The discovery and development of onium salt cationic photoinitiators

The story of the discovery and development of onium salt photoinitiators for cationic polymerization is chronicled. The chemistry of the synthesis of these compounds is outlined, and the mechanisms of their initiation are discussed briefly. Among the most useful of these types of photoinitiators are diaryliodonium and triarylsulfonium salts, which are used widely for photoinduced cationic crosslinking reactions. From the very beginning, onium salt photoinitiated cationic polymerizations have found use in a multitude of practical applications. Specifically discussed in this article are the use of onium salts in coatings, adhesives, printing inks, release coatings, stereolithography, holographic recording, photocurable composites, and microelectronic photoresists. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 4241–4254, 1999     

Visible and long‐wavelength photoinitiated cationic polymerization

A new system for efficiently carrying out cationic photopolymerizations with visible and long‐wavelength UV light is described. This system is based on the principle that certain onium salt cationic photoinitiators can be reduced by free radicals produced by the hydrogen abstraction reactions of photoexcited ketones. Thus, when camphorquinone, benzil, 2‐isopropylthioxanthone, and 2‐ethylanthraquinone are irradiated in the presence of a monomer that can serve as a hydrogen donor, the resulting monomer‐bound radical rapidly reduces a diaryliodonium salt or a dialkylphenacylsulfonium salt, and the resulting monomer‐centered cations initiate the polymerizations of epoxides, vinyl ethers, and heterocyclic compounds. Onium salts with high reduction potentials, such as triarylsulfonium salts, do not undergo sensitization by this new system. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 39: 343–356, 2001     

Synergistic interaction of epoxides and N‐vinylcarbazole during photoinitiated cationic polymerization

A kinetic study was conducted of the independent photoinitiated cationic polymerization of a number of epoxide monomers and mixtures of these monomers with N‐vinylcarbazole. The results show that these two different classes of monomers undergo complex synergistic interactions with one another during polymerization. It was demonstrated that N‐vinylcarbazole as well as other carbazoles are efficient photosensitizers for the photolysis of both diaryliodonium and triarylsulfonium salt photoinitiators. In the presence of large amounts of N‐vinylcarbazole, the rates of the cationic ring‐opening photopolymerization of epoxides are markedly accelerated. This effect has been ascribed to a photoinitiated free‐radical chain reaction that results in the oxidation of monomeric and polymeric N‐vinylcarbazole radicals by the onium salt photoinitiators to generate cations. These cations can initiate the ring‐opening polymerization of the epoxides, leading to the production of copolymers. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 3697–3709, 2000     

Photoinduced and thermally induced cationic polymerizations using S,S‐dialkyl‐S‐(3,5‐dimethylhydroxyphenyl)sulfonium salts

A study of the photoinitiated and thermally initiated cationic polymerizations of several monomer systems with S,S‐dialkyl‐S‐(3,5‐dimethylhydroxyphenyl)sulfonium salt (HPS) photoinitiators bearing different lengths of alkyl chains on the positively charged sulfur atom has been conducted. HPS photoinitiators are capable of photoinitiating the cationic polymerization of a wide variety of epoxy and vinyl ether monomers directly on irradiation with short‐wavelength UV light. Aryl ketone photosensitizers are effective in extending the spectral response of these photoinitiators into the long‐wavelength UV region. Kinetic studies with real‐time infrared spectroscopy show that HPS photoinitiators exhibit good efficiency in the polymerization of epoxide and vinyl ether monomers. Comparative studies also demonstrate that S,S‐dimethyl‐S‐(3,5‐dimethyl‐2‐hydroxyphenyl)sulfonium salts are more active photoinitiators than their isomeric S,S‐dimethyl‐S‐(3,5‐dimethyl‐4‐hydroxyphenyl)sulfonium salt counterparts. Both types of HPS photoinitiators display reversible photolysis as a result of facile termination reactions that take place between the growing chains ends with the photogenerated sulfur ylides. Preliminary studies have shown that HPS photoinitiators can also be employed as thermal initiators for the cationic ring‐opening polymerization of epoxides at moderate temperatures. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 2570–2587, 2003     

