Rapid energy-efficient manufacturing of polymers and composites via frontal polymerization.

Thermoset polymers and composite materials are integral to today's aerospace, automotive, marine and energy industries and will be vital to the next generation of lightweight, energy-efficient structures in these enterprises, owing to their excellent specific stiffness and strength, thermal stability and chemical resistance1-5. The manufacture of high-performance thermoset components requires the monomer to be cured at high temperatures (around 180 °C) for several hours, under a combined external pressure and internal vacuum 6 . Curing is generally accomplished using large autoclaves or ovens that scale in size with the component. Hence this traditional curing approach is slow, requires a large amount of energy and involves substantial capital investment6,7. Frontal polymerization is a promising alternative curing strategy, in which a self-propagating exothermic reaction wave transforms liquid monomers to fully cured polymers. We report here the frontal polymerization of a high-performance thermoset polymer that allows the rapid fabrication of parts with microscale features, three-dimensional printed structures and carbon-fibre-reinforced polymer composites. Precise control of the polymerization kinetics at both ambient and elevated temperatures allows stable monomer solutions to transform into fully cured polymers within seconds, reducing energy requirements and cure times by several orders of magnitude compared with conventional oven or autoclave curing approaches. The resulting polymer and composite parts possess similar mechanical properties to those cured conventionally. This curing strategy greatly improves the efficiency of manufacturing of high-performance polymers and composites, and is widely applicable to many industries.

Polymers with autonomous life-cycle control.

The lifetime of man-made materials is controlled largely by the wear and tear of everyday use, environmental stress and unexpected damage, which ultimately lead to failure and disposal. Smart materials that mimic the ability of living systems to autonomously protect, report, heal and even regenerate in response to damage could increase the lifetime, safety and sustainability of many manufactured items. There are several approaches to achieving these functions using polymer-based materials, but making them work in highly variable, real-world situations is proving challenging.

Localization of Spiropyran Activation.

Functionalization of planar and curved glass surfaces with spiropyran (SP) molecules and localized UV-induced activation of the mechanophore are demonstrated. Fluorescence spectra of UV-irradiated SP-functionalized surfaces reveal that increases in surface roughness or curvature produce more efficient conversion of the mechanophore to the open merocyanine (MC) form. Further, force-induced activation of the mechanophore is achieved at curved glass-polymer interfaces and not planar interfaces. Minimal fluorescence signal from UV-irradiated SP-functionalized planar glass surfaces precluded mechanical activation testing. Curved glass-polymer interfaces are prepared by SP functionalization of E-glass fibers, which are subsequently embedded in a poly(methyl methacrylate) (PMMA) matrix. Mechanical activation is induced through shear loading by a single fiber microbond testing protocol. In situ detection of SP activation at the interface is monitored by fluorescence spectroscopy. The fluorescence increase during interfacial testing suggests that attachment of the interfacial SP molecule to both fiber surface and polymer matrix is present and able to achieve significant activation of SP at the fiber-polymer matrix interface. Unlike previous studies for bulk polymers, SP activation is detected at relatively low levels of applied shear stress. By linking SP at the glass-polymer interface and transferring load directly to that interface, a more efficient mechanism for eliciting the SP response is achieved.

Interfacial Mechanophore Activation Using Laser-Induced Stress Waves.

A new methodology is developed to activate and characterize mechanochemical transformations at a solid interface. Maleimide-anthracene mechanophores covalently anchored at a fused silica-polymer interface are activated using laser-induced stress waves. Spallation-induced mechanophore activation is observed above a threshold activation stress of 149 MPa. The retro [4+2] cycloaddition reaction is confirmed by fluorescence microscopy, XPS, and ToF-SIMS measurements. Control experiments with specimens in which the mechanophore is not covalently attached to the polymer layer exhibit no activation. In contrast to activation in solution or bulk polymers, whereby a proportional increase in mechanophore activity is observed with applied stress, interfacial activation occurs collectively with spallation of the polymer film.

