Method for making multiple chemically functional oligomers

Description

TECHNICAL FIELD
The present invention relates to linear and multidimensional oligomers that include multiple chemically functional crosslinking end cap (terminal) groups, and, preferably, to oligomers that have four crosslinking functionalities at each end of its linear backbone or each multidimensional arm. We call these products "multifunctional oligomers." Composites made from these oligomers generally have improved toughness, thermomechanical stability, and thermo-oxidative stability because of the higher number of crosslinks that form upon curing. They constitute engineering thermoplastics. Blends are prepared from mixtures of the oligomers and compatible polymers, oligomers, or both.
The present invention also relates to methods for making the multifunctional oligomers by condensing novel end cap reactive monomers with appropriate-reactive monomers for the chains of the respective chemical backbones, and to the multiple chemically functional end cap monomers themselves.
BACKGROUND ART
The thermosetting resins that are commonly used today in fiber-reinforced composites cannot be reshaped after thermoforming. Because errors in forming cannot be corrected, these thermosetting resins are undesirable in many applications. In addition, these thermosetting resins, made from relatively low molecular weight monomers, are relatively low molecular weight, and often form brittle composites that have relatively low thermal stabilities.
Although thermoplastic resins are well known, practical aerospace application of high performance, fiber-reinforced thermoplastic resins is relatively new. Fiber in such composites toughens and stiffens the thermoplastic resin. While the industry is exploring lower temperature thermoplastic systems, like fiber-reinforced polyolefins or PEEKs, our focus is on high performance thermoplastics suitable for example, for primary structure in advanced high speed aircraft including the High Speed Civil Transport (HSCT). These materials should have high tensile strength, and high glass transitions. Such materials are classified as "engineering thermoplastics." At moderate or high temperatures, the low performance, fiber-reinforced thermoplastic composites (polyolefins or PEEKS, for example) lose their ability to carry loads because the resin softens. Thus, improved thermal stability is needed for advanced composites to find applications in many aerospace situations. The oligomers of the present invention produce advanced composites.
Advanced composites should be thermoplastic, solvent resistant, tough, impact resistant, easy to process, and strong. Oligomers and composites that have high thermomechanical stability and thermo-oxidative stability are particularly desirable.
While epoxy-based composites like those described in U.S. Pat. No. 5,254,605 are suitable for many applications, their brittle nature and susceptibility to degradation often force significant design concessions when these epoxies are selected for aerospace applications. The epoxies are inadequate for applications which require thermally stable, tough composites, especially when the composites are expected to survive for a long time in a hot, oxidizing environment. Recent research has focused on polyimide composites to achieve an acceptable balance between thermal stability, solvent. resistance, and toughness for these high performance applications. Still the maximum temperatures for use of the polyimide composites, such as those formed from PMR-15, can only be used at temperatures below about 600.degree.-625.degree. F. (315.degree.-330.degree. C.), since they have glass transition temperatures of about 690.degree. F. (365.degree. C.). PMR composites are usable in long term service (50,000 hours) at about 350.degree. F. (170.degree. C.). They can withstand temperatures up to about 600.degree. F. (315.degree. C.) for up to about five hundred hours.
PMR-15 prepregs, however, suffer significant processing limitations that hinder their adoption because the prepreg has a mixture of the unreacted monomer reactants on the fiber-reinforcing fabric, making them sensitive to changes in temperature, moisture, and other storage conditions, which cause the prepregs to be at different stages of cure. The resulting composites have varying, often unpredictable properties. Aging these PMR prepregs even in controlled environments can lead to problems. The reactants on the prepreg are slowed in their reaction by keeping them cold, but the quality of the prepreg depends on its absolute age and on its prior storage and handling history. And, the quality of the composite is directly proportional to the quality of the prepregs. In addition, the PMR monomers are toxic or hazardous (especially MDA), presenting health and safety concerns for the workforce. Achieving complete formation of stable imide rings in the PMR composites remains an issue. These and other problems plague PMR-15 composites.
The commercial long chain polyimides also present significant processing problems. AVIMID-N and AVIMID-KIII (trademarks of E.I. duPont de Nemours) resins and prepregs differ from PMRs because they do not include aliphatic chain terminators which the PMRs use to control molecular weight and to retain solubility of the PMR intermediates during consolidation and cure. Lacking the chain terminators, the AVIMIDs can chain extend to appreciable molecular weights. To achieve these molecular weights, however, the AVIMIDs (and their LARC cousins) rely on the melting of crystalline powders to retain solubility or, at least, to permit processing. It has proven difficult to use the AVIMIDs in aerospace parts both because of their crystalline melt intermediate stage and the PMR plague that these AVIMID prepregs also suffer aging.
So, research continues and is now turning toward soluble systems like those we described in our earlier patents, including acetylenic-terminated AVIMID-KIII prepregs of the Hergenrother (NASA-Langley) type. For these soluble systems, many different polyimide sulfone compounds have been synthesized to provide unique properties or combinations of properties. For example, Kwiatkowski and Brode (U.S. Pat. No. 3,839,287) synthesized monofunctional, maleic-capped linear polyarylimides. Holub and Evans (U.S. Pat. No. 3,729,446) synthesized similar maleic or nadic-capped, imido-substituted polyester compositions.
For imides and many other resin backbones we have shown surprisingly high glass transition temperatures, reasonable processing parameters and constraints for the prepregs, and desirable physical properties for the composites by using soluble oligomers having difunctional caps, especially those with nadic caps. Linear oligomers of this type include two crosslinking functionalities at each end of the resin chain to promote crosslinking upon curing. Linear oligomers are "monofunctional" when they have one crosslinking functionality at each end. The preferred oligomers from our earlier research were "difunctional," because they had two functional groups at each end. Upon curing, the crosslinking functionalities provide sites for chain extension. Because the crosslinks were generally the weakest portions of the resulting composite, we improved thermo-oxidative stability of the composites by including two crosslinks at each junction. We built in redundancy, then, at each weak point. We maintained solubility of the reactants and resins using, primarily, phenoxyphenyl sulfone chemistries. Our work during the past fifteen years across a broad range of resin types or chemical families is described in the following, forty-nine U.S. Patents (all of which we incorporate by reference):
______________________________________ U.S.INVENTOR PAT. NO. TITLE ISSUE DATE______________________________________Lubowitz 4,414,269 Solvent Resistant Poly- November 9, 1983et al. sulfone and Polyether- sulfone CompositesLubowitz 4,476,184 Thermally Stable Poly- October 9, 1984et al. sulfone Compositions for Composite StructuresLubowitz 4,536,559 Thermally Stable August 20, 1985et al. Polyimide Polysulfone Compositions for Composite StructuresLubowitz 4,547,553 Polybutadiene Modified October 15, 1985et al. Polyester CompositionsLubowitz 4,584,364 Phenolic-Capped Imide April 22, 1986et al. Sulfone ResinsLubowitz 4,661,604 Monofunctional Cross- April 28, 1987et al. linking ImidophenolsLubowitz 4,684,714 Method for Making August 4, 1987et al. Polyimide OligomersLubowitz 4,739,030 Difunctional End-Cap April 19, 1988et al. MonomersLubowitz 4,847,333 Blended Polyamide July 25, 1989et al. OligomersLubowitz 4,851,495 Polyetherimide July 25, 1989et al. OligomersLubowitz 4,851,501 Polyethersulfone July 25, 1989et al. Prepregs, Composites, and BlendsLubowitz 4,868,270 Heterocycle Sulfone September 19, 1989et al. Oligomers and BlendsLubowitz 4,871,475 Method for Making October 3, 1989et al. Polysulfone and Polyethersulfone OligomersLubowitz 4,876,328 Polyamide Oligomers October 24, 1989et al.Lubowitz 4,935,523 Crosslinking June 19, 1990et al. ImidophenylaminesLubowitz 4,958,031 Crosslinking September 18, 1990et al. NitromonomersLubowitz 4,965,336 High Performance October 23, 1990et al. Heterocycle Oligomers and BlendsLubowitz 4,980,481 Pyrimidine-Based End- December 25, 1990et al. Cap Monomers and OligomersLubowitz 4,981,922 Blended Etherimide January 1, 1991et al. OligomersLubowitz 4,985,568 Method of Making January 15, 1991et al. Crosslinking Imidophenyl- aminesLubowitz 4,990,624 Intermediate February 5, 1991et al. Anhydrides Useful for Synthesizing EtherimidesLubowitz 5,011,905 Polyimide Oligomers April 30, 1991et al. and BlendsLubowitz 5,066,541 Multidimensional November 19, 1991et al. Heterocycle Sulfone OligomersLubowitz 5,071,941 Multidimensional Ether December 10, 1991et al. Sulfone OligomersLubowitz 5,175,233 Multidimensional Ester December 29, 1991et al. or Ether Oligomers with Pyrimidinyl End CapsLubowitz 5,082,905 Blended Heterocycles January 21, 1992et al.Lubowitz 5,087,701 Phthalimide Acid February 11, 1992et al. HalidesLubowitz 5,104,967 Amideimide Oligomers April 14, 1992et al. and BlendsLubowitz 5,409,105 Polyamides April 28, 1992et al.Lubowitz 5,112,939 Oligomers Having May 12, 1992et al. Pyrimidinyl End CapsLubowitz 5,115,087 Coreactive Imido May 19, 1992et al. Oligomer BlendsLubowitz 5,116,935 High Performance May 26, 1992et al. Modified Cyanate Oligomers and BlendsLubowitz 5,120,819 High Performance June 9, 1992et al. HeterocyclesLubowitz 5,126,410 Advanced Heterocycle June 30, 1992et al. OligomersLubowitz 5,144,000 Method for Forming September 1, 1992et al. Crosslinking OligomersLubowitz 5,151,487 Method of Preparing a October 1, 1992et al. Crosslinking OligomerLubowitz 5,155,206 Amideimide Oligomers, October 13, 1992et al. Blends and Sizings for Carbon Fiber Compo- sitesLubowitz 5,159,055 Coreactive Oligomer October 27, 1992et al. BlendsLubowitz 5,175,234 Lightly-Crosslinked December 29, 1992et al. PolyimidesLubowitz 5,175,304 Halo- or Nitro- December 29, 1992et al. Intermediates Useful for Synthesizing EtherimidesLubowitz 5,198,526 Heterocycle Oligomers March 30, 1993et al. with Multidimensional MorphologyLubowitz 5,210,213 Multidimensional May 11, 1993et al. Crosslinkable OligomersLubowitz 5,216,117 Amideimide Blends June 1, 1993et al.Lubowitz 5,227,461 Extended Difunctional July 13, 1993et al. End-Cap MonomersLubowitz 5,239,046 Amideimide Sizing For August 24, 1993et al. Carbon FiberLubowitz 5,268,519 Lightly Crosslinked December 7, 1993et al. Etherimide OligomersLubowitz 5,286,811 Blended Polyimide February 15, 1994et al. Oligomers and Method of Curing PolyimidesLubowitz 5,328,964 Blended Polyimide July 12, 1994et al. OligomersLubowitz 5,344,894 Polyimide Oligomers September 6, 1994et al. and Blends______________________________________
The heterocycles (i.e., oxazoles, thiazoles, or imidazoles) use a processing principle more akin to the AVIMIDs than the phenoxyphenyl sulfone solubility principle of our other resins. The heterocycles have poor solubility, even with our "sulfone" chemistries, but they at least form liquid crystals or soluble crystals in strong acids. To produce non-crystalline (amorphous) composites, We capitalize on the ability of our heterocycles to melt at the same temperature range as the cure and promote crosslinking in the melt. With relatively low molecular weight, capped, heterocycle oligomers, we can autoclave process these materials. Autoclave processing is a significant achievement for these heterocycles which present to the industry, perhaps, the most challenging problems. The polybenzoxazoles we produced, in addition, are useful at temperatures up to about 750.degree.-775.degree. F. (400.degree.-413.degree. C.), since they have glass transition temperatures of about 840.degree. F. (450.degree. C.). We describe multifunctional heterocycle and heterocycle sulfones in copending U.S. patent application Ser. No. 08/327,180 filed Oct. 21, 1994, now U.S. Pat. No. 5,594,089 which we incorporate by reference.
Some aerospace applications need composites which have even higher use temperatures than these polybenzoxazoles while maintaining toughness, solvent resistance, ease of processing, formability, strength, and impact resistance. Southcolt et al. discuss the problems of the prior art imide systems and the advantages of our soluble monofunctional and difunctional nadic-capped imide systems in the article: Southcott et al., "The development of processable, fully imidized, polyimides for high-temperature applications,"6 High Perform. Polym., 1-12 (U.K. 1994). For these extremely demanding requirements, our multidimensional oligomers (i.e., oligomers that have three or more arms extending from a central organic hub to yield three-dimensional morphology) have superior processing parameters over more conventional, linear oligomers that might produce composites having these high thermal stabilities. Our multidimensional oligomers can satisfy the thermal stability requirements and can be processed at significantly lower temperatures. Upon curing the end caps, the multidimensional oligomers crosslink so that the thermal resistance of the resulting composite is markedly increased with only a minor loss of stiffness, matrix stress transfer (impact resistance), toughness, elasticity, and other mechanical properties. We can achieve glass transition temperatures above 950.degree. F. (510.degree. C.) with composites cured from our difunctional multidimensional oligomers (which we call "star-burst" oligomers). Of course, a full range of use temperatures are possible by selecting the hubs (which usually is an aromatic moiety), the backbone monomers used in the arms, end caps, and number of crosslinking functionalities per cap.
We now believe we can achieve even better properties in advanced composites by including an even higher number of crosslinking functionalities than the mono- or difunctional systems of the linear or multidimensional resins discussed in our earlier patents or patent applications. The higher density of crosslinks provide redundancy at those locations in the macromolecular, cured composite which are most susceptible to thermal degradation.
SUMMARY OF THE INVENTION
The present invention provides oligomers that produce advanced composites with high thermomechanical stability and high thermo-oxidative stability by using four crosslinking functionalities (i.e., unsaturated hydrocarbon moieties) at each end of the oligomer. Upon curing, the crosslinking functionalities on adjacent oligomers form four parallel linkages in the composite to provide the improved stabilities. The oligomers, however, retain the preferred properties of our difunctional oligomers with respect to handling and processing. The composites we form from our multiple chemically functional oligomers have even higher thermal stabilities for comparable backbone and molecular weight and have higher compressive strengths than our composites formed using our mono- or difunctional oligomers. The preferred oligomers generally have soluble, stable, fully aromatic backbones. Sulfone (--SO.sub.2 --) or other electronegative linkages ("L") selected from the group consisting of --SO.sub.2 --, --S--, --CO--, --(CF.sub.3).sub.2 C--, or --(CH.sub.3).sub.2 C-- in the backbones between aromatic groups provide improved toughness for the composites and provide the improved solubility for the oligomers that is so important to effective processing. A typical .backbone usually has repeating units of the general formula:
--Ar--O--Ar--L--Ar--O--Ar--
wherein Ar is an aromatic radical (and preferably phenylene) and L is an electronegative linkage as previously defined. In this description we will refer to "L" as a sulfone. Any of the identified electronegative groups can be substituted, however, for --SO.sub.2 --.
The four caps at each end of the backbone of a linear oligomer or at the end of each arm of a multidimensional oligomer provide areas of high stiffness in the composite product. These stiff, highly crosslinked areas are relatively lightly interspersed in a thermoplastic matrix, yielding superior composites for aerospace applications. Generally, highly crosslinked matrices yield high compressive strength but the composites are brittle. Thermoplastics are tough but have significantly lower compressive strengths. In the present invention, the multiple chemically functional end caps produce highly crosslinked micelles within the resin matrix equivalent in size roughly to colloidal particles. These micelles enhance resin interactions that are vital to achieve high compressive strengths by, we believe, adsorbing the linear polymer chains onto the micelle surfaces and linking multiple linear chains. Thus, we achieve thermoplastics with high compressive strength.
Our preferred four functional crosslinkable, thermoplastic oligomers are formed by reacting in the appropriate stoichiometry an end cap monomer with one or more reactants selected to form the predominant and characteristic backbone linkage by which we identify the nature of the resulting oligomer (i.e., ether, ester, imide, amide, amideimide, carbonate, sulfone; etc.) in a suitable solvent under an inert atmosphere. The soluble oligomers generally have a weight average molecular weight (MW) of between about 5,000 and 40,000, preferably between about 5,000-15,000, and more preferably between 10,000-15,000. We generally try to synthesize oligomers to the highest MWs we can provided that the oligomers remain soluble in conventional processing solvents. In these ranges, the oligomer will have thermoplastic characteristics.
Multidimensional oligomers include an organic hub and three or more substantially identical radiating arms, each arm terminating with a residue of a multifunctional crosslinking end cap monomer. Suitable hubs radicals are described in the patents we earlier incorporated by reference with respect to our monofunctional and difunctional oligomer research, although we prefer a 1,3,5-phenylene (i.e., benzenetriyl). For multiple chemically functional end caps, we prefer linear morphology over multidimensional morphology became linear systems are easier to prepare to have significant MW in the backbone between the caps. Such high MW better allows the micelles that form on crosslinking to provide their advantages to the compressive strength.
We can also blend our linear or multidimensional oligomers as we did with the difunctional systems. A blend might include a linear oligomer with a comparable linear polymer, a multidimensional oligomer with a multidimensional polymer, a linear oligomer with a multidimensional oligomer, or the like. By "polymer," we mean a resin that does not include the crosslinking functionalities of our oligomers. By "oligomer," we mean any molecular weight moiety that includes crosslinking functionalities at its ends to allow it to react (chain-extend) to increase the effective molecular weight when the oligomer cures to form a composite. By "crosslinking functionality," we mean a terminating, unsaturated hydrocarbon group that can be thermally or chemically activated when the resin is in the melt to covalently bond to an adjacent, corresponding moiety on another oligomer.
A blend will generally include substantially equimolar amounts of the oligomer and a polymer. The polymer will generally have the same backbone structure and MW as the oligomer (or it might have a higher MW since the oligomer will chain-extend upon curing). We prepare blends by mixing miscible solutions of the oligomers and polymers.
Prepregs and composites are the most preferred products of the oligomers and blends, although we can also prepare varnishes, films, and coatings. Some oligomers are also suitable as sizings for carbon fibers. We can also prepare PMR-analogs where reactive monomers are prepregged. By "composite," we mean the product of curing and consolidating the oligomers to produce high MW chains through crosslinking, chain extension.

BEST MODE CONTEMPLATED FOR CARRYING OUT THE INVENTION
We will first discuss elements that are relatively independent of the resin chemistries before discussing the details of the end cap monomers and, finally, the individual resin chemistries.
1. Overriding Principles and Common Features
The weight average molecular weight (MW) of the multiple chemically functional oligomers of the present invention should provide thermoplastic character to the oligomer and generally should be between 5,000 and 40,000, but preferably between about 10,000 and 35,000, and still more preferably between 15,000 and 30,000. Such weights are usually achievable by using between 1-20 molecules of each reactant in the backbone (with two caps, of course, for linear systems) and often between 1-5 molecules of each reactant, as those of ordinary skill will recognize. We seek to synthesize the highest MW that we can which will remain soluble and easy to process. We seek the highest MW that we can successfully synthesize repeatedly and reliably. Within the preferred range, the oligomers are relatively easy to process to form composites that are tough, have impact resistance, possess superior thermomechanical properties, and have superior thermo-oxidative stability. When oligomers having MW less than about 5,000 are cured by crosslinking, the thermosetting character of the material is increased so that the ability to thermoform the product may be drastically reduced or eliminated.
Solubility of the oligomers becomes an increasing problem as chain length increases. Therefore, from a solubility standpoint, we prefer shorter chains for processing, if the resulting composites retain the desired properties. That is, the chains should be long enough to yield thermoplastic characteristics to the composites but short enough to keep the oligomers soluble during the reaction sequence.
We represent the oligomers of the present invention by the formulae: .xi.--R.sub.4 --.xi. for linear oligomers or .differential..paren open-st.A--.xi.).sub.w for multidimensional oligomers wherein w=3 or 4; .xi. is the residue of a multiple chemically functional end cap monomer; .differential. is a "w" valent, multidimensional organic hub; A is a multidimensional arm, and R.sub.4 is a divalent, linear, aromatic, aliphatic, or alicyclic organic radical. Preferred backbones (R.sub.4 or A) are aromatic chains to provide the highest thermal stability where the predominant backbone linkages are selected from the group consisting of:
imide
amideimide
etherimide
ether
ether sulfone
arylene sulfide (PPS)
ester
ester sulfone
amide
carbonate
cyanate ester and
esteramide.
We use "linear" to mean generally in a line or in one plane and to distinguish readily from "multidimensional" where we produce 3-D systems, "Linear" systems are not perfectly straight, because of carbon chemistry. "Linear" systems are the conventional morphology for polymer chemistry resulting from "head-to-tail" condensation of the reactants to form a chain. "Multidimensional" oligomers include a hub from which three or more arms extend.
We seek thermally stable oligomers suitable for high temperature advanced composites. Such oligomers generally include a high degree of aromatic groups. The stable aromatic bond energies produce an oligomer with outstanding thermal stability. Acceptable toughness and impact resistance is gained through selection of the linkages within the linear chains or in the arms of aromatic groups radiating in our multidimensional oligomers from the central aromatic hub. These toughening linkages are ethers, esters, and the electronegative ("sulfone") linkages (L) selected from the group consisting of --CO--, --SO.sub.2 --, --S--, --(CF.sub.3).sub.2 C--, or --(Me.sub.3).sub.2 C, that we earlier discussed. Generally, --CO-- and --SO.sub.2 -- groups are preferred for cost, convenience, and performance. The group --S--S-- should be avoided, since it is too thermally labile.
We retain processability in our oligomers by keeping them soluble in conventional processing solvents through the inclusion of soluble segments in their backbones. The backbones generally are formed by condensing two monomer reactants A.sub.e and B.sub.e with chain extension quenched with our multiple chemically functional end cap monomers. A.sub.e is an acid monomer reactant and Be is a base. A.sub.e and B.sub.e produce the characteristic backbone linkage --.delta..sub.e -- for which we name the oligomer. The linear oligomers have the general formula: ##STR6## wherein m typically is a small integer between 0 and 20. To achieve solubility, we prefer that at least one of A.sub.e or B.sub.e include a soluble repeating unit of the formula:
--.O slashed.--L.O slashed.-- or
--.O slashed.--O--.O slashed.--L--.O slashed.--O--.O slashed.--
wherein
.O slashed.=phenylene and
L=--SO.sub.2 --, --S--, --CO--,--(CF.sub.3).sub.2 C--, or --(CH.sub.3)C--.
Generally, the A.sub.e and B.sub.e use our phenoxyphenyl sulfone solubility principle. By analogy, we include the same principles in our multidimensional oligomers.