Long‐wavelength‐absorbing dialkylphenacylsulfonium salt photoinitiators: Synthesis and photoinduced cationic polymerization

A series of sulfonium salt photoinitiators with the general structure Ar′S⁺CH₃(C₁₂H₂₅)SbF, where Ar′ is phenacyl (I), 2‐indanonyl (II), 4‐methoxyphenacyl (III), 2‐naphthoylmethyl (IV), 1‐anthroylmethyl (V), or 1‐pyrenoylmethyl (VI), were prepared with a novel, simple one‐pot process that involves the reaction of an α‐bromoalkylarylketone (Ar′Br) with the dialkylsulfide (CH₃SC₁₂H₂₅) in the presence of sodium hexafluroantimonate in 2‐butanone at room temperature. The photoreactivity of photoinitiators II–VI were evaluated and compared to the unsubstituted analogue, I, in the polymerization of a variety of epoxide monomers. Real‐time infrared spectroscopy and differential scanning photocalorimetry studies revealed that the indanonyl initiator II is more active than I. However, sulfonium salts IV–VI, which contain polycyclic aromatic structures, are much less effective as cationic photoinitiators. Interestingly, photoinitiator III is either more or less reactive compared to I, depending on the monomer used. Our work also showed that the efficiency of the unsubstituted phenacylsulfonium salt I can be significantly enhanced through the use of photosensitizers. Mechanistic aspects of the photopolymerization studies are discussed. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 1433–1442, 2000     

Design and synthesis of highly reactive photopolymerizable epoxy monomers

The synthesis of a series of novel cationically photopolymerizable epoxide monomers bearing benzyl, allyl, and propargyl acetal and ether groups that can stabilize free radicals was carried out. These monomers display enhanced reactivity in cationic photopolymerization in the presence of certain onium salt photoinitiators. Specifically, this article describes schemes for the synthesis of cycloaliphatic epoxy monomers bearing free‐radical stabilizing groups. During UV irradiation of an onium salt cationic photoinitiator, the aryl radicals that are generated abstract labile protons present in such monomers to generate the corresponding carbon‐centered radicals. Subsequently, these radicals can interact with the onium salt by a redox mechanism to induce the decomposition of these salts. The overall result is that additional cationic species are generated by this mechanism that increase the rate and extent of the cationic ring‐opening polymerization of the epoxide monomer. An investigation of the photopolymerizations of the monomers prepared during this work was carried out using Fourier transform real‐time infrared spectroscopy, and conclusions were drawn with respect to the relationship between their structures and reactivity. © 2001 John Wiley & Sons, Inc. J Polym Sci Part A: Polym Chem 39: 2385–2395, 2001     

Phenothiazine photosensitizers for onium salt photoinitiated cationic polymerization

Phenothiazine compounds bearing a wide range of different substituents are excellent photosensitizers for onium salt cationic photoinitiators. These photosensitizers are generally operative in the mid‐ and long‐range regions of the UV spectrum and are especially useful for enhancing the rate of photoinitiated cationic polymerization carried out utilizing both filtered and broadband UV emission sources. In this article, the syntheses of several different substituted phenothiazines are described and the ability of these compounds to photosensitize the photolysis of different onium salt photoinitiators is evaluated. Attempts were made to correlate the structure and spectral characteristics of the phenothiazines with their efficiency of photosensitization in the cationic photopolymerizations of several typical epoxide and vinyl ether monomers. © 2001 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 39: 1187–1197, 2001     

Supramolecular diaryliodonium salt‐crown ether complexes as cationic photoinitiators

