Frontal polymerization (FP) is a promising alternative manufacturing method for thermoset-based fiber-reinforced polymer composites (FRP) in comparison with the traditional autoclave/oven-curing method, due to its rapid curing process, low energy consumption, and low cost. Optimizing the weight contents of initiators relative to the resin’s mass is needed to adjust the mechanical properties of FRPs in industrial applications. This study investigates the effect of varying the photo-initiator (PI) weight content on tensile properties and the frontal polymerization characteristics, including the front velocity, front temperature, and degree of cure, in the FP process of the epoxy resin. Specifically, a dual-initiator system, including PI and thermal-initiator (TI), is used to initiate the polymerization process by ultraviolent (UV) light. The weight content of the TI is fixed at 1 w%, and the relative PI concentration is varied from 0.2 w% to 0.5 wt%. Results show that increasing the PI amount from 0.2 wt% to 0.3 wt% significantly improves the front velocity and the degree of cure by about two times. Increasing the PI content from 0.3 wt% to 0.4 wt% results in 15% and 26% higher degree of cure and front velocity, respectively. Moreover, due to the different front velocity in the top and bottom regions of the specimen, the specimens with 0.4 wt% PI exhibited a curved shape. The specimen with 0.5 wt% PI is thermally degraded and foamed. By comparing tensile properties, it is found that increasing the PI concentration from 0.2 wt% to 0.3 wt% improves the tensile strength and Young’s modulus by 3.91% and 7%, respectively, while the tensile strength and the Young’s modulus of frontal polymerized specimens are on average 8% and 14% higher than traditionally oven-cured ones, respectively.
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Controllable Frontal Polymerization and Spontaneous Patterning Enabled by Phase‐Changing Particles
Frontal polymerization provides a rapid, economic, and environmentally friendly methodology to manufacture thermoset polymers and composites. Despite its efficiency and reduced environmental impact, the manufacturing method is underutilized due to the limited fundamental understanding of its dynamic control. This work reports the control and patterning of the front propagation in a dicyclopentadiene resin by immersion of phase‐changing polycaprolactone particles. Predictive and designed patterning is enabled by multiphysical numerical analyses, which reveal that the interplay between endothermic phase transition, exothermic chemical reaction, and heat exchange govern the temperature, velocity, and propagation path of the front via two different interaction regimes. To pattern the front, one can vary the size and spacing between the particles and increase the number of propagating fronts, resulting in tunable physical patterns formed due to front separation and merging near the particles. Both single‐ and double‐frontal polymerization experiments in an open mold are performed. The results confirm the front–particle interaction mechanisms and the shapes of the patterns explored numerically. The present study offers a fundamental understanding of frontal polymerization in the presence of heat‐absorbing second‐phase materials and proposes a potential one‐step manufacturing method for precisely patterned polymeric and composite materials without masks, molds, or printers.
more » « less- Award ID(s):
- 1933932
- NSF-PAR ID:
- 10449140
- Publisher / Repository:
- Wiley Blackwell (John Wiley & Sons)
- Date Published:
- Journal Name:
- Small
- Volume:
- 17
- Issue:
- 42
- ISSN:
- 1613-6810
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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