Accelerated Thermal Depolymerization of Cyclic Polyphthalaldehyde with a Polymeric Thermoacid Generator.

Thermally triggerable polymer films that degrade at modest temperatures (≈85 °C) are created from a blend of cyclic polyphthalaldehyde (cPPA) and a polymeric thermoacid generator, poly(vinyl tert-butyl carbonate sulfone) (PVtBCS). PVtBCS depolymerizes when heated, generating acid which initiates the depolymerization of cPPA into volatile byproducts. The mass loss onset for 2 wt% PVtBCS/cPPA is 22 °C lower than the onset for neat cPPA alone in dynamic thermogravimetric analysis experiments. Increased concentrations of PVtBCS increase the rate of depolymerization of cPPA. Raman spectroscopy reveals that the monomer, o-phthalaldehyde, is the main depolymerization product of the acid-catalyzed depolymerization of cPPA. The PVtBCS/cPPA blend is a promising material for the design and manufacture of transient electronic packaging and polymers.

Regioisomer-Specific Mechanochromism of Naphthopyran in Polymeric Materials.

Transformation of naphthopyran into a colored merocyanine species in polymeric materials is achieved using mechanical force. We demonstrate that the mechanochemical reactivity of naphthopyran is critically dependent on the regiochemistry, with only one particular substitution pattern leading to successful mechanochemical activation. Two alternative regioisomers with different polymer attachment points are demonstrated to be mechanochemically inactive. This trend in reactivity is accurately predicted by DFT calculations, reinforcing predictive capabilities in mechanochemical systems. We rationalize the reactivity differences between naphthopyran regioisomers in terms of the alignment of the target C-O pyran bond with the direction of the applied mechanical force and its effect on mechanochemical transduction along the reaction coordinate.

Force-induced activation of covalent bonds in mechanoresponsive polymeric materials.

Mechanochemical transduction enables an extraordinary range of physiological processes such as the sense of touch, hearing, balance, muscle contraction, and the growth and remodelling of tissue and bone. Although biology is replete with materials systems that actively and functionally respond to mechanical stimuli, the default mechanochemical reaction of bulk polymers to large external stress is the unselective scission of covalent bonds, resulting in damage or failure. An alternative to this degradation process is the rational molecular design of synthetic materials such that mechanical stress favourably alters material properties. A few mechanosensitive polymers with this property have been developed; but their active response is mediated through non-covalent processes, which may limit the extent to which properties can be modified and the long-term stability in structural materials. Previously, we have shown with dissolved polymer strands incorporating mechanically sensitive chemical groups-so-called mechanophores-that the directional nature of mechanical forces can selectively break and re-form covalent bonds. We now demonstrate that such force-induced covalent-bond activation can also be realized with mechanophore-linked elastomeric and glassy polymers, by using a mechanophore that changes colour as it undergoes a reversible electrocyclic ring-opening reaction under tensile stress and thus allows us to directly and locally visualize the mechanochemical reaction. We find that pronounced changes in colour and fluorescence emerge with the accumulation of plastic deformation, indicating that in these polymeric materials the transduction of mechanical force into the ring-opening reaction is an activated process. We anticipate that force activation of covalent bonds can serve as a general strategy for the development of new mechanophore building blocks that impart polymeric materials with desirable functionalities ranging from damage sensing to fully regenerative self-healing.

Biomimetic Self-Healing.

Self-healing is a natural process common to all living organisms which provides increased longevity and the ability to adapt to changes in the environment. Inspired by this fitness-enhancing functionality, which was tuned by billions of years of evolution, scientists and engineers have been incorporating self-healing capabilities into synthetic materials. By mimicking mechanically triggered chemistry as well as the storage and delivery of liquid reagents, new materials have been developed with extended longevity that are capable of restoring mechanical integrity and additional functions after being damaged. This Review describes the fundamental steps in this new field of science, which combines chemistry, physics, materials science, and mechanical engineering.

Structural reinforcement of microvascular networks using electrostatic layer-by-layer assembly with halloysite nanotubes.

