CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/691,833, filed Jun. 29, 2018; U.S. Provisional Application No. 62/798,047, filed Jan. 29, 2019; and U.S. Provisional Application No. 62/831,250, filed Apr. 9, 2019; all of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION
Field of the Invention

Embodiments in accordance with the present invention relate generally to a single component composition containing mass polymerizable polycycloolefin monomer(s) and a catalyst which is activated photolytically by a compound capable of generating Bronsted acid with a counterion capable of coordinating and activating the latent catalyst useful as three-dimensional (3D) printing materials. The compositions so formed exhibit high mechanical properties, specifically exhibiting high impact strength having utility in a variety of applications including as 3D ink compositions, among other uses. More specifically, this invention relates to room temperature stable single component compositions encompassing norbornene (NB) and dicyclopentadiene (DCPD) based olefinic monomers and an oxygen sensitive catalyst system which is activated under photolytic conditions thereby undergoing mass polymerization to form solid objects, including films, vias, patterned lines, among others.

Description of the Art

Recently there has been an increased interest in developing 3D ink compositions which can produce 3D objects having finer structures at micron levels. A few of the recently introduced 3D ink systems are capable of continuous production of 3D objects which are useful in a variety of diversified applications including for example tissue engineering to electronic components. See for example, J. M. DeSimone et al., Science, Vol. 347, pp 1349-1352 (2015), where it is disclosed a continuous liquid interface production (CLIP), which is controlled by a “dead zone” to avoid any oxygen sensitivity of the 3D ink materials employed therein, which allows fabrication of a series of objects at much faster speed and with high resolution such that the objects so formed can feature patterns in the 50 to 100 micron range.

WO2017/068590 A1 discloses a series of 3D inkjet printing materials using dicyclopentadiene compounds polymerizable by ring-opening metathesis polymerization methods.

U.S. Pat. No. 9,909,022 B2 discloses various ink compositions which when printed and cured forms organic thin films on a substrate. Such ink compositions are contemplated to be used in organic light emitting diode (OLED) displays. The compositions disclosed therein are generally curable polyethylene glycol acrylates and polyol acrylates, which are known to be not stable under temperatures higher than 200° C.

Accordingly, there is still a need for developing 3D printing materials that can be cured at a faster speed and exhibit desirable thermal and mechanical properties for fabricating industrially useful 3D objects, films and patterned features at a lower cost. Such compositions may find other uses such as for example as optical coating compositions which can be applied onto various desirable surfaces using conventional methods such as spin coating or slot die coating, among others. In addition, such coatings can be a single layer or a plurality of layers containing such compositions.

Thus, it is an object of this invention to provide 3D printing compositions that overcome the gaps faced by the art. More specifically, it is an object of this invention to provide a single component composition that will mass polymerize rapidly under inert atmospheres to form 3D objects under the conditions of 3D printing system. It is further an object of this invention to provide stable single component mass polymerizable composition with no change in viscosity at or below normal storage conditions but which undergoes mass polymerization only under the 3D process conditions.

Other objects and further scope of the applicability of the present invention will become apparent from the detailed description that follows.

SUMMARY OF THE INVENTION

Surprisingly, it has now been found that by employing a single component filler composition, it is now possible to form three dimensional objects having improved thermal and mechanical properties, most notably the compositions of this invention can be tailored to desirable thermo-mechanical properties. For example, the compositions of this invention can be tailored to exhibit glass transition temperatures (T_g) higher than 150° C., high heat distortion temperature (HDT, higher than 50° C. at 1.82 MPa/264 psi), high elongation to break (greater than 100 percent), high impact strength (Izod impact strength of about 50 J/m or higher) and high tensile strength (greater than 50 MPa). It is also important to note that the compositions of this invention can be mass polymerized under photolytic conditions at a faster speed and thus can be employed in any of the 3D technologies, including layer by layer approach, inkjet formulations and in the stereolithographic applications involving continuous liquid interface production of 3D objects. The compositions of this invention are expected to exhibit faster photopolymerizing capabilities thus enabling to form a wide variety of objects of different sizes, including sizes greater than 10 inches and structural details lower than 50 μm. Further, compositions of this invention are also expected to exhibit low shrinkage due to their rigid polycycloolefinic structure. In addition, as the components of this invention undergo fast mass polymerization upon application they do not leave behind any fugitive small molecules which needs further processing. Generally, no other small molecule additives need to be employed thus offering additional advantages. Most importantly, the compositions of this invention are stable (i.e., no change in viscosity) at ambient atmospheric conditions including up to 35° C. for several hours, and undergo mass polymerization only under photolytic conditions.

Accordingly, there is provided a single component composition encompassing:

a) one or more monomers of formula (I):

[Image Omitted]

wherein:

m is an integer 0, 1 or 2;

[Image Omitted] is a single bond or a double bond;

R₁, R₂, R₃and R₄are the same or different and each independently selected from the group consisting of hydrogen, halogen, methyl, ethyl, linear or branched (C₃-C₁₆)alkyl, (C₂-C₁₆)alkenyl, perfluoro(C₁-C₁₂)alkyl, (C₃-C₁₂)cycloalkyl, (C₆-C₁₂)bicycloalkyl, (C₆-C₁₂)bicycloalkenyl(C₁-C₁₂)alkyl, (C₁-C₁₄)tricycloalkyl, methoxy, ethoxy, linear or branched (C₃-C₁₆)alkoxy, (C₂-C₆)acyl, (C₂-C₆)acyloxy, hydroxy(C₁-C₁₆)alkyl, (C₂-C₆)acyloxy(C₁-C₁₆)alkyl, (C₆-C₁₄)aryl, (C₆-C₁₄)aryl(C₁-C₆)alkyl, perfluoro(C₆-C₁₄)aryl, perfluoro(C₆-C₁₄)aryl(C₁-C₃)alkyl, (C₆-C₁₄)aryloxy, (C₆-C₁₄)aryl(C₁-C₆)alkoxy, tri(C₁-C₆)alkoxysilyl and a group of formula (A):

—Z-Aryl (A)

wherein:

Z is a bond or a group selected from the group consisting of:

(CR₅R₆)_a, O(CR₅R₆)_a, (CR₅R₆)_aO, (CR₅R₆)_a—O—(CR₅R₆)_b, (CR₅R₆)_a—O—(SiR₅R₆)_b, (CR₅R₆)_a—(CO)O—(CR₅R₆)_b, (CR₅R₆)_a—O(CO)—(CR₅R₆)_b, (CR₅R₆)_a—(CO)—(CR₅R₆)_b, where a and b are integers which may be the same or different and each independently is 1 to 12;

R₅and R₆are the same or different and each independently selected from the group consisting of hydrogen, methyl, ethyl, linear or branched (C₃-C₆)alkyl, methoxy, ethoxy, linear or branched (C₃-C₆)alkyloxy, (C₂-C₆)acyl, (C₂-C₆)acyloxy, phenyl and phenoxy;

Aryl is phenyl or phenyl substituted with one or more of groups selected from the group consisting of methyl, ethyl, linear or branched (C₃-C₆)alkyl, hydroxy, methoxy, ethoxy, linear or branched (C₃-C₆)alkyloxy, (C₂-C₆)acyl, (C₂-C₆)acyloxy, phenyl and phenoxy; or

one of R₁or R₂taken together with one of R₃or R₄and the carbon atoms to which they are attached to form a (C₅-C₉)cycloalkyl or a (C₆-C₁₂)bicycloalkyl ring optionally containing one or more double bonds;

b) optionally one or more monomers of formula (IV):

[Image Omitted]

wherein

[Image Omitted] is a single bond or a double bond;

R₁₆and R₁₇are the same or different and each independently selected from the group consisting of hydrogen, methyl, ethyl, linear or branched (C₃-C₆)alkyl, methoxy, ethoxy, linear or branched (C₃-C₆)alkyloxy, acetoxy, (C₂-C₆)acyl, phenyl and phenoxy; or

R₁₆taken together with R₁₇and the carbon atoms to which they are attached to form a (C₅-C₉)cycloalkyl or a (C₆-C₁₂)bicycloalkyl ring optionally containing one or more double bonds;

R₁₈is hydrogen, halogen, methyl, ethyl, linear or branched (C₃-C₁₆)alkyl, (C₆-C₁₀)aryl, (C₆-C₁₀)aryl(C₁-C₆)alkyl, hydroxy, methoxy, ethoxy, linear or branched (C₃-C₁₆)alkoxy, (C₆-C₁₀)aryloxy, (C₆-C₁₀)aryl(C₁-C₆)alkoxy, —O(CO)R₁₉and —O(CO)OR₁₉, where R₁₉is methyl, ethyl, linear or branched (C₃-C₁₆)alkyl, (C₆-C₁₀)aryl and (C₆-C₁₀)aryl(C₁-C₆)alkyl;

c) a latent organo-transition metal catalyst comprising a metal selected from the group consisting of ruthenium and osmium; and

d) a compound capable of releasing a Bronsted acid when subjected to photolytic conditions; and wherein

said composition is in a clear liquid form at room temperature.