Diaryliodonium salts spontaneously form crystalline 1:1 supramolecular complexes at room temperature in good to excellent yields with 18‐crown‐6 ether and its cyclohexano‐ and benzo‐substituted analogs. The complexes were characterized using IR, UV, MS, ¹H, and ¹³C‐NMR spectroscopy and by single crystal X‐ray crystallography. The analytical data obtained were consistent with a structure in which the positively charged iodine atom of diaryliodonium cation is positioned above and over the center of the crown ether ring with the positively charged iodine atom coordinated to the crown ether oxygen atoms. The diaryliodonium salt‐crown ether complexes are photosensitive and were used to carry out the photoinitiated cationic polymerizations of a number of mono‐ and difunctional monomers. During irradiation with UV light, the supramolecular complexes undergo photolysis with the generation of a Brønsted acid and with the concomitant release of the crown ether. When used as photoinitiators, the crown ether that is released markedly influences the kinetics of the subsequent cationic polymerization of the monomer. Further studies demonstrated that the photolysis of diaryliodonium salt‐crown ether supramolecular complexes can be photosensitized using typical‐electron transfer photosensitizers. Free radical‐promoted photosensitization using typical unimolecular free radical photoinitiators such as 2,2‐dimethoxy‐2‐phenylacetophenone also takes place readily. © 2012 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2013     

Novel pyridinium salts as cationic thermal and photoinitiators and their photosensitization properties

Novel pyridinium salts [N‐(α‐phenylbenzyl)‐, N‐(1‐naphthylmethyl)‐, or N‐cinnamyl p‐ or o‐cyanopyridinium hexafluoroantimonates] were synthesized by the reaction of p‐ or o‐cyanopyridine and the corresponding bromides followed by anion exchange with KSbF₆. These pyridinium salts polymerized epoxy monomers at lower temperatures than previously reported for N‐benzyl‐2‐cyanopyridinium hexafluoroantimonate. The o‐substituted pyridinium salts showed higher activity than the p‐substituted ones, and the crosslinked epoxy polymers cured with these initiators showed higher glass‐transition temperatures. These pyridinium salts photoinitiated radical polymerization as well as cationic polymerization. The photopolymerization was accelerated by the addition of aromatic ketones as photosensitizers. © 2002 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 40: 1037–1046, 2002     

Photoinitiated cationic polymerization of epoxy alcohol monomers

A series of epoxy alcohols were prepared by simple, straightforward methods. These compounds were very reactive monomers that polymerized rapidly on UV irradiation in the presence of cationic photoinitiators. The kinetics of the cationic photopolymerization of these monomers were studied with diaryliodonium salt photoinitiators and real‐time IR spectroscopy. The rate of epoxide ring‐opening polymerization was enhanced markedly by the presence of the hydroxy group. Using model compounds, the monomers were shown to polymerize via an activated monomer mechanism. Simple epoxy alcohols polymerized to give polymers with a hyperbranched structure. The novel monomers also were observed to accelerate the rate of the photopolymerization of mono‐ and multifunctional epoxides. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 389–401, 2000     

A quinoxaline derivative as a long wavelength photosensitizer for diaryliodonium salts

This article reports the use of a quinoxaline derivative as a photosensitizer for diaryliodonium salt photoinitiators. 2,3‐bis(3,4‐bis(decyloxy)phenyl)‐5,8‐bis(2,3‐dihydrothieno[3,4‐b][1,4]dioxin‐5‐yl)quinoxaline (DOPEQ), is a highly conjugated compound with strong absorption bands at wavelengths ranging from 300 to 550 nm and is shown to facilitate photoinitiated cationic polymerization of heterocyclic monomers such as oxiranes and oxetanes. The polymerizations are initiated at room temperature by using long wavelength UV light in the presence of diphenyliodonium hexafluorophosphate (Ph₂I⁺PF). The polymerizations are monitored by optical pyrometry (OP). It is also possible to initiate photopolymerizations with ambient solar irradiation in the presence of this photosensitizer dye. © 2009 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 48: 209–213, 2010     

Modification of photoinitiated cationic epoxide polymerizations by sulfides

The addition of sulfides has a marked effect on the rates of onium salt induced photoinitiated cationic ring‐opening polymerizations of epoxide monomers. Various behaviors have been observed that depend on the structure of the sulfide. Dialkyl sulfides strongly inhibit the photopolymerizations of these monomers, whereas diaryl sulfides have a retarding effect on the photopolymerizations. Real‐time infrared spectroscopy and optical pyrometry have been employed as analytical methods to probe the kinetic effects of the addition of a variety of sulfides on cationic epoxide ring‐opening photopolymerizations. A mechanism is proposed that involves the formation of sulfonium salts as intermediates. The observations made in this study have important implications for cationic photopolymerizations in general and for photoinitiated cationic ring‐opening polymerizations of epoxides in particular. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 2504–2519, 2005     