In multidimensional oligomers of all resin types, the organic hub (.differential.) includes a plurality of rays or spokes radiating from the hub in the nature of a star to provide multidimensional crosslinking through suitable terminal groups with a greater number (i.e. higher density) of crosslinking bonds than linear arrays provide. Usually the hub will have three radiating chains to form a "Y" pattern. In some cases, we use four chains. Including more chains may lead to steric hindrance as the hub is too small to accommodate the radiating chains. We prefer a trisubstituted phenyl hub (i.e., a benzenetriyl) with the chains being symmetrically placed about the hub.
Although the preferred aromatic moieties are aryl groups (such as phenylene, biphenylene, and naphthylene), other aromatic groups can be used, if desired, since the stabilized aromatic bonds will also probably provide the desired thermal stability. For example, we can use azaline (melamine) (i.e., ##STR7## or pyrimidine (i.e., ##STR8## groups.
We make prepregs from the oligomers of the present invention by the conventional method of impregnating a suitable fabric or other reinforcement with a mixture of the oligomer and a solvent. We can add suitable coreactants to the solvent when preparing prepregs, especially those having maleic end caps, as taught in our earlier patents.
We can also prepare prepregs for composites, especially for PPS resins, by interleaving layers of fabric with layers of a resin film comprising an oligomer or blend, and then subjecting the resultant stack of interleaved materials to heat and pressure sufficient to "flow" the oligomer into the fabric and to crosslink the oligomer to form the fiber-reinforced composite. According to a further alternative, we can spin the oligomer into fibers, and weave these fibers with fibers of reinforcing material to produce a prepreg. This prepreg is cured in a manner comparable to the method of forming a composite from interleaved oligomer film and fabric layers. Finally, especially for PPS resins, we can use the powder impregnation technology common for prepregging PPS.
We cure the conventional prepregs by conventional vacuum bag autoclave techniques to crosslink the end caps. Temperatures suitable for curing are in the range of 150.degree.-650.degree. F. (65.degree.-345.degree. C.). The resulting product is a cured, thermally stable, solvent-resistant composite. Post-curing to ensure essentially complete addition polymerization through the four-caps likely is desirable if not essential. The composites have stiff, highly crosslinked micelles dispersed in a thermoplastic matrix. The crosslinked oligomer may also be used as an adhesive without curing. Such adhesives may be filled, if desired.
Blended oligomers typically comprise a substantially equimolar amount of the oligomer and a comparable polymer that is incapable of crosslinking with the selected crosslinkable oligomers. These blends merge the desired properties of crosslinking oligomers with those of the noncrosslinking polymer to provide tough, yet processable, resin blends. The comparable polymer is usually synthesized by condensing the same monomer reactants of the crosslinking oligomer and quenching the polymerization with a suitable terminating group. The terminating group lacks the hydrocarbon unsaturation common to the oligomer's end cap monomers. In this way, the comparable polymer has the identical backbone to that of the crosslinkable oligomer but does not have the crosslinkable end caps. Generally the terminating group will be a simple anhydride (such as benzoic anhydride), phenol, or benzoyl acid chloride to quench the polymerization and to achieve a MW for the comparable polymer substantially equal to or initially higher than that of the crosslinkable oligomer.
We can prepare blends by combining the oligomers of the present invention with corresponding linear or multidimensional, monofunctional or difunctional oligomers of our earlier patents or our copending patent applications. We can blend three or more components. We can blend different resins (i.e., advanced composite blends corresponding to those blends described in U.S. patent application Ser. No. 07/619,677 or coreactive oligomer blends corresponding to these blends described, e.g., in U.S. Pat. Nos. 5,115,087 and 5,159,055).
With blends, we can increase the impact resistance of imide composites over the impact resistance of pure imide resin composites without significantly reducing the solvent resistance. A 50--50 molar blend of oligomer and polymer is what we prefer and is formed by dissolving the capped oligomer in a suitable first solvent, dissolving the uncapped polymer in a separate portion of the same solvent or in a second solvent miscible with the first solvent, mixing the two solvent solutions to form a lacquer, and applying the lacquer to fabric in a conventional prepregging process (often called "sweep out").
Although the polymer in the blend often originally has the same length backbone (i.e., MW) as the oligomer, we can adjust the properties of the composite formed from the blend by altering the ratio of MWs for the polymer and oligomer. It is probably nonessential that the oligomer and polymer have identical repeating units, but that the oligomer and polymer merely be compatible in the mixed solution or lacquer prior to sweeping out the blend as a prepreg. Of course, if the polymer and oligomer have identical backbones, compatibility in the blend is more likely to occur.
Solvent resistance may decrease markedly if the comparable polymer is provided in large excess to the crosslinkable oligomer in the blend.
The blends might be semi-interpenetrating networks (i.e., IPNs) of the general type described by Egli et al. "Semi-Interpenetrating Networks of LARC-TPI" available from NASA-Langley Research Center or in U.S. Pat. 4,695,610.
We prepare prepregs of the oligomers or blends by conventional techniques. While woven fabrics are the typical reinforcement, the fibers can be continuous or discontinuous (in chopped or whisker form) and may be ceramic, organic, carbon (graphite), or glass, as suited for the desired application.
As shorthand, we may use the term "multifunctional" to describe oligomers having four chemically functional groups in each end cap.
Although para isomers are shown for the reactants and the oligomers (and para isomers are preferred), other isomers of the monomer reactants are possible. Meta-isomers may be used to enhance solubility and to achieve melt-flow at lower temperatures, thereby yielding more soluble oligomers with enhanced processing characteristics. The isomers (para- and meta-) may be mixed. Substituents may create steric hindrance problems in synthesizing the oligomers or in crosslinking the oligomers into the final composites, but substituents can be used if these problems can be avoided.
Therefore, each aryl group for the monomer reactants may include substituents for the replaceable hydrogens, the substituents being selected from the group consisting of halogen, alkyl groups having 1-4 carbon atoms, and alkoxy groups having 1-4 carbon atoms. We prefer having no substituents.
Our oligomers and blends are heat-curable resin systems. By the term "heat-curable resin system" we mean a composition containing reactive monomers, oligomers, and/or prepolymers which will cure at a suitably elevated temperature to an infusible solid, and which composition contains not only the aforementioned monomers, oligomers, etc., but also such necessary and optional ingredients such as catalysts, co-monomers, rheology control agents, wetting agents, tackifiers, tougheners, plasticizers, fillers, dyes and pigments, and the like, but devoid of microspheres or other "syntactic" fillers, continuous fiber reinforcement, whether woven, non-woven (random), or tridirectional, and likewise devoid of any carrier scrim material, whatever its nature.
By the term "syntactic foam" we mean a heat-curable resin system which contains an appreciable volume percent of preformed hollow beads or "microspheres." Such foams are of relatively low density, and generally contain from 10 to about 60 weight percent of microspheres, and have a density, upon cure, of from about 0.50 g/cm.sup.3 to about 1.1 g/cm.sup.3 and preferably have loss tangents at 10 GHz as measured by ASTM D 2520 of 0.008 or less. The microspheres may consist of glass, fused silica, or organic polymer, and range in diameter from 5 to about 200 .mu.m, and have densities of from about 0.1 g/cm.sup.3 to about 0.4 g/cm.sup.3 to about 0.4 g/cm.sup.3.
By the term "matrix resin" we mean a heat-durable resin system which comprises the major part of the continuous phase of the impregnating resin of a continuous fiber-reinforced prepreg or composite. Such impregnating resins may also contain other reinforcing media, such as whiskers, micro fibers, short hopped fibers, or microspheres. Such matrix resins are used to impregnate the primary fiber reinforcement at levels of between 10 and 70 weight percent, generally from 30 to 40 weight percent. Both solution and/or melt impregnation techniques may be used to prepare fiber reinforced prepregs containing such matrix resins. The matrix resins may also be used with chopped fibers as the major fiber reinforcement, for example, where pultrusion techniques are involved.
If the linear or multidimensional oligomers include Schiff base or heterocycle linkages (oxazoles, thiazolds, or imidazoles), the composites may be conductive or semiconductive when suitably doped. The dopants are preferably selected from compounds commonly used to dope other polymers, namely, (1) dispersions of alkali metals (for high activity) or (2) strong chemical oxidizers, particularly alkali perchlorates (for lower activity). We do not recommend arsenic compounds and elemental halogens, while active dopants, are too dangerous for general usage.
The dopants apparently react with the oligomers or polymers to form charge transfer complexes. N-type semiconductors result from doping with alkali metal dispersions. P-type semiconductors result from doping with elemental iodine or perchlorates. We recommend adding the dopant to the oligomer or blend prior to forming the prepreg.
While research into conductive or semiconductive polymers has been active, the resulting compounds (mainly polyacetylenes, polyphenylenes, and polyvinylacetylenes) are unsatisfactory for aerospace applications because the polymers are unstable in air; unstable at high temperatures; brittle after doping; toxic because of the dopants; or intractable. These problems are overcome or significantly reduced with the conductive oligomers of the present invention.
While conventional theory holds that semiconductive polymers should have (1) low ionization potentials, (2) long conjugation lengths, and (3) planar backbones, there is an inherent trade-off between conductivity, toughness, and ease of processing, if these constraints are followed. To overcome the processing and toughness shortcomings common with Schiff base, oxazole, imidazole, or thiazole polymers, the oligomers of the present invention generally include "sulfone" linkages interspersed along the backbone providing a mechanical swivel for the rigid, conductive segments of the arms.
Having described the common features, we next turn to the end cap monomers that characterize the structure and performance of the oligomers of the present invention.
2. The Multiple Chemically Functional End Cap Monomers
End cap monomers of the present invention include organic compounds of the formula: ##STR9## wherein .O slashed.=phenylene;
Z= ##STR10## i=1 or 2; E= ##STR11## R.sub.3 =independently, any of lower alkyl, lower alkoxy, aryl, aryloxy, or hydrogen;
G=--CH.sub.2 --, --S--, --O--, or --(Me).sub.2 C--;
T=allyl or methallyl;
Me=methyl;
.beta.=--COX, --COOH, ##STR12## --O--.O slashed.--COOH, --O--.O slashed.--COX, --X, --O--R.sub.8 OH, --O--R.sub.8 OCN, ##STR13## or --O--.O slashed.--NH.sub.2, or --NO.sub.2. X=halogeno, and preferably chlorine;
R=a divalent residue of a diol or nitrophenol; and
R.sub.8 =the residue of an amino/acid (preferably, phenylene).
Preferably, i=2 so that the monomers have four crosslinking functionalities (i.e., the hydrocarbon unsaturation at the chain end). Other organic unsaturation, however, also can be used. The end capping functionality (E) can also be a cyanate or vinyl selected from: ##STR14## wherein R.sub.3 =hydrogen, lower alkyl, lower aryl, lower alkoxy, or lower aryloxy.
Ethynyl, trimethylsilylethynyl, phenylethynyl, or benzyl cyclobutane end caps may also be used, if desired. These end caps will probably allow curing at lower temperatures, and will probably produced composites of lower thermal stability.
Preferred end cap monomers for forming oligomers with multiple chemically functional oligomers are phenols having the formula: ##STR15## wherein Z= ##STR16## --.O slashed.--=phenylene; ROH=--.O slashed.--OH or --.O slashed.--L--.O slashed.--OH;
R.sub.1 =any of lower alkyl, lower alkoxy, aryl, substituted alkyl, substituted aryl (including in either case hydroxyl or halo-substituents on replaceable hydrogens), aryloxy, or halogen;
L=--SO.sub.2 --, --CO--, --S--, --(CF.sub.3).sub.2 C--, or --(Me).sub.2 C--;
i=1 or 2;
j=0, 1, or 2;
G=--CH.sub.2 --, --S--, --O--, --SO.sub.2 --, --(Me)CH--, or --(Me).sub.2 C--; and
Me=methyl (i.e., --CH.sub.3).
Preferably, j=0, so there are no R.sub.1 substituents. Also, preferably, i=2, so each phenol monomer has four nadic functionalities. These phenol end cap monomers link to the backbone with an ether or ester linkage. The nadic caps are illustrative of the capping moieties as those skilled in the art will recognize based in our issued patents, copending applications, and the remainder of this specification.
The phenol monomers can be made by several mechanisms. For example, the halide end cap ##STR17## is condensed with the diol HO--.O slashed.--SO.sub.2 --.O slashed.--OH or HO--.O slashed.--OH to yield the desired cap. The halide end cap is formed by condensing: ##STR18## While a 1,3,5-halodiaminobenzene is shown, and this isomer is preferred, the 1,2,4-halodiaminobenzene isomer might also be used.
The acid or acid halide end cap monomer can be made in a similar way substituting, however, a diaminobenzoic acid for the halodiaminobenzene. Again, we prefer the 1,3,5-isomer, but note that the 2,3-, 2,4-, 2,5-, 3,4-, and 3,5-diaminobenzoic acid isomers are known. The 1,3,5-isomer provides maximum spacing between groups, which likely is important. An extended acid halide monomer can be made by reacting: ##STR19## to protect the amines (probably using the 2,4-diaminonitrobenzene isomer), extracting the nitro functionality with HO--.O slashed.--COOH to yield: ##STR20## saponifying the imides to recover the amines, recondensing the amines with the acid halide described above, and, finally, converting the carboxylic acid to the acid halide, yielding: ##STR21##
Alternatively, an acid halide end cap monomer of the formula: ##STR22## is made by condensing (Z).sub.2 --.O slashed. with a dibasic aromatic carboxylic acid in the Friedel-Crafts reaction.
It may also be possible to make an acid halide cud cap of the formula: ##STR23## or a corresponding phenol by condensing the halide monomer with HO--.O slashed.--COX in the Ullmann ether synthesis over a Cu catalyst. Here, the halide monomer should be dripped into the diol, if making the extended phenol.
For the preparation of imides where an anhydride is an important functionality for the end cap monomer, we extend the four functional phenol monomer of formula (II) either with nitrophthalic anhydride ##STR24## or phthalic anhydride acid chloride (i.e., trimelleitic acid halide anhydride) to form an ether or ester analog having an active anhydride. The analog, then, has the formula: ##STR25## wherein Q=ether or ester. We can make another extended anhydride by condensing: ##STR26## to yield: ##STR27## Extended anhydrides link to the backbone with an imide linkage.
For the preparation of heterocycles, esters, or other oligomers, we can prepare another extended acid monomer by condensing nitrobenzoic acid (or the acid halide) with the extend phenol monomer of formula (II) to yield: ##STR28## Alternatively, we can condensed the anhydride of formula (IV A) or (IV B) with an amino/acid, like aminobenzoic acid, to yield: ##STR29## self-condensation of the amino/acid needs to be avoided, so it should be added dropwise to the anhydride. The acids can be readily converted with SOCl.sub.2 to their acid halide (--COX) analog. The acid or acid halide end cap monomers link to the backbone with ester, oxazole, or imidazole linkages, for example.
We can prepare amine extended caps by reacting the halide monomer with aminophenol to yield: ##STR30## or aminobenzoic acid with the extended phenol monomer (taking care to avoid self-condensation of the amino/acid) to yield: ##STR31##
We can prepare the amine end cap monomer by converting a --COX functionality to an amine through the acid amide in the presence of ammonia, as described in U.S. Pat. No. 4,935,523.
The remainder of this specification will usually illustrate only the nadic end cap monomers, but those skilled in the art will understand that any of the other crosslinking functionalities could substitute for the nadic group.
A pyrimidine ring can be substituted for the phenylene ring in formula (I) to form end cap monomers analogous to those described in our U.S. Pat. Nos. 4,980,481 and 5,227,461. The aromatic character of the pyrimidine ring should provide substantially the same benefits as the phenylene ring. The thermo-oxidative stability of the resulting composites, however, might be somewhat less than that achieved for the phenyl end cap monomers. The pyrimidine precursors are described in U.S. Pat. Nos. 3,461,461 and 5,227,461, The compound: ##STR32## permits halo-pyrimidine end cap monomers for use in ether syntheses. These halo-pyrimidine caps have the formula: ##STR33##
From these examples of extended monomers, those skilled in the art will recognize the wide range of monomers that might be used to introduce multifunctional capping. Furthermore, if stepwise synthetic pathways are used, the extended caps do not necessarily need to be separately synthesized and recovered (see, e.g., the ether and ester syntheses which follow).
We will next discuss the principal chemical families of resins that we can prepare using the multiple chemically functional ("multifunctional") end cap monomers. These multiple chemically functional oligomers are analogous to the monofunctional and difunctional oligomers described in our issued patents and copending patent applications.
3. Imide Oligomers
We preferably prepare our imide oligomers by condensing suitable diamines and dianhydrides with an extended anhydride end cap monomer of formula (IV A) or (IV B) or an extended amine end cap monomer of formula (VII) or (VIII) in a suitable solvent in an inert atmosphere. The synthesis is comparable to the processes used for forming our analogous difunctional or monofunctional oligomers as described in U.S. Pat. Nos. 4,536259; 5,011,905; and 5,175,234.
Such polyimide oligomers exhibit a stable shelf life in the prepreg form, even at room temperature, and have acceptable handling and processing characteristics comparable to those of K-III or PMR-15. They also likely display shear/compression/tensile properties comparable to or better than PMR-15, and improved toughness, especially when reinforced with high modulus carbon fibers. The composites are essentially fully imidized, so they are stable, insensitive to environmental conditions, and nonhazardous.
We will discuss linear polyimides first and then their multidimensional counterparts.
a. Linear polyimides
We achieve impact resistance and toughness in aromatic polyimides by including "sulfone" linkages (L) between the predominant imide linkages that characterize the backbone. The "sulfone" linkages act as joints or swivels between the aryl groups that we use to maximize the thermal stability. Thus, we select "sulfone" diamines and "sulfone" dianhydrides as the preferred reactants in the simultaneous condensation of multiple chemically functional end caps with the diamines and dianhydrides.
Although we do not prefer imide composites that include aliphatic segments when we use our multiple chemically functional end caps, we can make aliphatic polyimides, particularly those which include residues of the dianhydride MCTC. Such aliphatic residues lower the melt temperature and allow the use of lower temperature end caps, such as oxynadic and dimethyloxynadic (DONA). The resulting aliphatic imide oligomers cure at lower temperatures than our aromatic oligomers, which may be an advantage in some applications. Generally we prefer fully aromatic backbones because the goal of multiple chemically functional end caps, particularly four functional caps, is to achieve the highest thermo-oxidative stability.
Sulfone (--SO.sub.2 --) or the other electronegative linkages (L) between aromatic groups provide improved toughness. Our preferred imides resist chemical stress corrosion, can be thermoformed, and are chemically stable, especially against oxidation.
i. Diamine reactants
Preferred diamines for the synthesis of imide oligomers that include our multiple chemically functional end caps have the formula:
H.sub.2 N--.O slashed.--O--.O slashed.--NH.sub.2 (i.e., ODA),
H.sub.2 N--.O slashed.--S--.O slashed.--NH.sub.2 (i.e., thiodianiline), or ##STR34## wherein R* and R' are aromatic radicals, at least one of R* and R' being a diaryl radical wherein the aryl rings are joined by a "sulfone" linkage (L), and t is an integer from 0 to 27 inclusive. Preferably R* is selected from the group consisting of --.O slashed.--D--.O slashed.-- wherein D is an electronegative linkage selected from --SO.sub.2 --, --(CF.sub.3).sub.2 C--, or --S-- and --.O slashed.-- is phenylene. R' is preferably selected from the group consisting of: --.O slashed.--, --.O slashed.--M--.O slashed.--, or
--.O slashed.--.O slashed.--
wherein M=--SO.sub.2 --, --S--, --O--, --(Me).sub.2 C--, or --(CF.sub.3).sub.2 C--.
The diamine, however, may be any of: ##STR35## wherein R.sub.5 =--.O slashed.--q--.O slashed.--
R.sub.6 =phenylene, biphenylene, naphthylene, or --.O slashed.--M--.O slashed.--
q=--SO.sub.2 --, --CO--, --S--, or --(CF.sub.3).sub.2 C--, and preferably --SO.sub.2 -- or --CO--;
m=an integer, generally less than 5, and preferably 0 or 1; and
the other variables are as previously defined.
U.S. Pat. Nos. 4,504,632; 4,058,505; 4,576,857, 4,251,417; and 4,251,418 describe other diamines that we can use. We prefer the aryl or polyaryl ether "sulfone" diamines previously described, since these diamines provide high thermal stability to the resulting oligomers and composites. We can use mixtures of diamines, but we generally use a single diamine in each backbone so that the resulting oligomers have reliably recurrent, predictable structure.
Our most preferred diamines are ODA, thiodianiline, 3,3'-phenoxyphenylsulfone diamine; 4,4'-phenoxphenylsulfone diamine; 4,4'-diaminodiphenylsulfone; 4,4'-diaminodiphenyl ether, and methylene diamine, or mixtures thereof. We often use a 50:50 molar mixture of 3,3'-phenoxyphenylsulfonediamine and 4,4'-diaminodiphenylsulfone (available from Ciba-Geigy Corp. under the trade designation "Eporal"). Higher temperature oligomers within the class of preferred oligomers can be prepared using the shorter chain diamines, particularly 4,4'-diaminodiphenylsulfone. The best results may be achievable by replacing the sulfone linkage --SO.sub.2 -- with a smaller linkage such as --O--, --S--, or --CH.sub.2 --.
The diamines often contain one or more phenoxyphenylsulfone groups, such as: ##STR36##
The molecular weights of the preferred aryl diamines described above vary from approximately 500-10,000. We prefer lower molecular weight diamines, became they are more readily available.
When the diamine has the formula (XI), the MW of these diamines vary from approximately 500 to about 2000. Using lower molecular weight diamines enhances the mechanical properties of the polyimide oligomers, each of which preferably has alternating ether "sulfone" segments in the backbones as indicated above, A typical oligomer will include up to about 20 to 40 diamine residues, and, generally, about 5.
We can prepare phenoxyphenyl sulfone diamines useful in this imide synthesis by reacting two moles of aminophenol with (n+1) moles of an aryl radical having terminal, reactive halide functional groups (dihalogens), such as 4,4'-dichlorodiphenyl sulfone, and n moles of a suitable bisphenol (also known as dihydroxy aryl compounds or diols). The bisphenol is preferably selected from the group consisting of:
2,2-bis-(4-hydroxyphenyl)-propane (i.e., bisphenol-A);
bis-(2-hydroxyphenyl)-methane;
bis-(4-hydroxyphenyl)-methane;
1,1 -bis-(4-hydroxyphenyl)-ethane;
1,2-bis-(4-hydroxyphenyl)-ethane;
1,1-bis-(3-chloro-4-hydroxyphenyl)-ethane;
1,1-bis-(3,5-dimethyl-4-hydroxyphenyl)-ethane;
2,2-bis-(3-phenyl-4-hydroxyphenyl)-propane;
2,2-bis-(4-hydroxynaphthyl)-propane
2,2-bis-(4-hydroxyphenyl)-pentane;
2,2-bis-(4-hydroxyphenyl)-hexane;
bis-(4-hydroxyphenyl)-phenylmethane;
bis-(4-hydroxyphenyl)-cydohexylmethane;
1,2-bis-(4-hydroxyphenyl)-1,2-bis-(phenyl)-ethane;
2,2-bis-(4-hydroxyphenyl)-1-phenylpropane;
bis-(3-nitro-4-hydrophenyl)-methane;
bis-(4-hydroxy-2,6-dimethyl-3-methoxyphenyl)-methane;
2,2-bis-(3,5-dichloro-4-hydroxyphenyl)-propane;
2,2-bis-(3-bromo4-hydroxyphenyl)-propane;
or mixtures thereof, as disclosed in U.S. Pat. No. 3,262,914. Again, bisphenols having aromatic character (i.e., absence of aliphatic segments), such as bisphenol A, are preferred. Other suitable bisphenols (which we also call "diols") include: ##STR37## The bisphenol may also be selected from the those described in U.S. Pat. Nos. 4,584,364; 4,661,604; 3,262,914; or 4,611,048.
