Metathesis polymerized olefin composites including sized reinforcement material

[0002] The present application is a continuation of U.S. application Ser. No. 09/148,459, now U.S. Pat. No. 6,040,363, filed Sep. 4, 1998, entitled METATHESIS POLYMERIZED OLEFIN COMPOSITES INCLUDING SIZED REINFORCEMENT MATERIAL by inventors Mark W. Warner, Steven D. Drake and Michael A. Giardello, the contents of which are incorporated herein by reference.

[0003] This application claims the benefit under 35 U.S.C. §119 of co-pending U.S. Provisional patent application Ser. No. 60/057,999 filed Sep. 5, 1997.

[0004] The present invention relates to articles made of reinforced metathesis polymerized olefins and cycloolefins, incorporating reinforcing materials, and methods for producing the same. More particularly, the invention relates to reinforced metathesis polymerized olefins and cycloolefins that are polymerized in the presence of a reinforcing material coated with a coupling or sizing agent.

[0005] Numerous polymers of olefins, especially polymers of cycloolefins, produced through metathesis polymerization reactions using a metathiesis catalyst are technologically and commercially important materials. Especially important are polymers of cycloolefins that are produced through Ring Opening Metathesis Polymerization (ROMP) reactions. Many such materials are tough and rigid, and have excellent chemical resistance. However, for many high performance applications, even higher stiffness and strength are desirable. In such applications, it is desirable to provide for reinforcement of the polyolefin structure.

[0006] Fiber reinforced polymer structures, generally, are known in the polymer art. Fiber reinforcement of polymers such as poly-dicyclopentadiene or other polymers of strained ring cycloolefins has been taught by Leach in U.S. Pat. No. 4,708,969. Improving the physical properties of a glass composite polydicyclopentadiene by heat treatment; is taught by Silver in U.S. Pat. No. 4,902,560. A reinforced norbornene polymer matrix including a glass mat reinforcement is taught by Sugawara et al. in U.S. Pat. No. 5,063,103.

[0007] However, it has been a problem to provide for a good interface or good adhesion between the reinforcement materials and polyolefins produced through metathesis polymerization reactions. Due to the poor interface between the reinforcement material anti the polyolefin, stiffness and strength are lost. Additionally, if such composite materials are exposed to fluids during use, the fluids “wick” along the surface of the reinforcement material, due to the poor adhesion, and eventually wet the entire reinforcement material. The presence of a fluid further adversely affects the adherence of the polyolefin to the reinforcement material, and causes further loss of stiffness and strength. The wicking can cause the resulting composite material to be permeable to liquid, making it not feasible for use with liquids.

[0008] Coupling agents, also referred to as sizing agents, are generally known in the polymer art to improve adhesion between reinforcement materials and polymer matrixes. However, it is known that coupling agents, and other impurities, adversely affect traditional metathesis catalysts, and are not usable with such catalysts. U.S. Pat. No. 4,902,560, specifically teaches that in dealing with a metathesis produced reinforced polymer matrix, the reinforcing agent should be “substantially completely free of surface coatings” and that “physical properties of structures prepared with glass containing surface treatments such as, e.g., coupling or sizing agents, deteriorate upon post-cure . . . ” See U.S. Pat. No. 4,902,560, Column 3, Lines 51-58.

[0009] U.S. Sugawara, et al. U.S. Pat. No. 5,063,103, teaches a method of coating a sized glass reinforcement mat with a hydrocarbon. A nor-bor-nene polymer is then polymerized with a metathesis catalyst system in the presence of the hydrocarbon coated glass mat to form a reinforced polymer structure. However, the metathesis catalyst never comes into contact with the sizing agent. The hydrocarbon binder layer covers the sizing agent such that it does not adversely affect the metathesis catalyst. The additional step of coating the sized glass mat prior to exposing it to the catalyst is expensive, time consuming, and burdensome.