We demonstrate a method for tailoring local mechanical properties near channel surfaces of vascular structural polymers in order to achieve high structural performance in microvascular systems. While synthetic vascularized materials have been created by a variety of manufacturing techniques, unreinforced microchannels act as stress concentrators and lead to the initiation of premature failure. Taking inspiration from biological tissues such as dentin and bone, these mechanical deficiencies can be mitigated by complex hierarchical structural features near to channel surfaces. By employing electrostatic layer-by-layer assembly (ELbL) to deposit films containing halloysite nanotubes onto scaffold surfaces followed by matrix infiltration and scaffold removal, we are able to controllably deposit nanoscale reinforcement onto 200 micron diameter channel surface interiors in microvascular networks. High resolution strain measurements on reinforced networks under load verify that the halloysite reduces strain concentrations and improves mechanical performance.

Biasing reaction pathways with mechanical force.

During the course of chemical reactions, reactant molecules need to surmount an energy barrier to allow their transformation into products. The energy needed for this process is usually provided by heat, light, pressure or electrical potential, which act either by changing the distribution of the reactants on their ground-state potential energy surface or by moving them onto an excited-state potential energy surface and thereby facilitate movement over the energy barrier. A fundamentally different way of initiating or accelerating a reaction is the use of force to deform reacting molecules along a specific direction of the reaction coordinate. Mechanical force has indeed been shown to activate covalent bonds in polymers, but the usual result is chain scission. Here we show that mechanically sensitive chemical groups make it possible to harness the mechanical forces generated when exposing polymer solutions to ultrasound, and that this allows us to accelerate rearrangement reactions and bias reaction pathways to yield products not obtainable from purely thermal or light-induced reactions. We find that when placed within long polymer strands, the trans and cis isomers of a 1,2-disubstituted benzocyclobutene undergo an ultrasound-induced electrocyclic ring opening in a formally conrotatory and formally disrotatory process, respectively, that yield identical products. This contrasts with reaction initiation by light or heat alone, in which case the isomers follow mutually exclusive pathways to different products. Mechanical forces associated with ultrasound can thus clearly alter the shape of potential energy surfaces so that otherwise forbidden or slow processes proceed under mild conditions, with the directionally specific nature of mechanical forces providing a reaction control that is fundamentally different from that achieved by adjusting chemical or physical parameters. Because rearrangement in our system occurs before chain scission, the effect we describe might allow the development of materials that are activated by mechanical stress fields.

Proton-coupled mechanochemical transduction: a mechanogenerated acid.

A novel mechanophore with acid-releasing capability is designed to produce a simple catalyst for chemical change in materials under mechanical stress. The mechanophore, based on a gem-dichlorocyclopropanated indene, is synthesized and used as a cross-linker in poly(methyl acrylate). Force-dependent rearrangement is demonstrated for cross-linked mechanophore samples loaded in compression, while the control shows no significant response. The availability of the released acid is confirmed by exposing a piece of insoluble compressed polymer to a pH indicator solution. The development of this new mechanophore is the first step toward force-induced remodeling of stressed polymeric materials utilizing acid-catalyzed cross-linking reactions.

Programmable microcapsules from self-immolative polymers.

For the autonomous repair of damaged materials, microcapsules are needed that release their contents in response to a variety of physical and chemical phenomena, not just by direct mechanical rupture. Herein we report a general route to programmable microcapsules. This method creates core-shell microcapsules with polymeric shell walls composed of self-immolative polymer networks. The polymers in these networks undergo a head-to-tail depolymerization upon removal of the triggering end group, leading to breakdown of the shell wall and subsequent release of the capsule's liquid interior. We report microcapsules with shell walls bearing both Boc and Fmoc triggering groups. The capsules release their contents only under conditions known to remove these triggering groups; otherwise, they retain their contents under a variety of conditions. In support of the proposed release mechanism, the capsule shell walls were observed to undergo physical cracking upon exposure to the triggering conditions.

