Self-catalysed frontal polymerisation enables fast and low-energy processing of fibre reinforced polymer composites

Frontal polymerisation has the potential to bring unprecedented reductions in energy demand and process time to produce fibre reinforced polymer composites. Production of epoxy-based fibre reinforced polymer parts with high fibre volume content, commonly encountered in industry, is however hindered by the heat sink created by the fibres and the mould, overcoming the heat output of the chemical reaction, thus preventing front propagation. We propose a novel self-catalysed frontal polymerisation manufacturing method based on the integration of thin resin channels in thermal contact with the composite stack as a strategy for low-energy production of high fibre volume fraction polymer composites without the need for a continuous energy input. Frontal polymerisation inside the resin channel proceeds faster and preheats the fabric stack, thus catalysing the process. Parts with up to 60% fibre content are successfully produced independently of the sample thickness. Fillers added within the resin channels provide means to tailor the frontal polymerisation process kinetics. The parts have a significantly higher glass transition temperature than those produced in a conventional oven, and comparable mechanical properties while energy consumption is reduced by over 99.5%.