In another aspect of this invention there is also provided a kit encompassing the composition of this invention for forming a three dimensional object.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments in accordance with the present invention are described below with reference to the following accompanying figures and/or images. Where drawings are provided, it will be drawings which are simplified portions of various embodiments of this invention and are provided for illustrative purposes only.

FIG. 1A shows dog bone shaped tensile bar made from a polymer made from the composition of this invention containing an antioxidant and a synergist before aging studies as described herein.

FIG. 1B shows the same dog bone shaped tensile bar made from a polymer made from the composition of this invention containing an antioxidant and a synergist after aging studies as described herein.

FIG. 1C shows the dog bone shaped tensile bar made from a polymer made from the composition of this invention containing no antioxidant and a synergist after aging studies as described herein.

DETAILED DESCRIPTION

The terms as used herein have the following meanings:

As used herein, the articles “a,” “an,” and “the” include plural referents unless otherwise expressly and unequivocally limited to one referent.

Since all numbers, values and/or expressions referring to quantities of ingredients, reaction conditions, etc., used herein and in the claims appended hereto, are subject to the various uncertainties of measurement encountered in obtaining such values, unless otherwise indicated, all are to be understood as modified in all instances by the term “about.”

Where a numerical range is disclosed herein such range is continuous, inclusive of both the minimum and maximum values of the range as well as every value between such minimum and maximum values. Still further, where a range refers to integers, every integer between the minimum and maximum values of such range is included. In addition, where multiple ranges are provided to describe a feature or characteristic, such ranges can be combined. That is to say that, unless otherwise indicated, all ranges disclosed herein are to be understood to encompass any and all sub-ranges subsumed therein. For example, a stated range of from “1 to 10” should be considered to include any and all sub-ranges between the minimum value of 1 and the maximum value of 10. Exemplary sub-ranges of the range 1 to 10 include, but are not limited to, 1 to 6.1, 3.5 to 7.8, and 5.5 to 10, etc.

As used herein, the expression “alkyl” means a saturated, straight-chain or branched-chain hydrocarbon substituent having the specified number of carbon atoms. Particular alkyl groups are methyl, ethyl, n-propyl, isopropyl, tert-butyl, and so on. Derived expressions such as “alkoxy”, “thioalkyl”, “alkoxyalkyl”, “hydroxyalkyl”, “alkylcarbonyl”, “alkoxycarbonylalkyl”, “alkoxycarbonyl”, “diphenylalkyl”, “phenylalkyl”, “phenylcarboxyalkyl” and “phenoxyalkyl” are to be construed accordingly.

As used herein, the expression “cycloalkyl” includes all of the known cyclic groups. Representative examples of “cycloalkyl” includes without any limitation cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, and the like. Derived expressions such as “cycloalkoxy”, “cycloalkylalkyl”, “cycloalkylaryl”, “cycloalkylcarbonyl” are to be construed accordingly.

As used herein, the expression “perhaloalkyl” represents the alkyl, as defined above, wherein all of the hydrogen atoms in said alkyl group are replaced with halogen atoms selected from fluorine, chlorine, bromine or iodine. Illustrative examples include trifluoromethyl, trichloromethyl, tribromomethyl, triiodomethyl, pentafluoroethyl, pentachloroethyl, pentabromoethyl, pentaiodoethyl, and straight-chained or branched heptafluoropropyl, heptachloropropyl, heptabromopropyl, nonafluorobutyl, nonachlorobutyl, undecafluoropentyl, undecachloropentyl, tridecafluorohexyl, tridecachlorohexyl, and the like. Derived expression, “perhaloalkoxy”, is to be construed accordingly. It should further be noted that certain of the alkyl groups as described herein, such as for example, “alkyl” may partially be fluorinated, that is, only portions of the hydrogen atoms in said alkyl group are replaced with fluorine atoms and shall be construed accordingly.

As used herein the expression “acyl” shall have the same meaning as “alkanoyl”, which can also be represented structurally as “R—CO—,” where R is an “alkyl” as defined herein having the specified number of carbon atoms. Additionally, “alkylcarbonyl” shall mean same as “acyl” as defined herein. Specifically, “(C₁-C₄)acyl” shall mean formyl, acetyl or ethanoyl, propanoyl, n-butanoyl, etc. Derived expressions such as “acyloxy” and “acyloxyalkyl” are to be construed accordingly.

As used herein, the expression “aryl” means substituted or unsubstituted phenyl or naphthyl. Specific examples of substituted phenyl or naphthyl include o-, p-, m-tolyl, 1,2-, 1,3-, 1,4-xylyl, 1-methylnaphthyl, 2-methylnaphthyl, etc. “Substituted phenyl” or “substituted naphthyl” also include any of the possible substituents as further defined herein or one known in the art.

As used herein, the expression “arylalkyl” means that the aryl as defined herein is further attached to alkyl as defined herein. Representative examples include benzyl, phenylethyl, 2-phenylpropyl, 1-naphthylmethyl, 2-naphthylmethyl and the like.

As used herein, the expression “alkenyl” means a non-cyclic, straight or branched hydrocarbon chain having the specified number of carbon atoms and containing at least one carbon-carbon double bond, and includes ethenyl and straight-chained or branched propenyl, butenyl, pentenyl and hexenyl groups. Derived expression, “arylalkenyl” and five membered or six membered “heteroarylalkenyl” is to be construed accordingly. Illustrative examples of such derived expressions include furan-2-ethenyl, phenylethenyl, 4-methoxyphenylethenyl, and the like.

As used herein, the expression “heteroaryl” includes all of the known heteroatom containing aromatic radicals. Representative 5-membered heteroaryl radicals include furanyl, thienyl or thiophenyl, pyrrolyl, isopyrrolyl, pyrazolyl, imidazolyl, oxazolyl, thiazolyl, isothiazolyl, and the like. Representative 6-membered heteroaryl radicals include pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, triazinyl, and the like radicals. Representative examples of bicyclic heteroaryl radicals include, benzofuranyl, benzothiophenyl, indolyl, quinolinyl, isoquinolinyl, cinnolyl, benzimidazolyl, indazolyl, pyridofuranyl, pyridothienyl, and the like radicals.

“Halogen” or “halo” means chloro, fluoro, bromo, and iodo.

In a broad sense, the term “substituted” is contemplated to include all permissible substituents of organic compounds. In a few of the specific embodiments as disclosed herein, the term “substituted” means substituted with one or more substituents independently selected from the group consisting of (C₁-C₆)alkyl, (C₂-C₆)alkenyl, (C₁-C₆)perfluoroalkyl, phenyl, hydroxy, —CO₂H, an ester, an amide, (C₁-C₆)alkoxy, (C₁-C₆)thioalkyl and (C₁-C₆)perfluoroalkoxy. However, any of the other suitable substituents known to one skilled in the art can also be used in these embodiments.

It should be noted that any atom with unsatisfied valences in the text, schemes, examples and tables herein is assumed to have the appropriate number of hydrogen atom(s) to satisfy such valences.

By the term “latent organo-transition metal catalyst” is meant organo-transition metal compounds that show little or no catalytic activity at a particular (usually ambient atmospheric conditions) temperature and initiate such activity upon exposure to suitable radiation.

By the term “three dimensional object” or “3D object” means any of the macroscale or microscale objects that can be formed from the compositions of this invention by any of the known techniques having a wide variety of applications including electronic, optoelectronic, and other applications.