[0010] It is desirable to provide a reinforced composite of a metathesis polymerized olefin polymer, especially a ROMP reaction polymerized cycloolefin polymer, and a process for making the same, wherein the polymer is polymerized with a metathesis catalyst in the presence of a reinforcing material having a coupling agent thereon, and the coupling agent provides for an improved interface between the polymer and the reinforcing material without significantly adversely affecting the polymerization reaction.

[0011] The present invention addresses these needs by using coupling agents which render a reinforcing material more compatible for a better interface with an olefin polymer that is polymerized through a metathesis polymerization reaction, but do not adversely poison or otherwise adversely affect the metalhesis catalyst or the polymerization reaction.

[0012] More particularly, a ruthenium or osmium carbene complex catalyst is used as the catalyst for the metathesis polymerization of olefin monomers, and the polymerization reaction takes place with the catalyst/monomer mixture in direct contact with a reinforcement material coated with a suitable coupling agent, and the coupling agent has minimal poisoning or other adverse affect on the catalyst.

[0013] Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description and claims.

[0014] Before embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of the composition and concentration of components set forth in the following description. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0015] The invention involves polymerization of olefins through olefin metathesis reactions, especially Ring Opening Metathesis Polymerization (ROMP) reactions, with a ruthenium or osmium carbene complex metathesis catalyst in the presence of a reinforcing material coated, or sized, with a coupling agent to produce polyolefinic composite materials incorporating the sized reinforcement material. The coupling agent provides for better adhesion between the reinforcement material and the polyolefin.

[0016] Suitable ruthenium and osmium carbene complex catalysts, the methods of synthesizing such catalysts, and suitable olefin monomers as well as the methods for performing and controlling the polymerization reaction, are disclosed in the following patents and patent application, all of which are incorporated herein by reference: U.S. Pat. Nos. 5,312,940 and 5,342,909; WO 97/20865.

[0017] Catalysts:

[0018] Generally suitable catalysts are ruthenium and osilum carbene complex catalysts disclosed in the above cited references.

[0019] The preferred ruthenium and osmium carbenie complex catalysts include those which are stable in the presence of a variety of functional groups including hycdroxyl, thiol, thioetlher, ketone, aldehyde, ester, ether, amine, imine, amide, nitro, carboxylic acid, disulfide, carbonate, isocyanate, carbodiimide, carboalkoxy, peroxy, anhydride, carbamate, and halogen. When the catalysts are stable in the presence of these groups, the starting monomers, impurities in the monomer, the coupling agents, any substituent groups on the catalyst, and other additives may include one or more of the above listed groups without deactivating the catalysts.

[0020] The catalyst preferably includes a ruthenium or osmium metal center that is in a +2 oxidation state, has an electron count of 16, and is pentacoordinated. These ruthenium or osmium carbene complex catalysts may be represented by the formula:

[0021] where:

[0022] M is O or Ru;

[0023] R and R¹may be the same or different and may be hydrogen or a substituent group which may be C₂-C₂₀alkenyl, C₂-C₂₀alkynyl, C₁-C₂₀alkyl, aryl, C₁-C₂₀carboxylate, C₁-C₂₀alkoxy, C₂-C₂₀alkenyloxy, C₂-C₂₀alkynyloxy, aryloxy, C₂-C₂₀alkoxycarbonyl, C₁-C₂₀alkylthio, C₁-C₂₀alkylsulfonyl and C₁-C₂₀alkylsulfiniyl. Optionally, the substituent group may be substituted with one or more groups selected from C₁-C₅alkyl, lhalide, C₁-C₅alkoxy, and phuenyl. The phienyl group may optionally be substiLuted witIh one or more groups selected from halide, C₁-C₅alkyl, and C₁-C₅alkoxy. Optionally, the substituent group may be substituted with one or more functional groups selected from hydroxyl, thiol, thioethler, ketone, aldehyde, ester, ether, amine, imine, amide, nitro, carboxylic acid, disulfide carbonate, isocyanate, carbodiimide, carboal koxy, peroxy, anhydride, carbamate, and halogen. In a preferred embodiment, R and R¹are the same or different and may be hydrogen, substituted aryl, uinsubstituted aryl, substituted vinyl, and unsubstituted vinyl; where the substituted aryl and substituted vinyl are each substituted withl one or more groups selected from hydroxyl, thiol, thioether, ketone, aldehyde, ester, ether, amine, imine, amide, nitro, carboxylic acid, disulfide, carbonate, isocyanate, carbodiimide, carboalkoxy, peroxy, anhydride, carbamate, and halogen, C₁-C₅allcyl, C₁-C₅alkoxy, unsubstituted phenyl, and phenyl substituted with halide, C₁-C₅alkyl or C₁-C₅alkoxy;

