ROMP Crosslinked Polymers for Microstructured Articles

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Solution Overview

Problem

Existing methods for manufacturing microstructured articles often face challenges in adequately filling polymer into microstructured features, leading to inefficiencies in production and potential issues with the articles' physical strength and toughness.

Innovation Solution

The use of crosslinked unsaturated polymers formed by ring opening metathesis polymerization (ROMP) of a monomer composition comprising a cyclic monomer with reactive double bonds, which allows for efficient molding of microstructured articles with features less than 2 mm, enabling fast production and minimal shrinkage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional polymer filling methods are used for microstructured features, then the manufacturing process is simple, but the polymer cannot adequately fill the microstructured features leading to poor physical strength and toughness

Engineering Contradiction:

Improvephysical strength and toughnessVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent changes the chemical parameters of the polymer system by using cyclic olefin monomers with reactive double bonds that undergo ROMP polymerization. This transformation changes the polymerization mechanism from conventional step-growth or chain-growth polymerization to metathesis polymerization, enabling complete filling of microstructured features while achieving superior physical strength and toughness in the final molded articles.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes the phase transition characteristics of cyclic olefin monomers during ROMP polymerization. The monomer composition transitions from a liquid or low-viscosity state that can easily fill microstructured features to a crosslinked polymer network state that provides excellent physical strength and toughness, resolving the contradiction between fillability and mechanical properties.

Inventive Principle:

Principle #36Phase transitions

2Productivity

If conventional molding methods are used for microstructured articles, then the process is straightforward, but the production time is extended and shrinkage occurs

Engineering Contradiction:

Improveproduction timeVSAvoiddimensional accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent changes the thermal and rheological parameters during ROMP polymerization to achieve rapid curing with minimal shrinkage. The ring-opening metathesis polymerization reaction proceeds with favorable volumetric changes compared to conventional polymerization methods, reducing shrinkage while maintaining fast production cycles for microstructured articles.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If microstructured features are made smaller to improve device performance, then the article functionality is enhanced, but the difficulty of adequately filling polymer into these features increases

Engineering Contradiction:

Improvearticle functionalityVSAvoidfilling difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the polymerization chemistry to ROMP, which enables complete filling of increasingly smaller microstructured features. The ring-opening mechanism and crosslinking behavior of cyclic olefin monomers allow polymer to penetrate and fill even sub-millimeter features completely, maintaining functionality while enabling smaller feature sizes for enhanced device performance.

Inventive Principle:

Principle #35Parameter changes

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

This approach results in microstructured articles with improved physical strength and toughness, efficient surface replication, and reduced production time, suitable for various applications including electronics and optical devices.

Implementation Method 1

microstructured articles comprise crosslinked unsaturated polymers formed by ring opening metathesis polymerization (ROMP) of a monomer composition, the monomer composition comprising a cyclic monomer having at least one reactive double bond

Methodology Applied

Scientific EffectRing opening metathesis polymerization (ROMP): Chemical Bonding

Data Source

PatentUS9370876B2Molded microstructured articles and method of making same

Publication Date: 2016.06.21 3M INNOVATIVE PROPERTIES CO

AI summary

Disclosed herein are microstructured articles that can be made by molding. The microstructured articles comprise crosslinked unsaturated polymers formed by ring opening metathesis polymerization (ROMP) of a monomer composition, the monomer composition comprising a cyclic monomer having at least one reactive double bond. The microstructured articles may be structured in that they comprise at least one microstructured feature having a dimension of less than about 2 mm, or less than about 500 um. The microstructured articles may also comprise a plurality of such microstructured features. Also disclosed herein are methods of making the microstructured articles.