Process for preparing interpenetrating polymer network objects employing rubber-modified polymers

Claim 1

A method of preparing a hard, shaped object comprising: (I) combining components comprising: (a) from about 10 to about 70 weight percent of multifunctional crosslinking composition; and (b) from about 3 to about 70 weight percent of polymer composition comprising: (1) up to about 90 weight percent of polymer composition of crosslinked polymer in the form of discrete particles having average diameters up to about 500 microns and being swellable in the crosslinking composition; and (2) at least about 10% by weight of the polymer composition of rubber-modified polymer comprising particles of an elastomer having a glass transition temperature below about 0° C. and having average diameters less than about 5 microns, said particles being overpolymerized to compromise from about 10% to about 80% by weight of monomeric species, said overpolymerized particles being polymerized to form macroparticles comprising from about 80% to about 98% of monomeric species, the macroparticles having average diameters less than about 200 microns; (II) blending the components at a temperature between about 30° C. and about 100° C. and at a pressure between about 5 and about 200 mm of mercury for a time sufficient to provide a smooth, tractable, substantially uniform polymerizable composition; (III) shaping the polymerizable composition into a shaped body, and; (IV) effecting polymerization of the body to provide the hard, shaped object.

Claim 2

A method of preparing a hard, shaped object comprising: (I) combining components comprising: (a) from about 10 to about 70 weight percent of multifunctional crosslinking composition; and (b) from about 3 to about 70 weight percent of polymer composition comprising: (1) up to about 90 weight percent of polymer composition of crosslinked polymer in the form of discrete particles having average diameters up to about 500 microns and being swellable in the crosslinking composition; and (2) at least about 10% by weight of the polymer composition of rubber-modified polymer comprising particles of an elastomer having a glass transition temperature below about 0° C. and having average diameters less than about 5 microns, said particles being overpolymerized to compromise from about 10% to about 80% by weight of monomeric species, said overpolymerized particles being polymerized to form macroparticles comprising from about 80% to about 98% of monomeric species, the macroparticles having average diameters less than about 200 microns; (II) blending the components at a temperature between about 30° C. and about 100° C. and at a pressure between about 5 and about 200 mm of mercury for a time sufficient to provide a smooth, tractable, substantially uniform polymerizable composition; (III) shaping the polymerizable composition into a shaped body, and; (IV) effecting polymerization of the body to provide the hard, shaped object.