By the term “derived” is meant that the polymeric repeating units are polymerized (formed) from, for example, polycyclic monomers, such as norbornene-type monomers in accordance with formulae (I) or (IV) wherein the resulting polymers are ring opened metathesis polymerized (ROMP), for example, the 2,3 double bond of norbornene-type monomers are ring opened and polymerized as shown below:

[Image Omitted]

Accordingly, in accordance with the practice of this invention there is provided a single component composition encompassing:

a) one or more monomers of formula (I):

[Image Omitted]

wherein:

m is an integer 0, 1 or 2;

[Image Omitted] is a single bond or a double bond;

R₁, R₂, R₃and R₄are the same or different and each independently selected from the group consisting of hydrogen, halogen, methyl, ethyl, linear or branched (C₃-C₁₆)alkyl, (C₂-C₁₆)alkenyl, perfluoro(C₁-C₁₂)alkyl, (C₃-C₁₂)cycloalkyl, (C₆-C₁₂)bicycloalkyl, (C₆-C₁₂)bicycloalkenyl(C₁-C₁₂)alkyl, (C₇-C₁₄)tricycloalkyl, methoxy, ethoxy, linear or branched (C₃-C₁₆)alkoxy, (C₂-C₆)acyl, (C₂-C₆)acyloxy, hydroxy(C₁-C₁₆)alkyl, (C₂-C₆)acyloxy(C₁-C₁₆)alkyl, (C₆-C₁₄)aryl, (C₆-C₁₄)aryl(C₁-C₆)alkyl, perfluoro(C₆-C₁₄)aryl, perfluoro(C₆-C₁₄)aryl(C₁-C₃)alkyl, (C₆-C₁₄)aryloxy, (C₆-C₁₄)aryl(C₁-C₆)alkoxy, tri(C₁-C₆)alkoxysilyl and a group of formula (A):

—Z-Aryl (A)

wherein:

Z is a bond or a group selected from the group consisting of:

(CR₅R₆)_a, O(CR₅R₆)_a, (CR₅R₆)_aO, (CR₅R₆)_a—O—(CR₅R₆)_b, (CR₅R₆)_a—O—(SiR₅R₆)_b, (CR₅R₆)_a—(CO)O—(CR₅R₆)_b, (CR₅R₆)_a—O(CO)—(CR₅R₆)_b, (CR₅R₆)_a—(CO)—(CR₅R₆)_b, where a and b are integers which may be the same or different and each independently is 1 to 12;

R₅and R₆are the same or different and each independently selected from the group consisting of hydrogen, methyl, ethyl, linear or branched (C₃-C₆)alkyl, methoxy, ethoxy, linear or branched (C₃-C₆)alkyloxy, (C₂-C₆)acyl, (C₂-C₆)acyloxy, phenyl and phenoxy;

Aryl is phenyl or phenyl substituted with one or more of groups selected from the group consisting of methyl, ethyl, linear or branched (C₃-C₆)alkyl, hydroxy, methoxy, ethoxy, linear or branched (C₃-C₆)alkyloxy, (C₂-C₆)acyl, (C₂-C₆)acyloxy, phenyl and phenoxy; or

one of R₁or R₂taken together with one of R₃or R₄and the carbon atoms to which they are attached to form a (C₅-C₉)cycloalkyl or a (C₆-C₁₂)bicycloalkyl ring optionally containing one or more double bonds;

b) optionally one or more monomers of formula (IV):

[Image Omitted]

wherein

[Image Omitted] is a single bond or a double bond;

R₁₆and R₁₇are the same or different and each independently selected from the group consisting of hydrogen, methyl, ethyl, linear or branched (C₃-C₆)alkyl, methoxy, ethoxy, linear or branched (C₃-C₆)alkyloxy, acetoxy, (C₂-C₆)acyl, phenyl and phenoxy; or

R₁₆taken together with R₁₇and the carbon atoms to which they are attached to form a (C₅-C₉)cycloalkyl or a (C₆-C₁₂)bicycloalkyl ring optionally containing one or more double bonds;

R₁₈is hydrogen, halogen, methyl, ethyl, linear or branched (C₃-C₁₆)alkyl, (C₆-C₁₀)aryl, (C₆-C₁₀)aryl(C₁-C₆)alkyl, hydroxy, methoxy, ethoxy, linear or branched (C₃-C₁₆)alkoxy, (C₆-C₁₀)aryloxy, (C₆-C₁₀)aryl(C₁-C₆)alkoxy, —O(CO)R₁₉and —O(CO)OR₁₉, where R₁₉is methyl, ethyl, linear or branched (C₃-C₁₆)alkyl, (C₆-C₁₀)aryl and (C₆-C₁₀)aryl(C₁-C₆)alkyl;

c) a latent organo-transition metal catalyst comprising a metal selected from the group consisting of ruthenium and osmium; and

d) a compound capable of releasing a Bronsted acid when subjected to photolytic conditions; and wherein said composition is in a clear liquid form at room temperature.

As used herein the Aryl may further include the following:

substituted or unsubstituted biphenyl of formula:

[Image Omitted]

substituted or unsubstituted naphthyl of formula:

[Image Omitted]

substituted or unsubstituted terphenyl of formula:

[Image Omitted]

substituted or unsubstituted anthracenyl of formula:

[Image Omitted]

substituted or unsubstituted fluorenyl of formula:

[Image Omitted]

where R_xin each occurrence is independently selected from methyl, ethyl, linear or branched (C₃-C₁₂)alkyl or (C₆-C₁₀)aryl.

The monomers employed in the composition of this invention are themselves known in the literature or can be prepared by any of the known methods in the art to make such or similar types of monomers.

In addition, the monomers as described herein readily undergo mass polymerization, i.e., substantially in their neat form without use of any solvents when polymerized under mass ring open metathesis polymerization (ROMP) conditions using certain transition metal catalysts, such as for example, organo-ruthenium and organo-osmium compounds. See for example, R. H. Grubbs et al., Handbook of Metathesis, Ed.: Wiley-VCH, Weinheim, Germany, 2003, R. H. Grubbs et al., Acc. Chem. Res. 2001, 34, 18-29, R. H. Grubbs et al., Angew. Chem. Int. Ed., 2006, 45, 3760-3765. Also, see U.S. Pat. No. 6,838,489, pertinent portions of which are incorporated herein by reference. The term “mass polymerization” as used herein shall have the generally accepted meaning in the art. That is, a polymerization reaction that is generally carried out substantially in the absence of a solvent. In some cases, however, a small proportion of solvent is present in the reaction medium. For example, such small amounts of solvent may be used to dissolve the latent catalyst and/or the activator or convey the same to the reaction medium. Also, some solvent may be used to reduce the viscosity of the monomer or to dissolve the monomer if it is in a solid form. In some cases the co-monomer, if employed, may itself serve as a solvent both to reduce the viscosity and/or to dissolve the co-monomer. The amount of solvent that can be used in the reaction medium may be in the range of 0 to 5 weight percent based on the total weight of the monomers employed. Any of the suitable solvents that dissolves the catalyst, activator and/or monomers can be employed in this invention. Examples of such solvents include alkanes, cycloalkane, toluene, THF, dichloromethane, dichloroethane, and the like.

Advantageously, it has now been found that one or more of the monomers themselves can be used to dissolve the latent catalyst as well as the activator and thus avoiding the need for the use of solvents. In addition, one monomer can itself serve as a solvent for the other monomer and thus eliminating the need for an additional solvent. For example, if first monomer of formula (I) is a solid at room temperature, then the second monomer of formula (I), which is liquid at room temperature can be used as a solvent for the first monomer of formula (I) which is a solid or vice versa. Therefore, in such situations more than one monomer can be employed in the composition of this invention.

However, in some embodiments only one monomer of formula (I) is employed which serves both as a solvent for the catalyst as well as the Bronsted acid generator, and is stable under ambient conditions. But rapidly undergoes mass polymerization under photolytic conditions, thus useful in various applications as contemplated by this invention.

Accordingly, it has now been surprisingly found that one or more monomers of formula (I) serve as raw materials for fabricating a three dimensional (3D) objects using any of the known 3D technologies. In general, the composition of this invention exhibits low viscosity, which can be below 100 centipoise at 25° C. and in some embodiments below 50 centipoise (cP) at 25° C. In some embodiments, the viscosity of the composition of this invention is less than 40 centipoise at 25° C. In some other embodiments the viscosity of the composition of this invention is in the range from about 10 to 40 centipoise at 25° C. In yet some other embodiments the viscosity of the composition of this invention is lower than 30 cP, lower than 20 cP, lower than 15 cP, lower than 12 cP at 25° C. In some embodiments it may be lower than 10 cP at 40° C. In some embodiments the viscosity of the composition of this invention is in the range from about 8 to 12 cP at 40° C.

When the composition of this invention contains two or more monomers, for example, they can be present in any desirable amounts that would bring about the intended benefit, including viscosity modification or improvement in thermal and mechanical properties or both. Accordingly, the molar ratio of first monomer of formula (I) to second distinct monomer of formula (I) can be from 1:99 to 99:1. In some embodiments, the molar ratio of first monomer of formula (I):second distinct monomer of formula (I) is in the range from 5:95 to 95:5; in some other embodiments it is from 10:90 to 90:10; it is from 20:80 to 80:20; it is from 30:70 to 70:30; it is from 60:40 to 40:60; and it is 50:50, and so on. Similarly, when more than two different monomers of formula (I) are employed, any ratios of such monomers can be used that would bring about the intended result.