[0024] X and X¹may be the same or different and may generally be hydrogen or any anionic liganid. An anionic ligand is any ligand whic)h when removed from a metal center in its closed shell electron configuration has a negative charge. In a preferred embodiment, X and X¹are thre same or different and may be halogen, hydrogen or a substitLLent group selected from C₁-C₂₀alkyl, aryl, C₁-C₂₀alkoxide, aryloxide, C₁-C₂₀alkyldiketone, aryldiketonate, C₁-C₂₀carboxylate, aryl or C₁-C₂₀allcylsulfonate, C₁-C₂o alkylthio, C₁-C₂₀alkylsulfonyl, and C₁-C₂₀alkylsulfinyl. The substituent groups may optionally be substituted with C₁-C₅alkyl, halogen, C₁-C₅akloxy or phenyl. The phenyl may be optionally substituted with halogen, C₁-C₅alkyl, or C₁-C₅alkoxy. In a more preferred embodiment, X and X¹are the same or different and may be Cl, Br, I, H or a substituent group selected from benzoate, C₁-C₅carboxylate, C₁-C₅alkyl, phenoxy, C₁-C₅alkoxy, C₁-C₅alkylthio, aryl, and C₁-C₅alkyl sulfonate. The substituent groups may be optionally substituted with C₁-C₅alkyl or a phenyl group. The pheniyl group may optionally be substituted with halogen, C₁-C₅alkyl or C₁-C₅alkcoxy. In an even more preferred embodiment, X and X¹are the same or different and are selected from Cl, CF₃CO₂, CH₃CO₂, CFH₂CO₂, (CH₃)₃CO, (CF₃)₂(CH₃)CO, (CF₃) (CH₃)₂CO, PhO, MeO, EtO, tosylate, mesylate, and trifluoromethanesulfonate. In the most preferred embodiment, X and X¹are both Cl; and L and L¹may be the same or different and may be generally be any neutral electron donor. A neutral electron donor is any ligand which, when removed from a metal center in its closed shiell electron configuration, has a neutral charge. In a preferred embodiment, L and L¹may be the same or different and may be phosphines, sulfonated phospliines, phosphites, phiosphinites, phosphonites, arsines, stibines, ethers, amines, amides, sulfoxides, carboxyls, nitrosyls, pyridines, and thioethers. In a more preferred embodiment, L and L¹are the same or different and are phosphines of the formula PR³R⁴R⁵where R³is a secondary alkyl or cycloaklyl and R⁴and R⁵are the same or different and are aryl, C₁-C₁₀primary alkyl, secondary alkyl, or cycloaklyl. In the most preferred embodiment, L and L¹are the same or different and are —P(cyclohexyl)₃, —P(cyclopentyl)₃, or —P(isopropyl)₃. L and L¹may also be —P(phenyl)₃.

[0025] A preferred group of catalysts are those where M is Ru; R¹and R are independently hydrogen or substituted or unsubstituted aryl or substituted or unsubstituted vinyl; X and X¹are Cl; and L and L¹are triphenylphosphines or trialkylphosphines such as tricyclopentylphosphine, tricyclohexylphosphine, and triisopropylphosphine. The substituted aryl and substituted vinyl. may each be substituted with one or more groups including C₁-C₅alkyl, halide, C₁-C₅alkoxy, and a phenyl group which may be optionally substituted with one or more halide, C₁-C₅alkyl, or C₁-C5 alkoxy groups. The substituted aryl and substituted vinyl may also be substituted with one or more functional groups including hydroxyl, thiol, thioether, ketone, aldehyde, ester, ether, amine, imine, amide, nitro, carboxylic acid, disulfide, carbonate, isocyanate, carbodiimide, carboalkoxy, peroxy, anhydride, carbamate, and halogen.