The dihalogens preferably are selected from the group consisting of: ##STR38## wherein X=halogen, preferably chlorine; and L=--S--, --SO.sub.2 --, --CO--, --(Me).sub.2 C--, and --(CF.sub.3).sub.2 C--, and preferably --SO.sub.2 -- or --CO--.
The condensation reaction for forming these phenoxyphenyl sulfone diamines creates diamine ethers that ordinarily include intermediate "sulfone" linkages. The condensation generally occurs through a phenate mechanism in the presence of K.sub.2 CO.sub.3 or another base in a DMSO/toluene solvent. The grain size of the K.sub.2 CO.sub.3 (s) should fall within the 100-250 ANSI mesh range.
ii. Dianhydride reactants
The dianhydride usually is an aromatic dianhydride selected from the group consisting of:
(a) pyromellitic dianhydride,
(b) benzophenonetetracarboxylic dianhydride (BTDA),
(c) para- and meta- dianhydrides of the general formula: ##STR39## but may be any aromatic or aliphatic dianhydride, such as 5-(2,5-diketotetrahydrofuryl-3-methyl-cyclohexene-1,2-dicarboxylic anhydride (MCTC) or those disclosed in U.S. Pat. Nos. 4,504,632; 4,577,034; 4,197,397; 4,251,417; 4,251,418; or 4,251,420. We can prepare dianhydrides by condensing 2 moles of an acid halide anhydride (e.g., trimellitic anhydride acid chloride) of the formula: ##STR40## wherein R.sub.2 is a C.sub.(6-13) trivalent aromatic radical (typically phenylene) with a diamine selected from those previously described. We can use mixtures of dianhydrides, as we do with the EPORAL diamines. We prefer a phenoxyphenyl sulfone dianhydride of the formula: ##STR41## particularly when the diamine is: ##STR42## where L is previously defined.
We cure the imide oligomers or prepregs (or those counterparts for the other backbone systems) to form composites in conventional vacuum bag techniques. We also often post-cure these imides (or any multiple chemically functional oligomer) as described in U.S. Pat. No. 5,116,935 to ensure that crosslinking is substantially complete. We can use the imide oligomers (like the counterparts we describe for the other resins backbones) as adhesives, varnishes, films, or coatings.
b. Multidimensional polyimides
We can prepare polyimides having multidimensional morphology by condensing the diamines, dianhydrides, and end cap monomers with a suitable amine hub, such as triaminobenzene. For example, we can react triaminobenzene with the phenoxyphenyl sulfone dianhydride, a phenoxyphenyl sulfone diamine, and either the extended anhydride end cap monomer or an extended amine end cap monomer to produce a multidimensional, crosslinkable polyimide. The resulting multidimensional oligomers should have surprisingly high thermal stabilities upon curing because of the multiple chemically functional end caps.
i. Multidimensional amine hubs
Suitable hubs include aromatic compounds having at least three amine functionalities. Such hubs include phenylene, naphthylene, biphenylene, or azaline amines, (including melamine radicals) or triazine derivatives described in U.S. Pat. No. 4,574,154 of the general formula: ##STR43## wherein R.sub.14 is a divalent hydrocarbon residue containing 1-12 carbon atoms (and, preferably, ethylene). We use "azalinyl" or "azaline" to mean triazines represented by the formula: ##STR44##
We can form another class of amine hubs by reacting the corresponding halo-hub (such as tribromobenzene) with aminophenol to form triamine compounds represented by the formula: .O slashed..brket open-st.O--.O slashed.--NH.sub.2 !.sub.3. We can react these triamine hubs with an anhydride end cap monomer or with suitable dianhydrides, diamines, and an extended anhydride or an amine end cap monomer. We could also use trimellitic anhydride as a reactant in some syntheses.
Another class of suitable amine hubs comprises amines having extended arms. For example, we can react phloroglucinol with p-aminophenol and 4,4'-dibromodiphenylsulfone under an inert atmosphere at an elevated temperature to achieve an amino terminated "star" hub of the general formula: ##STR45##
ii. Multidimensional anhydride hubs
In a manner analogous to the extended anhydride end cap monomers, we can prepare additional hubs for these multidimensional polyimides by reacting the corresponding hydroxy-substituted hub (such as phloroglucinol) with nitrophthalic anhydride to form trianhydride hubs represented by the formula: ##STR46## We can react the trianhydride with a aliamine and the extended anhydride end cap monomer. Of course, we can condense the extended anhydride end cap monomer directly with an amine hub to prepare a multidimensional polyimide oligomer or can condense the extended amine end cap monomers directly with the trianhydride.
Similarly, the hub can be an amine or anhydride derivative made from the polyols of U.S. Pat. No. 4,709,008 that we will describe in greater detail later in this specification.
We present the following examples to better illustrate various features of the present invention as it relates to imides.
EXAMPLE 1 ##STR47##
In a flask fitted with a stirrer, thermometer, Barrett trap condenser, and a nitrogen inlet tube, we mix 8.04 g (0.074 moles) p-aminophenol, 86.97 g (0.38 moles) bisphenol-A, 281.22 g dimethylsulfoxide (DMSO), and 167.40 g toluene and stir. After purging with dry nitrogen, add 67.20 g of a 50% solution of sodium hydroxide and raise the temperature to 110.degree.-120.degree. C. Remove the water from the toluene azeotrope, and then the toluene, until the temperature reaches 160.degree. C. Cool the reaction mixture to 110.degree. C., and add 120 g (0.42 moles) 4,4'dichlorodiphenylsulfone as a solid. Reheat the mixture to 160.degree. C. and hold for 2 hours. After cooling to room temperature, filter the mixture to remove sodium chloride, which precipitates, and coagulate the product in a blender from a 2% sodium hydroxide solution containing 1% sodium sulfite. Recover the oligomer from the solution by washing the coagulate with 1% sodium sulfite.
U.S. Pat. Nos. 3,839,287 and 3,988,374 disclose other methods for preparing phenoxyphenylsulfone diamines of this general type.
EXAMPLE 2 ##STR48##
Charge a reaction flask fitted with a stirrer, condenser, thermometer, and a dry N.sub.2 purge with a 60% slurry of the diamine of Example 1 in NMP. In an ice bath, gradually add a 10% solution of BDTA and an anhydride end cap monomer in NMP. After stirring for 15 min. in the ice bath, remove the bath and stir for 2 hr. Recover the oligomer by precipitating in water and drying with alcohol (i.e., MeOH).
Adjust the formula weight of the oligomer by adjusting the proportions of reactants and the reaction scheme, as will be known to those of ordinary skill in the art.
EXAMPLE 3 ##STR49##
Fit a reaction flask with a stirrer, thermometer, Barrett trap condenser, and N.sub.2 inlet tube and charged 10.91 g (0.1 moles) of p-aminophenol, 40.43 g (0.18 moles) bisphenol A, 168.6 g DMSO, and 79.23 g toluene. After purging with nitrogen, add 36.42 g of a 50% solution of sodium hydroxide and raise the temperature to 110.degree.-120.degree. C. to remove the water from the toluene azeotrope, and then the toluene until the temperature reaches 160.degree. C. Cool the reaction mixture to 110.degree. C., and add 65.22 g (0.23 moles) 4,4' dichlorodiphenylsulfone as a solid. Heat the mixture to 160.degree. C. and hold for 2 hours. After cooling to room temperature, filter the mixture to remove sodium chloride. Form a coagulate in a blender by adding 2% sodium hydroxide solution containing 1% sodium sulfite. Remove the coagulate and wash it with 1% sodium sulfite.
EXAMPLE 4 ##STR50##
Use the procedure followed in Example 2, except substitute a suitable amount of the diamine of Example 3 for the diamine of Example 1.
EXAMPLE 5 ##STR51##
Use the procedure of Example 1, using 2.18 g (0.02 moles) of p-aminophenol, 49.36 g (0.216 moles) of bisphenol-A, and 64.96 g (0.226 moles) of 4,4'-dichlorodiphenyl-sulfone.
EXAMPLE 6 ##STR52##
Follow the procedure in Example 2, substituting the diamine of Example 5, the extended anhydride end cap monomer, and phenoxyphenylsulfone dianhydride as the reactants.
EXAMPLE 7 ##STR53##
The oligomers obtained in any of Examples 2, 4, and 6 can be impregnated on epoxy-sized T300/graphite fabric style (Union Carbide 35 million modulus fiber 24.times.24 weave) by first obtaining a 10 to 40% solution of resin in NMP or another appropriate aprotic solvent including DMAC or DMF. The solutions can then be coated onto the dry graphite fabric to form prepregs with 38 wt. % resin. The prepregs can be dried to less than 1 percent volatile content, cut into 6.times.6-inch pieces, and stacked to obtain a consolidated composite of approximately 0.080 inch. The stacks of prepregs can then be vacuum bagged and consolidated under 100-200 psi in an autoclave heated for a sufficient time �probably for 1-2 hours at 575.degree.-600.degree. F. (300.degree.-315.degree. C.)! to induce cure. If dimethyl oxynadic or oxynadic anhydride capped systems are used, the prepregs likely would be cured for 16 hours at 400.degree. F. (210.degree. C.).
EXAMPLE 8 ##STR54##
Prepare graphite fabric prepregs, at 36 percent resin solids, using the resins of Example 2, 4, and 6 by solvent impregnation from a dilute NMP or another aprotic solvent solution. The graphite fabric is spread on a release film of FEP. Sweep the prepregging solution (having approximately 10-40 wt. % oligomer) into the fabric and allow it to dry, repeating on alternating sides, until the desired .weight of resin is applied. The prepregs can then be dried 2 hours at 275.degree. F. (135.degree. C.) in an air-circulating oven.
Stack seven piles of each prepreg, double-wrapped in release-coated 2-mil Kapton film, and sealed in a vacuum bag for curing. Place each vacuum bag assembly in an autoclave and heat to about 575.degree.-600.degree. F. (300.degree.-315.degree. C.) at a rate of 1.degree.-2.degree. F./min. (0.5.degree.-1.degree. C./min.). Upon reaching 575.degree.-600.degree. F. (300.degree.-315.degree. C.), hold the temperature substantially constant for about 2 hr to complete the cure. To enhance high temperature properties, post-cure for about 4-8 hr at 600.degree.-625.degree. F. (315.degree.-330.degree. C.).
EXAMPLE 9 ##STR55##
Samples of the cured composites of Example 8 can be machined into 1.times.0.5-inch coupons, placed in bottles containing methylene chloride, and observed to determine if ply separation occurs. The composites will likely remain intact, with only slight swelling, after immersion for up to 2 months.
c. Post-curing
In another aspect of the invention, we can improve the thermal stability of the imide composites by post-curing the composites at temperatures of up to approximately 625.degree.-650.degree. F. (315.degree.-330.degree. C.). Post-curing is desirable for all resin types. It promotes complete linking. Such post-curing treatment advantageously raises the dynamic mechanical analysis peak (and .beta.-transition) of the treated composites, presumably by causing full crosslinking of the end cap functionalities. Preferably, we carry out the post-curing treatment of the composites at a temperature of about 625.degree.-650.degree. F. (315.degree.-330.degree. C.) for a period of approximately 2-4 hours, but this period may vary somewhat depending upon the particular composite being treated.
The thermal stabilities achievable with such post-curing treatment are significantly higher than those generally realized without the treatment. For example, for a difunctional polyimide oligomer having a MW of about 15,000 and prepared as previously described by reacting a difunctional imidoaniline end cap, 4,4'-phenoxyphenylsulfone dianhydride, and a 50:50 molar mixture of 3,3'-phenoxyphenylsulfone diamine and 4,4'-diaminodiphenylsulfone, post-curing at a temperature of approximately 625.degree.-650.degree. F. (315.degree.-330.degree. C.) resulted in a DMA transition temperature of about 350.degree. F. (177.degree. C.), some 40.degree.-50.degree. F. (20.degree.-25.degree. C.) higher than without such treatment. We believe there will be a comparable benefit from post-curing four functional oligomers of the present invention.
In carrying out the post-cure treatment, a prepreg is first formed by impregnating a fabric with a polyimide oligomer. The fabric can be any of the types previously described. We heat the prepreg at an elevated temperature (e.g. 450.degree. F. (232.degree. C.)) and under pressure (e.g. 100 psi) for a time sufficient to cure the prepreg and form a composite. We then post-cure the resulting composite at a temperature of approximately 625.degree.-650.degree. F. (315.degree.-330.degree. C.) for a time sufficient to improve the thermal stability. During post-curing, the remaining unreacted crosslinking functionalities re-orient and react to produce a nearly fully linked chain.
Post-curing applies to all the resin backbones. It ensures more complete reaction of the capping functionalities. We recommend it for all our multifunctional oligomer systems.
The bisphenol may be in phenate form, or a corresponding sulfhydryl can be used. Of course, can use we fixtures of bisphenols and bisulfhydryls.
Bisphenols of the type described are commercially available. Some may be easily synthesized by reacting a dihalogen intermediate with bis-phenates, such as the reaction of 4,4'-dichlorophenylsulfone with bis(disodium biphenolate). Preferred dihalogens in this circumstance are those we discussed for forming diamines.
d. Multidimensional acid hubs
While acid hubs are not used in the imides, we describe them here while discussing extended hubs. We can convert the triazine derivatives described in U.S. Pat. No. 4,574,154 to acid halides by reacting the amine functionalities with phthalic acid anhydride to form imide linkages and terminal acid functionalities (that we convert to acid halides). We can also use the triazine derivatives of U.S. Pat. No. 4,617,390 (or the acid halides) as the hub for multidimensional heterocycles.
By reacting polyol aromatic hubs, such as phloroglucinol, with nitrobenzoic acid or nitrophthalic acid to form ether linkages and terminal carboxylic acid functionalities, we produce acid hubs. The nitrobenzoic acid products would have three active sites while the nitrophthalic acid products would have six; each having the respective formula: ##STR56## Of course we can use other nitro/acids.
We can react extended triamine hubs of the formula: ##STR57## with an acid anhydride (i.e., trimellitic acid anhydride) to form a polycarboxylic acid hub of the formula: ##STR58## the hub being characterized by an intermediate ether and imide linkage connecting aromatic groups. We can also use thio-analogs in accordance with U.S. Pat. No. 3,933,862.
4. Amideimide Oligomers
Polyamideimides are generally injection-moldable, amorphous, engineering thermoplastics which absorb water (swell) when subjected to humid environments or immersed in water. Typically polyamideimides are described in the following patents: U.S. Pat. No. 3,658,938; U.S. Pat. No. 4,628,079; 4,599,383; 4,574,144; or 3,988,344. Their thermomechanical integrity and solvent-resistance can be greatly enhanced by capping amideimide backbones with the four functional end cap monomers.
Classical amideimides have the characteristic repeating unit: ##STR59## in the backbone, usually obtained by reacting equimolar amounts of trimellitic acid halide anhydride and a diamine to form a polymer of the formula: ##STR60## wherein R* is the residue of the diamine and m represents the polymerization factor. While we can make amideimides of this type, and quench them to oligomers by using an extended amine end cap monomer mixed with the diamine and trimellitic acid halide anhydride (see Example 38), we also make more varied amideimide oligomers.
Our oligomers can also be four functional capped homologs of the TORLON amideimides.
a. Linear amideimides
The amideimdes of the present invention generally include linkages of the following general nature along the backbone: ##STR61## wherein R.sub.8 =an aromatic, aliphatic, or alicyclic radical, and preferably a phenoxyphenyl sulfone; and
R.sub.11 =a trivalent organic radical, typically a C.sub.(6-3) aromatic radical such as phenylene.
R.sub.8 is the residue of a diamine and, throughout the amidemide chain, can be the same or different depending on whether we use a single diamine or a mixture of diamines. We prepare random or block copolymers. We can prepare an amide-amide-imide-imide linkage, for example, by condensing 2 moles of an acid halide anhydride (e.g., trimellitic anhydride acid halide) of the general formula: ##STR62## with a diamine of the formula: H.sub.2 N--R.sub.8 --NH.sub.2 to produce an intermediate dianhydride. The linkage is characterized by a plane of symmetry about the R.sub.8 residue. We can use any of the diamines described for the imides.
R.sub.11 is commonly phenylene, so that the products are classical amideimides.
We can prepare the corresponding amideimide of the general formula: ##STR63## if we use the acid anhydride (e.g., trimellitic acid anhydride): ##STR64## instead of the acid halide anhydride (e.g., trimellitic anhydride acid halide), because the imide forms before the amide. This reaction proceeds through a dicarboxylic acid intermediate.
We can also prepare true amideimides as our U.S. Pat. No. 5,155,206 describes. In the present invention we condense an appropriate four functional end cap n-monomer with the reactants in place of the imidoaniline or acid halide caps used in our earlier patents.
We can synthesize true amideimides of the present invention by several schemes. To obtain repeating units of the general formula: ##STR65## we mix an acid halide anhydride, particularly trimellitic anhydride acid chloride: ##STR66## with a diamine from those described for the imides and with an extended amine end cap in the ratio of n: n: 2 wherein n=an integer. The acid halide anhydride reacts with the diamine to form an intermediate dianhydride which will condense with the remaining diamine and the amine end cap monomer. The reaction may be carried out in two distinct states under which the dianhydride is first prepared by mixing substantially equimolar amounts (or excess diamine) of the acid halide anhydride and diamine followed by the addition of a mixture of the diamine and the end cap monomer. Of course, the diamine used to form the dianhydride may differ from that used in the second stage of the reaction, or there can be a mixture of diamines from the outset.
We can synthesize the related amideimide having repeating units of the general formula: ##STR67## by reacting the acid anhydride with the diamine to form an intermediate dicarboxylic acid, which can then react with more diamine, another diamine, or an amine end cap monomer to complete the oligomer. Again, the reaction can be divided into steps.
The amideimide oligomers will probably improved if the condensation of the dianhydride/dicarboxylic acid with the aliamine and end cap monomer is done simultaneously rather than sequentially.
While the oligomers we describe use an amine end cap, we can synthesize corresponding oligomers by using an acid halide end cap or even an anhydride end cap, if the diamine is provided in excess. The reaction mixture generally comprises the anhydride acid halide (--COX) or the acid anhydride (--COOH), the end cap monomer, and the diamine with the synthesis completed in one step.
All reactions should be conducted under an inert atmosphere. Reducing the temperature of the reaction mixture, such as by using an ice bath, can slow the reaction rate and can assist in controlling the oligomeric product.
As suggested in U.S. Pat. No. 4,599,383, the diamine may be in the form of its derivative OCN--R--NCO, if desired.
We cart multifunctionally cap any amideimide described in U.S. Pat. Nos. 4,599,383; 3,988,374; 4,628;079; 3,658,938; and 4,574,144 with an appropriate crosslinking end cap monomer, such as the acid halide end cap, to convert the polymers to four functional oligomers of the present invention.
We can use a sequential or homogeneous reaction scheme to condense the reactants with sequential synthesis preferred to avoid side reactions. Generally we condense a dianhydride or diacid halide (depending on whether the acid halide anhydride or simply the acid anhydride is used) diamine, and an extended anhydride end cap monomer of formula (II). That is, we can prepare the dianhydride or diacid halide by the condensation of a diamine with the acid anhydride or acid halide anhydride followed by addition of additional diamine and the end cap to complete the synthesis. Four functional analogs of the amideimides described in our U.S. Pat. Nos. 5,104,967; 5,155,206; 5,216,117; and 5,239,046 can be prepared.
b. Multidimensional amideimides
The multidimensional polyamideimide oligomers include oligomers of the general formula: ##STR68## and other four functional, multidimensional amideimide oligomers analogous to the monofunctional and difunctional multidimensional amideimide oligomers our U.S. Pat. Nos. 5,227,461; 5,104,967; or 5,155,206 describe.
Diacid halide reactants
The diacid halide (or dicarboxylic acid �i.e., dibasic acid!; general formula: XOC--R.sub.9 --COX) may include an aromatic chain segment (i.e., R.sub.9) selected from the group consisting of:
(a) phenylene;
(b) naphthylene;
(c) biphenylene;
(d) a polyaryl "sulfone" divalent radical of the general formula:
--.O slashed.--O--.O slashed.--L*--.O slashed.--O--.O slashed.--
wherein
L*=--S--, --O--, --CO--, --SO.sub.2 --, --(Me.sub.3).sub.2 C--, or --(CF.sub.3).sub.2 C--,
(e) a divalent radical having conductive linkages, illustrated by Schiff base compounds, selected from the group consisting of: ##STR69## wherein R is selected from the group consisting of: phenylene; biphenylene; naphthylene; or a divalent radical of the general formula: --.O slashed.--W--.O slashed.-- wherein W=--SO.sub.2 -- or --CH.sub.2 --; and g=0-4; or
(f) a divalent radical of the general formula:
--R.sub.10 --NHCO--.O slashed.--CONH--
wherein R.sub.10 =a C.sub.2 to C.sub.12 divalent aliphatic, alicyclic, or aromatic radical, and, preferably, phenylene (as described in U.S. Pat. No. 4,556,697).
The preferred diacid halide is a dibasic carboxylic acid halide of a divalent organic radical selected from the group consisting of: ##STR70## wherein m is an integer, generally from 1-5, and the other variables are as previously defined.
The most preferred acid halides include: ##STR71##
We can prepare Schiff base diacid halides by the condensation of aldehydes and aminobenzoic acid halide (or other amine/acids) in the general reaction scheme: ##STR72## or similar syntheses.
U.S. Pat. No. 4,504,632, &doses other diacid halides that we can use including:
adipylchloride,
malonyl chloride,
succinyl chloride,
glutaryl chloride,
pimelic acid dichloride,
suberic acid dichloride,
azelaic acid dichloride,
sebacic acid dichloride,
dodecandioic acid dichloride,
phthaloyl chloride,
isophthaloyl chloride,
terephthaloyl chloride,
1,4-naphthalene dicarboxylic acid dichloride, and
4,4'-diphenylether dicarboxylic acid dichloride.