Force-induced redistribution of a chemical equilibrium.

Spiropyran (SP) mechanophores (mechanochemically reactive units) can impart the unique functionality of visual stress detection to polymers and have potential for use in smart materials with self-sensing capabilities. These color-generating mechanophores were incorporated into polyurethane via step growth polymerization. Polyurethane, which is inherently a versatile engineering polymer, possesses an optimized balance of mechanical toughness and elasticity to allow for investigation of the kinetics of the mechanochemical response of the SP mechanophore in the bulk polymer via fluorescence and absorbance measurements. The stress-induced 6-π electrocyclic ring-opening to the colored merocyanine (MC) form of the mechanophore was quantified by measuring the change in absorbance of the polymer, while it was held at constant strain. The closing kinetics of the mechanophore was also studied by fluorescence imaging. Finally, the effects of mechanical strain on the equilibrium between the SP and MC forms are reported and discussed.

Masked cyanoacrylates unveiled by mechanical force.

Mechanical damage of polymers is often a destructive and irreversible process. However, desirable outcomes may be achieved by controlling the location of chain cleavage events through careful design and incorporation of mechanically active chemical moieties known as mechanophores. It is possible that mechanophores can be used to generate reactive intermediates that can autopolymerize or cross-link, thus healing mechanically induced damage. Herein we report the generation of reactive cyanoacrylate units from a dicyanocyclobutane mechanophore located near the center of a polymer chain. Because cyanoacrylates (which are used as monomers in the preparation of superglue) autopolymerize, the generated cyanoacrylate-terminated polymers may be useful in self-healing polymers. Sonication studies of polymers with the mechanophore incorporated into the chain center have shown that selective cleavage of the mechanophore occurs. Trapping experiments with an amine-based chromophore support cyanoacrylate formation. Additionally, computational studies of small-molecule models predict that force-induced bond cleavage should occur with greater selectivity for the dicyanocyclobutane mechanophore than for a control molecule.

Rapid Degradation of Poly(lactic acid) with Organometallic Catalysts.

Poly(lactic acid) (PLA) is an effective sacrificial material for the creation of vascular networks in thermoset polymers and composites. The high thermal stability of PLA limits its applications as an embedded sacrificial template in high-temperature-resistant thermoset matrices. Here, we demonstrate faster and more efficient PLA degradation at temperatures lower than previously reported using two organometallic catalysts: tin(II) oxalate (Sn(Oxa)) and tin(II) acetate (Sn(Ac)2). We process Sn(Oxa) by two separate methods to obtain a significant difference in the specific surface area (SSA) of the catalyst particles and compare PLA degradation performance in a thermogravimetric analysis (TGA) instrument. Changing the SSA of Sn(Oxa) by a factor of ∼20 reduces the PLA degradation onset temperature by 37 °C. The total degradation time of PLA films also decreases after blending with Sn(Oxa) having a higher SSA. We also find Sn(Ac)2 lowers the degradation onset of PLA by 53 °C compared to Sn(Oxa) with a similar SSA. In addition, Sn(Ac)2 decreases the time for complete degradation of PLA films by an order of magnitude compared to Sn(Oxa) at 200 °C. Films with a significantly lower Sn(Ac)2 concentration compared to Sn(Oxa) degrade much faster at lower temperatures up to 160 °C. Finally, PLA films with different loadings of Sn(Ac)2 are embedded in an epoxy thermoset matrix and subsequently vascularized at elevated temperatures in a vacuum oven. Microchannel formation is observed at 170 °C using Sn(Ac)2, reducing the temperature required for vaporization of embedded sacrificial polymer compared to Sn(Oxa) catalyst. Sn(Ac)2 can potentially reduce the energy, time, and amount of catalyst required for degrading PLA into volatile products for sacrificial applications.

A new self-healing epoxy with tungsten (VI) chloride catalyst.