[0026] Particularly preferred catalysts can be represented by the formulas:

[0027] where Cy is cyclopentyl or cyclohexyl, and Ph is phenyl.

[0028] The most preferred catalysts can be represented by the formula:

[0029] where Cy is cyclopenotyl or cyclohexyl, and Ph is phenyl.

[0030] The catalysts described above are useful in p olymerization of a wide variety of olefin monomers tlhroug metatlesis pcolymerizationo, particularly ROMP of cycloolefins.

[0031] Monomaers:

[0032] Suitable monomers include olefinis that can be polymerized by any of the ruthenium or osmium metathesis polymerization cat a lysts that were discussed arbove.

[0033] The olefin monomers may be unfunctionalized or functionalized to contain one or more functional groups selected from the group consisting of hydiroxyl, thaiol, thioether, ketone, aldehyde, ester, ether, amine, imine, amidie, nitro, carboxylic acid, disulfide, carbonate, isocyanate, carbodiimide, carboalkoxy, peroxy, anhydride, carbamate, and halogen. The olefin may be a strained cyclic olefin, or unstrained cyclic olefin, each of which may be functionclized or unfunctionalized.

[0034] Preferred monomers include functionalized or unfunctionalized cyclic olefins that are polymerized through ROMP reactions. This polymerization process includes contacting a functionalized or unfunctionalized cyclic olefin with a ruthenium or osmium metathesis catalysts discussed above. The cyclic olefins may be strained or unstrained and may be monocyclic, bicyclic, or multicyclic olefins. If the cyclic olefin is functionalized, it may contain one or more functional groups including hydroxyl, thiol, thioether, ketone, aldlehyde, ester, ether, amine, imine, amide, nitro, carboxylic acid, disulfide, carbonate, isocyanate, carbodiimide, carboalkoxy, peroxy, anhydride, carbamate, and halogen.

[0035] Suitable cyclic olefin monomers include monomers disclosed in U.S. Pat. No. 4,943,621 to Janda, et al., U.S. Pat. No. 4,324,717 to Layer, and U.S. Pat. No. 4,301,306 to Layer, all of which are herein incorporated by reference.

[0036] Suitable cyclic olefin monomers include norbornene-type monomers which are characterized by the presence of at least one norbornene group which can be substituted or unsubstituted. Suitable norbornene type monomers include substituted norbornenes and unsubstituted norbornene, dicyclopentadiene, di(methyl) dicyclopentadiene, dilhydrodicyclopentadiene, cyclopentadiene trimers, tetramers of cyclopentadiene, tetracyclododecene, and substituted tetracyclododecenes. Common norbornene-type monomers can be represented by the following formulas:

[0037] wherein R and R¹may be tlie same or different and may be hydrogen or a substitute group which may be a halogen, C₁-C₁₂alkyl groups, C₂-C₁₂alkylene groups, C₆-C₁₂cycloalkyl groups, C₆-C₁₂cycloalkylene groups, and C₁-C₁₂aryl groups or R and R¹together form saturated or unsaturated cyclic groups of from 4 to 12 carbon atoms with the two ring carbon atoms connected thereto, said ring carbon atoms forming part of and contributing to the 4 to 12 carbon atoms in the cyclic group.

[0038] Less common norbornene type monomers of the following formulas are also suitable:

[0039] wherein R and R¹have the same meaning as indicated above and n is greater than 1. For example, cyclopentadiene tetramers (n=2), cyclopentadiene pentamers(n=3) and hexacyclopentadecene (n=2) are suitable monomers for use in this invention.