We prefer polyaryl or aryl diacid halides to achieve the highest thermal stabilities in the resulting oligomers and composites. Particularly preferred compounds include intermediate "sulfone" (i.e. electronegative) linkages (i.e., "L") to improve the toughness of the resulting oligomers.
Suitable diacid halides include compounds made by reacting nitrobenzoic acid with a bisphenol (which might also be called a dihydric phenol, dialcohol, or diol). The reaction is the counterpoart of that for making diamines. The bisphenol is preferably selected from the group previously described for the imide synthesis. We prefer having aromatic character (i.e., absence of aliphatic segments), such as bisphenol-A. While we prefer bisphenol-A (because of cost and availability), we can use the other bisphenols to add rigidity to the oligomer without significantly increasing the average formula weight Over bisphenol-A residues, and, therefore, can increase the solvent resistance. Random or block copolymers from using different bisphenols are possible (here as well as with the other backbones).
c. Amideimide sizings
A major problem encountered in improving high temperature mechanical and physical properties of reinforced resin composites occurs because of inadequate transfer of induced matrix stress to the reinforcement. The matrix also helps to prevent the fiber from buckling. Sizing is often applied to the reinforcing fibers to protect the fibers during processing and to enhance bonding at this interface between the fibers and the resin matrix thereby more efficiently transferring the load and stabilizing the fiber. Sizings are essentially very thin films of resin (less than a few wt %) applied to the fibers. To be effective, sizings should be relatively high MW materials that form a relatively uniform coating. Commercially available sizings include epoxy sizings under the trade designations UC309 and UC314 from Amoco, G or W from Hercules, EP03 from Hoechst and high performance sizings under the trade designations L30N, L20N, UC0121 or UC0018 from Amoco. Commercially available sizings are unsatisfactory because they are generally monomers or low MW materials that often only partially coat the fibers and, as a result, minimally improve composite properties. There is a need, therefore, for improved sizings, especially for carbon fibers intended for high performance composites.
We described improved sizings for carbon fibers using an amideimide polymer or a difunctional amideimide oligomer in our U.S. Pat. Nos. 5,155,206 and 5,239,046. We can now prepare analogous four functional amideimide sizings, although they likely would provide little improvement over polymeric amideimide sizings since capping between the matrix and sizing would be disorganized and incomplete at best. The amideimide polymer, a difunctional oligomer, the four functional oligomers of the present invention, or blends of any of these polymers and oligomers might be used. A four functional amideimide sizing is probably best when using a four functional oligomer as the matrix for a sizing, the amideimide should have a MW above 10,000, and, preferably, above 20,000. Actually, the MW should be as high as one can achieve. As for the polymers and difunctional oligomers, a preferred four functional amideimide oligomer is formed by condensing trimellitic anhydride acid chloride with bis(4-aminophenoxyphenyl) sulfone and either an extended amine, an acid chloride, or a phenol end cap monomer.
When the matrix is an oligomer that includes crosslinking functionalities of the nature suggested for the capped sizings of the present invention, it is probably wise that the caps on the oligomer and on the sizings be the same or at least chemically comparable. That is, for example, we prefer to use nadic caps in our oligomers and nadic caps for the amideimide sizing.
We believe that the amideimide sizings provide a high concentration of hydrogen bonding sites to promote coupling between the sizing and the matrix. Both the imide and amide linkages include heteroatoms. The capped materials may actually form chemical (covalent) bonds for even stronger interaction between the sizing and matrix, or the end caps might cause addition polymerization to provide even higher MW sizings on the fiber. We believe higher MW sizings have better properties.
The sizings impart improved elevated temperature mechanical and environmental stability to carbon fiber/oligomer composites in which the matrix resin is selected from imides, amides, amideimides, esters, ethers, sulfones, ether sulfones, heterocycles, carbonates, and almost any other commercial resin including epoxies, PMR-15, K-III, or the like. We use these multifunctional amideimide sizings in the same manner as conventional sizings.
We next provide some examples of proposed syntheses of polyamideimides.
EXAMPLE 10
React a diamine with two moles of trimellitic acid anhydride to form a dicarboxylic acid intermediate by adding the diamine dropwise to the trimellitic acid anhydride. Convert the intermediate to the corresponding diacid chloride in the presence of SOCl.sub.2, and then condense the intermediate with the diamine and an extended amine end cap monomer to yield the desired product.
If excess diamine is used, use an acid halide end cap to form the product.
EXAMPLE 11
React a diamine with trimellitic anhydride acid chloride to yield a dianhydride intermediate. Condense the intermediate with an amine end cap monomer and a diamine to yield the desired product.
Typically, this reaction involves mixing, for example, the four nadic-capped acid chloride end cap monomer: ##STR73## wherein NA is nadic and .O slashed. is phenylene with trimellitic acid chloride anhydride: ##STR74## in NMP or another suitable solvent and, then, adding the diamine:
H.sub.2 N--.O slashed.--O--.O slashed.--SO.sub.2 --.O slashed.--O--.O slashed.--NH.sub.2
in NMP (i.e., the same solvent). We prepare the diamine by reacting para- or meta-aminophenol with ##STR75##
It may be possible to obtain the amideimide in another fashion, involving protecting the amine functionalities in the cap that ultimately form the amide linkages with phthalic anhydride; condensing the protected phthalic imide acid chloride end cap monomer the diamine, and trimellitic acid chloride anhydride; saponifying the resulting product to yield a bis(diamino) oligomer; and completing the capping by condensing a phthalimide acid halide end cap monomer, such as those in U.S. Pat. No. 5,087,701, and, preferably the dinadic acid chloride monomer. Our concern with this scheme is whether the saponification reaction will also break the imide linkages in the backbone.
EXAMPLE 12
Condense triaminobenzene with a trimellitic acid anhydride or acid chloride and an amine end cap monomer to yield the desired multidimensional product. Any amine hub can be used in place of triaminobenzene.
EXAMPLE 13
React an amine hub with the dicarboxylic acid intermediate of Example 15, a diamine, and an extended amine end cap in the ratio of 1 mole of hub: (w)(m+1) moles of intermediate:(w)(m) moles of diamine: w moles of end cap to prepare the desired multidimensional product.
EXAMPLE 14
React an amine hub with the dianhydride intermediate of Example 11, a diamine, and the extended amine end cap in the ratio of 1 mole hub: (w)(m+1) moles dianhydride: (w)(m) moles diamine: w moles end cap to yield the desired product.
EXAMPLE 15
React an acid or acid halide hub, like cyuranic acid, with a diamine, a dicarboxylic acid intermediate of Example 10, and an acid halide end cap in the ratio of 1 mole hub: (w)(m+1) moles diamine: (w)(m) moles intermediate: w moles cap to yield the desired product.
EXAMPLE 16
React an amine hub with a dicarboxylic acid intermediate (or dihalide) of Example 10 and the extended amine end cap in the ratio of 1 mole hub :.w moles intermediate: w moles cap to yield the desired product.
EXAMPLE 17
React an amine hub with the dicarboxylic acid intermediate of Example 10, a diamine, and an acid halide end cap in the ratio of 1 mole hub: w moles intermediate: w moles diamine, and w moles cap to form the desired product.
EXAMPLE 18
React an amine hub with the dianhydride intermediate of Example 10, a diamine, and an acid halide end cap in the ratio of 1 mole hub: (w)(m) moles intermediate: (w)(m) moles diamine: w moles cap to form the desired product.
EXAMPLE 19
React an amine hub with the dicarboxylic acid intermediate of Example 10, a diamine, and an extended amine end cap in the ratio of 1 mole hub: (w)(m+1) moles intermediate: (w)(m) moles diamine: w moles cap to form the desired product.
EXAMPLE 20
React an amine hub with trimellitic anhydride acid halide, a diamine, and an acid halide end cap in the ratio of 1 mole hub: w moles trimellitic anhydride acid halide: w moles diamine: w moles cap to form the desired product. Preferably the reaction occurs in two steps with the reaction of the hub and trimellitic anhydride acid halide followed by the addition of an amine end cap.
EXAMPLE 21
React an amine hub with trimellitic acid anhydride and an extended amine end cap in the ratio of 1 mole hub: w moles trimellitic acid anhydride: w moles cap to form the desired product.
EXAMPLE 22
React an amine hub with trimellitic acid anhydride, a diamine, and an extended amine end cap in the ratio of 1 mole hub: 2w moles acid anhydride: w moles diamine: w moles cap to yield the desired product. Preferably the cap and half of the acid anhydride are mixed to form an end cap conjugate prior to mixing the reactants to form the oligomer. It also may be wise to mix the remaining acid anhydride with the hub to form an acid hub conjugate prior to adding the diamine and end cap conjugate. In an alternate synthesis we use an anhydride end cap monomer.
Alternatively, make the product by reacting the hub with the dianhydride intermediate of Example 11 and an extended amine end cap.
EXAMPLE 23
React an amine hub with the dianhydride intermediate of Example 11, a diamine, and either an extended anhydride end cap conjugate formed by reacting an amine end cap with an acid halide anhydride (like trimellitic acid chloride anhydride) or the anhydride end cap monomer in the ratio of 1 mole hub: w moles intermediate: w moles end cap conjugate.
Alternatively, prepare the product by reacting the hub with an acid anhydride followed by reaction with a diamine, the diacid intermediate of Example 10, and an amine end cap. Stepwise addition of the diamine to the extended hub followed by addition of the diacid intermediate and amine end cap will reduce competitive side reactions.
EXAMPLE 24
React an amine hub with an acid anhydride (like trimellitic acid anhydride) to form an acid hub intermediate. React the intermediate with a diamine, a dicarboxylic acid or acid halide intermediate of Example 10, and an acid halide end cap in the ratio of 1 mole hub intermediate: (w)(m+1) moles diamine: (w)(m) moles dicarboxylic acid intermediate: w moles end cap to yield the desired product.
Alternatively, prepare the product by reacting an amine hub with the dianhydride intermediate of Example 11, a first diamine, an acid anhydride, a second diamine, and an acid halide end cap in a stepwise reaction.
EXAMPLE 25
React an amine hub with the dianhydride intermediate of Example 11, a aliamine, and an extended amine end cap in the ratio of 1 mole hub: 2w moles intermediate: w moles diamine: w moles cap to yield the desired product.
EXAMPLE 26
React an acid hub with a diamine, an acid anhydride, and an amine end cap in the ratio of 1 mole hub: w moles diamine: w moles acid anhydride: w moles cap to yield the desired product. Preferably the reaction includes the steps of reacting the acid anhydride with the end cap monomer prior to addition of the hub and diamine.
EXAMPLE 27
React an acid hub with a diamine to form an amine extended hub conjugate. React the conjugate with an acid halide anhydride, a second diamine, and an acid halide end cap to yield the desired product. Preparing an end cap conjugate by reacting the second diamine with the acid halide cap (adding the cap dropwise to the diamine) prior to the addition of the other reactants reduces side or competitive reactions. In this case, for example, the acid hub is added dropwise to the diamine to promote substantially complete addition of the free amino groups with the hubs acid functionalities and to minimize addition of a hub to both ends of the diamine. We take similar precautions in making the other conjugates we describe in these examples.
EXAMPLE 28
React an acid hub with a diamine, the acid intermediate of Example 10, and an extended amine end cap in the ratio of 1 mole hub: w moles diamine: w moles intermediate: w moles cap. Preferably, the reaction occurs in two stages with the hub being mixed with the diamine to form an amine conjugate to which the acid or acid halide intermediate and cap is added in a simultaneous condensation.
EXAMPLE 29
React an acid hub with a diamine, the acid intermediate of Example 10, and an extended amine cap in the ratio of 1 mole hub: (w)(m+1) moles diamine: (w)(m) moles intermediate: w moles cap to yield the desire product. The reaction preferably involves the step of preparing the amine conjugate described in Example 33.
EXAMPLE 30
React two moles of an extended amine end cap with about (m+2) moles of trimellitic acid anhydride, and about (2m+1) moles of bis(4-aminophenoxyphenyl)sulfone:
H.sub.2 N--.O slashed.--SO.sub.2 --.O slashed.--O--.O slashed.--SO.sub.2 --.O slashed.--NH.sub.2,
to yield the desired product. To avoid side or competitive reactions, prepare a dicarboxylic acid intermediate by mixing the acid anhydride and diamine in the ratio of about 2 moles acid anhydride: 1 mole diamine prior to adding the remaining reactants for simultaneous condensation to the oligomer.
EXAMPLE 31
Follow the method of Example 10 except substitute aniline for the amine cap. The product is a comparable amideimide polymer of similar MW and structure to the oligomer of Example 10 but being incapable of crosslinking because of the lack of crosslinking sites (hydrocarbon unsaturation) in the end caps. The aniline provides MW control and quenches the amideimide condensation.
We can obtain comparable noncrosslinking amideimide polymers using the methods of Examples 11-30 substituting aniline, benzoic acid, or similar compounds to quench the syntheses, as will be understood by those of ordinary skill. In analogous manner, we can make corresponding, noncrosslinking polymers for any oligomer we describe in this specification, and we can use these polymers in blends.
EXAMPLE 32
Mix solutions of the amideimide oligomer of Example 10 and the amideimide polymer made in accordance with Example 31 to prepare a blend that either can be swept out into fiber reinforcement to form a prepreg of an amideimide blend or that can be dried to recover the blend. The blend generally includes substantially equimolar amounts of the oligomer and polymer, although the ratio can be varied to control the properties of the blend.
EXAMPLE 33
Dissolve an extended amine end cap and bis(4-aminophenoxyphenyl) sulfone in N,N'-dimethylacetamide (DMAC). Cool the solution to -10.degree. C. under nitrogen. While stirring, acid trimellitic anhydride acid chloride dropwise and hold the temperature below 0.degree. C. one hour. Next add triethylamine (TEA) dropwise and stir 30 minutes. Add DMAC and stir 3 more hours. Finally, add pyridine and acetic anhydride. Stir the viscous mixture 3 hours. Filter off the hydrochloride salt and precipitate the product in a blender with water. Filter, wash the precipitate the product with distilled water and then dry.
Alternatively, the imidization reaction can be induced thermally by heating the mixture to about 300.degree.-350.degree. F. (150.degree.-175.degree. C.) for several hours followed by precipitating the product in water and washing with MeOH.
EXAMPLE 34 ##STR76##
Make an amideimide oligomer in accordance with Example 10.
Make a relative high MW polyether polymer by condensing a diol of the general formula:
HO--.O slashed.--O--.O slashed.--O--.O slashed.--O--.O slashed.--OH
with Cl--.O slashed.--Cl and phenol or chlorobenzene (to quench the polymerization) under an inert atmosphere in the same solvent as used with the amideimide oligomer or another solvent miscible with that of the amideimide oligomer.
Mix the two solutions to form a lacquer or varnish of an advanced composite blend. Prepreg the lacquer or dry it prior to curing the blend to an advanced amideimide/ether composite. This advanced composite blend could be mixed with a Z*.sub.k --B--Z*.sub.k oligomer to form a coreactive oligomer blend, which would, then, be prepregged and cured. "Z*" is a cyclobutane, amine, phenol, or thioether.
For additional discussion of advanced composite blends, see section 14. Section 15 discusses coreactive oligomer blends in more detail.
EXAMPLE 35 ##STR77##
Prepare a multidimensional, polyether sulfone polymer by reacting phloroglucinol with Cl--.O slashed.--Cl and HO--.O slashed.--O--.O slashed.--SO.sub.2 --.O slashed.--O--.O slashed.--OH. Quench the polymerization with either chlorobenzene or phenol. The condensation occurs in a suitable solvent under an inert atmosphere. The product is not recovered from the solvent.
Prepare a multidimensional, ester oligomer in the same solvent as used for the polymer or in another miscible solvent by condensing cyuranic acid chloride with a phenol end cap. The oligomer product is not recovered, but the reaction mixture is mixed with the polyether polymer product and a phenoxyphenyl sulfone diamine (i.e., Z--B--Z, such as bis(4-aminophenoxyphenyl) sulfone) to form a multidimensional advanced composite blend of coreactive oligomers that can be prepregged or dried prior to curing the ester oligomer to form a multidimensional, polyester/polyether-sulfone, advanced composite.
Generally, in coreactive oligomer blends, the resins are selected to tailor the physical properties of the resulting block copolymer composites. Such blends with multiple chemically functional oligomers are counterparts to the coreactive oligomer blends U.S. Pat. Nos. 5,115,087 and 5,159,055 describe. For example, we can achieve stiffening for a composite made from ethersulfone oligomer of the present invention by adding a benzoxazole oligomer as a coreactant. Those skilled in the art will recognize the benefits to be gained through coreactive oligomer blends. The ethersulfone toughens the relatively stiff and rigid heterocycle oligomers, which is particularly important for the preparation of films.
To prepare ethers, the phenol or halide end cap is mixed with suitable diols and dihalogens or with suitable dinitrohydrocarbons and diols. To prepare esters, the phenol end cap or acid halide end cap is mixed with suitable diols and diacids, both as will be explained in greater detail later in this specification.
5. Etherimides
The polyetherimides and polysulfoneimides of the present invention are analogous to the oligomers described in U.S. Pat. Nos. 4,851,495 and 4,981,922 and have the general formula: ##STR78## wherein .rho.=--O-- or --S--;
.xi.=the residue of an end cap;
R.sub.11 =a trivalent C.sub.(6-13) aromatic organic radical;
R.sub.13 =a divalent C.sub.(6-30) aromatic organic radical; and
m=a small integer (the "polymerization factor") typically from 1-5.
We prepare the polyetherimide oligomers by several reaction schemes. One method for synthesizing the polyetherimides involves the simultaneous condensation of about 2m+2 moles of nitrophthalic anhydride with about m+1 moles of aliamine, about m moles of a diol, and the extended amine end cap or the extended phenol end cap in a suitable solvent under an inert atmosphere. The diol may actually be in the form of a phenate.
In this reaction, the diamines (which preferably have aromatic ethersulfone backbones) react with the anhydride of the nitrophthalic anhydride to form dinitro intermediates and the diol reacts with the nitro-functionality to form an ether linkage as described in our U.S. Pat. Nos. 4,851,495 and 4,981,922. The end caps quench the polymerization.
Another method comprises the simultaneous condensation of: ##STR79## in the ratio of XII:XIII:XIV:XV=l:l:m:m, wherein v=halo- or nitro-. The product has the general formula previously described. The reaction conditions are generally comparable to those described in U.S. Pat. Nos. 3,847,869 and 4,107,147.
Alternatively, we prepare the polyetherimides by reacting a polyetherimide polymer made by the self-condensation of a phthalimide salt of the formula: ##STR80## wherein M.sub.2 is an alkali metal ion or ammonium salt or hydrogen with quenching crosslinking end cap moieties of the formula: ##STR81## and a halogeno cap of the formula: ##STR82## wherein Z is an end cap and X is a halogen.
The self-condensation proceeds is described in U.S. Pat. No. 4,297,474 in a dipolar aprotic solvent We introduce the end cap moieties either during the self-condensation to quench the polymerization or following completion of the polymerization and recovery of the polyetherimide polymer from methanol (i.e., post-polymerization capping).
Another etherimide synthesis comprises the simultaneous condensation of about 2m+2 moles of nitrophthalic anhydride with about m+1 moles of diol, m moles of diamine, and 2 moles of the extended amine end cap in a suitable solvent under an inert atmosphere.
In any of the syntheses, we can replace the diol by a comparable disulfhydryl. We can use mixtures of diols and disulfhydryls, of course, but we prefer pure diols.
We can synthesize the oligomers in a homogeneous reaction scheme wherein all the reactants are mixed at one time (and this scheme is preferred), or in a stepwise reaction. We can mix the diamine and diols, for example, followed by addition of the nitrophthalic anhydride to initiate the polymerization and thereafter addition of the end caps to quench it. Those skilled in the art will recognize the different methods that might be used. To the extent possible, we minimize undesirable competitive reactions by controlling the reaction steps (i.e., addition of reactants) and the reaction conditions.
Although we can use any diol (i.e., bisphenol) previously described, for etherimides, we prefer a diol selected from the those described in U.S. Pat. Nos. 4,584,364; 3,262,914; or 4,611,048 or a polyaryl diol selected from the group consisting of:
HO--Ar--OH;
HO--Ar--.SIGMA.--Ar'--.SIGMA.--Ar--OH;
HO--Ar'--.SIGMA.--Ar--.SIGMA.--Ar'--OH;
wherein
.SIGMA.=--CH.sub.2 --, --(Me).sub.2 C--, --(CF.sub.3).sub.2 C--, --O--, --S--, --SO.sub.2 -- or --CO--;
Ar'= ##STR83## Ar= ##STR84## R.sub.1 =lower alkyl, lower alkoxy, aryl, aryloxy, substituted alkyl, substituted aryl, halogen, or mixtures thereof;
g=0-4;
k.sub.1 =0-3; and
j=0, 1, or 2.
The preferred diols include hydroquinone; bisphenol-A; p,p'-biphenol; 4,4'-dihydroxydiphenylsulfide; 4,4'-dihydroxydiphenylether; 4,4'-dihydroxydiphenylisopropane; or 4,4'-dihydroxydiphenylhexafluoropropane. We prefer to use a single diol rather than mixtures of diols. Actually, for the reactants in any of our syntheses, we prefer to use a pure compound rather than a mixture. We often seek the highest purity available for the selected reactant because we seek to make the highest MWs we can synthesize.
We prefer bisphenol-A as the diol because of cost and availability. The other diols can be used, however, to add rigidity to the oligomer and can increase the solvent resistance. Random or a block copolymers are possible by using mixed diols as the reactant, but we do not prefer them.
In the coreactive oligomer blends (Section 15), we can use these diols as the Z*.sub.k --B--Z*.sub.k oligomers wherein k=1.
Suitable diamines include those diamines described with reference to the imide synthesis or elsewhere in this specification.
In at least one synthesis of the etherimides, a compound of the formula: ##STR85## is an intermediate or reactant (i.e., it is a halogeno end cap). We form this intermediate by reacting the corresponding extended amine end cap with halo- or nitrophthalic anhydrides described in U.S. Pat. Nos. 4,297,474 and 3,847,869, which also are incorporated by reference.
We synthesize multidimensional etherimides by reacting the anhydride hub with compounds of formulae (XII) through (XV), previously described. Those skilled in the art will recognize other mechanisms to make multidimensional etherimide oligomers based on the mechanisms we illustrated for the imides and amideimides.
Our etherimide oligomers can be four functional capped homologs of the ULTEM or KAPTON etherimides that are commercially available.
