Advanced Catalytic Concepts for Frontal Polymerization

Thermosets are cross-linked polymers that are used in numerous high-performance applications due to their excellent heat, chemical, and dimensional stability. Traditionally, they are manufactured through energy-inefficient and cost-intensive bulk polymerization methods, requiring the entire component to be heated for an extended period of time. In many cases, the concept of frontal polymerization represents an environmentally friendly and cost-effective alternative. First, an external stimulus locally initiates a self-sustaining reaction cascade. The resulting thermal polymerization front subsequently propagates through the reaction vessel and enables directional growth of the thermoset, which continues until either the monomer resin is fully consumed or excessive heat loss prevents further propagation. Thus, chemical control is lost once the polymerization process is initiated. In the first part of this project, the chemical lability of such polymerization fronts is investigated, and possible influencing factors based on the composition of the monomer resin are identified. This knowledge is then used to deliberately control the propagation of the polymerization front using special catalysts and additives, and to apply it in novel manufacturing concepts. Finally, the monomer resins are further modified to enable reprocessing and multi-generational recycling of the resulting thermosets.