced foams with elongated cells, there is a need for rapid, versatile, and energy-efficient methods that also control the local order and macroscopic alignment of cellular elements. Here, a fast and convenient method is described to obtain anisotropic structural foams using frontal polymerization. Foams are fabricated by curing mixtures of dicyclopentadiene and a blowing agent via frontal ring-opening metathesis polymerization (FROMP). The materials are characterized using microcomputed tomography (micro-CT) and an image analysis protocol to quantify the morphological characteristics. The cellular structure, porosity, and hardness of the foams change with blowing agent, concentration, and resin viscosity. Moreover, a full factorial combination of variables is used to correlate each parameter with the structure of the obtained foams. The results demonstrate the controlled production of foams with specific morphologies using the simple and efficient method of frontal polymerization.

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.