6. Polysulfoneimides
We can prepare polysulfoneimide oligomers corresponding to the etherimides and analogous to those described and claimed in U.S. patent application Ser. No. 07/241,997 by reacting about m+1 moles of a dianhydride with about m moles of a diamine and about 2 moles of an extended amine end cap. The resulting oligomer has the general formula: ##STR86## wherein R and R' are divalent aromatic organic radicals having from 2-20 carbon atoms. R and R' may include halogenated aromatic C.sub.(6-20) hydrocarbon derivatives; alkylene radicals and cycloalkylene radicals having from 2-20 carbon atoms; C.sub.(2-8) alkylene terminated polydiorganosiloxanes; and radicals of the formula: ##STR87## wherein p=--CO--, --SO.sub.2 --, --O--, --S--; or C.sub.(1-5) alkane, and preferably, --CH.sub.2 -- so that the sulfoneimide remains aromatic. Comparable polymers, usable in blends of the sulfonamides, are described in U.S. Pat. No. 4,107,147, which we incorporate by reference. U.S. Pat. No. 3,933,862 describes other aromatic dithio dianhydrides.
7. Polyamides
We prepare linear or multidimensional polyamides (i.e., arylates or nylons) by condensing dicarboxylic acid halides (i.e., a diacid or a dibasic acid) with diamines in the presence of an acid halide end cap or extended amine end cap. These polyamides are analogous to the polyamide oligomers U.S. Pat. Nos. 4,876,326; 5,109,105; 4,847,333 describe.
We prepare multidimensional amides by condensing a nitro, amine, or acid halide hub with suitable diamines, diacid halides, and the extended amine end cap or the acid halide end cap to form oligomers of the general formulae: ##STR88## wherein P=a residue of a diamine, Q=a residue of a diacid halide, and .differential., .xi. and w were previously defined.
Examples of proposed amide syntheses follow.
EXAMPLE 36
Prepare a multidimensional amide oligomer by reacting: ##STR89## under an inert atmosphere to yield: ##STR90##
EXAMPLE 37
Prepare another multidimensional amide oligomer by reacting: ##STR91## under an inert atmosphere to yield: ##STR92##
EXAMPLE 38
Prepare a multidimensional amide oligomer by reacting: ##STR93## (or simply the acid hub, a diamine, and an acid halide end cap monomer) under an inert atmosphere to yield: ##STR94##
Competitive side reactions between the reactants in Example 38 will likely hinder the yield of this product and will make isolation of the product difficult. We enhance yield by adding the reactants serially, which might impair the physical properties of the resulting oligomers or composites made from the oligomers.
EXAMPLE 39
Use a etheramine hub to make a multidimensional amide oligomer by reacting: ##STR95## under an inert atmosphere to yield: ##STR96##
EXAMPLE 40
Prepare a multidimensional amide using an extended anhydride end cap by reacting: ##STR97## under an inert atmosphere to yield: ##STR98##
EXAMPLE 41
React melamine with an extended anhydride end cap to yield: ##STR99##
EXAMPLE 42
Prepare another multidimensional amide oligomer by reacting about 1 mole of cyuranic acid halide with about 3 moles of phenylenediamine and about 3 moles of the extended anhydride end cap to yield: ##STR100##
We expect better yield of the fully substituted hub by reacting the anhydride with aminobenzoic acid and converting the free carboxylic acid functionality to an amine followed by condensation of rite resulting extended amine with the acid halide hub.
8. Polyesters
We prepare polyesters by condensing the previously described diacid halides and diols. The linear oligomers are four functional analogs of those compounds described in U.S. patent application Ser. No. 07/137,493. We make multidimensional polyesters using phenol or acid hubs (particularly cyuranic acid) with suitable diols and diacid halides. These multidimensional polyester oligomers are analogs of those compounds described in U.S. patent applications Ser. Nos. 07/167,656 and 07/176,518 or in U.S. Pat. Nos. 5,175,233 and 5,210,213. We prefer to use a thallium catalyst when making multidimensional polyesters to ensure complete addition of the hub.
Commercial polyesters, when combined with well-known dilutents, such as styrene, do not exhibit satisfactory thermal and oxidative resistance to be useful for aircraft or aerospace applications. Polyarylesters (i.e., arylates) are often unsatisfactory. These resins often are semicrystalline, making them insoluble in laminating solvents, intractable in fusion, and subject to shrinking or warping during composite fabrication. Those polyarylesters that are soluble in conventional laminating solvents often remain soluble in these same solvents in composite form, thereby limiting their usefulness in aerospace structural composites. The high concentration of ester groups contributes to resin strength and tenacity, but also makes the resin susceptible to rite damaging effects of water absorption. High moisture absorption by commercial polyesters can lead to distortion of the composite when it is loaded at elevated temperature.
We prepare high performance, aerospace, polyester advanced composites, however, using crosslinkable, end capped polyester imide ether sulfone oligomers that have an acceptable combination of solvent resistance, toughness, impact resistance, strength, processability, formability, and thermal resistance. By including Schiff base (--CH.dbd.N--), imidazole, thiazole, or oxazole linkages in the oligomer chain, the linear, advanced composites can have semiconductive or conductive properties when appropriately doped.
Preferred linear polyethers or polyesters have the general formula: ##STR101## wherein .xi.=a crosslinkable end cap to improve the solvent resistance of the cured oligomer in the advanced composite; and
A and B=linear residues of respective diacid halides and diols;
.A-inverted.=ether or ester; and
t=0-27 (i.e., it is the "polymerization factor").
Generally, A and B are linear aromatic moieties having one or more aromatic rings, such as phenylene, biphenylene, naphthylene, or compounds of the general formula:
--.O slashed.--.lambda.--.O slashed.--
wherein .lambda. is any of --CO--; --O--; --S--; --SO.sub.2 --; --(CH.sub.3).sub.2 C--; --(CF.sub.3).sub.2 C--; --CH.dbd.N--; oxazole, imidazole, or thiazole. For most applications, the linking groups will be selected from --SO.sub.2 --, --S--, --O--, --CO--, --(CH.sub.3).sub.2 C--, and --(CF.sub.3).sub.2 C--. The oligomer usually is a polyester imide ether sulfone.
A or B preferably have the general formula:
--.O slashed.--.OMEGA.--.O slashed.--.PSI.--.O slashed.--.OMEGA.--.O slashed.--
wherein
.OMEGA.=--O--, --SO.sub.2 --, or --S--, provided that .OMEGA.=--SO.sub.2 -- only if .PSI.=--SO.sub.2 --;
.PSI.=--CO-- or --SO.sub.2 --; and
.O slashed.=phenylene.
We usually prepare these polyester oligomers by reacting:
2 moles of a crosslinkable end cap acid halide;
n moles of an aromatic diacid halide or of a difunctional chain including a plurality of aryl rings linked with at least one linkage selected from the group consisting of --SO.sub.2 --, --O--, --S--, --CO--, --(CH.sub.3).sub.2 C--, --(CF.sub.3).sub.2 C--, or mixtures thereof throughout the chain, the chain having an acid halide functionality on each end; and
n+1 moles of an aromatic bisphenol (i.e., a diol having terminal --OH functionalities
or by reacting:
2 moles of a crosslinkable phenol end cap;
n+1 moles of an aromatic diacid halide or of a difunctional chain including a plurality of aryl rings linked with at least one linkage selected from the group consisting of --SO.sub.2 --, --O--, --S--, --CO--, --(CH.sub.3).sub.2 C--, --(CF.sub.3).sub.2 C--, or mixtures thereof throughout the chain, the chain having an add halide functionality on each end; and
n moles of an aromatic bisphenol.
We have previously described the suitable diacid and diol reactants.
Because the aromatic polyester resins synthesized in accordance with this invention have appreciable molecular weight between the reactive groups, even in thermoset formulations, the oligomers will retain sufficient plasticity to be processable during fabrication prior to crosslinking of the end caps to thermoset composites. If possible, we synthesize thermoplastic formulations with even higher molecular weights. The polyesters preferably have MWs between about 5000-40,000, and, more preferably, between about 15,1300-25,000.
We make a particularly preferred polyester oligomer of the present invention by condensing a diacid halide with an excess of a diol to form an extended diol having intermediate ester linkages. This extended diol is then reacted with excess 4,4'-dichlorodiphenylsulfone to yield a second intermediate dihalogen. The dihalogen can be condensed with a phenol end cap or the caps can be added in two steps by reacting the dihalogen with (H.sub.2 N).sub.2 --.O slashed.--OH followed by reacting the tetra-amine intermediate (i.e., bis(2,4-diaminophenyl)ether) with an acid halide end cap from our U.S. Pat. No. 5,087,701. We prefer nadic caps. This stepwise reaction is illustrated then, as follows: ##STR102## wherein E= ##STR103## and, particularly, ##STR104##
In this sequential or step-wise synthesis, the caps effectively become: ##STR105## when the acid halide caps condense with the free terminal amines on the extended ether/ester backbone (i.e., Cmpd. 3). Similar stepwise syntheses are available for reaction sequences that can produce terminal acid halides (--COX), phenols (--OH), or halides (--X), as will be understood from this single example. Preferably, steps 2 and 3 are done simultaneously by combining the diol of step 1 with the dihalogen and diaminophenol in a single reaction flask.
Although illustrated in four steps, isolation and transfer between steps is unnecessary until the product forms. An acid acceptor is added incrementally at each step along with the sequential monomer reactant. The product is isolated by precipitation in water with water washing thereafter. The product is a phenoxy phenyl sulfone alternating diester. Preferred diacid halides have D as ##STR106## The preferred diols are those where A is ##STR107##
We can achieve glass transition temperatures of about 950.degree. F. (510.degree. C.), although we can easily tailor the properties of the resulting oligomers within broad ranges.
Preferred multidimensional ether or ester oligomers have a central, aromatic hub and three, radiating, ether or ester chains, as shown in the general formula: ##STR108## wherein .A-inverted.=ether or ester;
w=3 or 4; ##STR109## R=a linear hydrocarbon radical, generally including ether and electronegative ("sulfone") linkages selected from the group consisting of --SO.sub.2 --, --S--, --(CH.sub.3).sub.2 C--, --CO--, and --(CF.sub.3).sub.2 C--, and generally being a radical selected from the group consisting of: ##STR110## n=an integer such that the average molecular weight of --R--T-- is up to about 3000 (and preferably 0 or 1);
q=--CO--, --SO.sub.2 --, --(CF.sub.3).sub.2 C--, --(CH.sub.3).sub.2 C--, or --S--; and
.xi.=is a residue of multiple chemically functional acid halide end cap or phenol end cap monomer;
We prepare multidimensional ether or ester oligomers of this type by reacting substantially stoichiometric amounts of a multi-substituted hub, such as trihydroxybenzene (i.e., phloroglucinol), with chain-extending monomers and crosslinking end cap monomers. Suitable chain-extending monomers include dicarboxylic acid halides, dinitro compounds, diols (i.e., dihydric phenols, bisphenols, or dialcohols), or dihalogens, in the same manner as making linear ethers or esters.
Multidimensional polyol hubs
The hub may be a polyol such as phloroglucinol or those tris(hydroxyphenyl)alkanes described in U.S. Pat. No. 4,709,008 of the general formula: ##STR111## wherein R.sub.15 is hydrogen or methyl and can be the same or different. These polyols are made by reacting, for example, 4-hydroxybenzaldehyde or 4-hydroxyacetophenone with an excess of phenol under acid conditions (as disclosed in U.S. Pat. No. 4,709,008; 3,579,542; and 4,394,469). We generally react the polyols with nitrophthalic anhydride, nitroaniline, nitrobenzoic acid, or a diacid halide to form the actual reactants (i.e., amines or acid halides) that are suitable as heterocycle hubs as will be understood by those of ordinary skill.
We can use the extended acid hub: ##STR112## that we described earlier. This hub is characterized by an intermediate ether and imide linkage connecting aromatic groups. Thio-analogs are also contemplated, in accordance with U.S. Pat. No. 3,933,862. Other acid or polyol hubs are equally suitable.
Generally the ratio of reactants is about 1 mole of the hub to at least 3 moles of end cap to at least 3 moles of polyaryl arms. The arms usually include phenoxyphenyl sulfone, phenoxyphenyl ether, or phenyl sulfone moieties to supply the desired impact resistance and toughness to the resulting advanced composite (through "sulfone" swivels) without loss of the desired thermal stability.
A second synthetic mechanism for making the multidimensional ether oligomers involves the reaction of a halogenated or polynitro aromatic hub with suitable amounts of diols and an extended add halide end cap monomer. Again, the reactants are mixed together and are generally reacted at elevated temperatures under an inert atmosphere. Generally for either mechanism, the reactants are dissolved in a suitable solvent such as benzene, toluene, xylene, DMAC, or mixtures and are refluxed to promote the reaction. We sometimes add TEA to catalyze the reaction.
We also can make suitable oligomers by directly reacting polyol hubs (such as phloroglucinol) or halogenated aromatic hubs directly with end cap groups having the corresponding halide, acid halide, or alcohol (phenol) reactive functionality.
Schiff base diols are prepared by the condensation of aldehydes and amines under the general reaction schemes: ##STR113##
We prepare suitable dinitro compounds by reacting nitrophthalic anhydride (as described in U.S. Pat. Nos. 4,297,474 and 3,847,869) with a diamine. In this case, suitable diamines include those described previously.
We prefer arms in the multidimensional oligomers that are short chains having formula weights below about 1500 per arm, and, preferably, about 500 per arm. Solubility of the oligomers becomes an increasing problem as the length of the backbones (arms) increases. Therefore, we prefer shorter backbones, so long as the resulting oligomers remain processable. That is, the backbones should be long enough to keep the oligomers soluble during the reaction sequence.
We also can make noncrosslinking ether or ester linear or multidimensional polymers for blends by the same synthetic methods as the oligomers with the substitution of a quenching cap for the crosslinking end cap. For example, phenol benzoic acid, or nitrobenzene can be used to quench (and control MW).
The following are examples of proposed ester syntheses.
EXAMPLE 43
Prepare an ester star oligomer by dissolving phloroglucinol dihydrate in a solution of H.sub.2 O and a solvent containing 27% xylene and 73% DMAC. In a Barrett trap under a bubbling N.sub.2 atmosphere, reflux the mixture to strip off the H.sub.2 O and, then, the xylene. After the stripping step, cool the resulting DMAC solution slowly to about 0.degree. C. before adding triethylamine (TEA) (30% excess) while stirring the solution. After 10 min. of stirring, add an acid halide end cap monomer, and rinse the product with DMAC. Continue stirring for 2 hours, before recovering a product by adding a suitable amount of HCl.
EXAMPLE 44
Prepare another ester star oligomer by dissolving phloroglucinol dihydrate in a xylene/DMAC mixture having about 740 g xylene and 2000 g DMAC. Reflux the mixture in a Barrett trap under a N.sub.2 atmosphere to strip H.sub.2 O, which the reaction generates. Upon heating to about 160.degree. C., strip the xylene from the mixture. Cool the DMAC solution to ambient, and add a phenol end cap monomer and TEA. Stir the resulting mixture in an ice bath while adding the acid chloride of bis-(4,4'-carboxyphenoxyphenylsulfone) is slowly. After the addition, continue stirring for 2 hr. The product is soluble in the reaction mixture, but coagulates in H.sub.2 O to a powder. Wash the powder with deionized water to remove residual chloride.
We have found that, when reacting, for example, phloroglucinol with an acid chloride end cap in DMAC and TEA that the resulting product is a mixture of di- and tri- substituted multidimensional ester oligomers. The condensation is difficult to drive to completion (i.e., replacement of all the --OH groups) to yield the desired product. We improve the yield of fully reacted multidimensional ester, however, by replacing the TEA with thallium ethoxide (Tl--OC.sub.2 H.sub.5). While thallium ethoxide is preferred, it is possible that any lower alkoxy or aryloxy substituent on the metal will be active as a catalyst. That is, methoxy, propoxy, isopropoxy, n-butoxy, phenoxy, or the like may also display catalytic activity.
Since the multidimensional polyester oligomers that we synthesize are often used without isolation of products (so we have complex mixtures in the prepreg), we believe that the new product made using a thallium catalyst, richer in the truly multidimensional ester product, will yield better composites than we achieved with the mixture of fully and partially reacted hubs that results when using TEA as a catalyst. In effect, the product is a blend of a linear and a multidimensional oligomer when the reaction is incomplete.
The method of using a thallium catalyst is equally applicable when using an acid halide hub such as cyuranic acid chloride with an extended phenol end cap monomer.
We believe that Tl--OC.sub.2 H.sub.5 will produce a higher yield of the tri-substituted hub. If the hub has more than three reactive hydroxyl or acid halide functionalities, the thallium ethoxide catalyst will promote more complete reaction (or substitution) than TEA.
9. Polyethers
We prepare polyethers or ethersulfones by condensing dinitro compounds or dihalogens and diols or by other conventional ether syntheses using a phenol end cap monomer or a halogeno end cap monomer.
We can use any previously described dihalogen.
We can prepare dinitro compounds by reacting nitrophthalic anhydride with the diamines, as we previously described. Of course, we can prepare dihalogens in the same way by replacing the nitrophthalic anhydride with halophthalic anhydride. We can condense nitroaniline, nitrobenzoic acid, or nitrophenol with dianhydrides, diacid halides, diamines, diols, or dihalogens to prepare other dinitro compounds that include amide, imide, ether, or ester linkages between the terminal phenyl radicals and the precursor backbones. The synthesis of the dinitro compounds or dihalogens can occur prior to mixing the other reactants with these compounds or the steps can be combined in suitable circumstances to directly react all the precursors into the oligomers. For example, we can prepare a polyarylether oligomer by simultaneously condensing a mixture of the phenol end cap, nitrophthalic anhydride, phenylene diamine, and HO--.O slashed.--O--.O slashed.--O--.O slashed.--O--.O slashed.--OH.
We can prepare a multidimensional ether by the simultaneous condensation of phloroglucinol with a dihalogen and a phenol end cap monomer. Those of ordinary skill will recognize the range of possible multidimensional polyether oligomers from this simple example.
We can also synthesize multidimensional oligomers of the formula: ##STR114## with an Ullmann aromatic ether synthesis followed by a Friedel-Crafts reaction, as will be further explained.
Here, R.sub.16 is ##STR115##
q=--SO--, --CO--, --S--, or --(CF.sub.3).sub.2 C--, and preferably --SO.sub.2 --, or --CO--.
To form the oligomers for formula (XIX), preferably a halosubstituted hub is reacted with phenol in DMAC with a base (NaOH) over a Cu Ullmann catalyst to produce art ether "star" with active hydrogens para- to the ether linkages. End caps terminated with acid halide functionalities can react with these active aryl groups in a Friedel-Crafts reaction to yield the desired product. For example, we react 1 mole of trichlorobenzene with about 3 moles of phenol in the Ullmann ether reaction to yield an intermediate of the general formula: .O slashed..brket open-st.O--.O slashed.!.sub.3 which we, then, react with about 3 moles of the extended acid halide end cap to produce the final, crosslinkable, ether/carbonyl oligomer.
Similarly, to form the oligomers of formula (XIX), the hub is extended preferably by reacting a halo-substituted hub with phenol in the Ullmann ether synthesis to yield the ether intermediate of the .O slashed..brket open-st.O--.O slashed.!.sub.3 compounds. This intermediate is mixed with the appropriate stoichiometric amounts of a diacid halide of the formula XOC--R.sub.16 --COX and an end cap of the formula (Z).sub.2 --.O slashed. �formula. (XX)! in the Friedel-Crafts reaction to yield the desired, chain-extended ether/carbonyl star and star-burst oligomers. We prepare end caps of this type by reacting 2 moles of Z--COOH or its acid halide with .O slashed..paren open-st.NH.sub.2).sub.2.
We can use coreactants with the ether or ethersulfone oligomers or coreactive oligomer blends that include these oligomers, including p-phenylenediamine; 4,4'-methylenedianiline; benzidine; lower alkyldiamines; or compounds of the general formula: ##STR116## wherein R.sub.17 =hydrogen, lower alkyl, or aryl; and
R.sub.18 =lower alkyl (having about 2-6 carbon atoms) or aryl.
Coreactants of this same general type are also probably usable with the amideimides or etherimides.
EXAMPLE 45
Prepare an ether star oligomer by charging DMAC, xylene, K.sub.2 CO.sub.3, and a multiple chemically functional phenol end cap to a reaction flask fitted with a stirrer, condenser, thermometer, and N.sub.2 purge. Add phloroglucinol dihydrate and reflux the mixture until all H.sub.2 O in the flask is expelled and no additional H.sub.2 O is generated. After cooling the resulting intermediate mixture, add about 3.0 moles of 4,4'-dichlorodiphenylsulfone and reheat the flask to about 150.degree. C. to strip the xylene from the solution. Continue refluxing for 16 hours at about 150.degree. C. Upon removal of all the xylene, heat the flask to about 160.degree.-164.degree. C. for 2 more hours. After cooling, recover the product by adding H.sub.2 O to induce coagulation while mixing the solution in a Waring blender. Wash the coagulate thoroughly with deionized water until the residual chloride is removed.
10. Polyaryl sulfide oligomers (PPS)
We can also prepare multiple chemically functional oligomers of the present invention for PPS backbones. These four functional oligomers are analogs of the reactive PPS oligomers we described in U.S. patent application Ser. No. 07/639,051.
A brief description of the state of the art for PPS resins is an appropriate introduction.
Edmonds U.S. Pat. No. 3,354,129 describes the preparation of poly(arylene sulfide) polymers by the reaction of an alkali metal sulfide with a polyhalo-substituted aromatic (preferably dihaloaromatic) compound wherein the halogen atoms are attached to ring carbon atoms in a polar organic compound at elevated temperature. A copper compound, such as cuprous and cupric sulfides, or halides, may be present to aid in the formation of the polymer. Molecular weight of the polymer is increased by heat treatment, either in the absence of oxygen or with an oxidizing agent. Molecular weight is increased due to crosslinking, lengthening of the polymer chain, or both.
Campbell U.S. Pat. No. 3,919,177 discloses the preparation of p-phenylene sulfide polymers by reacting p-dihalobenzene, a suitable source of sulfur, an alkali metal carboxylate, and a preferably liquid organic amide. Both of the alkali metal carboxylate and the organic amide components serve as polymerization aids. The alkali metal carboxylate may typically be lithium acetate, lithium propionate, sodium acetate, potassium acetate, or the like. The organic amide may typically be formamide, acetamide, N-methylformamide, or N-methyl-2-pyrrolidone. (NMP). A variety of sulfur sources can be used, including alkali metal sulfides, thiosulfates, thiourea, thioamides, elemental sulfur, carbon disulfide, carbon oxysulfide, thiocarbonates, thiocarbonates, mercaptans, mercaptides, organic sulfides, and phosphorus pentasulfide.
Crouch et al. U.S. Pat. No. 4,038,261 describes a process for the preparation of poly(arylene sulfide)s by contacting p-dihalobenzene, a polyhalo aromatic compound having greater than two halogen substituents, an alkali metal sulfide, lithium carboxylate or LiCl, NMP, and an alkali metal hydroxide. The use of a polyhalo compound results in the formation of a branched chain polymer of reduced melt flow that can be spun into fibers. The alkali metal sulfide can be charged to the reaction in hydrated form or as an aqueous mixture with an alkali metal hydroxide.
