Kinetic and Chemical Effects of Clays and Other Fillers in the Preparation of Epoxy–Vinyl Ether Composites Using Radical-Induced Cationic Frontal Polymerization

[Image: see text] Addition of fillers to formulations can generate composites with improved mechanical properties and lower the overall cost through a reduction of chemicals needed. In this study, fillers were added to resin systems consisting of epoxies and vinyl ethers that frontally polymerized through a radical-induced cationic frontal polymerization (RICFP) mechanism. Different clays, along with inert fumed silica, were added to increase the viscosity and reduce the convection, results of which did not follow many trends present in free-radical frontal polymerization. The clays were found to reduce the front velocity of RICFP systems overall compared to systems with only fumed silica. It is hypothesized that chemical effects and water content produce this reduction when clays are added to the cationic system. Mechanical and thermal properties of composites were studied, along with filler dispersion in the cured material. Drying the clays in an oven increased the front velocity. Comparing thermally insulating wood flour to thermally conducting carbon fibers, we observed that the carbon fibers resulted in an increase in front velocity, while the wood flour reduced the front velocity. Finally, it was shown that acid-treated montmorillonite K10 polymerizes RICFP systems containing vinyl ether even in the absence of an initiator, resulting in a short pot life.