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.

Isothermal frontal polymerization (IFP) is a directional polymerization that uses the Trommsdorff, or gel, effect to produce gradient materials for optical applications. When a solution of methyl methacrylate and a thermal initiator contacts a polymer seed (a small piece of polymer), a viscous region is formed in which the polymerization rate is faster because of the Trommsdorff effect. Using the optical techniques of laser line deflection (Weiner's method) and shadowgraphy along with controls, we obtained definitive experimental evidence of IFP. Moreover, we were able to measure accurately and precisely the front position and front concentration profile as a function of time by monitoring IFP systems and controls of various initiator concentrations and cure temperatures. The experimental data were compared with theoretical predictions from a model using mass‐diffusion and radical polymerization kinetics. The model reproduced the decrease of the propagation time and showed an increase in the propagation velocity for an increase in the initiator concentration and/or cure temperature. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 5774–5786, 2005

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Using a newly developed low-temperature frontal polymerization technique, poly(methyl methacrylate) (PMMA) matrices were prepared with nonuniform distributions of organic nonlinear optical dyes, with potential use as optical limiters. This technique affords lower temperature conditions than have been used before. A PMMA tube was filled with a dye, the initiator tert-butyl peroxide, and methyl methacrylate (MMA). Curing at 4°C resulted in a radial gradient of dye. An axial dye gradient was observed when MMA was overlaid and polymerization effected from a dye-doped PMMA seed using tricaprylmethyl ammonium persulfate as the initiator. In both cases, polymerization reactions were observed as a result of isothermal frontal polymerization with the subsequent formation of a nonlinear concentration distribution of the optical dye dopants. Low temperatures are desirable to eliminate thermal and photothermal degradation of temperature-sensitive dyes during the polymerization. The preparation of long polymer rods with organic dye gradients on the scale of several centimeters can also be realized with the use of low-temperature polymerization and the gradients controlled by the concentration of initiator.

Diffusion of small molecules into glassy polymers is quite complicated and almost always non-Fickian. Little work has been done with the diffusion of low molecular weight polymers that are liquids at room temperature (such as poly(dodecyl acrylate)) into their miscible monomers. We have studied three molecular weights under 20 000 to determine if poly(dodecyl acrylate) diffusion into dodecyl acrylate could be treated with Fick's law and if so to determine the values of the diffusion coefficients. We compare two methods for measuring the diffusion of dodecyl acrylate into poly(dodecyl acrylate): We used laser line deflection (Wiener's method) and improved upon the method from published reports. We also used the dependence of pyrene's fluorescence on the viscosity to measure the concentration distribution, and thus to extract the diffusion coefficient. After an initial relaxation period, diffusion in all cases followed Fick's law with a single concentration-independent diffusion coefficient. Comparison of the diffusion coefficients obtained by both methods yielded the same order of magnitude for the diffusion coefficients (10(-7) cm2/s) and showed the same trend in the dependence on the average molecular weight of the polymer (a decrease in the diffusion coefficient with an increase in the molecular weight).