Frontal copolymerization is a process in which a spatially localized reaction zone propagates into a mixture of two monomers, converting them into a copolymer. In the simplest case of free‐radical copolymerization, a mixture of monomers and initiator is placed into a test tube. Reaction is initiated at one end of the tube, and a self‐sustained thermal wave, in which chemical conversion occurs, develops and propagates through the tube. We develop a mathematical model of the frontal copolymerization process and analytically determine the structure of the polymerization wave, the propagation velocity, maximum temperature, and degree of conversion of the monomers. Specifically, we examine their dependence on reactivity ratios as well as other kinetic parameters, monomer feed composition, and exothermicity of the reactions. Our analytic results are in good quantitative agreement with both direct numerical simulations of the model and experimental data, which are also presented in the paper.Dependence of front velocity on monomer feed composition for different heat release parameters.imageDependence of front velocity on monomer feed composition for different heat release parameters.
We observed that the velocities of descending thermoset polymerization fronts were strongly affected by the orientation of the tube. The front remained approximately perpendicular to the gravitational vector but propagated almost 1.8 times as fast at 75° along the axis of the tube. We performed a study of the velocity and front‐shape dependence on orientation with propagating fronts of triethylene glycol dimethacrylate with peroxide initiator and acrylamide/bisacrylamide polymerization in dimethyl sulfoxide with persulfate initiator. The percentage increase of velocity was independent of the initiator concentration but strongly dependent on the viscosity. Convection under the front flowed away from the tube wall nearest the vertical axis and was stronger as the angle increased. The front shape also changed, becoming significantly distorted near the wall from which the convection originated. We applied a simple geometric argument to explain the angular dependence for small angles on the basis of the assumption that convection did not affect the velocity of propagation normal to the front. The increase in velocity along the tube axis could be explained by a projection of the normal velocity onto the tube axis, following a 1/cosθ dependence. For higher angles, the convection was not sufficiently strong to maintain a level front. When the difference from a 180° orientation was considered, the velocity dependence exactly followed the geometric relationship. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 3504–3508, 2002
Frontal polymerization is a mode of polymerization in which a localized zone of reaction propagates through the coupling of thermal diffusion and the Arrhenius dependence of the reaction rate. The dependence of the front propagation velocity on the initial composition has been determined in initially miscible binary systems of a free-radically cured diacrylate and an amine-or cationically cured epoxy resin. A minimum of the velocity as a function of the monomer mole fraction is observed if the two polymerizations occur independently. Excellent agreement with an analytical description was found with the diacrylate and an amine-cured epoxy but not for a diacrylate and a cationically cured one because of the effect of HCl impurities on the peroxide.
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