In general, the compositions in accordance with the present invention encompass the above described one or more of the monomer of formula (I) and if needed additional monomers of formula (I) distinct from each other, as it will be seen below, various composition embodiments are selected to provide properties to such embodiments that are appropriate and desirable for the use for which such embodiments are directed, thus such embodiments are tailorable to a variety of specific applications.

For example, as already discussed above, proper combination of distinctive monomers of formula (I) makes it possible to tailor a composition having the desirable viscosity, thermal and mechanical properties. In addition, as described further herein it may be desirable to include other polymeric or monomeric materials as additives, such as for example inorganic nanoparticles which are compatible to provide desirable optical properties depending upon the end use application. Accordingly, the compositions of this invention can also include other polymeric materials and/or nanoparticles which will bring about such intended benefit. Examples of such polymers include without any limitation, various functionalized polynorbornenes, polystyrene, poly(α-methylstyrene), poly(vinyl-toluene), copolymers of α-methylstyrene and vinyl-toluene, and the like. Other polymers that may be suitable as additives in the compositions of this invention include elastomeric polymers, including a wide variety of rubbers, both natural and synthetic rubber. Non-limiting examples of synthetic rubbers include polyisobutylene (PIB), polybutadiene, polyisoprene, random and block copolymers of butadiene and/or isoprene with styrene, styrene-butadiene rubbers (SBR), chloroprene rubbers, and the like. In some embodiments certain of these polymers and/or nanoparticles also function as viscosity modifiers depending upon the type of monomers employed. Accordingly, in some embodiments of this invention polystyrene is used as viscosity modifier. In some other embodiments various functionalized polynorbornenes are used as additional components in the composition of this invention. Non-limiting examples of such suitable polynorbornenes, include without any limitation polybutylnorbomene, polyhexylnorbornene, polydecylnorbomene, and the like. Any amount of polymer additives can be employed herein that will bring about the intended benefit. Accordingly, in some embodiments the amount of polymer additive employed may range from about 0.5 weight percent to about 20 weight percent; in some other embodiments such amount ranges from about 1 weight percent to about 10 weight percent.

The compositions in accordance with the present invention may further contain optional additives as may be useful for the purpose of improving properties of both the composition and the resulting object made therefrom. Such optional additives for example may include anti-oxidants and synergists. Any of the anti-oxidants that would bring about the intended benefit can be used in the compositions of this invention. Non-limiting examples of such antioxidants include pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate) (IRGANOX™ 1010 from BASF), 3,5-bis(1,1-dimethylethyl)-4-hydroxy-octadecyl ester benzenepropanoic acid (IRGANOX™ 1076 from BASF) and thiodiethylene bis[3-(3,5-di-tert.-butyl-4-hydroxy-phenyl)propionate] (IRGANOX™ 1035 from BASF). Non-limiting examples of such synergists include certain of the secondary antioxidants which may provide additional benefits such as for example prevention of autoxidation and thereby degradation of the composition of this invention and extending the performance of primary antioxidants, among other benefits. Examples of such synergists include, tris(2,4-ditert-butylphenyl)phosphite, commercially available as IRGAFOS 168 from BASF, among others.

Advantageously, it has further been found that the compositions of this invention can also contain additional monomers. In some embodiments, the composition according to this invention may further contain one or more second monomer selected from the monomer of formula (IV).

In this aspect of the invention, it has now been found that monomers of formula (IV) provides further advantages. Namely, the monomers of formula (IV) depending upon the nature of the monomer may impart high thermo-mechanical properties, thus it can be tailored to meet the need. In addition, the monomers of formula (IV) may exhibit low viscosity and good solubility for the latent catalyst and/or activator, among various other advantages.

Again, any amount of monomers of formula (I) with a monomer of formula (IV) can be employed to form the compositions of this invention. Accordingly, the molar ratio of monomer of formula (I) to monomer of formula (IV) can be from 1:99 to 99:1. In some embodiments, the molar ratio of monomer of formula (I):monomer of formula (IV) is in the range from 5:95 to 95:5; in some other embodiments it is from 10:90 to 90:10; it is from 20:80 to 80:20; it is from 30:70 to 70:30; it is from 60:40 to 40:60; and it is 50:50, and so on. Similarly, when more than one monomer of formula (I) and more than one monomer of formula (IV) are employed, any ratios of such monomers can be used that would bring about the intended result.

In some embodiments the composition according to this invention encompasses a monomer of formula (I) wherein m is 1 and each of R₁, R₂, R₃and R₄are hydrogen. In some other embodiments the composition according to this invention encompasses a monomer of formula (I) wherein m is 0 and at least one of R₁, R₂, R₃and R₄is other than hydrogen and is a group as defined above and the remaining R₁, R₂, R₃and R₄are hydrogen.

In some embodiments the composition according to this invention encompasses a monomer of formula (IV) where R₁₈is hydrogen. In some embodiments the composition according to this invention encompasses a monomer of formula (IV) where Rib is methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, tert-butyl, phenyl, benzyl, phenethyl, methoxy, ethoxy, phenoxy, benzyloxy, acetoxy and benzoyl.

In some embodiments the composition of this invention encompasses first and second monomer of formula (I) distinct from each other, wherein said first monomer is of formula (I) wherein m is 1 and each of R₁, R₂, R₃and R₄are hydrogen; and wherein said second monomer is of formula (I) wherein m is 0, R₁is decyl and each of R₂, R₃and R₄are hydrogen.

Accordingly, any of the monomers within the scope of monomer of formula (I) can be employed in the composition of the invention. Representative examples of monomer of formula (I) include the following without any limitations:

[Image Omitted]

Representative examples of monomer of formula (IV) include the following without any limitations:

[Image Omitted]

In some embodiments the composition of this invention encompasses one or more monomer of formula (I), which is selected from the group consisting of:

tetracyclododecene (TD);

2-phenethyl-1,2,3,4,4a,5,8,8a-octahydro-1,4:5,8-dimethanonaphthalene (PETD);

2-hexyl-1,2,3,4,4a,5,8,8a-octahydro-1,4:5,8-dimethanonaphthalene (HexylTD);

2-decyl-1,2,3,4,4a,5,8,8a-octahydro-1,4:5,8-dimethanonaphthalene (DecylTD);

5-butylbicyclo[2.2.1]hept-2-ene (BuNB);

5-hexylbicyclo[2.2.1]hept-2-ene (HexylNB);

5-decylbicyclo[2.2.1]hept-2-ene (DecylNB);

5-phenethylbicyclo[2.2.1]hept-2-ene (PENB);

5-(2-([1,1′-biphenyl]-4-yloxy)ethyl)bicyclo[2.2.1]hept-2-ene;

bicyclo[2.2.1]hept-5-en-2-ylmethyl acetate (MeOAcNB);

1,4-di(bicyclo[2.2.1]hept-5-en-2-yl)butane (NBBuNB);

3a,4,4a,5,8,8a,9,9a-octahydro-1H-4,9:5,8-dimethanocyclopenta[b]naphthalene (one of trimers of cyclopentadiene, CPD3, also known as TCPD1); and

5-(2-([1,1′-biphenyl]-2-yloxy)ethyl)bicyclo[2.2.1]hept-2-ene (NBEtO-2-PhPh).

In some embodiments the composition of this invention further includes a monomer of formula (IV), which is dicyclopentadiene (DCPD). It should be noted that mixtures in any combination of aforementioned monomers of formula (I) and monomers of formula (IV) can be employed in the compositions of this invention so as to obtain the intended benefit for forming the desirable 3D objects and can be tailored in accordance with the properties required for the formation of such 3D objects.

In a further embodiment of this invention, the composition contains any of the latent catalyst that would bring about the mass polymerization as described herein under ROMP conditions. Generally, such suitable latent catalysts include a number of known organo-transition metal complexes, such as organo-ruthenium or organo-osmium compounds, among others. For example, U.S. Pat. No. 9,328,132 B2, pertinent portions of which are incorporated herein, discloses a series of organo-ruthenium compounds, which are pre-catalysts for the olefin metathesis reactions, all of such catalysts may be suitable as latent catalysts in the compositions of this invention.

