Radiation curable polymers

• US 9,359,499 B2
• Filed: 05/04/2012
• Issued: 06/07/2016
• Est. Priority Date: 05/05/2011
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Cernohous, Jeffrey Jacob
• Primary Examiner(s): Choi, Ling
• Assistant Examiner(s): Whiteley, Jessica E
• Application Number:
  US13/821,851
• Publication Number:
  US 20140121291A1
• Time in Patent Office: 1,495 Days
• Field of Search: 522/33, 522/6, 522/71, 522/189, 522/184, 520/1
• US Class Current: 1/1
• CPC Class Codes: C08J 2367/04 Polyesters derived from hydroxy carboxylic acids, e.g. lactones C08J2367/06 takes precedence
• CPC Class Codes: C08J 3/005 Processes for mixing polymers
• CPC Class Codes: C08J 3/28 Treatment by wave energy or particle radiation
• CPC Class Codes: C08L 2205/22 Mixtures comprising a continuous polymer matrix in which are dispersed crosslinked particles of another polymer
• CPC Class Codes: C08L 33/06 of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
• CPC Class Codes: C08L 67/04 Polyesters derived from hydroxycarboxylic acids, e.g. lactones C08L67/06 takes precedence

Abstract

A polymeric matrix is melt processed with reactive monomers or oligomers that are miscible in the polymeric matrix. Upon initial melt processing and mixing, the reactive monomers or oligomers contained within the resulting polymeric matrix are cured with actinic radiation to form a polymeric alloy. The alloy of the polymeric matrix and the cured polymer possesses a non-equilibrium morphology and a surface energy that is effectively secured for a desired application and use after subsequent compounding.

Claims

1. A melt processable composition comprising a melt processable polymeric alloy containing a polymeric matrix and a cured polymer wherein the melt processable polymeric matrix and the cured polymer have a stable, non-equilibrium morphology.

2. A composition according to claim 1, wherein the cured polymer is derived from a precursor monomer or oligomer that is miscible in the polymeric matrix during melt processing and wherein the precursor monomer or oligomer is present in the matrix in an amount ranging from about 1 weight percent to about 90 weight percent.

3. A composition according to claim 1, wherein the cured polymer is derived from one or more monomers or oligomers selected from acylic esters, methacrylic esters, styrene, styrene derivatives, vinyl ethers, vinyl esters, vinyl pyridines, vinyl pyrolidinones, vinyl oxazoles, vinyl oxazolines, vinyl halides, acrylonitrile, acrylamide, acrylamide derivatives, oligomeric polyether, oligomeric polyester, oligomeric polysiloxanes, and oligomeric polyolefins, wherein the oligomers are functionalized with at least one ethylenically unsaturated monomer.

4. A composition according to claim 3, wherein the monomer or oligomer has at least one moiety that is ethylenically unsaturated.

5. A composition according to claim 3, wherein the monomer or oligomer is hydrophilic, hydrophobic, or amphiphilic.

6. A composition according to claim 3, further comprising an initiator for the derivation of the cured polymer.

7. A composition according to claim 6, wherein the initiator is a photoinitiator and the photoiniator is benzoin, benzophenone, or thioxanthone derivatives.

8. A composition according to claim 1, further comprising one or more antioxidants, light stabilizers, fibers, blowing agents, foaming additives, antiblocking agents, heat stabilizers, impact modifiers, biocides, compatibilizers, flame retardants, plasticizers, tackifiers, colorants, processing aids, lubricants, coupling agents, and pigments.

9. A composition according to claim 1, wherein the polymeric matrix is one or more of polyamides, polyimides, polyurethanes, polyolefins, polystyrenes, polyesters, polycarbonates, polyketones, polyureas, polyvinyl;

resins, polyacrylates, and polymethylacrylates.

10. A method comprising curing by actinic radiation a portion of a melt processed polymeric matrix, wherein the polymeric matrix has a curable monomer or curable oligomer dispersed in the polymeric matrix and the polymeric matrix comprising the cured monomer or cured oligomer have a stable, non-equilibrium morphology.

13. The method according to claim 10, wherein actinic energy includes ultraviolet radiation, visible light radiation, and electronic beam radiation.

11. A method comprising melt processing a polymeric matrix having a curable monomer or curable oligomer and irradiating the polymeric matrix to form a cured polymer in the polymeric matrix, wherein the melt processable polymeric matrix and the cured polymer are in a stable, non-equilibrium morphology.

12. A method according to claim 11, wherein irradiating occurs above a T_g or T_m value of the polymeric matrix.

14. A method according to claim 11, further comprising palletizing the polymeric matrix and cured polymer.