Vinyl functional interpenetrating network polymers produced by physically mixing vinyl functional resins with thermoplastic resin compositions, methods of use and methods of preparation

1. A method of producing a pseudo interpenetrating network (SIPN) composition or an interpenetrating polymer network (IPN) composition, comprising:

physical alloy mixing of at least one vinyl functional thermoset resin with at least one thermoplastic resin;

wherein the two resins are miscible when the mixture has a viscosity during mixing of at least 10,000 cPs measured at the temperature of mixing, and wherein the mixture has a Reynolds number during mixing that is below 2100.

2. The method of claim 1 , wherein the two resins are sufficiently miscible when the mixture has a viscosity during mixing of at least 5000 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.

3. The method of claim 1 , wherein the two resins are sufficiently miscible at a mixing viscosity of 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 or a SIPN while still in the liquid state.

4. The method of claim 1 , wherein the two resins are sufficiently miscible at a mixing viscosity of at least 5,000 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.

5. The method of claim 4 , wherein the SIPN composition or IPN composition is cured, and upon curing comprises one or more of:

i) a flexural yield stress greater than 45 MPa;

ii) an elongation in the range of between 6.5% to 35%;

iii) a HDT in the range of between 65 and 125° C.;

iv) an unnotched Izod strength of greater than 3 Joules/cm;

v) a modulus in the range of between 1.5 GPa and 3.8 GPa;

vi) a linear shrinkage less than 2%; or

vii) a volume shrinkage of less than 6%.

6. The method of claim 4 , wherein the SIPN composition or IPN composition is cured, and upon curing comprises:

i) a flexural yield stress greater than 45 MPa;

ii) an elongation in the range of between 6.5% to 35%;

iii) a HDT in the range of between 65 and 125° C.;

iv) an unnotched Izod strength of greater than 3 Joules/cm;

v) a modulus in the range of between 1.5 GPa and 3.8 GPa;

vi) a linear shrinkage less than 2%; and

vii) a volume shrinkage of less than 6%.

7. The method of claim 1 , wherein the mixture has a viscosity that produces a substantial portion of laminar flow during the mixing.

8. The method of claim 1 , wherein the Reynolds number in the mixer during mixing of the resin composition is below 2000.

9. A method of producing a moulded product comprising:

a) selecting at least one liquid IPN or SIPN resin composition produced according to the method of claim 1 ;

b) catalyzing the IPN or SIPN with at least one catalyzing agent; and

c) pouring or pumping the resin composition into a mould and allowing it to cure.

10. A continuous liquid interpenetrating polymer network (IPN) production process, comprising:

pumping a 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 a predetermined exit temperature of about 14° C. for thermoset/polycaprolactone IPNs of about 4° C. for VINNAPAS 8588/thermoset liquid IPNs, and exit temperatures lower than 4° C. for some higher molecular weight polystyrene and acrylic thermoplastic thermoset IPNs.

11. The method of claim 1 , wherein the method further comprises dissolving the at least one thermoplastic resin is dissolved in a chlorinated solvent selected from one or more of the following: trichloroethane, dichloroethane, and carbon tetrachloride, and then mixing the solution with the at least one vinyl functional thermoset resin.

12. The method of claim 11 , wherein the at least one vinyl functional thermoset resin is a liquid vinyl functional thermoset.

13. The method of claim 12 , wherein the at least one thermoplastic resin is 10% to 30% PMMA, relative to the total weight of polymers in the SIPN composition or IPN composition.

14. The method of claim 12 , wherein the at least one thermoplastic resin is 10% to 30% polystyrene, relative to the total weight of polymers in the SIPN composition or IPN composition.

15. The method of claim 14 , wherein the temperature is held at between 18° C. to 22° C. when mixing the solution with the at least one liquid vinyl functional thermoset resin.

16. The method of claim 12 , wherein the at least one thermoplastic resin is 10% to 30% of at least one soluble thermoplastic, relative to the total weight of polymers in the SIPN composition or IPN composition.

17. The method of claim 16 , wherein the temperature is held at between 18° C. to 22° C. when mixing the solution with the at least one liquid vinyl functional thermoset resin.

18. The method of claim 12 , wherein the at least one thermoplastic resin is 10% to 30% ABS, relative to the total weight of polymers in the SIPN composition or IPN composition.

19. The method of claim 18 , wherein the temperature is held at between 18° C. to 22° C. when mixing the solution with the at least one liquid vinyl functional thermoset resin.