Reaction injection molding, polymeric

Poly(dicyclopentadiene). The development of polydicyclopentadiene [25038-78-2] for reaction injection molding is an area which has generated much interest. The polyDCPD is obtained via metathesis polymerization of high purity (usually greater than 98%) DCPD. Excellent reviews (61—62) of the chemistry and properties of polyDCPD have been pubHshed. The patent Hterature of polyDCPD synthesis, catalysts, modifiers, and appHcations is dominated by Hercules (44 patents) and B. F. Goodrich (43 patents) in the U.S. Other participants are Orkem, SheU, Nippon Zeon, and Teijin. 

Reaction-Injection Molding and Reactive Casting. Reaction-iajection molding (RIM) (22) and reactive casting (23) have been demonstrated on nylon-6, which is polymerized by catalytic ring opening and linear recondensation of S-caprolactam (qv) (24). 

Liquid Composite Molding (LCM) is the common name for several similar processes for the manufacturing of polymeric fiber reinforced composites. Widely used processes that belong to this class are Resin Transfer Molding (RTM), Vacuum-Assisted Resin Injection (VARI), and Structural-Reaction Injection Molding (S-RIM). 

Tungsten-based catalysts with a Lewis base promoter are used in the polymerization of dicyclopentadiene also isolated from the C5 stream-cracker fraction.150,155 The product poly(dicyclopentadiene) or Metton resin has unusual physical and chemical properties. It is processed together with elastomers to increase viscosity of the end product by using reaction injection molding (RIM) technology.155... 

Nylon-6 can also be produced from molten caprolactam using strong bases as catalysts (anionic polymerization) this is used as the basis of monomer casting and reaction injection molding (RIM). Anionic polymerization proceeds much faster than the hydrolytic route but products retain catalysts which may need to be extracted. 

Reaction Injection Molding. RIM uses the anionic polymerization of nylon-6 to carry out polymerization in the mold. A commercial process involves the production of block copolymers of nylon-6 and a polyether by mixing molten caprolactam, catalyst, and polyether prepolymer, and reacting in a mold (27,28). 

Dicyclopentadiene is also polymerized with tungsten-based catalysts. Because the polymerization reaction produces heavily cross-linked resins, the polymers are manufactured in a reaction injection molding (RIM) process, in which all catalyst components and resin modifiers are slurried in two batches of the monomer, The first batch contains the catalyst (a mixture of WClg and WOCl4), additives, and fillers the second batch contains the co-catalyst (a combination of an alkylaluminum compound and a Lewis base such as ether), antioxidants, and elastomeric fillers. Mixing two liquids in a mold results 111 a rapid polymerization reaction. 

The liquid monomers are suitable for bulk polymerization processes. The reaction can he conducted in a mold (casting, reaction injection molding), continuously on a conveyor (block and panel foam production), or in an extruder (thermoplastic polyurethane elastomers and engineering thermoplastics). Also, spraying of the monomers onto the surface of suitable substrates provides insulation barriers or cross-linked coatings. 

The ring-opening metathesis polymerization of dicyclopentadiene was monitored by ultrasonic spectroscopy.16 The thermoset poly(dicyclopentadiene) is formed by ringopening and cross-linking in a reaction injection molding system. A reaction cell with a plastic window was constructed for use with pulse echo ultrasonic spectroscopy. Realtime measurements of density, longitudinal velocity, acoustic modulus and attenuation were monitored. Reaction kinetics were successfully determined and monitored using this technique. 

Reaction injection molding (RIM) is a fast, low-pressure, low-temperature, low-cost process for one-step conversion of reactive liquids into large finished solid plastic products. Liquid polyol and liquid diisocyanate are mixed by impingement, pumped instantly to fill a large mold cavity, and polymerize/ cure rapidly to form a thermoset polyurethane product. The cured polymer may be a stiffly flexible product such as automotive bumper covers, front ends, and trim or a rigid foamed product such as furniture and housings (cabinets) for computers, business machines, TY and radio. 

To date, low volumes of materials have been produced commercially from norbomene and cyclo-octene. Numerous products are expected to result from the materitd produced by the ROMP of dicyclopentadiene in a RIM (reaction injection molding) process. In a RIM process, two streams of a monomer are mixed in the mold where it is polymerized to the final part. In this case, one of the monomer streams contains a tungsten complex while the second contains an alkyl aluminum activator. When the two streams of dicyclopentadiene are mixed, the metathesis catalyst is formed and the monomer is ROMP polymerized (equation 12). 

Kresta, J.E., Reaction Injection Molding and Fast Polymerization Reactions, pp. 11-30, Plenum Press, New York (1982). 

Specimen Preparation. These polymers were polymerized using a Krauss-Maffei PU 80/40 RIM (reaction injection molding) machine using a suitable catalyst (Witco Fomrez UL-28). 6 x 6" x 1/8" pla-... 

Stanford, J.L. Still, R.H. Stepto, R.F.T. In "Reaction Injection Molding and Fast Polymerization Reactions" Kresta, J.E., Ed. POLYMER SCIENCE AND TECHNOLOGY SERIES Vol. 18, p.31 Plenum, 1982. 

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