Vinyl Functional Interpenetrating Network Polymers Produced by Physically Mixing Vinyl Functional Resins with Thermoplastic Resin Compositions, Methods of Use and Methods of Preparation

Abstract

The present disclosure pertains to methods and/or systems for making a SIPN and/or an IPN by physically mixing at least one vinyl functional thermoset with at least one thermoplastic resin. For example, a method of producing a resin composition comprising: mixing at least one vinyl functional thermoset resin with at least one thermoplastic resin wherein: the two resins are sufficiently miscible at a mixing viscosity of at least at least 5,000 cPs measured at the temperature of mixing and the mixing results in sufficient laminar flow such that a substantial portion of the resin mixture forms an IPN and/or a SIPN. The IPNs and/or SPINs formed have one or more superior properties over mixtures of the same resins.

1 . A method of making a SIPN (pseudo interpenetrating network by physical alloy mixing of at least one vinyl functional thermoset with at least one thermoplastic resin. 
     
     
         2 . A method of making an IPN (interpenetrating polymer network by physical alloy mixing of a vinyl functional thermoset with a thermoplastic resin. 
     
     
         3 . A method of producing a resin composition comprising: a mixture of at least one vinyl functional thermoset resin with at least one thermoplastic resin wherein: the two resins are sufficiently miscible when the mixture has a viscosity during mixing of between at least 5,000 cPs, 10,000 cPs, 25,000 cPs, 50,000 cPs, 100,000 cPs, 200,000 cPs, 300,000 cPs, or 500,000 cPs to 1,000,000 cPs at the temperature of mixing and the two resins are capable of forming a SIPN or an IPN while still in the liquid state. 
     
     
         4 - 5 . (canceled) 
     
     
         6 . A method of producing a resin composition comprising: a mixture of at least one vinyl functional thermoset resin with at least one thermoplastic resin wherein: the two resins are sufficiently miscible at a mixing viscosity of between at least 5,000 cPs, 10,000 cPs, 25,000 cPs, 50,000 cPs, 100,000 cPs, 200,000 cPs, 300,000 cPs, or 500,000 cPs to 1,000,000 cPs measured at the temperature of mixing and upon sufficient laminar flow mixing, the two resins form an IPN or a SIPN resin composition while still in the liquid state that is substantially free of thermoplastic micelles. 
     
     
         7 . (canceled) 
     
     
         8 . A method of producing a resin composition comprising: a mixture of at least one vinyl functional thermoset resin with at least one thermoplastic resin wherein: the two resins are sufficiently miscible at a mixing viscosity of between at least 5,000 cPs, 10,000 cPs, 25,000 cPs, 50,000 cPs, 100,000 cPs, 200,000 cPs, 300,000 cPs, or 500,000 cPs to 1,000,000 cPs measured at the temperature of mixing and, upon sufficient laminar flow mixing, the two resins form an IPN or a SIPN resin composition while still in the liquid state that is substantially free of thermoplastic micelles, wherein the resin composition upon curing has a flexural yield stress greater than 45 MPa, 90 MPa, 120 MPa 140 MPa, 150 MPa or 165 MPa, an elongation of between 8% to 20%, 14% to 25%, 6.5% to 35%, a HDT between 65 and 120 degrees C., or 80 and 100 degrees C., an unnotched Izod strength greater than 3 Joules/cm, a modulus between 2.5 GPa and 3.6 GPa, or 1.5 GPa and 3.8 GPa, and a linear shrinkage less than 0.05, 0.1, 0.5, 0.8, 1, 1.2, 1.5, 1.8 or 2%, and volume shrinkage of less than 0.15, 0.3, 1.5, 2.4, 3, 3.6, 4.5, 5.4, or 6%. 
     
     
         9 . The method of making an IPN as claimed in  claim 2 , the method comprising: a mixture of a vinyl functional thermoset resin with a thermoplastic resin wherein the mixture has a viscosity that produces a substantial portion of laminar flow during the mixing. 
     
     
         10 - 11 . (canceled) 
     
     
         12 . The method of making an IPN as claimed in  claim 2 , wherein 10% to 30% of at least one soluble thermoplastic is dissolved in a chlorinated solvent selected from one or more of the following:
 trichloroethane, dichloroethane, and carbon tetrachloride and then mixing this solution with a liquid vinyl functional thermoset, and holding the temperature range between 18° C. to 22° C.   
     
     
         13 . The method of making an IPN as claimed in  claim 12 , wherein the thermoplastic is one of ABS or polystyrene or PMMA. 
     
     
         14 . A method for producing an IPN or a SIPN resin composition by mixing at least one vinyl functional thermoset resin with at least one thermoplastic resin solution wherein the two resins are sufficiently miscible and the mixture has a Reynolds number during mixing that is below 2100. 
     
     
         15 . (canceled) 
     
     
         16 . A method of producing a moulded product comprising:
 (a) selecting at least one liquid IPN resin composition made with the method disclosed in  claim 2 ;   (b) catalysing the IPN with at least one catalysing agent;   (c) pouring or pumping the resin composition into a mould and allowing it to cure.   
     
     
         17 . (canceled) 
     
     
         18 . A method based on a continuous liquid IPN production process that involved pumping the resin mixture through a heat exchanger/chiller plant and static mixer configuration of sufficient length to produce laminar flow for the creation of a liquid IPN at the nominated exit temperature between 14° C. for thermoset/polycaprolactone IPNs down to 4° C. for VINNAPAS 8588/thermoset liquid IPNs and even lower exit temperatures for some higher molecular weight polystyrene and acrylic thermoplastic thermoset IPNs. 
     
     
         19 . A method of making an SIPN as claimed in  claim 1 , the method comprising: a mixture of a vinyl functional thermoset resin with a thermoplastic resin wherein the mixture has a viscosity that produces a substantial portion of laminar flow during the mixing. 
     
     
         20 . The method of making an SIPN as claimed in  claim 1 , wherein 10% to 30% of at least one soluble thermoplastic is dissolved in a chlorinated solvent selected from one or more of the following: trichloroethane, dichloroethane, and carbon tetrachloride and then mixing this solution with a liquid vinyl functional thermoset, and holding the temperature range between 18° C. to 22° C. 
     
     
         21 . The method of making an SIPN as claimed in  claim 20 , wherein the soluble thermoplastic is one of ABS or polystyrene or PMMA. 
     
     
         22 . A method of producing a moulded product comprising:
 (a) selecting at least one liquid SIPN resin composition made with the method disclosed in  claim 1 ;   (b) catalysing the SIPN with at least one catalysing agent;   (c) pouring or pumping the resin composition into a mould and allowing it to cure.