Review on Frontal Polymerization Behavior for Thermosetting Resins: Materials, Modeling and Application

Abstract

The traditional curing methods for thermosetting resins are energy-inefficient and environmentally unfriendly. Frontal polymerization (FP) is a self-sustaining process relying on the exothermic heat of polymerization. During FP, the external energy input (such as UV light input or heating) is only required at the initial stage to trigger a localized reaction front. FP is regarded as the rapid and energy-efficient manufacturing of polymers. The precise control of FP is essential for several manufacturing technologies, such as 3D printing, depending on the materials and the coupling of thermal transfer and polymerization. In this review, recent progress on the materials, modeling, and application of FP for thermosetting resins are presented. First, the effects of resin formulations and mixed fillers on FP behavior are discussed. Then, the basic mathematical model and reaction-thermal transfer model of FP are introduced. After that, recent developments in FP-based manufacturing applications are introduced in detail. Finally, this review outlines a roadmap for future research in this field.

Degree of Cure, Microstructures, and Properties of Carbon/Epoxy Composites Processed via Frontal Polymerization

“…To date, there has been very little research concentrating on the FP of thermoset composites. The effects of fiber volume fractions on the frontal velocity and reaction temperature of carbon/dicylopentadiene (DCPD) thermoset composites are investigated by Luo et al [ 33 ]. The equivalent thermal conductivity increases slowly at low fiber volume fractions but significantly at high volume fractions, impacting the heat flux distribution and potentially increasing frontal velocity [ 34 ].…”

A Mechanism-Based Reaction–Diffusion Model for Accelerated Discovery of Thermoset Resins Frontally Polymerized by Olefin Metathesis

“…With a sufficient temperature rise, the polymerization front continues to propagate through the unreacted monomer phase until all reactants are consumed or significant heat loss stalls the reaction. Due to their self-sustaining nature, FP-curing routes have become a cost-effective and environmentally friendly alternative to the traditional, more resource-intensive manufacturing processes. − This advancement has spurred their versatile application in the efficient production of high-performance polymers, thermosets, composites, and hydrogels. − …”