Radical photoinduced cationic frontal polymerization in porous media

Two different interpenetrating phase composites were produced using a radical photoinduced cationic frontal polymerization process. The composites were based on polyurethane (PU) and aluminium open‐cell foams impregnated with a formulation of a cycloaliphatic epoxy with different concentrations of a cationic photoinitiator and a thermal initiator. The influence of both types of initiators on the frontal polymerization features was systematically evaluated for the PU foam. It was found to occur only when the concentration of both initiators was greater than 0.5 wt%, leading to full conversion of the epoxy in the whole volume of the 15 mm thick composite samples within less than 100 s. The maximum temperature reached by the propagation front was in the range 275–305 °C depending on the type of formulation, leading to pores in the epoxy phase and extensive degradation of the PU phase. In the case of the opaque aluminium foam, an additional layer of pure resin was required on the UV‐exposed surface, which corresponded to a critical mass of a few grams to ensure sufficient heat generation and trigger the front propagation. © 2020 Society of Chemical Industry Interpenetrating phase composites are produced using a radical photoinduced cationic frontal polymerization process with polyurethane and aluminium open‐cell foams impregnated with epoxy resin formulations.