[0040] Other specific examples of monomers suitable for use in this invention include:

[0041] ethylidenenorborniene,

[0042] methyltetracyclododecene,

[0043] methylnorborinene,

[0044] ethylnorbornene,

[0045] dimethylnorbornene and similar derivatives,

[0046] norbornadiene,

[0047] cyclopentene,

[0048] cycloheptene,

[0049] cyclooctene,

[0050] 7-oxanorbornene,

[0051] 7-oxanorboriiene derivatives,

[0052] 7-oxabicyclo[2.2.1]hept-5ene derivatives,

[0053] 7-oxanorbornadiene,

[0054] cyclododecene,

[0055] 2-norbornene, also named bicyclo[2.2.1]-2-heptene and substituted bicyclic norbornenes,

[0056] 5-methyl-2-norbornene,

[0057] 5,6-dimethyl-2-norbornene,

[0058] 5-ethyl-2-norbornene,

[0059] 5-butyl-2-norbornene,

[0060] 5-hexyl-2-norbornene,

[0061] 5-dodecyl-2-norbornene,

[0062] 5-isobutyl-2-norbornene,

[0063] 5-octadecyl-2-norbornene,

[0064] 5-isopropyl-2-norbornene,

[0065] 5-phenyl-2-norbornene,

[0066] 5-p-toluyl-2-norbornene,

[0067] 5-a-naphthyl-2-norbornene,

[0068] 5-cyclohexyl-2-norbornene,

[0069] 5,5-dimethyl-2-norbornene,

[0070] dicyclopentadiene (or cyclopentadiene dimer),

[0071] dihydrodicyclopentadiene (or cyclopentene cyclopentadiene codimer),

[0072] methyl-cyclopentadiene dimer,

[0073] ethyl-cyclopentadiene dimer,

[0074] tetracyclododecene, also named 1,2,3,4,4a,5,8,8a-octahydro-1,4:5,8-dimethyanonaphthalene

[0075] 9-methyl-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene, also named 1,2,3,4,4a,5,8,8a-octahydro-2-metlhyl-4,4:5,8-dimethanonaphthalene

[0076] 9-ethyl-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene,

[0077] 9-propyl-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene,

[0078] 9-hexyl-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene,

[0079] 9-decyl-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene,

[0080] 9,10-dimethyl-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene,

[0081] 9-ethlyl, 10-methyl-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene,

[0082] 9-cyclohexyl-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene,

[0083] 9-chloro-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene,

[0084] 9-bromo-tetracyclo[6.2.1.1^3,6.0^2,7]-4-dodecene,

[0085] cyclopentadiene-trimer,

[0086] methyl-cyclopentadiene-trimer,

[0087] and the like.

[0088] In a preferred embodiment, the cyclic olefin is cyclobutene, dimethyl dicyclopentadiene, cyclopentene, cycloheptene, cyclooctene, cyclononene, cyclodecene, cyclooctadiene, cyclononadiene, cyclododecene, norbornene, norbornadiene, 7-oxanorbornene, 7-oxanorbornadiene, and dicyclopentadiene; each of which may be functionalized or unfunctionalized. In a more preferred embodiment, the cyclic olefin is dicyclopentadiene. Suitable dicyclopentadiene is comniiercially available, for example, from Lyondell uncler the trademarks Lyondell 108 and Lyondell 103. Preferably, the olefin monomer has a ptirity greater than about 95 percent by weight.

[0089] This invention contemplates preparation of homopolymers, as well as random and block copolymers and terpolymers of tlhe suitable monomers discussed above.

[0090] Reinforcemenit Materials:

[0091] Suitable reinforcing materials include those that add to the strength or stiffness of the polymer composite when incorporated with the polymer. Reinforcing material can be in the forim of filaments, fibers, rovings, mats, weaves, fabrics, knitted material, cloth or other known structures. Preferably, the reinforcing material is in filament or fiber form or fibers that are knitted into a fabric.

