Solventless DCPD Prepolymer Viscosity Control
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Solution Overview
Problem
High purity dicyclopentadiene (DCPD) is too viscous at temperatures below 100° F., making it difficult to use in fabrication processes like reaction injection molding (RIM) without heating, which can lead to rapid curing and structural flaws in constructs.
Innovation Solution
A solventless prepolymer formulation comprising at least 92% pure dicyclopentadiene, a reactive ethylene monomer, and a curing catalyst, where the reactive ethylene monomer's weight percentage is adjusted to achieve a desired viscosity at ambient or lower temperatures, allowing for flowable and controlled curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high purity DCPD is used, then the properties of the polymeric construct are improved, but the viscosity becomes too high for processing at temperatures below 100° F.
Solution Approach 1:
The patent changes the chemical composition parameters of the prepolymer formulation by incorporating specific ratios of reactive ethylene monomers (norbornene, styrene, butadiene) alongside high purity DCPD. This compositional parameter change maintains the superior properties of high purity DCPD while adjusting the viscosity to be suitable for processing at temperatures below 100° F.
2Ease of manufacture
If heating is applied to reduce viscosity, then the formulation becomes flowable for RIM processing, but rapid curing occurs resulting in structural flaws
Solution Approach 1:
The patent introduces reactive ethylene monomers as intermediary substances that serve dual functions: they act as viscosity modifiers enabling flowable processing at lower temperatures, and they serve as diluents that slow the polymerization rate. This intermediary approach allows RIM processing to proceed at temperatures below 100° F. without causing rapid curing and structural flaws.
3Ease of manufacture
If solvents are used to reduce viscosity, then the formulation becomes flowable, but defects are introduced into the construct
Solution Approach 1:
The patent extracts and eliminates the need for non-reactive solvents from the formulation. Instead, it uses reactive ethylene monomers as the diluting agent, which are incorporated into the final polymer matrix through polymerization. This extraction of harmful solvents while maintaining flowability through reactive monomers ensures defect-free construction.
4Use of energy by stationary object
If ambient temperature processing is used, then energy consumption is reduced, but the high viscosity of high purity DCPD prevents processing
Solution Approach 1:
The patent changes the physical parameters of the formulation by incorporating reactive ethylene monomers in specific ratios (0.1-10 wt% based on total monomer content). This compositional change reduces the viscosity of high purity DCPD at ambient temperatures, enabling processing without heating and thereby reducing energy consumption while maintaining processability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the use of high purity DCPD in various fabrication processes at ambient temperatures, preventing rapid curing and structural flaws, while maintaining the superior properties of high purity DCPD, and avoiding the use of solvents that can introduce defects.
Implementation Method 1
a reactive ethylene monomer, wherein: the quantity of reactive ethylene monomer in the prepolymer composition is calculated to provide the prepolymer composition with a selected viscosity at a selected operating temperature
Implementation Method 2
curing the deposited prepolymer composition to form the polymeric construct
Data Source
AI summary
This invention relates to a prepolymer formulation comprising dicyclopentadiene that is at least 92% pure wherein the prepolymer formulation is flowable at ambient temperatures by virtue of the addition of a reactive ethylene monomer to the formulation.