Gaughan U.S. Pat. No. 4,716,212 describes the preparation of poly(arylene sulfide ketone)s by reaction of a polyhalobenzophenone such as 4,4'-dichlorobenzophenone and a mixture of sodium hydrosulfide and sodium hydroxide.
Satake et al. U.S. Pat. Nos. 4,895,892 and 4,895,924 both disclose melt stable poly(arylene thioether ketone)s. The '892 patent describes blends of an arylene thioether ketone polymer with a thermoplastic resin such as poly(arylene thioether)s, aromatic polyether ketones, polyamides, polyamideimides, polyesters, polyether sulfones, polyether imides, poly(phenelyene ether)s, polycarbonates, polyacetals, fluoropolymers, polyolefins, polystryrene, polymethyl methacrylate, ABS, and elastomers such as fluororubbers, silicone rubbers, polyisobutylenes, hydrogenated SBR, polyamide elastomers and polyester elastomers. U.S. Pat. No. 4,895,924 patent discloses the preparation of poly(arylene thioetherketone) fibers by melt spinning of polymers and blends of the type disclosed in U.S. Pat. No. 4,895,892.
Blackwell U.S. Pat. No. 4,703,081 describes a ternary polymer alloy comprising a poly(arylene sulfide), a poly(amideimide) and a poly(aryl sulfone). The poly(arylene sulfide) is prepared, for example, by reaction of p-dichlorobenzene and sodium sulfide in NMP. Various other di- and tri- halo aromatics are mentioned as monomers for use in the preparation of the poly(arylene sulfide)s.
Johnson et at. U.S. Pat. No. 4,690,972 describes the preparation of poly(arylene sulfide) compositions by incorporating additives which affect the crystalline morphology, followed by heating and cooling steps. Among the preferred arylene sulfides are poly(phenylene sulfide) and poly(phenylene sulfide ketone). The additive is preferably a poly(arylene ether ketone) such as 1,4-oxyphenoxy-p,p'-benzophenone.
Leland et al. U.S. Pat. No. 4,680,326 describes poly(arylene sulfide) compositions having a combination of good cracking resistance and electrical insulation resistance. The compositions include a reinforcing material, polyethylene, and an organosilane.
Skinner U.S. Pat. No. 4,806,407 describes blends of p-phenylene sulfide polymers and melt extrudable polymers such as non-halogenated polymers and copolymers of olefins, halogenated homopolymers (polyvinylidene fluoride, polyvinyl chloride, polychlorotrifluoroethylene, and the like), ethylene/acrylic copolymers (e.g., "Surlyn"), and both aromatic and aliphatic polyamides.
We incorporate these PPS patents by reference.
The present invention provides oligomers useful in the preparation of poly(arylene sulfide) �PPS! polymers having favorable thermomechanical and thermo-oxidative properties, having other advantageous performance properties, and having favorable processing characteristics in the preparation of such composites. The composites have high solvent resistance, moisture resistance, toughness, and impact resistance.
We react (n) equivalents of a dihaloaromatic compound, (n+1) equivalents of a sulfur compound that is reactive with the dihaloaromatic compounds to form thioethers, and 2 equivalents of the halogeno (i.e., halide) end cap monomer to obtain an oligomer corresponding to the formula: ##STR117## where: Ar and Ar.sub.1 are arylene;
.mu. is an integer such that the oligomer has about molecular weight of between about 500 and about 40,000;
.xi. is a residue of a halogeno end cap monomer, and the other variables are as previously defined.
We prepare composites from the oligomers in the form of films, coatings, moldings, fibers, and other structures useful in engineering applications. We expect that PPS composites produced from these oligomers will exhibit exceptional toughness and impact resistance for PPS.
When used for preparation of various forms of polymer products, the oligomers of the invention exhibit especially favorable processing characteristics. Their melt and plastic flow properties are especially advantageous for the preparation of moldings and composites without the necessity of solvents. Because the oligomers crosslink by an addition of "step growth" mechanism, curing of moldings or composites can be conducted without significant outgassing of solvents or condensation products, thereby yielding polymer products of exceptional structural and dimensional integrity. Adhesives comprising the oligomers of the invention, and the polymeric products obtained by curing thereof, we can prepare without outgassing of either reaction products or solvents.
The oligomers are crosslinkable by addition or step growth reaction of the unsaturated moieties of the end caps analogous to the PPS oligomers of 07/639,051. In this respect they differ from the polymers of U.S. Pat. No. 3,354,129, which are crosslinked through functional groups provided in the linear backbone, and from the polymers of U.S. Pat. No. 4,038,261, in which linear chains are branched and crosslinked by incorporation of a minor proportion of trihaloaromatic compound in a polymerization mixture comprising p-dihalobenzene and sulfur compound.
We can prepare oligomers of the present invention in both linear and multidimensional form. We prepare the linear oligomers by reacting n equivalents of a dihaloaromatic compound (i.e., a dihalogen), n+1 equivalents of a sulfur compound that is reactive with the dihalo-aromatic compounds to form thioethers, and 2 equivalents of halogeno end cap monomer. Crosslinking of the oligomer may subsequently take place under curing conditions. The multidimensional oligomers, of course, use an appropriate hub.
Generally, the sulfur compound used in the preparation of the oligomer is characterized by its reactivity with halo organic compounds to produce thioethers. Preferably, the sulfur compound comprises an alkali metal sulfide, an alkali metal sulfohydride, or an alkali metal bisulfide. Among the various other sulfur compounds which may optionally be used in the reaction are alkali metal thiosulfates, thioamides, elemental sulfur, carbon disulfide, carbon oxysulfide, thiocarbonates, thiocarbonates, mercaptans, mercaptides, organic sulfides and phosphorus pentasulfide. If the sulfur compound used is other than an alkali metal sulfide or bisulfide, we include a base in the reaction charge. If the sulfur compound is an alkali metal bisulfide, the use of a base is not strictly necessary, but we prefer to include it. If the sulfur compound is an alkali metal sulfide, a base is unnecessary.
For the PPS synthesis, preferred dihalogens include:
1,2-dichlorobenzene
1,3-dichlorobenzene
1,4-dichlorobenzene
2,5-dichlorotoluene
1,4-dibromobenzene
1,4-diodobenzene
1,4-difluorobenzene
2,5-dibromoaniline
1,4-di-n-butyl-2,5-dichlorobenzene
1,4-di-n-nonyl-2,6-dibromobenzene
2,5-dichlorobenzamide
1-acetamido-2,4-dibromoanphthalene
4,4'-dichlorobiphenyl
p-chlorobromobenzene
p,p'-dichlorodiphenylether
o,p'-dibromodiphenylamine
4,4'-dichlorobenzophenone and
4,4'-dichlorodiphenylsulfone.
We could use any dihalogen we described earlier.
Preparation of the oligomer is preferably carried out in the presence of a polymerization aid such as a liquid organic amide, a carboxylic acid salt, or both. In the preparation of conventional poly(arylene sulfide) polymers, such aids are effective in increasing the average MW of the polymerization product. In the process of the invention, such polymerization aids are effective in controlling and limiting the molecular weight distribution within a narrow range of variability.
Conditions for carrying out the reaction to form the oligomer are essentially the same as those described in U.S. Pat. Nos. 3,354,129 and 3,919,177. The reaction may be carried out, for example, by contacting the dihalogen, the sulfur compound, and the end cap monomer in a polar solvent at a temperature of from about 125.degree. to about 450.degree. C., preferably from about 175.degree. to about 350.degree. C. The amount of polar solvent may vary over a wide range, typically from about 100 to about 2500 ml per mole of the sulfur compound.
Alkali metal carboxylates that may be employed in the reaction generally correspond to the formula:
R.sub.20 COO(M.sub.3)
where R.sub.20 is a hydrocarbyl radical selected from alkyl, cycloalkyl, and aryl and combinations thereof such as alkylaryl, alkylcycloalkyl, cydoalkylalkyl, arylalkyl, arylcycloalkyl, alkylarylakyl and alkylcycloalkylalkyl, the hydrocarbyl radical having 1 to about 20 carbon atoms, and M.sub.3 is an alkali metal selected from the group consisting of lithium, sodium, potassium, rubidium and cesium. Preferably, R.sub.20 is an alkyl radical having 1 to about 6 carbon atoms or a phenylene radical. Most preferably, it is phenylene. M.sub.3 is lithium or sodium, n-lost preferably lithium. If desired, employ the alkali metal carboxylate as a hydrate or-as a solution or dispersion in water.
Examples of some alkali metal carboxylates that we might use in the process include lithium acetate, sodium acetate, potassium acetate, lithium propionate, sodium propionate, lithium 2-methylpropionate, rubidium butyrate, lithium valerate, sodium valerate, cesium hexanoate, lithium heptanoate, lithium 2-methyloctanoate, potassium dodecanoate, rubidium 4-ethyltetradecanoate, sodium octadecanoate, lithium cyclohexanecarboxylate, cesium cyclododecanecarboxylate, sodium 3-methlcyclopentanecarboxylate, potassium cyclohexylacetate, potassium benzoate, lithium benzoate, sodium benzoate, potassium m-toluate, lithium phenylacetate, sodium 4-phenylcyclohexanecarboxylate, potassium p-tolylacetate, lithium 4-ethylcyclohexylacetate, and the like, or fixtures thereof.
The organic amides used in the method of this invention should be substantially liquid at the reaction temperatures and pressures. Examples of some suitable amides are N,N-dimethylformamide, N,N-dipropylbutyramide, N-methyl-.xi.-caprolactam, hexamethyl-phosphoramide, tetramethylurea, and the like, or mixtures thereof.
When we use alkali metal carboxylates and organic amides for control of the oligomer formation reaction, we carry out the reaction at about 235.degree. C. and about 450.degree. C., preferably about 240.degree. C. to about 350.degree. C. When the alkali metal carboxylate is a sodium, potassium, rubidium, or cesium salt of an aromatic carboxylic acid, i.e., an acid in which the carboxyl group is attached directly to an aromatic nucleus, the temperature should be within the range of from about 255.degree. C. to about 450.degree. C., preferably from about 260.degree. C. to about 350.degree. C. The reaction time is within the range of from about 10 minutes to about 3 days and preferably about 1 hour to about 8 hours. Preferably, we use about 0-5 to about 2 moles metal carboxylate compound per mole of the dihaloaromatic compound. When we use NMP as the organic amide component of the reactor charge, we use it in substantially equal molar proportion with the dihalogen compound.
We use the PPS oligomers in melt or solution form for the preparation of films, moldings, and composites. Curing at a temperature in the range of between about 480.degree. and about 640.degree. F. (250.degree. to 340.degree. C.) causes step growth reaction between the unsaturated moieties of the end groups, resulting in the formation of high molecular weight polymers having superior thermal and mechanical properties and solvent resistance. We initiate the curing reaction either thermally or chemically. Where the oligomer has a relatively high molecular weight, for example, greater than 10,000 preferably about 15,000 to 25,000, the polymer produced on curing is thermoformable. Where the molecular weight is below 10,000, especially in the range of between about 1000 and about 6000, the cured resin is likely a thermoset material, which we seek to avoid.
We prepare multidimensional PPS oligomers by reacting w(n) equivalents of a dihalogen, w(n+1) equivalents of a sulfur compound that is reactive with dihalogen to form thioethers, one equivalent of a polyhalo hub having w halogen substituents, and w equivalents of a halogeno end cap monomer.
In the preparation of either linear or multidimensional PPS oligomers, it is generally preferred that the dihalogen comprises a dihalobenzene such as, for example, p-dichlorobenzene or m-dichlorobenzene, and the sulfur compound be an alkali metal sulfide such as sodium sulfide, which can be prepared in situ by reaction of an alkali metal hydrosulfide and a base. An advantageous method for the preparation of arylene sulfide oligomers front an alkali metal hydrosulfide is described in U.S. Pat. No. 4,716,212.
We can make blends suitable for composites, for example, by mixing a PPS oligomer of the invention with a macromolecular or oligomeric polymer that is essentially incapable of crosslinking with the crosslinkable oligomer. Such blends merge the desired properties of crosslinking oligomers and non-crosslinking polymers to provide tough, yet processable, resin blends. We can use a variety of macromolecular or oligomeric polymers, most typically a poly(arylene sulfide) prepared by reaction of a dihalogen with a sulfur compound of the type used in the preparation of the oligomer, the reaction being quenched with a suitable non-crosslinking terminal group. Generally, we would prepare such poly(arylene sulfide)s by the methods described in U.S. Pat. Nos. 3,354,129, 3,919,177, and 4,038,261. Most preferably, we would prepare the non-crosslinking polymer and crosslinkable oligomer from the same dihaloaromatic and sulfone compound, thus enhancing compatibility between oligomer and polymer. The quenching agent is typically a monohaloaromatic compound such as chlorobenzene.
The blends also encompass the advanced composites blends of poly(arylene sulfide) oligomers blended with poly(amide imide)s and poly(aryl sulfone)s analogous to the blends described in U.S. Pat. No. 4,703,081. Blends may also comprise the various polymers used in the blends described in U.S. Pat. No. 4,595,892.
The melt flow characteristics of PPS oligomers are such that PPS may be used in melt rather than solution form in various applications, including the preparation of composites. In this regard, PPS is similar to the heterocycle liquid crystals.
For maximum mechanical properties of coatings or composites prepared front PPS oligomers or blends, we prefer that the halogeno substituents of the dihalogen have a predominantly p-orientation. For processability, however, the most favorable results are generally provided by use of the m-isomer, so processing and final properties compete, forcing a trade when designing the formulation. The m-isomer may also be preferable for adhesives. In certain instances, it may be advantageous to provide a blend of m- and p-isomers having a mix of properties tailored to the particular application of the cured oligomer.
The end cap monomer can be ##STR118## (i.e., a pyrimidine cap) when making these PPS oligomers or their related polyethers.
The following examples illustrate the invention with respect to PPS oligomers.
EXAMPLE 46
Place hydrated Na.sub.2 S in N-methylpyrrolidone (NMP) in a glass reaction flask and heat to 160.degree. C. while the flask is flushed with nitrogen for a time sufficient to dehydrate the Na.sub.2 S. Add p-dichlorobenzene (88.2g) and a halogeno end cap monomer to the dehydrated solution, and the resulting mixture is sealed in a glass tube. The mixture contained in the tube is heated at 230.degree. C. for 45 hours, then at 225.degree. C. for 20 hours, and then at 260.degree. C. for 24 hours. A product precipitating from the reaction mixture comprises a four functional PPS oligomer.
EXAMPLE 47
Prepare a multidimensional PPS oligomer by reaction of Na.sub.2 S, p-dichlorobenzene, 1,3,5-trichlorobenzene, and a halogeno end cap monomer. The preparation procedure is substantially as described in Example 51, except that the trichlorobenzene is added together with the p-dichlorobenzene and the end cap.
11. Carbonates
We prepare multiple chemically functional carbonate oligomers by reacting a diol (sometimes also referred to as a dihydric phenol), a carbonyl halide, and a phenol end cap in a manner similar to the reaction described in U.S. Pat. No. 4,814,421, which is incorporated by reference. While we can use any diol, we prefer diols having the formula:
HO--.O slashed.--A--.O slashed.--OH
wherein A is
(i) a divalent hydrocarbon radical containing 1-15 carbons,
(ii) a halogen substituted divalent hydrocarbon radical containing 1-15 carbons, or
(iii) divalent groups such as --S--, --SS--, --SO.sub.2 --, --SO--, --O--, or --CO--.
We prefer the aromatic diols, especially the diol: HO--.O slashed.--SO.sub.2 --.O slashed.--OH.
The carbonyl halide is a carbonate precursor and commonly is phosgene, but the reaction can also use a diarylcarbonate or a bishaloformate of a dihydric phenol or of a glycol.
The reaction proceeds by interfacial polymerization as described in U.S. Pat. Nos. 3,028,365; 3,334,154; 3,275,601; 3,915,926; 3,030,331; 3,169,121; 3,027,814; and 4,188,334, which are incorporated by reference. Generally rite phenol reactants are dissolved or dispersed in aqueous caustic, adding the mixture to a water immiscible solvent, and contacting the reactants thereafter with rite carbonate precursor in the presence of a catalyst and under controlled pH conditions.
The catalyst is usually a tertiary amine (like TEA), quaternary phosphonium compounds, or quarternary ammonium compounds.
The water immiscible solvents include methylene chloride, 1,1-dichloroethane, chlorobenzene, toluene, or the like.
The reaction can also be used to make mono- and difunctional polycarbonate oligomers by substituting an imidophenol end cap monomer from our U.S. Pat. Nos. 4,980,481; 4,661,604; 4,739,030; and 5,227,461 for the four functional phenol end cap monomer. The difunctional imidophenol end cap monomers have the general formula: ##STR119## where E is an unsaturated hydrocarbon as previously defined.
We can prepare arylate/carbonate copolymers by the reaction of phosgene with diacid halides in the solvent: phase with a diol like bisphenol-A in the solute phase using 3,5-di(nadicylimino)benzoyl chloride or the extended acid halide end cap monomer, and can prepare multidimensional carbonates using a suitable polyhydric hub like phloroglucinol. Multidimensional arylate/carbonates, of course, can use an acid or acid halide hub, like cyuranic acid. Those skilled in the art will recognize the mechanisms which are analogous to those for our other linear and multidimensional oligomers.
Step wise condensation similar to the four-step process described for the esters will also lead to carbonates. Here, a long-chain four factional amine having intermediate, characteristic carbonate linkages is formed by condensing the diol with a carbonyl halide and ##STR120## followed by reaction of the four terminal amines (i.e., two at each end of the chain in the carbonate compound): ##STR121## With an acid halide end cap monomer (see, e.g., U.S. Pat. No. 5,087,701) to yield the Z links of the characteristic four functional end caps.
12. Polyesteramides
The linear oligomers are characterized by having a pair of alternating ester linkages (e.g., ##STR122## followed by a pair of alternating amide linkages (e.g., ##STR123## as generally illustrated for polymeric homologs in U.S. Pat. No. 4,709,004 or by having sequential amide/ester linkages. The preferred esteramides are prepared by condensing an amino/phenol compound (like aminophenol; preferably, 4-�2-p-hydroxyphenyl)isopropyl!-4'-amino diphenyl ether) or other amino/phenols described in U.S. Pat. No. 4,709,004 with a diacid halide, especially terephthaloyl chloride, and four functional add halide end cap monomer following generally the process of Imai et al. in J. Polymer Sci., 1981, 19, pp. 3285-91 which is discussed in U.S. Pat. No. 4,709,004 (both of which are incorporated by reference). We alter the Imai process by using the end cap monomer to quench the reaction and to provide an oligomeric product. In the preferred synthesis, the oligomer is likely to include a mixture of the following recurring units: ##STR124## as the diacid halide reacts in a head-to-tail sequence or head/head - tail/tail sequence.
Multidimensional esteramides condense a polybasic acid, polyol, or polyamine hub with a suitable end cap monomer or with arm extenders, like the amino/phenol compounds, amino/add compounds, diacid halides, and diamines, as appropriate and as previously described for the other resin systems.
13. Cyanates and Cyanate Esters
We can also apply the technique of multiple chemically functional oligomer to the cyanate resin system. Typical resins in the cyanate family are described in U.S. Pat. No. 5,134,421, which we incorporate by reference. Cyanate resins are characterized by the reactive functionality --OCN, but we use the term to include the thio cyanate cousins --SCN as well. Cyanate resins are prepared by reacting diols or polyols (in the case of multidimensional morphology) with a cyanogen halide, especially cyanogen chloride or bromide. The synthesis is well known and is described in U.S. Pat. Nos. 3,448,079; 3,553,244; and 3,740,348, for example; each of which is also incorporated by reference. The cyanate functionality self-polymerizes to form cyanate esters either with or without a suitable catalyst (such as tin octoate).
Therefore, to prepare linear cyanate oligomers of the present invention, diols are converted to dycanate (i.e., N.tbd.C--O--R.sub.4 --O--C.tbd.N where R.sub.4 is the residue of an organic diol) in the presence of cyanogen halide and the phenol end cap monomers of formula (II) are also connected to the corresponding cyanate using the same reaction. Then, the chain terminating cyanate end cap is mixed with the cyanate to control the self-polymerization which yields a cyanate ester having four crosslinking sites at each end. The multidimensional synthesis is analogous but involves a polyol hub converted to the cyanate, mixed with the dicyanate and cyanate end cap monomer, and polymerized.
Suitable catalysts for the cyanate resin systems of the subject invention are well known to those skilled in the art, and include the various transition metal carboxylates and naphthenates, for example zinc octoate, tin octoate, dibutyltindilaurate, cobalt naphthenate, and the like; tertiary amines such as benzyldimethylamine and N-methylmorpholine; imidazoles such as 2-methylimidazole; acetylacetonates such as iron (III) acetylacetonate; organic peroxides such as dicumylperoxide and benzoylperoxide; free radical generators such as azobisisobutyronitrile; organophosphines and organophosphonium salts such as hexyldiphenylphosphine, triphenylphosphine, trioctylphosphine, ethyltriphenylphosphonium iodide and ethyltriphenylphosphonium bromide; and metal complexes such as copper bis�8-hydroxyquinolate!. Combinations of these and other catalysts may also be used.
Any diol we previously described can be converted to the cyanate analog and used in this synthesis. For high MWs, however, we prefer to use a soluble dicyanate, especially:
NCO--.O slashed.--O--.O slashed.--SO.sub.2 --.O slashed.--O--.O slashed.--OCN
Similarly, any polyol hub we previously described can be converted to the corresponding polycyanate analog to serve as the hub (a) in the synthesis of multidimensional cyanate ester oligomers.
The thiocyanates exhibit essentially the same chemistry.
14. Advanced Composite Blends
Advanced composite blends comprise at least one crosslinking oligomer and at least one polymer wherein the backbones of the oligomer(s) and polymer(s) are front different chemical families. Such blends present promise for tailoring the mechanical properties of composites while retaining ease of processing. At their simplest, the composites are mixed chemical blends of a linear or multidimensional crosslinking oligomer of one chemical family, such as a imide, and a linear or multidimensional polymer, unable to crosslink, from a different chemical family, such as ethersulfone. Generally the polymer has a MW that is initially higher than that of the oligomer, but the formula weight of the oligomeric portion of the blend will increase appreciably during curing through addition (i.e. homo-) polymerization between the crosslinking functionalities. The ratio of oligomer(s) to polymer(s) can be varied to achieve the desired combination of physical properties. Usually the ratio is such that the addition polymer (i.e., composite) formed during curing of the oligomer constitutes no more than about 50 mol % of the total.
While two component blends are preferred, the blends can be more complex mixtures of oligomers or polymers with or without coreactants. The blends may even include coreactive oligomers as will be explained (i.e., diamines, diols, or ##STR125## resins). We can also form blends of these multiple chemically functional oligomers with corresponding monofunctional or difunctional oligomers from our earlier patents and patent applications.