[0092] Representative suitable reinforcement materials inscLude barium sulfate; minerals, such as glass, carbon, graphite, ceramic, boron, and the like; metallic materials; organic polymers, such as aromatic polyamides inctuding the aramici fibers, such as Kevlar®, and polybenzimide, polybenzoxazol, polybenzothiazol, polyesters, and the like; polyolefins; fluoropolymer, such as Halar®; cellullosic materials; and other material known to be useful as reinforcing material for polymer systems. Examples of othier commercially available reinforcing materials include the following products: Fiberfrax® from Unifrax Corporation, Interfil® from Akzo Nobel, and wollastonite from Nyco. Fiber glass or fiber glass knitted into a fabric are preferred.

[0093] Coupling/Sizing Agents:

[0094] The reinforcing materials are “sized”, i.e., treated or coated withi a coupling agent, often also referred to as a sizing or bonding agent, to render them more compatible for adhering with thle olefin polymer matrix. As used herein, “coupling agent” means any material that can be applied to a reinforcing material that provides for an improved interface or adlhesion between the reinforcement materials and the polyolefin.

[0095] “Compatable coupling agents” as used herein include those coupling agents that are capable of being used in the presence of the metathesis polymerization reactions, preferably Ring opening Metathesis Polymerization (ROMP) reactions, which are catalyzed with a ruthenium or osmium catalyst, without adversely affecting the catalyst or the polymerization reaction. Compatable coupling agents include conventional coupling agents which do not include functional groups that will poison or adversely effect the metathesis polymerization reaction or catalyst.

[0096] Compatable coupling agents include a variety of conventional chromium; silane; titanate; zirconate, zirco-aluminate, and hydroxyl terminated amphaphilic coupling agents. Preferably, those which do not contain the following functionalities: vinyl ethers; active oxygen functionalities such as hydroperoxides or activated epoxides; acetylenes; and other Lewis bases that may poison or adversely affect the ruthenium or osntium catalyst.

[0097] In a more preferable embodiment, the coupling agents also do not include thiols, primary amines, terminal epoxides, and certain conjugated diene functionalities. However, in certain of these embodiments, where the coupling agent is applied to the reinforcing material in an acidic environment, coupling agents having thiols, primary amines, terminal epoxides, and certain conjugated diene functionalities may be used.

[0098] In an even more preferable embodiment, the coupling agent does not include any of the following functionalities: vinyl ethers; active oxygen functionalities such as hiydroperoxides and activated epoxides; terminal epoxides; thiols; acetylenes; certain conjugated dienes; amines and other Lewis bases that may poison or adversely affect the ruthenium or osmium catalysts.

[0099] Preferable chromium coupling agents include chromium complexes such as methacrylatochromic chloride complex, and other similar such complexes that may contain larger alkyl groups, for example, ethacrylatochromic complexes, propacrylatochromic complexes, butacrylatochromic complexes, etc. The most preferred coupling agents include the methacrylatochromic chloride complex. Such methacrylatochromic chloride complex coupling agents are commercially available from Du Pont under the trademark Volan®, Volan A®, or Volan L®.

[0100] Preferable silane coupling agents include the following chemicals listed below, which are commercially available from Degussa under the corresponding Degussa Designation Number listed below:

[0101] Other preferable silane coupling agents include the following chemicals listed below, which are commercially available from Dow Corning under the corresponding Dow Corning Designation Numher listed below:

[0102] Other preferable silane coupling agents include the following chemicals listed below, which are commmercially available from Union Carbide under the corresponding Union Carbide Designation Number listed

[0103] Suitable titanate coupling agents are commercially available from Dupont under the trademark Tyzor. Suitable zirconate coupling agents are commercially available from Kenrich under the Trademark Ken-react, and suitable zirco-aluminate coupling agents are commercially available from Rhone-Poulenc.

[0104] Suitable liydroxyl terminated amphaphilic coupling agents include the following which are commercially available from Chartwell:

[0105] The coupling agent is applied to the reinforcing material prior to the polymerization reaction wherein the reinforcing material is incorporated into the polyolefin article. Suitable methods for applying the coupling agent include dipping, spraying, brushing, rolling or other methods known in the art for applying a coupling agent to a reinforcing material. The coupling agent is applied to the reinforcing material to provide at least a partial coating and in an amount such that the coupling agent improves the interface or adhesion between the reinforcing materials and the polyolefin.