Accordingly, the composition of this invention encompasses a latent catalyst which is an organo-ruthenium compound selected from the group consisting of compounds of formulae (IIA), (IIB), (IIIA), (IIIB) and (IIIC):

[Image Omitted]

and

wherein:

- X is a halogen or an anionic ligand;
- Y is selected from the group consisting of O and S;
- Y′ is OR₉SR₉and —N═CHC(O)O(C₁-C₆)alkyl, where R₉is selected from the group consisting of methyl, ethyl, linear or branched (C₁-C₆)alkyl, (C₆-C₁₀)aryl, methoxy, ethoxy, linear or branched (C₁-C₆)alkoxy, (C₆-C₁₀)aryloxy, —OCH(CH₃)C(O)N(CH₃)(OCH₃);
- L is PR₃or O═PR₃, where R is independently selected from the group consisting of isopropyl, sec-butyl, tert-butyl, cyclohexyl, bicyclo(C₅-C₁₀)alkyl, phenyl, benzyl, isopropoxy, sec-butoxy, tert-butoxy, cyclohexyloxy, phenoxy and benzyloxy; or
- X and L form a bidentate anionic ligand of the formula X-L;
- R₇is selected from the group consisting of isopropyl, sec-butyl, tert-butyl, substituted or unsubstituted cyclohexyl, substituted or unsubstituted phenyl, substituted or unsubstituted biphenyl and substituted or unsubstituted naphthyl;
- R₈is selected from the group consisting of methyl, ethyl, linear or branched (C₁-C₆)alkyl, (C₆-C₁₀)aryl, methoxy, ethoxy, linear or branched (C₁-C₆)alkoxy, (C₆-C₁₀)aryloxy, —NHCO(C₁-C₆)alkyl, —NHCO-perfluoro(C₁-C₆)alkyl, —SO₂N((C₁-C₆)alkyl)₂and —NO₂;
- Ar₁, Ar₂and Ar₃are the same or different and each independently selected from the group consisting of substituted or unsubstituted phenyl, substituted or unsubstituted biphenyl and substituted or unsubstituted naphthyl;

wherein said substituents are selected from the group consisting of methyl, ethyl, iso-propyl, tert-butyl and phenyl.

It should be noted that in the above formulae (IIA), (IIB), (IIIA), (IIIB) and (IIIC), X can include any of the halogens. Is some embodiments X is chlorine, bromine and iodine.

Generally, any of the latent organo-transition metal catalyst that would bring about ring open metathesis polymerization of the monomers of formula (I) and monomer of formula (IV), if present, can be employed in the composition of this invention. More specifically, organo-ruthenium or organo-osmium compounds that show little or no activity at ambient temperatures can be employed. That is, the latent catalysts that are stable at or near room temperature are more suitable in the composition of this invention. The latent catalysts may be activated by a variety of conditions, including without any limitation acid and chemical activation. The chemical activation may include use of thermal acid generators or photo acid generators.

Several of the latent catalysts that are suitable to be employed in the compositions of this invention are known in the literature or can be readily made by any of the known procedures in the art. See for example, Grubbs, et al., Organometallics, 2011, 30 (24): 6713-6717; Sutar et al., Angew. Chem. Int. Ed. 2016, 55, 764-767; Leitgeh, et al., Monatsh Chem (2014) 145:1513-1517; van Hensbergen, et al., J. Mater. Chem. C. 2015, 3, 693-702; Grubbs, et al., J. Am. Chem. Soc., 2009, 131, 203802039; Zak, et al., Eur. J. Inorg. Chem., 2014, 1131-1136; Gawin, et al., ACS Catal. 2017, 7, 5443-5449. As noted above, further examples of such catalysts can also be found in U.S. Pat. No. 9,328,132. Accordingly, a few of the exemplary latent catalysts, which are organo-ruthenium compounds, without any limitation maybe selected from the group consisting of:

[Image Omitted]

1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)(tricyclohexylphosphine)-(2-oxobenzylidene)ruthenium(VI) chloride

[Image Omitted]

- where X=halogen, —OR_a, —O(CO)R_a—OSO₂R_a, where R_ais (C₁-C₁₂)alkyl, (C₃-C₁₂)cycloalkyl, (C₆-C₁₄)aryl;

[Image Omitted]

- where X is Cl or I and R₁₀is hydrogen, NO₂or Cl;

[Image Omitted]

As noted, the composition of this invention further contains a compound capable of releasing a Bronsted acid when subjected to suitable photolytic conditions. The anion, for example chloride, of so released Bronsted acid activates the latent catalyst. Surprisingly it has now been found that certain of the known photoactive active compounds, such as for example, a class of substituted xanthone derivatives can be used for this purpose.

Accordingly, in some embodiments such xanthone derivatives are of the formula (V):

[Image Omitted]

Wherein Y is halogen; and R₃₀and R₃₁are the same or different and independently of each other selected from hydrogen, methyl, ethyl, linear or branched (C₃-C₁₂)alkyl, (C₃-C₁₂)cycloalkyl, (C₆-C₁₂)bicycloalkyl, (C₇-C₁₄)tricycloalkyl, (C₆-C₁₀)aryl, (C₆-C₁₀)aryl(C₁-C₃)alkyl, (C₁-C₁₂)alkoxy, (C₃-C₁₂)cycloalkoxy, (C₆-C₁₂)bicycloalkoxy, (C₇-C₁₄)tricycloalkoxy, (C₆-C₁₀)aryloxy(C₁-C₃)alkyl and (C₆-C₁₀)-aryloxy. In some embodiments Y is fluorine, chlorine, bromine and iodine. In some embodiments Y is chlorine. In some other embodiments R₃₀is hydrogen and R₃₁is selected from the group consisting of methoxy, ethoxy, n-propoxy, iso-propoxy, butoxy, and the like.

Further, it has also been found that a variety of substituted triazines of the formula (VI) are also suitable as a compound capable of releasing a Bronsted acid when subjected to suitable photolytic conditions.

[Image Omitted]

wherein

R₃₂, R₃₃and R₃₄are the same or different and independently of each other selected from the group consisting of halogen, methyl, ethyl, linear or branched (C₃-C₁₂)alkyl, trihalomethyl, pentahaloethyl, linear or branched perhalo(C₃-C₁₂)alkyl, (C₆-C₁₀)aryl, (C₆-C₁₀)aryl(C₁-C₃)alkyl, perhalo(C₆-C₁₀)aryl, perhalo(C₆-C₁₀)arylperhalo(C₁-C₃)alkyl, substituted or unsubstituted five membered or six membered heteroaryl(C₂-C₄)alkenyl and substituted or unsubstituted (C₆-C₁₀)aryl(C₂-C₄)alkenyl provided that one of R₃₂, R₃₃and R₃₄is trihalomethyl, pentahaloethyl, linear or branched perhalo(C₃-C₁₂)alkyl.

Representative examples of the compounds of formula (V) may be listed as follows:

[Image Omitted]

Representative examples of the compounds of formula (VI) without any limitation may be enumerated as follows:

[Image Omitted]

Advantageously, it has now been found that any of the compounds of formula (V) or compounds of formula (VI) which generates a Bronsted acid when subjected to photolytic conditions can be used in the compositions of this invention. The generated Bronsted acid will activate the latent catalysts of fonnulae (IIA), (IIB), (IIIA), (IIIB) or (IIIC) thereby initiating the ROMP of monomers of formula (I), and monomers of formula (IV), if present, thus causing the compositions of this invention to form 3D objects. Generally, any of the Bronsted acids can cause such activation of catalyst. Non-limiting examples of such Bronsted acids include without any limitation hydrofluoric acid, hydrochloric acid, hydrobromic acid, hydroiodic acid, trifluoroacetic acid, trifluoromethanesulfonic acid, and the like. In some embodiments the Bronsted acid generated is hydrochloric acid.

In some embodiments the compounds of formula (V) can be activated at certain wavelength of the electromagnetic radiation which can generally range from about 240 nm to 400 nm. Accordingly, any of the compounds which are active in this electromagnetic radiation can be employed in the compositions of this invention which are stable to the 3D fabrication methods. In some embodiments the wavelength of the radiation to activate the compounds of formula (V) is 260 nm. In some other embodiments the wavelength of the radiation to activate the compounds of formula (V) is 310 nm. In yet some other embodiments the wavelength of the radiation to activate the compounds of formula (V) is 395 nm.

However, any of the other known photoactive active compounds which generate the Bronsted acid for the latent catalysts employed herein can also be used in the composition of this invention. All such compounds are part of this invention.

In some embodiments of this invention the composition of this invention may additionally contain other photosensitizer compounds which can activate the organo-transition compound in order to facilitate the mass polymerization of the monomers of formula (I) and monomers of formula (IV), if present. For this purpose, any suitable sensitizer compound can be employed in the compositions of the present invention. Such suitable sensitizer compounds include, photosensitizers, such as, anthracenes, phenanthrenes, chrysenes, benzpyrenes, fluoranthenes, rubrenes, pyrenes, xanthones, indanthrenes, and mixtures thereof. In some exemplary embodiments, suitable sensitizer components include mixtures thereof. Generally, the photosensitizers absorb energy from the radiated light source and transfers that energy to the desirable substrate/reactant, which in the present invention is the compound of formula (V) employed in the composition of this invention.

