Frontal polymerization is a mode of converting monomer into polymer via a localized reaction zone that propagates. Such fronts can exist with free-radical polymerization or epoxy curing. The necessary conditions for the existence of the free-radical frontal polymerization regime are considered. The physicochemical properties of monomers are classified in connection with complications arising in the experiments, including low conversion, convection and bubbles. The density gradient in the reaction zone leading to front decay is the most insidious problem. The analysis of forces that can withstand the Taylor instability allowed us to overcome experimental difficulties and develop approaches to polymerize low-viscosity monomers in the frontal mode. The factors affecting front shape, velocity, conversion, and molecular weight are considered.Historically, frontal polymerization has been performed in neat monomer but we have been able to obtain fronts of very reactive monomers in high-boiling-point solvents including water, DMSO and DMF. Periodic frontal polymerization modes have been observed, including single and multi-point spin modes in which 'hot spots' (local high-temperature regions) migrate around the front as it propagates. We investigated experimentally the occurrence of the different modes as a function of the initial temperature and the intensity of heat losses and made a qualitative comparison to the results of theoretical analyses based on infinitely narrow reaction zone models.The future directions of research with frontal polymerization are considered, especially with regard to applications to materials synthesis.

Several properties of propagating fronts of addition polymerization were studied. A power function could be fit to the velocity dependence on initiator concentration, but not with the exponents predicted by current models or in agreement with other published work. Bubbles from the volatile by‐products of initiator decomposition were found to affect the front velocity and curvature. The front velocity for triethylene glycol dimethacrylate polymerization was found to depend linearly on temperature over a moderate range. The conversion of methacrylic acid in fronts varied greatly with initiator type and concentration. Benzoyl peroxide produced much lower conversion than t‐butyl peroxide, but fronts with tBPO propagated slower. A dual initiator system of BPO and tBPO produced rapidly propagating fronts with good conversion but the contribution of each initiator to the velocity was not additive. The possibility of chain branching was considered. The apparent molecular weight distributions were very broad, often trimodal, and found to depend on initiator type and concentration as well as the tube diameter. The temperature profiles were measured and found to be very sharp for BPO and broader for tBPO but both had front temperatures in excess of 200°C, indicating a high ceiling temperature. © 1995 John Wiley & Sons, Inc.

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Frontal polymerization is a process in which a spatially localized reaction zone propagates into a monomer, converting it into a polymer. In the simplest case of free-radical polymerization, a mixture of a monomer and initiator is placed into a test tube. Upon reaction initiation at one end of the tube, a self-sustained thermal wave, in which chemical conversion occurs, develops and propagates through the tube. We develop a mathematical model of the frontal polymerization process and analytically determine the structure of the polymerization wave, the propagation velocity, maximum temperature, and degree of conversion of the monomer. Specifically, we examine their dependence on the kinetic parameters of the reaction, the initial temperature of the mixture, and the initial concentrations of the initiator and monomer. Our analytic results are in good quantitative agreement with both direct numerical simulations of the model and experimental data (on butyl acrylate polymerization), which are also presented in the paper.

We studied ascending fronts of acrylamide polymerization in dimethyl sulfoxide in which the reactants in solution are converted to a gel at a higher temperature than the solution. We have calculated the stability boundary (the critical viscosity at which convection occurs) as a function of the front velocity. We found that in a two-dimensional system the presence of walls does stabilize the front compared to an infinite plane, but the shape of the boundary is not affected. Experimental fronts exhibited antisymmetric convection for low viscosities and low front velocities, as predicted by our calculations. However, the experimentally determined boundary differed significantly from the calculated ones, the experimental fronts being more stable. The shapes of the boundaries differ, and we propose this is caused by the temperature dependence of the viscosity, which is not treated in our analysis.