[0106] Methods for Making Reinforced Articles:

[0107] The reinforced polyolefin composite articles are made using methods such that the metathesis polymerization of the monomer occurs in the presence of the sized reinforcing materials. Suitable methods of making the reinforced articles include a variety of polymer processing techniques, such as: casting, centrifugal casting, pultrusion, molding, rotational molding, open molding, reaction injection molding (RIM), resin transfer molding (RTM), pouring, vacuum impregnation, surface coating, filament winding and othiecr methods known to be useful for producing reinforced polymer articles. Preferably, the reinforced polymer structures are manufactured through centrifugal casting or filament winding.

[0108] The polymerization reaction is carried out within or on the casts, cast tubes, molds, mandrels or other structures used in the above named methods, in the presence of the sized reinforcing material to create reinforced ietathesis polymerized polymer articles.

[0109] Reaction and Processing Conditions:

[0110] The parameters for the metathesis polymerization reactions used in the current invention, such as the atmosphere, the ratio of catalyst to monomer, the reaction temperatures, the solvents that may be used, the additives and other agents that may be present during the polymerization reaction, and the methods for carrying out the metathesis polymerization are disclosed in the incorporated references identified above.

[0111] Generally the polymerization of the olefin is carried out by adding the desired ruthenium or osmium carbene metathesis catalyst to the monomer starting material which has been heated to a starting resin temperature. Alternatively, the catalyst may be first added to the monomer starting material and the mnixture then heated to the required temperature. The starting resin temperature is not critical; but, as is known, this temperature does affect the rate of the polymerization reaction. Generally the reaction temperature will be in the range of about 0° C. to about 100° C., and preferably about 25° C. to about 45° C.

[0112] The ratio of catalyst to starting material is not critical and can within the range from about 1:5 to about 1:200,000 by mole. Ratios of catalyst to starting material of between about 1:2,000 and 1:15,000 by iiole are preferred. The invention may be practiced using catalyst/starting material ratios outside of the above ranges.

[0113] The monomer starting material may optionally be refluxed, run through absorption purification, and degassed before the catalyst is added; although, none of these proceduries is necessary to practice the invention.

[0114] If a gel modification additive, cross-linking agent, or other additive is used it is preferred that the additives be added before the catalyst; although, thi is not critical.

[0115] Although it is preferred that the reaction be conducted in the absence of a solvent this is not critical. Possible solvents that may be used include organic, protic, or aqueous solvents which are inert under the reaction conditions. Examples of suitable solvents may include aromatic hydrocarbons, chlorinated hydrocarbons, ethers, alipabtic hydrocarbons, alcohols, watler, or mixtures thereof.

[0116] After polymerization is complete (i.e., after the article has “cured”) the polyolefin article may be post cured to initiate increased cross-linking. As is known, additional cross-linlking may be accomplished by post-curing at an elevated temperature. As is well known in the art, other methods may be used to postcure the polyolefin material.

[0117] Unlike previous catalyst systems, the catalyst/monomer starting material mixture employed by the present invention may remain liquid for a considerable period of time depending on the temperature and the amount of gel modification additive present. This characteristic of thre present catalyst system allows polyolefin articles to be made using a variety of polymer processing techniques discussed above.

[0118] The monomer starting material may also include a flame-retarding agent to reduce the flammability of the polyolefin. The flame-retarding agent must be capable of being usedi iin the presence of the metathesis polymerization reactions catalyzed with a ruthenium or osinium catalyst, without adversely affecting the catalyst or the polymerization reaction. Suitable flame-retarcling agents include conventional flame-retarding agents which do not include functional groups that will poison or adversely effect the metathesis polymerization reaction or catalyst. Such flame retardants are commercially available from Clariant under the trademarks EXOLIT IFR-11 and EXOLIT IFR-10.

