Radical induced cationic frontal polymerization for rapid out-of-autoclave processing of carbon fiber reinforced polymers

Radical induced cationic frontal polymerization (RICFP) is considered as a promising method for processing of fiber reinforced polymers (FRPs). Optimization of the local heat flow is required to pave the way for its adaptation to an industrial processing method. In this work we present an overview on the role of the mold design on the frontal polymerization characteristics and resulting chemical properties. Mold properties were found of significant influence on the front characteristics. Highly insulating molds allowed for the highest front temperatures and velocities while consequent delayed cooling is suggested beneficial for the monomer conversion in neat polymer and FRP systems. An optimized mold configuration was subsequently used for FRP production, allowing for self-sustaining RICFP in FRPs with fiber volume fractions (Vfs) up to 45.8%. A processing window was moreover defined relating the Vf and required heat generation to the potential formation of a self-sustaining or supported front.