Synthesis and characterization of second‐generation S,S‐dialkyl‐S‐(dimethylhydroxyphenyl)sulfonium salt photoinitiators

A new, simplified method has been developed for the synthesis of S,S‐dialkyl‐S‐(dimethylhydroxyphenyl)sulfonium salt cationic photoinitiators. This novel method has successfully been used for the preparation of S,S‐dialkyl‐S‐(3,5‐dimethyl‐4‐hydroxyphenyl)sulfonium and S,S‐dialkyl‐S‐(3,5‐dimethyl‐2‐hydroxyphenyl)sulfonium salts showing a wide variation in the length and structure of the alkyl chains on the positively charged sulfur atom. These photoinitiators can also be prepared with a wide variety of different anions. The manipulation of the lengths of the alkyl chains permits the design of compatible photoinitiators for highly nonpolar monomers and oligomers such as epoxy‐functional silicones, epoxidized polybutadiene, and epoxidized vegetable oils. This article describes the synthesis and characterization of these photoinitiators. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 2556–2569, 2003     

Photosensitization of carbazole derivatives in cationic polymerization with a novel sensitivity to near‐UV light

Photosensitizers based on the carbazole structure were designed and developed for cationic polymerization. Along with triarylsulfonium and diaryliodonium salts, the carbazole derivatives showed a high photosensitization effect in the cationic photopolymerization of epoxides. The photophysical properties of the carbazole derivatives were studied in terms of electronic absorption, fluorescence, and phosphorescence spectrometry. Moreover, a unique photosensitization mechanism of the carbazole derivatives was discussed after studies of the fluorescence quenching, redox behavior, and kinetics of the photopolymerization by time‐resolved fluorescence spectrometry, cyclic voltammetry, and photo differential scanning calorimetry, respectively. The results confirmed the redox photosensitization of the carbazole derivatives in cationic polymerization. The photosensitization of the carbazole and its ring or N‐alkylated derivatives occurred predominantly in singlet excited states at the rate of the diffusion limit, whereas the carbazole derivatives with carbonyl substituents sensitized onium salts via triplet excited states on the basis of the Rehm–Weller equation in the photoinduced electron‐transfer process. © 2000 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 38: 90–100, 2000     

Novel N‐methylbenzothiazolium salts as hardeners for epoxy and acrylate monomers

Novel N‐methylbenzothiazolium salts [N‐methyl‐2‐benzylthiobenzothiazolium, N‐methyl‐2‐(4‐nitrobenzylthio)benzothiazolium, N‐methyl‐2‐(1‐ethoxycarbonylethylthio)benzothiazolium, and N‐methyl‐2‐methylthiobenzothiazolium hexafluoroantimonates] were synthesized by the reaction of the corresponding 2‐substituted benzothiazole with dimethylsulfate, followed by anion exchange with KSbF₆. These benzothiazolium salts cationically polymerized an epoxy monomer by photoirradiation. They also polymerized an acrylate monomer via a photoradical process. The use of aromatic compounds such as 2‐ethyl‐9,10‐dimethoxyanthracene as photosensitizers was effective in enhancing the polymerization. These benzothiazolium salts also served as thermal cationic initiators. © 2003 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 41: 3828–3837, 2003     

Photoinitiated cationic oligomerization of aryl 1-propenyl ethers

A series of aryl 1-propenyl ethers (ArPE) were prepared by the isomerization of the corresponding allyl aryl ethers (AArE) and used for photoinduced cationic polymerization studies. Attempted polymerization reactions using diaryliodonium salts as photoinitiators generally resulted in low yields of oligomers. Further studies revealed that these compounds have much lower reactivity in cationic vinyl polymerization as compared to their alkyl analogues. Moreover, side reactions resulting from chain transfer due to Friedel–Crafts alkylations take place and compete with vinyl polymerization. These side reactions are responsible for the low molecular weights observed in the cationic photopolymerization of aryl 1-propenyl ether monomers. © 1999 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 37: 3017–3025, 1999     