[0119] The monomer starting material may optionally include additives such as fillers, binders, plasticizers, pigments, dyes, etc., as is known in the art. However, because of the functional group tolerance of the catalysts, additives which cannot be used with other catalyst systems in the preparation of metathesis polymerized articles can be used.

[0120] The following examples are intended to exemplify embodiments of the invention and are not to be construed as limitations thereof.

[0121] A two inch diameter reinforced polydicyclopentadiene (PolyDCPD) pipe was produced using a centrifugal casting method. A fiberglass fabric was used as the reinforcing material. The fiberglass fabric was sized with a methacrylatochromic chloride conmplex coupling agent purchased from Du Pont under the trademark “Volan”. The following components were mixed to make the DCPD resin/catalyst mixture:

[0122] The following process steps were then used to produce the pipe:

[0123] 1. The Volan Sized Fiberglass Fabric was rolled around a tube (mandrel) smaller than the inside diameter of the desired finished pipe. The number of layers and weight of the fabric may vary with the diameter and pressure rating of the finished pipe.

[0124] 2. The fabric and tube were inserted into the mold tube, and the tube was spun at a high enough revolutions per minute (RPM) to “unwind” the fabric from the mandrel.

[0125] 3. After the mandrel was withdrawn, plugs were inserted into each end of the mold tube. One of the plugs included a port which could be sealed after injecting the resin/catalyst mixture into the tube through the port.

[0126] 4. A premeasured amount of the above resin/catalyst mixture formulation was injected into the tube through the port in the end plug. The amount of resin depends upon the desired wall thickness and diameter of the finished pipe.

[0127] 5. The tube was spun at a speed which will result in approximately 75 G's of force on the outside of the mold tube. A temperature of 85-950° F. was maintained by keeping the temperature of the room in which the pipe was produced at this temperature. This insured that the mold, glass and resin are all the same temperature.

[0128] 6. The tube was allowed to spin until the mixture gelled, which was for approximately 30 minutes (the resin exothermed and gelled during this time).

[0129] 7. The mold tube and pipe were removed from the spinning machine and placed in a post cure oven for 30 minutes at 300° F.

[0130] 8. The pipe was removed from the mold tube, the ends of the pipe were trimnmed, and the mold tube was recycled.

[0131] Upon removal of the pipe, no significant odor of DCPD was noticed, indicating minimal amounts of residual monomer after curing.

[0132] End caps were then adhesively bonded onto each end of the sized pipe so that a hydrostatic pressure test could be performed. The hydrostatic pressure test was performed in accordance with ASTM procedure D1599. The sized pipe was pressurized up to about 1500 pounds per sqtiare inch (psi) before failing by actually tearing the fiberglass fabric. There was no weepage up to this point, indicating that the pipe was substantially impermeable, and there was no pathway for leakage along ant unreacted monomer.

[0133] In a second test, the sized pipes had a liquid red clyde applied to the end of the pipe. The pipe made with tilt Volan sized fabric did not exhibit any red dye penietration or “wicking”, even after several hours.

[0134] In a comparative example, a control sample of two inch diameter reinforced PolyDCPD pipe was produced in tale same manner described in Example 1, except that the fiberglass fabric was sized with an amino silane coupling agent.

[0135] Upon removal of the pipe after curing, heavy odor of DCPD was noticed, indicating unreacted DCPD monomer.

[0136] End caps were then adhesively bonded onto each end of the pipe so that a hydrostatic pressure test could be performed in accordance with ASTM procedure D1599. At the city water pressure of approximately 80 psi, general weepage through the wall of the pipe was noted. It was later determined that the water was being forced into the woven roving through the ends of the pipe, and out the woven roving due to the incompatible finish on the woven roving deactivating the catalyst at the interface between the polymer and the reinforcing material.

[0137] In the second test, the amino-silane sized pipe had a liquid red dye applied to the end of the pipe. The pipe made with standard amino-silave sized woven roving “wicked” the red dye at least ½ inch along the reinforcing glass fibers within a few minutes.