Using self-healing materials in commercial applications requires healing chemistry that is cost-effective, widely available and tolerant of moderate temperature excursions. We investigate the use of tungsten (VI) chloride as a catalyst precursor for the ring-opening metathesis polymerization of exo-dicyclopentadiene (exo-DCPD) in self-healing applications as a means to achieve these goals. The environmental stability of WCl6 using three different delivery methods was evaluated and the associated healing performance was assessed following fracture toughness recovery protocols. Both as-received and recrystallized forms of the WCl6 resulted in nearly complete fracture recovery in self-activated tests, where healing agent is manually injected into the crack plane, at 12wt% WCl6 loading. In situ healing using 15wt% microcapsules of the exo-DCPD produced healing efficiencies of approximately 20%.

Core-Shell Microcapsules Containing Flame Retardant Tris(2-chloroethyl phosphate) for Lithium-Ion Battery Applications.

Flame retardant tris(2-chloroethyl phosphate) (TCP) is successfully encapsulated in core-shell poly(urea-formaldehyde) microcapsules by in situ polymerization. The microcapsules are electrochemically stable in lithium-ion (Li-ion) battery electrolytes and thermally stable to ca. 200 °C. Thermal triggering of these microcapsules at higher temperatures ruptures the shell wall, releasing the liquid core (flame retardant), and NMR spectroscopy confirms the presence of the flame retardant in the electrolyte solution. Li-ion pouch cell experiments demonstrate that microencapsulation of TCP and its incorporation into the battery electrolyte provide latent fire retardants that improve battery safety while maintaining inherent battery performance and cycling capability.

Self-Protecting Epoxy Coatings with Anticorrosion Microcapsules.

The corrosion of steel substrates causes damage that is costly to repair or replace. Current protective coatings predominately rely on environmentally harmful anticorrosive agents and toxic solvents to protect the underlying substrate. The use of lawsone (2-hydroxy-1,4-napthoquinone) together with a water-based epoxy coating provides an environmentally friendly alternative for common protective coatings. Microencapsulated lawsone embedded in an epoxy coating allows the anticorrosive agent to remain dormant until released by damage and delivered directly onto the steel substrate. UV-vis analysis confirms successful encapsulation of lawsone in a polyurethane shell wall and reveals up to 8 wt % lawsone in the capsule cores. Uniform dry film thickness and inflicted damaged are verified with ultrasound and optical microscopy. Visual and electrochemical analysis demonstrates that this self-protective scheme leads to a 70% corrosion inhibition efficiency in a neutral salt water solution.

Enhanced Mixing of Microvascular Self-Healing Reagents Using Segmented Gas-Liquid Flow.

Microvascular self-healing systems have previously been demonstrated to restore large-scale damage and achieve repeated healing of multiple damage events in polymers. However, the healing performance of these systems is often limited because the laminar nature of flow in microchannels  results in poor mixing of two-part self-healing reagents. In this paper, we introduce segmented gas-liquid flow (SGLF) to enhance the mixing of reagents in microvascular self-healing systems. In SGLF, discrete liquid slugs containing self-healing reagents are separated by gas bubbles while flowing through a single microchannel. Recirculating streamlines within the liquid slugs can enhance the mixing of miscible liquids such as healing reagents. We investigate the effect of SGLF on mixing and healing for a two-stage chemistry used to restore large-scale damage in thermoset polymers. Additionally, we employ SGLF to deliver an epoxy-thiol chemistry, enabling the repeated recovery of fracture toughness in glass fiber-reinforced composites. In both systems, the mixing of healing agents delivered by SGLF is enhanced compared to alternative microvascular delivery strategies. For the two-stage chemistry, SGLF increases the maximum damage size that can be healed by 25% compared to laminar single-phase flow. Furthermore, there are concomitant increases in the extent of polymerization and the mechanical properties of the restored material, including a fivefold increase in the peak load sustained during a push-out test. For the epoxy-thiol chemistry, SGLF enables multiple healing cycles with healing efficiency above 100%. On the basis of these results, we envision that SGLF could improve performance for a variety of microvascular self-healing systems with different host materials, damage modes, and healing chemistries.