Any amount of latent catalyst and the compound of formula (V) can be employed in the composition of this invention which will bring about the intended result. Generally, the molar ratio of monomer:latent catalyst:compound of formula (V) or a compound of formula (VI) is in the range of 10,000:1:1 to 5,000:1:1 or lower. In some other embodiments, the compound of formula (V) is employed at higher level than the latent catalyst, for example, such ranges may include monomer:latent catalyst:photo active initiator is 10,000:1:2, 10,000:1:4 or higher. In some other embodiments such monomer:latent catalyst:photo active initiator is 15,000:1:4, 20,000:1:4 or higher.

Advantageously, it has further been found that the composition according to this invention forms a substantially three dimensional object when mass polymerized, generally, when exposed to suitable radiation at a wavelength in the range from 260 nm to 400 nm. That is to say, when the composition of this invention is exposed to suitable radiation, the monomers undergo mass polymerization to form solid objects under routine 3D printing technologies.

In some embodiments the composition of this invention undergoes mass polymerization when exposed to suitable UV irradiation which is substantially free of any monomer or volatile oligomeric product.

It has also been found that various other viscosity modifiers that are compatible with the compositions of this invention can also be employed in order to modulate the viscosity of the composition before subjecting it to the mass polymerization conditions. Suitable examples of such viscosity modifiers include transparent polymers such as for example polystyrene, polyesters (polyethylene terphthalate, PET), and the like.

Accordingly, in some embodiments of this invention there is provided a composition comprising one or more monomers of formula (I), optionally one or more monomers of formula (IV), a latent catalyst, a compound of formula (V) as described hereinabove. Any of the monomers of formula (I) as described hereinabove can be used in this aspect of the invention, optionally in combination with one or more monomers of formula (IV). The monomers of formula (I) featuring a viscosity below 50 centipoise are generally employed. When more than two monomers of formula (I) are employed the first monomer is completely miscible with the second monomer and forms a clear solution. When the composition is exposed to suitable irradiation and fabricated under suitable 3D printing conditions forms a 3D object.

In another embodiment of this invention, the composition of this invention encompasses a mixture of dicyclopentadiene (DCPD), 5-butylbicyclo[2.2.1]hept-2-ene (BuNB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)(tricyclohexylphosphine)-(2-oxobenzylidene)-ruthenium(VI) iodide and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In another embodiment of this invention, the composition of this invention encompasses a mixture of dicyclopentadiene (DCPD), 5-hexylbicyclo[2.2.1]hept-2-ene (HexylNB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)(tricyclohexylphosphine)-(2-oxobenzylidene)ruthenium(VI) iodide and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In another embodiment of this invention, the composition of this invention encompasses a mixture of dicyclopentadiene (DCPD), 5-decylbicyclo[2.2.1]hept-2-ene (DecylNB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In yet another embodiment of this invention, the composition of this invention encompasses a mixture of dicyclopentadiene (DCPD), 5-phenethylbicyclo[2.2.1]hept-2-ene (PENB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In yet another embodiment of this invention, the composition of this invention encompasses a mixture of 5-phenethylbicyclo[2.2.1]hept-2-ene (PENB), 5-(2-([1,1′-biphenyl]-2-yloxy)ethyl)bicyclo[2.2.1]hept-2-ene (NBEtO-2-PhPh), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In yet another embodiment of this invention, the composition of this invention encompasses a mixture of dicyclopentadiene (DCPD), tetracyclododecene (TD), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In yet another embodiment of this invention, the composition of this invention encompasses a mixture of dicyclopentadiene (DCPD), tetracyclododecadiene (TDD), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In yet another embodiment of this invention, the composition of this invention encompasses a mixture of tetracyclododecene (TD), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In another embodiment of this invention, the composition of this invention encompasses a mixture of dicyclopentadiene (DCPD), 5-decylbicyclo[2.2.1]hept-2-ene (DecylNB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)(tricyclohexylphosphine)-(2-oxobenzylidene)-ruthenium(VI) iodide and 2-(4-methoxystyryl)-4,6-bis(trichloromethyl)-1,3,5-triazine.

In a further aspect of this invention there is also provided a kit for forming a three dimensional object. There is dispensed in this kit a composition of this invention. Accordingly, in some embodiments there is provided a kit in which there is dispensed one or more monomers of formula (I), optionally one or more monomers of formula (IV) and a compound of formula (V), so as to obtain a desirable result and/or for intended purpose. Further, said kit comprises a latent catalyst as described herein. The monomers of formulae (I) or (IV) are the ones as described hereinabove.

In some embodiments, the aforementioned kit encompasses two or more monomers of formula (I) distinct from one another as described hereinabove. In some other embodiments the kit of this invention encompasses at least two monomers wherein first monomer facilitates dissolution of the second monomer and/or the latent catalyst and the additives as described hereinabove. Any of the monomers of formula (I) as described herein can be used in this embodiment. The molar ratio of first and the second monomer of formula (I) contained in these components can vary and may range from 1:99 to 99:1, or 10:90 to 90:10, 20:80 to 80:20, 30:70 to 70:30, 60:40 to 40:60 or 50:50, and so on. In some other embodiments the kit may encompass a composition wherein dispensed more than two monomers of formula (I), each distinct from one another. Further, as noted the first monomer of formula (I) is completely soluble in the second monomer of formula (I) to form a clear solution at room temperature. In some embodiments the monomer mixture may become a clear solution at slightly elevated temperature, such as for example, 30° C. or 40° C. or 50° C., before they undergo mass polymerization. In another aspect of this embodiment of this invention the composition of this invention undergoes mass polymerization when exposed to a suitable radiation for a sufficient length of time to form a 3D object. That is to say that the composition of this invention when used in a suitable 3D printing system capable of exposing to a suitable radiation forms a desirable 3D object. Generally, as already noted above, such polymerization can take place when exposed to suitable radiation at a wavelength from about 260 nm to 400 nm or higher. The exposure can be at stages from 260 nm to 400 nm or at suitable wavelengths as described herein. By practice of this invention it is now possible to form 3D objects using any of the known 3D printing technologies.

In some embodiments the kit according to this invention contains at least two monomers of formula (I) distinct from one another, wherein one monomer is completely soluble in the other monomer, and when said composition is exposed to radiation at 395 nm for a sufficient length of time it forms a three dimensional object.

In some embodiments, the kit as described herein encompasses a composition, which contains a mixture of dicyclopentadiene (DCPD), 5-butylbicyclo[2.2.1]hept-2-ene (BuNB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)(tricyclohexylphosphine)-(2-oxobenzylidene)-ruthenium(VI) iodide and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In some embodiments, the kit as described herein encompasses a composition, which contains a mixture of dicyclopentadiene (DCPD), 5-hexylbicyclo[2.2.1]hept-2-ene (HexylNB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)(tricyclohexylphosphine)-(2-oxobenzylidene)ruthenium(VI) iodide and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In some embodiments, the kit as described herein encompasses a composition, which contains a mixture of tetracyclododecene (TD), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In some other embodiments, the kit as described herein encompasses a composition, which contains a mixture of dicyclopentadiene (DCPD), tetracyclododecene (TD), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In another embodiment, the kit as described herein encompasses a composition, which contains a mixture of dicyclopentadiene (DCPD), 5-decylbicyclo[2.2.1]hept-2-ene (DecylNB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In yet another embodiment of this invention, the kit as described herein encompasses a composition, which contains a mixture of dicyclopentadiene (DCPD), tetracyclododecadiene (TDD), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In yet another embodiment of this invention, the kit as described herein encompasses a composition, which contains a mixture of 5-phenethylbicyclo[2.2.1]hept-2-ene (PENB), 5-(2-([1,1′-biphenyl]-2-yloxy)ethyl)bicyclo[2.2.1]hept-2-ene (NBEtO-2-PhPh), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In yet another embodiment of this invention, the kit as described herein encompasses a composition, which contains a mixture of dicyclopentadiene (DCPD), 5-phenethylbicyclo[2.2.1]hept-2-ene (PENB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium and 1-chloro-4-propoxy-9H-thioxanthen-9-one (CPTX).

In yet another embodiment of this invention, the kit as described herein encompasses a composition, which contains a mixture of dicyclopentadiene (DCPD), 5-decylbicyclo[2.2.1]hept-2-ene (DecylNB), 1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)(tricyclohexylphosphine)-(2-oxobenzylidene)-ruthenium(VI) iodide and 2-(4-methoxystyryl)-4,6-bis(trichloromethyl)-1,3,5-triazine.

As noted, the compositions of this invention can be used in any of the known three dimensional (3D) printing technologies and other printing technologies. A few of the 3D printing procedures known in the art include continuous liquid interface production (CLIP), layer by layer approach (LBL), inkjet printing and frontal polymerization method, such as frontal ring open metathesis (FROMP) technique, see for example Robertson et al., Nature, Vol. 557, 223-227 (2018).