The oligomer is preferably selected from imidesulfone; ethersulfone; cyanate ester; carbonate; amide; esteramide; imide; ether; ester; estersulfone; etherimide; or amideimide. That is, any of the oligomers we have described.
In advanced composite blends oligomers or coreactive oligomer blends are further blended with a noncrosslinking polymer having a backbone from a different chemical family. The polymer can be from any one of the families described for the oligomers, but the oligomeric and polymeric backbones must be different to form what we elect to call an advanced composite (i.e. mixed chemical) blend. The resulting blend may yield IPN or semi-IPN morphology in the consolidated resin (composite) state.
Preferably the polymer's MW initially is greater than that of the oligomer, because the MW of the oligomer in the cured composite will increase through addition polymerization. The cured composite from an advanced composite blend will have a blend of two, "long" molecules, and will not suffer from a broad distribution of MWs or a mismatch of MW that reduces the physical properties obtainable in some prior art blends, such as those Kwiatkowski suggested in U.S. Pat. No. 3,658,939.
Preferred oligomer/polymer combinations in the advanced composite blends of this invention include: amideimide/imide; imide/amide; ester/amide; ester/imide; and ester/esteramide.
Advanced composite blends allow tailoring of the properties of high performance composites. They allow averaging of the properties of resins from different families to provide composites that do not have as severe shortcomings as the pure compounds. The resulting composites have a blending or averaging of physical properties, which makes them candidates for particularly harsh conditions.
Although the concept of advanced composite blends is probably best suited to linear morphology, the advanced composite blends of the present invention also include multidimensional oligomers and polymers. We prefer linear morphology because the resulting composites have mixtures of polymers of relatively large and roughly equivalent MW. The individual polymers are similar in structure. We have found it difficult in many circumstances to process multidimensional oligomers that have appreciable MW, so the properties of composites made from multidimensional advanced composite blends might suffer because of diversity of MW. Furthermore, the addition polymerization reaction for multidimensional oligomers results in formation of a complex, 3-dimensional network of crosslinked oligomers that is difficult or impossible to match with the multidimensional polymers, because these polymers simply have extended chains or short chains. That is, upon curing, the multidimensional oligomers crosslink to chemically interconnect the arms or chains through the end caps, thereby forming a network of interconnected hubs with intermediate connecting chains. The connecting chains have moderate MW, although the oligomer can add appreciable MW upon curing. In contrast, the polymer (which does not crosslink) simply has a hub with arms of moderate MW. While, for linear morphology, the disadvantages of blended composites that have a wide diversity of average MW polymers as constituents can be overcome by curing relatively low MW oligomers into relatively high MW cured polymers that are roughly equivalent to the polymer constituents, the polymers in the multidimensional morphology are likely to have average MW lower than the oligomeric component. Therefore, we believe we can achieve the best results for the present invention with systems having linear morphology where it is easier to achieve MW harmony in the composite.
Although we have yet to verify our theory experimentally, it may be possible and desirable to synthesize the polymeric component of the multidimensional advanced composite blend when curing the oligomer, and, in that way, forming relatively comparable oligomeric and polymeric networks. To achieve this effect, we would mix, for example, a multidimensional oligomer with comparable polymeric precursors, suck as triamines and tricarboxylic acid halides. Upon curing, the precursors would condense to form amide linkages to form bridges between hubs in a manner comparable to the oligomeric connecting chains.
The potential problem of structural mismatch and the proposed solution for achieving comparable MW in multidimensional advanced composite blends likely also applies to coreactive oligomer blends to some degree so that homopolymerization and addition polymerization compounds remain comparable.
To overcome the problem of different MW between the oligomer and polymer in the composite, we theorize that it may be possible to prepare a blend that includes the oligomer and polymeric precursors. For example, we can mix a polyether oligomer of the general formula: ##STR126## wherein .xi. is the residue of a four functional end cap monomer with polyamide polymeric precursors of the general formula: ##STR127## so that, upon curing, the oligomer crosslinks and the polymeric precursors condense through the amine and acid to form a polyamide polymer. This approach may be best suited for the lower curing oligomers. The product may include addition polymers and block copolymers of the oligomer and one or both of the polymeric precursors. A Michaels addition might occur between the oligomer and amine multidimensional polymer, which would be undesirable.
The oligomers may be formed by the attachment of arms to the hub followed by chain extension and chain termination. For example, phloroglucinol may be mixed with p-aminophenol and 4,4'-dibromodiphenylsulfone and reacted under an inert atmosphere at an elevated temperature to achieve an amino-terminated "star" of the general formula: ##STR128## that can be reacted with suitable diacid halides, dianhydrides, and end caps to yield an amide, amideimide, imide, or other oligomer. By substituting 2,4-diaminophenol for aminophenol, an ethersulfone compound of the formula: ##STR129## can be prepared. When reacted with an acid halide end cap monomer to produce Z end groups the product is a multiple chemically functional ether sulfone multidimensional oligomer. Extended amides, imides, etc. could also be prepared resulting in multidimensional oligomers with a high density of crosslinking functionalities.
As we have discussed, the oligomers can be synthesized in a homogeneous reaction scheme wherein all the reactants are mixed at one time, or in a stepwise reaction scheme wherein (1) the radiating chains are affixed to the hub and the product of the first reaction is subsequently reacted with the end cap groups or (2) extended end cap compounds are formed and condensed with the hub. Homogeneous reaction is preferred, resulting undoubtedly in a mixture of oligomers because of the complexity of the reactions. The products Of the processes (even without distillation or isolation of individual species) are preferred oligomer mixtures which can be used without further separation to form the desired advanced composites.
We can synthesize linear or multidimensional oligomers from a mixture of four or more reactants thereby forming extended chains. Adding components to the reaction liquor, however, adds complexity to the reaction and to its control. Undesirable competitive reactions may result or complex mixtures of macromolecules having widely different properties may form, because the mixed chain extenders and chain terminators compete with one another.
The hub may also be a polyol such as those described in U.S. Pat. No. 4,709,008. These polyols are made by reacting; for example, 4-hydroxybenzaldehyde or 4-hydroxyacetophenone with an excess of phenol under acid conditions (as disclosed in U.S. Pat. Nos. 4,709,008; 3,579,542; and 4,394,469). The polyols may also be reacted with nitrophthalic anhydride, nitroaniline, nitrophenol, or nitrobenzoic acid to form other compounds suitable as hubs as will be understood by those of ordinary skill.
In synthesizing the polymers, we use quenching compounds to regulate the polymerization (i.e., MW) of the comparable polymer, so that, especially for linear systems, the polymer has a MW initially substantially greater than the crosslinkable oligomer. For thermal stability, we prefer an aromatic quenching compound, such as aniline, phenol, or benzoic acid chloride. We generally make the noncrosslinking polymer by the same synthetic method as the oligomer with the substitution of a quenching cap for the crosslinking end cap. Of course, we may adjust the relative proportion of the reactants to maximize the MW.
While the best advanced composite blends are probably those where the individual oligomers and polymers in the blend are of modest MW and those in which the oligomer and polymer are initially in equimolar proportions, we can prepare other compositions, as will be recognized by those of ordinary skill in the art. Solvent resistance of the cured composite may decrease markedly if the polymer is provided in large excess to the oligomer in the blend.
The advanced composite blends may include multiple oligomers or multiple polymers, such as a mixture of an amideimide oligomer, an amide oligomer, and an imide polymer or a mixture of an amideimide oligomer, an amideimide polymer, and an imide polymer (i.e..blended amideimide further blended with imide). When we use polyimide oligomers, the advanced composite blend can include a coreactant, such as p-phenylenediamine, benzidine, or 4,4'-methylenedianiline. Ethersulfone oligomers can include these imide coreactants or anhydride or anhydride-derivative coreactants, as described in U.S. Pat. No. 4,414,269. We can use other combinations of oligomers, polymers, and coreactants, as will be recognized by those of ordinary skill in the art.
As discussed above, the oligomeric component of the advanced composite blend may itself be a blend of the oligomer and a compatible polymer from the same chemical family, further blended with the compatible polymer from the different family. The advanced composite blends generally include only one oligomeric component unless coreactive oligomers are used.
Advanced composite blends are illustrated as follows.
EXAMPLE 48 ##STR130##
The polyamideimide oligomer of Example 10 is dissolved in a suitable solvent. Make a relative high average formula weight polyether polymer condensing the diol:
HO--.O slashed.--O--.O slashed.--O--.O slashed.--O--.O slashed.--OH
with Cl--.O slashed.--Cl and phenol (to quench the polymerization) under an inert atmosphere in the same solvent as used with the polyamideimide oligomer or another miscible solvent.
Mix the two solutions to form a lacquer of the advanced composite blend. Prepreg or dry the lacquer prior to curing to an advanced amideimide/ether composite.
EXAMPLE 49 ##STR131##
Prepare a multidimensional, polyether sulfone polymer by reacting phloroglucinol with Cl--.O slashed.--Cl and HO--.O slashed.--O--.O slashed.--SO.sub.2 --.O slashed.--O--.O slashed.--OH, quenching the polymerization with either .O slashed.--Cl or phenol to yield a polymeric product. The condensation occurs in a suitable solvent under an inert atmosphere. Do not recover the product from the solvent.
Prepare a multidimensional, polyester oligomer in the same solvent as used for the polymer or in another miscible solvent by condensing cyuranic acid chloride with a phenol end cap. Do not recover the product, but mix the oligomeric reaction mixture with the polymer product to form a varnish of a multidimensional advanced composite blend. Prepregg or dry the varnish prior to curing to form a multidimensional, polyester/polyethersulfone, advanced composite.
15. Coreactive oligomer blends
Block copolymers are promising for tailoring the mechanical properties of composites while retaining ease of processing. The present invention also comprises blends of two or more coreactive oligomers analogous to those blends described in U.S. Pat. No. 5,159,055. The oligomers are terminated with mutually interreacting caps that allow formation of the block copolymer(s) upon curing. We can increase stiffness in this way in an otherwise flexible oligomer, although the four crosslinks themselves increase stiffness. For example, we can achieve stiffening for a composite made from an ethersulfone oligomer by adding an imide oligomer as a coreactant. Those skilled in the art will recognize the benefits to be gained through coreactive oligomer blends. Generally, at least one of the oligomers in the coreactive oligomer blend will include four crosslinking functionalities at each end of the backbone.
We generally prepare block copolymers formed from the coreactive oligomer blends by blending an oligomer of the general formula:
.xi.--R.sub.4 --.xi.
wherein
R.sub.4 =a divalent hydrocarbon radical, as we have described; and
.xi.=a four functional hydrocarbon residue of an end cap monomer used to form the oligomer
with a coreactive oligomer of the general formula:
Z*.sub.k --B--Z*.sub.k
wherein
k=1, 2, or 4;
B=a hydrocarbon backbone treat is from file same or a different chemical family as R.sub.4 ;
Z*=a hydrocarbon residue including a segment selected from the group consisting of: ##STR132## .rho.=--O-- or --S--; and --.O slashed.--=is phenylene.
Preferably we select the oligomeric backbones from the group consisting of imidesulfones, ethersulfones, carbonates, esteramides, amides, ethers, esters, estersulfones, imides, etherimides, amideimides, cyanate esters, and, more preferably, the ethers, esters, sulfones, or imides. Generally, the hydrocarbons are entirely aromatic with phenylene radicals between the linkages that characterize the backbones. The oligomers can be linear or multidimensional in their morphology. The components of these coreactive blends should have overlapping melt and curing ranges so that the crosslinking functionalities are activated at substantially the same time, so that flow of the blend occurs simultaneously, and so that, for heterocycles, the chain-extension occurs in the melt where the products are soluble. Matching the melt and curing ranges requires a selection of the chemistries for the coreactive blend components, but achieving the match is readily within the skill of the ordinary artisan.
The coreactive oligomer blends can comprise essentially any ratio of the coreactive oligomers. Changing the ratio of ingredients, of course, changes the physical properties in the final composites. Curing the coreactive oligomers involves mutual (interlinking) polymerization and addition polymerization. Therefore, we generally use equimolar mixtures of the ingredients (i.e., the .xi. and Z* components) in the blends.
The individual oligomers should initially have relatively low MW (preferably no more than and, generally, around 10,000) and, accordingly, should remain relatively easy to process until the curing reaction when extended chain and block copolymers form to produce the composite. A complex mixture of at least three types of addition polymer form upon curling.
The coreactive oligomer blends can also include noncrosslinking polymers, as desired, to provide the desired properties in the composites. That is, the coreactive blend may include the two crosslinking oligomers and a noncrosslinking compatible polymer, thereby forming a blend with three or more resin components.
We can prepare oligomers of the general formula .xi.--R.sub.4 --.xi. or Z*.sub.k --B--Z*.sub.k by reacting suitable end cap monomers with the monomer reactants that are commonly used to form the desired backbones. For example, we prepare an imidesulfone as we have already described by reacting a sulfone diamine with a dianhydride. We prepare ethersulfones by reacting a suitable dialcohol (i.e. diol, bisphenol, or dihydric phenol) with a dihalogen as described in U.S. Pat. No. 4,414,269. Similarly, the end cap monomers for the Z*.sub.k --B--Z*.sub.k oligomers generally are selected from the group consisting of aminephenol, aminobenzoic acid halide, H.sub.2 N--.O slashed.--SH, .O slashed.--W, or the like, wherein W=--OH, --NH.sub.2, or --COX. The Z*.sub.k --B--Z*.sub.k oligomers include any diamines; diols, or disulfhydryls we have previously described. In this circumstance, k=1.
Upon curing, the oligomers homopolymerize (i.e. addition polymerize) by crosslinking and form block copolymers through the Michaels addition reaction between the hydrocarbon unsaturation of one oligomer and the amine, hydroxyl, or sulfhydryl group of the other. The reaction of fire hydrocarbon unsaturation of one oligomer with the functionality of the other follows the mechanism described in U.S. Pat. No. 4,719,283 to form a cyclohexane linkage by bridging across the double bond. With the acetylene (triple) unsaturation, a cyclohexene ring results.
The Michaels addition reaction is illustrated as follows: ##STR133## wherein V=--NH--, --O--, or --S--. For the other end caps, we believe a reverse Diels-Alder decomposition reaction (induced by heating the oligomers) results in the formation of a reactive maleic moiety and the off-gassing of a cyclopentadiene. The methylene bridge decomposes to the maleic compound at about 625.degree.-670.degree. F. (330.degree.-355.degree. C.) while the --O-- bridge decomposes at the lower temperature of about 450.degree. F. (230.degree. C.).
The reactive group might also be --CNO instead of the amine, but we do not recommend use of these dicyanates.
While we have described preferred embodiments, those skilled in the art will readily recognize alterations, variations, and modifications which might be made without departing from the inventive concept. Therefore, interpret the claims liberally with the support of the full range of equivalents known to those of ordinary skill based upon this description. The examples are given to illustrate the invention and not intended to limit it. Accordingly, limit the claims only as necessary in view of the pertinent prior art.

Claims

1. A method for making a multiple chemically functional oligomer, comprising the steps of:
(a) condensing diaminophenol with either a linear or multidimensional intermediate selected from the group: ##STR134## wherein R.sub.4 is a divalent organic aromatic radical;
R.sub.# is R.sub.4 or bond;
.differential.is a "w" valent organic aromatic hub radical;
w is 3 or 4; and
.alpha. is a functionality reactive with --OH
or with reactive monomers that condense to yield (I) or (II), the condensation yielding a four-functional, linear or multidimensional bisamine of the formula: ##STR135## wherein R.sub..beta. is the residue of the diaminophenol/intermediate condensation;
.O slashed. is phenylene; and
.A-inverted. is the residue of the .alpha.-/--OH condensation; and
(b) condensing the bisamine of step (a) with an acid halide of the formula: ##STR136## to yield an oligomer of the formula: ##STR137## wherein .delta. is phenylene or pyrimidinylene;
i is 1 or 2;
E is ##STR138## G is --CH.sub.2 --, --C(HR.sub.3)--, --C(R.sub.3).sub.2 --, --S--, --SO.sub.2 --, --O--, or --CO--;
R.sub.3 is lower alkyl, lower alkoxy, aryl, aryloxy, or hydrogen;
.THETA. is --C.tbd.N, --O--C.tbd.N, --S--C.tbd.N, or --CR.sub.3 =C(R.sub.3).sub.2 ;
T is allyl or methallyl; and
Me is methyl.
2. A method of making multiple chemically functional oligomer, comprising the steps of:
(a) condensing a multiple chemically functional acid halide of the formula: ##STR139## with a linear or multidimensional intermediate having functionalities reactive with the --COX or with monomers which condense to yield such an intermediate, the condensation yielding an oligomer, wherein
E is ##STR140## .THETA. is --C.tbd.N, --O--C.tbd.N, --S--C.tbd.N, or --CR.sub.3 .dbd.C(R.sub.3).sub.2 ;
R.sub.3 is hydrogen, lower alkyl, lower alkoxy, aryl, or aryloxy;
Me is methyl;
T is methallyl or allyl;
.delta. is phenylene or pyrimidinylene;
X is halogen;
G is --CH.sub.2 --, --C(HR.sub.3)--, --C(R.sub.3).sub.2 --, --S--, --SO.sub.2 --, --O--, or --CO--; and
i is 1 or 2;
(b) optionally, blending the oligomer with at least one compatible polymer from a chemical family different from the oligomer; and
(c) optionally, combining the oligomer of step (a) or the blend of step (b) with a second oligomer of the general formula:
Z*.sub.k --B--Z*.sub.k
wherein
k is 1, 2, or 4;
Z is a functionality reactive with E; and
B is an aromatic, aliphatic, or mixed aromatic and aliphatic backbone.
3. The product of the process of claim 1, claim 1, or claim 2.
4. The oligomer of claim 3 wherein i is 2 so that there are four unsaturated hydrocarbon moieties available for crosslinking.
5. An advanced composite blend comprising a mixture of at least one oligomer of claim 3 and at least one compatible polymer from a chemical family different from the oligomer.
6. The blend of claim 5 wherein the oligomer is selected from the group consisting of imidesulfone, ether, ethersulfone, amide, imide, ester, estersulfone, esteramide, etherimide, amideimide, cyanate ester, and carbonate.
7. The blend of claim 6, wherein the oligomer and polymer are selected from the following table of oligomer/polymer pairs:
______________________________________OLIGOMER POLYMER______________________________________amideimide imideimide amideimideamideimide heterocycleamideimide heterocycle sulfoneimide heterocycleimide heterocycle sulfoneimide amideamide imideester amideamide esterestersulfone amideester esteramideamide estersulfoneester imideimide esterestersulfone imide______________________________________
8. The blend of claim 5 further comprising a second oligomer of the general formula:
Z*.sub.k --B--Z*.sub.k ;
wherein
k=1, 2, or 4;
B is an aromatic, aliphatic, or mixed aromatic and aliphatic backbone;
Z* is a hydrocarbon residue including a segment selected from the group consisting of: --.O slashed.--NH.sub.2, --.O slashed.--SH, --.O slashed.--OH, ##STR141## E is selected from the group consisting of: ##STR142## .THETA.is --C.tbd.N, --O--C.tbd.N, --S--C.tbd.N, or --CR.sub.3 .dbd.C(R.sub.3).sub.2 ;
G is --CH.sub.2 --, --C(HR.sub.3)--, --C(R.sub.3).sub.2 --, --S--, --SO.sub.2 --, --O--, or --CO--;
T is methallyl or allyl;
Me is methyl
i is 1 or 2; and
R.sub.3 is hydrogen, lower alkyl, lower alkoxy, aryl, or aryloxy.
9. A method for preparing a multiple chemically functional oligomer comprising reacting a crosslinking end cap monomer of the formula:
(Z--).sub.1 --.delta.--.beta.
with a monomer having a functionality reactive with the .beta. of the end cap monomer, wherein:
.delta.=phenylene or pyrimidinylene;
Z= ##STR143## .beta.=an organic radical selected from the group consisting of: --COX, ##STR144## --O--.O slashed.--COOH, --O--.O slashed.--COX, --X, --O--R*.sub.8 --OH, --O--R*.sub.8 --OCN, ##STR145## --O--.O slashed.--NH.sub.2, --NO.sub.2 ; X=halogen;
R.sub.8 and R*.sub.8 =a divalent organic aromatic radical;
E= ##STR146## G=--CH.sub.2 --, --C(HR.sub.3)--, --C(R.sub.3).sub.2 --, --S--, --SO.sub.2 --, --O--, or --CO--;
T=allyl or methallyl; and
Me=methyl;
R.sub.3 =lower alkyl, lower alkoxy, aryl, aryloxy, or hydrogen and;
.THETA.=--C.tbd.N, --O--C.tbd.N, --S--C.tbd.N, or --CR.sub.3 =C(R.sub.3).sub.2 ;
provided that .THETA. is not --CN, --OCN, or --SCN, when .beta. is --OCN.
10. The method of claim 1 wherein R.sub.4 is an aromatic, aliphatic, or alicyclic hydrocarbon having repeating units and a predominant linkage between such repeating units selected from the group consisting of imide, imide sulfone, amideimide, ester, ether, ether sulfone, esteramide, sulfide, amide, carbonate, cyanate ester, or mixtures thereof.
11. The method of claim 10 wherein R.sub.4 is aromatic.
12. The method of claim 11 wherein R.sub.4 is an imide formed by the condensation of a dianhydride and a diamine.
13. The method of claim 11 wherein R.sub.4 is an ester formed by the condensation of a diol and a diacid or diacid halide.
14. The method of claim 11 wherein the predominant linkage in R.sub.4 is an ether.
15. The method of claim 11 wherein the predominant linkage in R.sub.4 is a carbonate.
16. The method of claim 11 wherein the intermediate is .alpha..paren open-st.R.sub.4 .paren close-st..alpha..
17. The method of claim 11 wherein the intermediate is .differential.--.brket open-st..paren open-st.R.sub.#- .paren close-st..alpha.!.sub.w.
