The synthesis and processing of most thermoplastics and thermoset polymeric materials rely on energy-inefficient and environmentally burdensome manufacturing methods. Frontal polymerization is an attractive, scalable alternative due to its exploitation of polymerization heat that is generally wasted and unutilized. The only external energy needed for frontal polymerization is an initial thermal (or photo) stimulus that locally ignites the reaction. The subsequent reaction exothermicity provides local heating; the transport of this thermal energy to neighboring monomers in either a liquid or gel-like state results in a self-perpetuating reaction zone that provides fully cured thermosets and thermoplastics. Propagation of this polymerization front continues through the unreacted monomer media until either all reactants are consumed or sufficient heat loss stalls further reaction. Several different polymerization mechanisms support frontal processes, including free-radical, cat- or anionic, amine-cure epoxides, and ring-opening metathesis polymerization. The choice of monomer, initiator/catalyst, and additives dictates how fast the polymer front traverses the reactant medium, as well as the maximum temperature achievable. Numerous applications of frontally generated materials exist, ranging from porous substrate reinforcement to fabrication of patterned composites. In this review, we examine in detail the physical and chemical phenomena that govern frontal polymerization, as well as outline the existing applications.

Chemical systems that remain kinetically dormant until activated have numerous applications in materials science. Herein we present a method for the control of gelation that exploits an inbuilt switch: the increase in pH after an induction period in the urease‐catalyzed hydrolysis of urea was used to trigger the base‐catalyzed Michael addition of a water‐soluble trithiol to a polyethylene glycol diacrylate. The time to gelation (minutes to hours) was either preset through the initial concentrations or the reaction was initiated locally by a base, thus resulting in polymerization fronts that converted the mixture from a liquid into a gel (ca. 0.1 mm min⁻¹). The rate of hydrolytic degradation of the hydrogel depended on the initial concentrations, thus resulting in a gel lifetime of hours to months. In this way, temporal programming of gelation was possible under mild conditions by using the output of an autocatalytic enzyme reaction to drive both the polymerization and subsequent degradation of a hydrogel.

The main goal of our research deals with a new greener and more efficient lignin modification method to optimize its structural performance as a phenol-formaldehyde resin filler. Through the appropriate increase in the phenolic hydroxyl content, added value as a raw material was intended. For that, a series of mixtures of zinc chloride–urea with different molar ratios was prepared to obtain deep-eutectic solvents (DESs). Two heating methods (oil bath and microwave heating) were compared and optimized. Microwave helps in reducing the preparation time but to the detriment of temperature control. On the other hand, heating with an oil bath provided better temperature control and homogeneity of the mixture. The preferable molar ratio of ZnCl₂–urea was 3 : 10 (T_g = −26.3 °C). The structural changes of the pretreated lignin samples were investigated by Fourier transformed infrared and X-ray photoelectron spectroscopies, scanning electron microscopy, induced coupled plasma and X-ray diffraction. Thermogravimetric analysis demonstrated significant differences in the thermal behavior of the recovered lignin as a result of DES treatment. The weight of lignin recovered was 4 times that of original lignin, indicating that the structure of lignin was transformed through the integration of Zn. The integration of Zn enhanced the thermal stability and enhanced lignin's reactivity towards phenol-formaldehyde resin formation. Phenol-formaldehyde resin containing the recovered lignin exhibited lower thermocuring temperatures and better thermostability than those without filler. To the best of our knowledge, this is the first report on the investigation of the structural transformations of lignin through its dissolution in urea–ZnCl₂ DES and subsequent use as filler for phenol formaldehyde resin synthesis.