In a CLIP approach, a 3D object is continuously formed by projecting a continuous sequence of UV images (generated by a digital light-processing (DLP) imaging unit or a laser to generate the part) through an oxygen permeable, UV-transparent window below a liquid resin bath containing the compositions of this invention. The dead zone created above the window maintains a liquid interface below the advancing part. Above the dead zone, the curing part is continuously drawn out of the resin bath. The suction forces resulted due to this drawing replenishes the resin bath at the same time. In this way various parts of different dimensions up to several centimeters with part resolution lower than 100 microns can be fabricated.

In a 3D inkjet printing technology, the compositions of this invention can be used as photopolymerizable ink compositions to form lines and vias on a substrate, typically on a silicon wafer. A wide variety of parts having utility in electronic and optoelectronic applications can thus be manufactured using the compositions of this invention. Non limiting examples of such applications include manufacturing of OLED devices on a variety of substrates, which can be produced substantially in a particle free environment at high yields. The compositions of this invention may act as organic encapsulant layers and/or as filler materials in some of such OLED devices.

Accordingly, in yet another aspect of this invention there is further provided a method of forming a three dimensional object comprising:

providing a homogeneous clear composition in a suitable container, the composition comprising one or more monomers of formula (I), a latent catalyst and a compound of formula (V) or a compound of formula (VI), optionally in combination with one or more monomers of formula (IV);

exposing to suitable UV radiation while drawing the composition from the container; and

forming a three dimensional object.

The 3D objects formed in accordance with the method of this invention exhibit excellent thermal and mechanical properties. In general, the properties of these objects can be tailored to intended end use. For example, the thermal properties of the 3D objects can be tailored to be stable up to 180° C. or higher depending upon the types of monomers of formula (I) in combination with monomers of formula (IV) employed to form such 3D objects. Similarly, the mechanical properties can also be tailored to desired mechanical properties simply by the selection of suitable monomers as described herein. In general, by tailoring the proper choice of monomers the parts possessing very high impact strength can be fabricated.

Accordingly, in some of the embodiments of this invention there is also provided a three dimensional object comprising the composition of this invention which exhibits excellent thermal and mechanical properties. In some embodiments of this invention the three dimensional objects made in accordance of this invention exhibits impact strength of at least 40 J/m. In some other embodiments the impact strength of the three dimensional objects formed from the composition of this invention is at least 60 J/m. In yet some other embodiments the impact strength of the three dimensional objects formed from the composition of this invention is at least 80 J/m, 100 J/m or higher, 140 J/m or higher or it can be higher than 160 J/m, such as for example higher than 170 J/m, higher than 180 J/m, higher than 200, 220, 240, 300 or 400 J/m, or even higher than 500, 550, 600, 700 or 800 J/m depending upon the types of monomers employed as described herein.

Advantageously, it has also been found that the compositions of this invention can be used as coating compositions in a variety of applications where there is a need for such coatings, particularly as optically transparent coatings. The compositions of this invention can be applied onto various desirable surfaces using any of the known conventional methods such as for example spin coating or slot die coating, among others. In addition, such coatings can be a single layer or a plurality of layers containing such compositions. In some embodiments the compositions of this invention are spin coated onto a suitable substrate and exposed to suitable UV radiation to cure and fix the composition onto a surface. In some other embodiments the steps of coating of the composition and subjecting to a suitable UV radiation was repeated several times to obtain a plurality of layers of the composition of this invention onto a desirable substrate.

As noted above, employing one or more additives, such as antioxidants in combination with synergists, it has now been found that the polymers made from the composition of this invention exhibits surprisingly superior stable properties after exposed to higher temperatures for a prolonged period of time. For example, it has now been found that the mechanical properties of the polymers made from the composition of this invention are essentially retained even after exposure to a temperature in the range of from about 70° C. to 120° C. for a period of from about one week to four weeks or longer. In some embodiments the polymers made from the composition of this invention exhibits loss of elongation to break (ETB) of about 50 percent to about 30 percent in one week and maintains that value thereafter for a period of about 2 to 6 weeks. In some other embodiments such ETB loss is only about 40 percent in the first week and maintains that value thereafter for a period of about 2 to 6 weeks.

The following examples are detailed descriptions of methods of preparation and use of certain compounds/monomers, polymers and compositions of the present invention. The detailed preparations fall within the scope of, and serve to exemplify, the more generally described methods of preparation set forth above. The examples are presented for illustrative purposes only, and are not intended as a restriction on the scope of the invention. As used in the examples and throughout the specification the ratio of monomer to catalyst is based on a mole to mole basis.

EXAMPLES

The following abbreviations have been used hereinbefore and hereafter in describing some of the compounds, instruments and/or methods employed to illustrate certain of the embodiments of this invention:

PENB—5-phenethylbicyclo[2.2.1]hept-2-ene; BuNB—5-butylbicyclo[2.2.1]hept-2-ene; HexylNB—5-hexylbicyclo[2.2.1]hept-2-ene; DecylNB—5-decylbicyclo[2.2.1]hept-2-ene; TD—tetracyclododecene; DCPD—dicyclopentadiene; NBEtO-2-PhPh—5-(2-([1,1′-biphenyl]-2-yloxy)ethyl)bicyclo[2.2.1]hept-2-ene; MeOAcNB—bicyclo[2.2.1]hept-5-en-2-ylmethyl acetate; ButylTD—2-butyl-1,2,3,4,4a,5,8,8a-octahydro-1,4:5,8-dimethanonaphthalene; HexylTD—2-hexyl-1,2,3,4,4a,5,8,8a-octahydro-1,4:5,8-dimethanonaphthalene; PETD—2-phenethyl-1,2,3,4,4a,5,8,8a-octahydro-1,4:5,8-dimethanonaphthalene; NBBuNB—1,4-di(bicyclo[2.2.1]hept-5-en-2-yl)butane; CPD3—3a,4,4a,5,8,8a,9,9a-octahydro-1H-4,9:5,8-dimethanocyclopenta[b]naphthalene; Ru-I—1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)(tricyclohexylphosphine)-(2-oxobenzylidene)ruthenium(VI) iodide; Ru-II—1,3-bis(2,4,6-trimethylphenylimidazolidin-2-ylidene)-(2-oxobenzylidene)-2-(((2,6-diisopropylphenyl-imino)methyl)phenoxy)ruthenium; CPTX—1-chloro-4-propoxy-9H-thioxanthen-9-one; IRGANOX™ 1076—3,5-bis(1,1-dimethylethyl)-4-hydroxy-octadecyl ester benzenepropanoic acid; IRGAFOS 168—tris(2,4-ditert-butylphenyl)phosphite; DSC—differential scanning calorimetry; TGA—thermogravimetric analysis.

Various monomers as used herein are either commercially available or can be readily prepared following the procedures as described in U.S. Pat. No. 9,944,818.

The following Examples demonstrate that the compositions of this invention are quite stable at ambient temperature conditions and even up to 35° C. for several days and can very readily be mass polymerized by exposing to a suitable radiation as specified below.

Example 1
Mass Polymerization of DCPD/BuNB

In a glass bottle, Ru-I (1 molar part) and CPTX (4 molar parts) were dissolved in a monomer mixture of DCPD/BuNB, 91/9 mole ratio (10,000 molar parts) without solvent to form a clear solution. The solution was UV light exposed for 3 minutes (LED 5 W, 395 nm). The solution turned to a solid indicating the monomer was fully polymerized, as confirmed by both DSC and TGA. The residue percentage from isothermal TGA (1 h at 100° C.) after UV exposure was >99%. The unexposed solution was free flowing even after 3 days at room temperature. This indicates that during the UV exposure CPTX releases a chloride ion that activates Ru-I catalyst.

Examples 2-27
Mass Polymerization of Various Monomers

The procedures of Example 1 were substantially repeated in these Examples 2 to 27 except that Ru-II was used as the latent catalyst, and various different monomers and loadings as listed in Table 1 were employed. In addition, in each of these experiments the solution was UV light exposed for 4 seconds (LED 1 J/cm²) to affect the masspolymerization. The monomer used in each of these Examples 2 to 27, catalyst loading and CPTX loading are summarized in Table 1.