Synthesis and cationic photopolymerization of 1-butenyl glycidyl ether

1-Butenyl glycidyl ether was prepared in high yield by the ruthenium-catalyzed isomerization of crotyl glycidyl ether. This ambifunctional monomer underwent facile photoinitiated cationic polymerization using diaryliodonium salts as photoinitiators. The progress of the polymerizations was followed using Fourier transform real-time infrared spectroscopy, and the reactivity of this monomer under various experimental conditions determined. A comparison of the rates of polymerization of the epoxy and vinyl ether groups suggested that the polymerization may take place by an intramolecular cyclization process that generates cyclic acetal units in the backbone of the polymer. It was further shown that crotyl glycidyl ether undergoes regioselective cationic ring-opening polymerization to give a polyether, and then isomerization was carried out to give an oligomer bearing reactive pendant 1-butenyl ether groups. © 1998 John Wiley & Sons, Inc. J Polym Sci A: Polym Chem 36: 1179–1187, 1998     

Dibenzophenazine derivatives as visible photosensitizers for diaryliodonium salts

The use of two dibenzo[a,c]phenazine derivatives, 10,13‐bis(2,3‐dihydrothieno[3,4‐b][1,4]dioxin‐5‐yl)dibenzo[a,c]phenazine and 10,13‐bis(4‐hexylthiophen‐2‐yl)dibenzo[a,c]phenazine are reported as photosensitizers for diaryliodonium salt photoinitiators. Novel dyes based on the dibenzo[a,c]phenazine skeleton are shown to be efficient in carrying out the cationic photopolymerizations. Representative examples of different types of monomers including epoxide, and vinyl monomers are polymerized in the presence of the photosensitizers and diphenyliodonium hexafluorophosphate (Ph₂I⁺PF). Polymerizations are initiated at room temperature using long wavelength UV and visible light, and monitored by optical pyrometry. The photopolymerization of an epoxide monomer via solar irradiation is also demonstrated. © 2011 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem, 2011     

Wavelength Flexibility in Photoinitiated Cationic Polymerization

The spectral sensitivity of onium salt photoinitiators in cationic polymerization can be tuned from the short wavelength region of the UV spectrum to wavelengths up to the visible region by using direct and indirect activation, respectively. Indirect activation is based on the electron transfer reactions between onium salts and free radical photoinitiators, appropriate sensitizers and compounds capable of forming charge transfer complexes. Bisacylphosphine oxides, dimanganese decacarbonyl in conjunction with alkyl halides and titanocene type photoinitiators such as Irgacure 784 were shown to be useful free radical promoters providing the possibility of performing cationic polymerization in the long wavelength and visible region. The synthetic routes to prepare block copolymers by using electron transfer photosensitization and free radical promoted cationic polymerization are also described.     

Reactivity of oxetane monomers in photoinitiated cationic polymerization

Studies of the onium salt photoinitiated cationic ring‐opening polymerizations of various 3,3‐disubstituted oxetane monomers have been conducted with real‐time infrared spectroscopy and optical pyrometry. The polymerizations of these monomers are typified by an extended induction period that has been attributed to the presence of a long‐lived tertiary oxonium ion intermediate formed by the reaction of the initially formed secondary oxonium ion with the cyclic ether monomer. Because the extended induction period in the photopolymerization of these monomers renders oxetane monomers of limited value for many applications, methods have been sought for its minimization or elimination. Three general methods have been found effective in markedly shortening the induction period: (1) carrying out the photopolymerizations at higher temperatures, (2) copolymerizing with more reactive epoxide monomers, and (3) using free‐radical photoinitiators as synergists. © 2005 Wiley Periodicals, Inc. J Polym Sci Part A: Polym Chem 43: 3205–3220, 2005