TABLE 1

Ru-II
CPTX

Example
Monomers
loading,
loading,

No.
(molar parts)
(molar parts)
(molar parts)

2
DCPD/DecylNB
1
4

80/20 molar ratio

(10,000)

3
DCPD/DecylNB
1
4

50/50 molar ratio

(10,000)

4
DCPD/DecylNB
1
4

20/80 molar ratio

(10,000)

5
DCPD/PENB
1
4

80/20 mole ratio

(10,000)

6
DCPD/PENB
1
4

50/50 mole ratio

(10,000)

7
DCPD/PENB
1
4

20/80 mole ratio

(10,000)

8
PENB/NBEtO-2-PhPh
1
4

90/10 molar ratio

(10,000)

9
DCPD/TD
1
4

80/20 mole ratio

(10,000)

10
DCPD/TD
1
4

50/50 mole ratio

(10,000)

11
DCPD/TD
1
4

20/80 mole ratio

(10,000)

12
TD
1
4

(10,000)

13
DecylNB/DCPD/NBEtO-2-PhPh
1
4

70/20/10 mole ratio

(10,000)

14
MeOAcNB
1
4

(10,000)

15
PETD
1
4

(10,000)

16
DecylNB/PETD
1
4

50/50 molar ratio

(10,000)

17
DecylNB/NBEtO-2-PhPh
1
4

90/10 mole ratio

(10,000)

18
PENB/NBEtO-2-PhPh
1
4

90/10 mole ratio

(10,000)

19
DecylNB/PETD/NBBuNB
1
4

49.5/49.5/1 mole ratio

20
PENB/CPD3
1
8

60/40 mole ratio

(10,000)

21
PENB/PETD/CPD3
1
8

40/10/50 mole ratio

(10,000)

22
PENB/CPD3
1
8

50/50 mole ratio

(10,000)

23
PENB/CPD3
1
8

75/25 mole ratio

(10,000)

24
DecylNB/PETD/CPD3
1
8

50/25/25 molar ratio

(10,000)

25
DecylNB/PETD/CPD3
1
8

50/40/10 molar ratio

(10,000)

26
DecylNB/DCPD/NBEtO-2-PhPh
1
4

70/20/10 mole ratio

(10,000)

with 1 wt % pDecylNB

27
HexylTD/CPD3
1
8

80/20

The following Examples 28 and 29 illustrate that the compositions of this invention are stable at ambient atmospheric conditions and the shelf life varies depending upon the monomer mixture employed and the catalyst.

Example 28
Shelf Life Studies

In a glass bottle, Ru-II (1 molar part) and CPTX (4 molar part) were dissolved in DCPD/DecylNB 80/20 mole ratio (10,000 molar parts) without solvent to form a clear solution. The unexposed solution was free flowing even after 3 weeks at room temperature.

Example 29
Shelf Life Studies

In a glass bottle, Ru-I (1 molar part) and CPTX (4 molar part) were dissolved in DCPD/DecylNB 80/20 mole ratio (10,000 molar parts) without solvent to form a clear solution. The unexposed solution at room temperature was gelled after 2 days.

The following Examples 30 to 33 illustrate that the compositions of this invention do not undergo mass polymerization under atmospheric conditions thus providing “dead zone” required for continuous liquid interface production (CLIP) of 3D objects as described hereinabove.

Example 30-33
Mass Polymerization in Different Atmospheres

The procedures of Example 1 were substantially repeated in these Examples 30 to 33 except that HexylNB was used as the monomer along with Ru-I as the latent catalyst and CPTX in molar parts as listed in Table 2. These compositions were then exposed to UV either under dry nitrogen, moist nitrogen, dry air or moist air atmospheric conditions. It is evident from the data summarized in Table 2, the compositions of this invention using Ru-I as the catalyst cannot be mass polymerized in the presence of air.

TABLE 2

Ru-I
CPTX

loading,
loading,

Example
Monomer
(molar
(molar

Visual

No.
(molar parts)
parts)
parts)
atmosphere
observation

30
HexylNB
1
4
dry N₂
solid

(10,000)

31
HexylNB
1
4
moist N₂
solid

(10,000)

32
HexylNB
1
4
dry air
liquid

(10,000)

33
HexylNB
1
4
moist air
liquid

(10,000)

Example 34

In a glass bottle, Ru-I (1 molar part) and 2-(4-methoxystyryl)-4,6-bis(trichloromethyl)-1,3,5-triazine (4 molar parts) were dissolved in DCPD/DecylNB, 80/20 mole ratio (10,000 molar parts) to form a clear solution. The solution was UV light exposed for 4 seconds (LED 1 J/cm²).

The solution turned to a solid indicating the monomer was fully polymerized, as confirmed by both DSC and TGA. The residue percentage from isothermal TGA (1 h at 100° C.) after UV exposure was >99%. The unexposed solution was free flowing for 2 hours at room temperature.

Example 35
Formation of 3D Objects

The composition of Example 1 can be used in this Example 35 to demonstrate the utility of the composition of this invention in forming 3D objects. The composition can be filled into a motorized syringe and slowly pushed out of the nozzle at a steady rate while exposing the nozzle to UV light (LED 1 J/cm²), the liquid coming out of the nozzle immediately will solidify forming a 3D object.

Examples 36-45
Impact Strength Measurements

In each of these Examples 36-45, in a glass bottle, Ru-II (1 molar part) and CPTX (8 molar parts) were dissolved in respective monomer or monomer mixtures without solvent to form a clear solution. Specific monomer or monomer mixture used in each of these Examples 36-45 are summarized in Table 3. The solution was heated to 70° C. and UV light exposed for 4 seconds (LED 270 mW/cm², 395 nm). The solution turned to a solid indicating the monomer or monomer mixture was fully polymerized, as confirmed by both DSC and TGA. The residue percentage from isothermal TGA (1 h at 100° C.) after UV exposure was >99% in each of these Examples 36-45. The unexposed solution was free flowing even after 21 days at room temperature in each of these Examples 36-45. This indicates that during the UV exposure CPTX releases a chloride ion that activates Ru-II catalyst. A sample was prepared for impact strength measurement in accordance with ASTM D256 and the impact strength was measured in each of these Examples 36-45 and the results are summarized in Table 3.

TABLE 3

Example
Monomers
Impact

No.
(molar parts)
Strength (J/m)

36
DecylNB/CPD3/PETD
240

50/25/25 mole ratio

37
DecylNB/CPD3/PETD
565

50/10/40 mole ratio

38
ButylTD
60

39
HexylTD
786

40
HexylTD/CPD3
771

99/1 mole ratio

41
HexylTD/CPD3
736

95/5 mole ratio

42
HexylTD/CPD3
603

90/10 mole ratio

43
HexylTD/CPD3
622

85/15 mole ratio

44
HexylTD/CPD3
473

80/20 mole ratio

45
DecylTD
578

Example 46
Aging Studies of the Polymer

In a glass bottle, Ru-II (1 molar part), CPTX (8 molar parts), IRGANOX 1076 (1 part by weight per 100 parts of polymer formed) and IRGAFOS 168 (0.5 part by weight per 100 parts of polymer formed) were dissolved in HexylTD (9,000 molar parts) and CPD3 (1,000 molar parts) without solvent to form a clear solution. The solution was heated to 50° C. and UV light exposed for 4 seconds (LED 270 mW/cm², 395 nm). The solution turned to a solid indicating the monomer was fully polymerized, as confirmed by both DSC and TGA. The residue percentage from isothermal TGA (1 h at 160° C.) after UV exposure was >99%. Dog bone shaped samples were prepared for tensile property measurements. The samples were kept at 85% humidity and 85° C. for 4 weeks. Initially there was a drop in elongation-to-break from 250% to 140% (in 1 week). However, at 2 and 4 weeks of sample testing under the same conditions, the samples showed no further changes. No color change (FIG. 1B) was observed even after 4 weeks of testing. FIG. 1A shows the dog bone sample before testing and FIG. 1B shows the sample after 4 weeks of the aging test.

Comparative Example 1

In a glass bottle, Ru-I (1 molar part) and ITX (2 molar parts) were dissolved in PENB (10,000 molar parts) without solvent to form a clear solution. The solution was UV light exposed for 3 minutes (LED 5 W, 395 nm). The solution was free flowing and no change in viscosity was observed indicating that the catalyst was still inactive under these conditions.

ITX is 2-isopropylthioxanthone of the following formula:

[Image Omitted]

Comparative Example 2

The procedures of Example 46 were substantially repeated in this Comparative Example 2 except that no IRGANOX 1076 or IRGAFOS 168 were added to the composition. The dog bone samples made from the resulting polymer showed significant drop in elongation-to-break (from 250 to 3%) after the first week of testing. As shown in FIG. 1C, significant color change was also observed just after first week of testing, indicating fast oxidation of the polymer is occurring, which results in the degradation of the properties.

Although the invention has been illustrated by certain of the preceding examples, it is not to be construed as being limited thereby; but rather, the invention encompasses the generic area as hereinbefore disclosed. Various modifications and embodiments can be made without departing from the spirit and scope thereof.