18. The product obtainable by the process of claim 16.
19. The product obtainable by the process of claim 17.
20. The method of claim 2 wherein the acid halide has the formula: ##STR147##
21. The method of claim 2 wherein the acid halide has the formula: ##STR148##
22. The product obtainable by the process of claim 20.
23. The product obtainable by the process of claim 21.
24. The product obtainable by the process of claim 22.
25. The product of claim 24 wherein i is 2.

REFERENCE TO RELATED APPLICATIONS

The present application is separately a continuation-in-part application based upon each of these seventeen, copending, U.S. Patent Applications: (1) 06/773,381 The present application is a continuation-in-part (CIP) based upon U.S. patent application Ser. No. 06/773,381, filed Sep. 5, 1985, which was a CIP based upon U.S. patent application Ser. No. 06/726,258, filed Apr. 23, 1985, now abandoned, and also a CIP based upon U.S. patent application Ser. No. 06/726,259, filed Apr. 23, 1985, now abandoned. (2) 07/137,493 The present application is a CIP based upon U.S. patent application Ser. No. 07/137,493, filed Dec. 23, 1987, which was a CIP based upon U.S. patent application Ser. No. 06/726,259, filed Apr. 23, 1985, now abandoned. (3) 07/167,656 The present application is a CIP based upon U.S. patent application Ser. No. 07/167,656, filed Mar. 14, 1988, which was a CIP based upon U.S. patent application Ser. No. 06/810,817, filed Dec. 17, 1985, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/726,258, filed Apr. 23, 1985, now abandoned, which in turn, was a CIP based upon each of the five following U.S. patent applications: (a) 06/519,394, filed Aug. 1, 1983, now abandoned; and (b) 06/673,229, filed Nov. 20, 1984, now U.S. Pat. No. 4,584,364, which was a continuation of U.S. patent application Ser. No. 06/576,790, filed Feb. 6, 1984, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/321,119, filed Nov. 13, 1981, now abandoned; and (c) 06/536,350, filed Sep. 27, 1983, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/519,394, filed Aug. 1, 1983, now abandoned; and (d) 06/505,348, filed Jun. 17, 1983, now U.S. Pat. No. 4,536,559; and (e) 06/651,862, filed Sep. 18, 1984, now abandoned, which was a CIP based upon each of the four applications that are listed above in (a)-(d) above. (4) 07/168,289 The present application is a CIP based upon U.S. patent application Ser. No. 07/168,289, filed Jun. 27, 1988. (5) 07/176,518 The present application is a CIP based upon U.S. patent application Ser. No. 07/176,518, filed Apr. 1, 1988, which was a CIP based upon U.S. patent application Ser. No. 06/810,817, filed Dec. 17, 1985, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/726,258, filed Apr. 23, 1985, now abandoned. (6) 07/212,404 The present application is CIP based upon U.S. patent application Ser. No. 07/212,404, filed Jun. 27, 1988, which was a CIP based upon U.S. patent application Ser. No. 06/773,381, filed Sep. 5, 1985, which was a CIP based upon U.S. patent application Ser. No. 06/726,258, filed Apr. 23, 1985, now abandoned, and also a CIP based upon U.S. patent application Ser. No. 06/726,259, filed Apr. 23, 1985, now abandoned. (7) 07/241,997 The present application is a CIP based upon U.S. patent application Ser. No. 07/241,997, filed Sep. 6, 1988, now U.S. Pat. No. 5,530,089, which was a divisional of U.S. patent application Ser. No. 07/016,703, filed Feb. 20, 1987, now U.S. Pat. No. 4,851,495. (8) 07/460,396 The present application is a CIP based upon U.S. patent application Ser. No. 07/460,396, filed Jan. 3, 1990, now U.S. Pat. No. 5,446,120, which was a continuation of U.S. patent application Ser. No. 07/223,308, filed Jul. 25, 1988, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/786,364, filed Oct. 7, 1985, now U.S. Pat. No. 5,871,475. (9) 07/619,677 The present application is a CIP based upon U.S. patent application Ser. No. 07/619,677, filed Nov. 29, 1990, which was a continuation of U.S. patent application Ser. No. 07/167,604, filed Mar. 14, 1988, now abandoned. (10) 07/539,051 The present application is a CIP based upon U.S. patent application Ser. No. 07/639,051, filed Jan. 9, 1991. (11) 08/043,824 The present application is a CIP based upon U.S. patent application Ser. No. 08/043,824, filed Apr. 6, 1993, now U.S. Pat. No. 5,367,083, which was a division based upon U.S. patent application Ser. No. 07/831,145, filed Jan. 13, 1992, now U.S. Pat. No. 5,216,117, which was a division of U.S. patent application Ser. No. 07/181,013, filed Apr. 13, 1988, now U.S. Pat. No. 5,104,967, which was a CIP based upon U.S. patent application Ser. No. 07/092,740, filed Sep. 3, 1987, now abandoned. (12) 08/079,999 The present application is a CIP based upon U.S. patent application Ser. No. 08/079,999, filed Jun. 21, 1993, now U.S. Pat. No. 5,403,666, which was a division of U.S. patent application Ser. No. 07/934,768, filed Aug. 24, 1992, now U.S. Pat. No. 5,239,046, which was a division of U.S. patent application Ser. No. 07/345,062, filed Apr. 28, 1989, now U.S. Pat. No. 5,155,026, which was a CIP based upon U.S. patent application Ser. No. 07/181,013, filed Apr. 13, 1988, now U.S. Pat. No. 5,104,967, which was a CIP based upon U.S. patent application Ser. No. 07/092,740, filed Sep. 3, 1987, now abandoned. (13) 08/159,823 The present application is a CIP based upon U.S. patent application Ser. No. 08/159,823, filed Nov. 30, 1993, now U.S. Pat. No. 5,455,115, which was a division based upon U.S. patent application Ser. No. 07/886,960, filed May 21, 1992, now U.S. Pat. No. 5,286,811, which was a division of U.S. patent application Ser. No. 07/353,588, filed May 18, 1989, now U.S. Pat. No. 5,116,935, which was a CIP based upon U.S. patent application Ser. No. 07/046,376, filed May 4, 1987, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/715,801, filed Mar. 22, 1985, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/536,264, filed Sep. 27, 1983, now abandoned. (14) 08/161,164 The present application is a CIP based upon U.S. patent application Ser. No. 08/161,164, filed Dec. 3, 1993, now abandoned, which was a division of U.S. patent application Ser. No. 07/176,518, filed Apr. 1, 1988, which was a CIP based upon U.S. patent application Ser. No. 06/810,817, filed Dec. 17, 1985, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/726,258, filed Apr. 23, 1985, now abandoned. (15) 08/232,682 The present application is a CIP based upon U.S. patent application Ser. No. 08/232,682, filed Apr. 25, 1994, now U.S. Pat. No. 5,516,846, which was a division of U.S. patent application 07/980,109, filed Nov. 23, 1992, now U.S. Pat. No. 5,344,894, which was a continuation of U.S. patent application Ser. No. 07/568,911, filed Aug. 13, 1990, now abandoned, which was a division of 07/046,376, filed May 4, 1987, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/810,818, filed Dec. 17, 1985, now abandoned, which was a CIP based upon U.S. patent application Ser. 06/715,801, filed Mar. 22, 1985, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/536,264, filed Sep. 27, 1983, now abandoned. (16) 08/269,297 The present application is a CIP based upon U.S. patent application Ser. No. 08/269,297, filed Jun. 30, 1994, which was a division of U.S. patent application Ser. No. 07/167,656, filed Mar. 14, 1988, which was a CIP based upon U.S. patent application Ser. No. 06/810,817, filed Dec. 17, 1985, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/726,258, filed Apr. 23, 1985, now abandoned, which, in turn, was a CIP based upon each of the five following U.S. patent applications (a) 06/519,394, filed Aug. 1, 1983, now abandoned; and (b) 06/673,229, filed Nov. 20, 1984, now U.S. Pat. No. 4,584,364, which was a continuation of U.S. patent application Ser. No. 06/576,790, filed Feb. 6, 1984, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/321,119, filed Nov. 13, 1981, now abandoned; and (c) 06/536,350, filed Sep. 27,1983, now abandoned, which was a CIP based upon U.S. patent application Ser. No. 06/519,394, filed Aug. 1, 1983, now abandoned; and (d) 06/505,348, filed Jun. 17, 1983, now U.S. Pat. No. 4,536,559; and (e) 06/651,862, filed Sep. 18, 1984, now abandoned, which was a CIP based upon each of the applications that are listed in (a)-(d) above. (17) 08/280,866 The present application is a CIP based upon U.S. patent application Ser. No. 08/280,866, filed Jul. 26, 1994, now U.S. Pat. No. 5,512,676, which was a division of a U.S. patent application 08/043,824, filed Apr. 4, 1993, now U.S. Pat. No. 5,267,083, which was a division of U.S. patent application Ser. No. 07/831,145, filed Jan. 13, 1992, now U.S. Pat. No. 5,216,117, which was a CIP based upon U.S. patent application Ser. No. 07/092,740, filed Sep. 3, 1987, now abandoned. (18) 08/327,942 The present application is a division based upon U.S. patent application Ser. No. 08/327,942, filed Oct. 21, 1994, which in turn claims CIP status from the 17 patent applications identified above.

US Referenced Citations (407)

Number	Name	Date
RE29316	Bargain et al.	Jul 1977
RE30922	Heilman et al.	May 1982
3105839	Renner	Oct 1963
3236705	Gilman et al.	Feb 1966
3236808	Goldberg et al.	Feb 1966
3262914	Goldberg et al.	Jul 1966
3265708	Stiteler	Aug 1966
3267081	Rudner et al.	Aug 1966
3313783	Iwakura et al.	Apr 1967
3354129	Edmonds et al.	Nov 1967
3355272	D'Alessandro	Nov 1967
3386969	Levine	Jun 1968
3408349	Matsunaga	Oct 1968
3431235	Lubowitz	Mar 1969
3435003	Craven	Mar 1969
3449442	Williams et al.	Jun 1969
3450711	Megna et al.	Jun 1969
3453236	Culbertson	Jul 1969
3454673	Schmidt	Jul 1969
3458486	Ray et al.	Jul 1969
3461461	Anthony et al.	Aug 1969
3528950	Lubowitz	Sep 1970
3530087	Hayes et al.	Sep 1970
3536670	Aciony et al.	Oct 1970
3562223	Bargain et al.	Feb 1971
3563951	Dormagen et al.	Feb 1971
3565549	Lubowitz et al.	Feb 1971
3592841	Broadhead	Jul 1971
3598768	Bach	Aug 1971
3609181	Lubowitz et al.	Sep 1971
3616193	Lubowitz et al.	Oct 1971
3624042	Lubowitz et al.	Nov 1971
3631222	Vogel	Dec 1971
3632428	Lubowitz et al.	Jan 1972
3635891	Lubowitz et al.	Jan 1972
3641207	Lauchlan	Feb 1972
3647529	Lubowitz et al.	Mar 1972
3652710	Holub	Mar 1972
3658764	Bargain et al.	Apr 1972
3658938	Kwiatkowski et al.	Apr 1972
3663507	Vogel	May 1972
3689464	Holub et al.	Sep 1972
3697308	Lubowitz et al.	Oct 1972
3697345	Lubowitz et al.	Oct 1972
3699074	Lubowitz et al.	Oct 1972
3699075	Lubowitz	Oct 1972
3708370	Lubowitz et al.	Jan 1973
3708439	Sayigh et al.	Jan 1973
3708459	Lubowitz	Jan 1973
3729446	Holub et al.	Apr 1973
3745149	Serafini et al.	Jul 1973
3748311	Burns et al.	Jul 1973
3748312	Burns et al.	Jul 1973
3749735	Loria	Jul 1973
3757088	Osborn	Sep 1973
3759777	Lubowitz et al.	Sep 1973
3761441	D'Alessandro et al.	Sep 1973
3763101	Jones et al.	Oct 1973
3770697	Holub et al.	Nov 1973
3772250	Economy et al.	Nov 1973
3773718	Klebe et al.	Nov 1973
3781240	Lubowitz et al.	Dec 1973
3781249	Lubowitz	Dec 1973
3787363	Stanland et al.	Jan 1974
3803081	Lubowitz	Apr 1974
3812159	Lubowitz	May 1974
3827927	Lubowitz et al.	Aug 1974
3839287	Kwiatkowski et al.	Oct 1974
3843593	Shell et al.	Oct 1974
3847867	Heath et al.	Nov 1974
3847869	Williams, III	Nov 1974
3852106	Incremona et al.	Dec 1974
3853815	Lubowitz	Dec 1974
3859252	Cho	Jan 1975
3879349	Bilow et al.	Apr 1975
3879393	Havera	Apr 1975
3879428	Heath et al.	Apr 1975
3887582	Holub et al.	Jun 1975
3890272	D'Alelio	Jun 1975
3895064	Brode et al.	Jul 1975
3896147	Stephen	Jul 1975
3897393	Lu	Jul 1975
3897395	D'Alelio	Jul 1975
3909507	Betts et al.	Sep 1975
3914334	Lubowitz et al.	Oct 1975
3919177	Campbell	Nov 1975
3920768	Kwiatkowski	Nov 1975
3925324	Gerard	Dec 1975
3933862	Williams, III	Jan 1976
3935167	Marvel et al.	Jan 1976
3935320	Chiu et al.	Jan 1976
3941746	Stephen	Mar 1976
3941883	Gshwend et al.	Mar 1976
3956320	Heath et al.	May 1976
3957732	Hirooka et al.	May 1976
3957862	Heath et al.	May 1976
3966678	Gruffaz et al.	Jun 1976
3966726	Toth et al.	Jun 1976
3966987	Suzuki et al.	Jun 1976
3970714	Bargain	Jul 1976
3972902	Heath et al.	Aug 1976
3988374	Brode et al.	Oct 1976
3993630	Darmory et al.	Nov 1976
3998786	D'Alelio	Dec 1976
4000146	Gerber	Dec 1976
4005134	Markezich	Jan 1977
4013600	Cassat	Mar 1977
4020069	Johnson et al.	Apr 1977
4026871	D'Alelio	May 1977
4038261	Crouch et al.	Jul 1977
4051177	Braden et al.	Sep 1977
4055543	D'Alelio	Oct 1977
4058505	D'Alelio	Nov 1977
4060515	D'Alelio	Nov 1977
4064289	Yokoyama et al.	Dec 1977
4075171	D'Alelio	Feb 1978
4097456	Barie	Jun 1978
4100137	Lemieux et al.	Jul 1978
4100138	Bilow et al.	Jul 1978
4101488	Ishizuka et al.	Jul 1978
4107125	Lovejoy	Aug 1978
4107147	Williams, III et al.	Aug 1978
4107153	Akijama et al.	Aug 1978
4107174	Baumann et al.	Aug 1978
4108837	Johnson et al.	Aug 1978
4108926	Arnold et al.	Aug 1978
4110188	Darms et al.	Aug 1978
4111879	Mori et al.	Sep 1978
4115231	Darms et al.	Sep 1978
4115362	Inata et al.	Sep 1978
4116937	Jones et al.	Sep 1978
4124593	Gschwend et al.	Nov 1978
4126619	Darms et al.	Nov 1978
4128574	Markezich et al.	Dec 1978
4132715	Roth	Jan 1979
4132716	Kvita et al.	Jan 1979
4134895	Roth et al.	Jan 1979
4142870	Lovejoy	Mar 1979
4158731	Baumann et al.	Jun 1979
4166168	D'Alelio	Aug 1979
4167663	Granzow et al.	Sep 1979
4168366	D'Alelio	Sep 1979
4172836	Baumann et al.	Oct 1979
4174326	Baumann et al.	Nov 1979
4175175	Johnson et al.	Nov 1979
4176223	Irwin	Nov 1979
4179551	Jones et al.	Dec 1979
4183839	Gagliani	Jan 1980
4187364	Darms et al.	Feb 1980
4189560	Roth et al.	Feb 1980
4193927	Baumann et al.	Mar 1980
4197397	D'Alelio	Apr 1980
4200731	Massey et al.	Apr 1980
4206106	Heilman et al.	Jun 1980
4218555	Antonoplos et al.	Aug 1980
4221895	Woo	Sep 1980
4225497	Baudouin et al.	Sep 1980
4225498	Baudouin et al.	Sep 1980
4231934	Oba et al.	Nov 1980
4234712	Keller et al.	Nov 1980
4237262	Jones	Dec 1980
4239883	Stenzenberger	Dec 1980
4244853	Serafini et al.	Jan 1981
4250096	Kvita et al.	Feb 1981
4251417	Chow et al.	Feb 1981
4251418	Chow et al.	Feb 1981
4251419	Heilman et al.	Feb 1981
4251420	Antonopolos et al.	Feb 1981
4255313	Antonopolos et al.	Mar 1981
4266047	Jablonski et al.	May 1981
4269961	Jones et al.	May 1981
4271079	Maeda et al.	Jun 1981
4273916	Jones et al.	Jun 1981
4276407	Bilow et al.	Jun 1981
4288583	Zahir et al.	Sep 1981
4288607	Bier et al.	Sep 1981
4289699	Oba et al.	Sep 1981
4293670	Robeson et al.	Oct 1981
4297472	Heiss	Oct 1981
4297474	Williams, III et al.	Oct 1981
4298720	Yamazaki et al.	Nov 1981
4299750	Antonopolos et al.	Nov 1981
4299946	Balme et al.	Nov 1981
4302575	Takekoshi	Nov 1981
4309528	Keseke et al.	Jan 1982
4323662	Oba et al.	Apr 1982
4338222	Limburg et al.	Jul 1982
4338225	Sheppard	Jul 1982
4344869	Blinne et al.	Aug 1982
4344870	Blinne et al.	Aug 1982
4351932	Street et al.	Sep 1982
4358561	Keske et al.	Nov 1982
4360644	Naarmann et al.	Nov 1982
4365068	Darms et al.	Dec 1982
4375427	Miller et al.	Mar 1983
4376710	Gardos et al.	Mar 1983
4381363	Reinhart, Jr.	Apr 1983
4389504	St. Clair et al.	Jun 1983
4393188	Takahashi et al.	Jul 1983
4395497	Naarmann et al.	Jul 1983
4400613	Popelish	Aug 1983
4405770	Schoenberg et al.	Sep 1983
4407739	Naarmann et al.	Oct 1983
4409382	Keller	Oct 1983
4410686	Hefner, Jr. et al.	Oct 1983
4414269	Lubowitz et al.	Nov 1983
4417039	Reinhardt et al.	Nov 1983
4417044	Parekh	Nov 1983
4418181	Monacelli	Nov 1983
4423202	Choe	Dec 1983
4429108	Stephens	Jan 1984
4438273	Landis	Mar 1984
4438280	Monacelli	Mar 1984
4446191	Miyadera et al.	May 1984
4448925	Hanson	May 1984
4460783	Nishikawa et al.	Jul 1984
4465809	Smith	Aug 1984
4467011	Brooks et al.	Aug 1984
4476184	Lubowitz et al.	Oct 1984
4476295	Stephens	Oct 1984
4482683	Quella et al.	Nov 1984
4485140	Gannett et al.	Nov 1984
4485231	Landis	Nov 1984
4489027	St. Clair et al.	Dec 1984
4504632	Holub et al.	Mar 1985
4507466	Tomalia et al.	Mar 1985
4510272	Loszewski	Apr 1985
4515962	Renner	May 1985
4519926	Basalay et al.	May 1985
4520198	D'Alelio et al.	May 1985
4526838	Fujioka et al.	Jul 1985
4533692	Wolfe et al.	Aug 1985
4533693	Wolfe et al.	Aug 1985
4533724	Wolfe et al.	Aug 1985
4535117	Mathis et al.	Aug 1985
4536559	Lubowitz et al.	Aug 1985
4547553	Lubowitz et al.	Oct 1985
4555563	Hefner et al.	Nov 1985
4556697	Curatolo et al.	Dec 1985
4556705	McCready	Dec 1985
4558120	Tomalia et al.	Dec 1985
4562231	Dean	Dec 1985
4562232	Smith	Dec 1985
4563498	Lucas	Jan 1986
4563514	Liu et al.	Jan 1986
4564553	Pellegrini et al.	Jan 1986
4567216	Qureshi et al.	Jan 1986
4567240	Hergenrother et al.	Jan 1986
4568737	Tomalia et al.	Feb 1986
4574144	Yates, III et al.	Mar 1986
4574148	Wicker, Jr. et al.	Mar 1986
4574154	Okamoto et al.	Mar 1986
4576857	Gannett et al.	Mar 1986
4577034	Durvasula	Mar 1986
4578470	Webb	Mar 1986
4579957	Kanayama et al.	Apr 1986
4584364	Lubowitz et al.	Apr 1986
4587329	Tomalia et al.	May 1986
4590363	Bernard	May 1986
4599383	Satoji	Jul 1986
4600769	Kumar et al.	Jul 1986
4604437	Renner	Aug 1986
4611022	Hefner, Jr.	Sep 1986
4611048	Peters	Sep 1986
4614767	Dean	Sep 1986
4615832	Kress et al.	Oct 1986
4616070	Zeiner et al.	Oct 1986
4616071	Holubka	Oct 1986
4617390	Hoppe et al.	Oct 1986
4624888	St. Clair et al.	Nov 1986
4628067	Chen, Sr. et al.	Dec 1986
4628079	Zecher et al.	Dec 1986
4629777	Pfeifer	Dec 1986
4631337	Tomalia et al.	Dec 1986
4638027	Mark et al.	Jan 1987
4640944	Brooks	Feb 1987
4649080	Fischer et al.	Mar 1987
4654410	Kashiwame et al.	Mar 1987
4657973	Endo et al.	Apr 1987
4657977	Peters	Apr 1987
4657987	Rock et al.	Apr 1987
4657990	Daoust et al.	Apr 1987
4660057	Watanabe et al.	Apr 1987
4661604	Lubowitz et al.	Apr 1987
4663378	Allen	May 1987
4663399	Peters	May 1987
4663423	Yamada et al.	May 1987
4663424	Stix et al.	May 1987
4663425	Evers et al.	May 1987
4675414	DeFusco et al.	Jun 1987
4680326	Leland et al.	Jul 1987
4680377	Matsumura et al.	Jul 1987
4684714	Lubowitz et al.	Aug 1987
4690972	Johnson et al.	Sep 1987
4691025	Domeier et al.	Sep 1987
4694064	Tomalia et al.	Sep 1987
4695610	Egli et al.	Sep 1987
4699975	Katto et al.	Oct 1987
4703081	Blackwell et al.	Oct 1987
4708983	Liang	Nov 1987
4709004	Dai	Nov 1987
4714768	Hemkielm et al.	Dec 1987
4716212	Gaughan	Dec 1987
4719283	Bartmann	Jan 1988
4727118	Egami	Feb 1988
4728742	Renner	Mar 1988
4730030	Hahn et al.	Mar 1988
4737550	Tomalia	Apr 1988
4739030	Lubowitz et al.	Apr 1988
4739075	Odagiri et al.	Apr 1988
4742166	Renner	May 1988
4748227	Matzner et al.	May 1988
4755584	Tomioka et al.	Jul 1988
4755585	Hanson et al.	Jul 1988
4757118	Das et al.	Jul 1988
4757128	Domb et al.	Jul 1988
4757150	Guggenheim et al.	Jul 1988
4759986	Marikar et al.	Jul 1988
4760106	Gardner et al.	Jul 1988
4764427	Hara et al.	Aug 1988
4766180	Wong	Aug 1988
4766197	Clendinning et al.	Aug 1988
4769424	Takekoshi et al.	Sep 1988
4769426	Iwasaki et al.	Sep 1988
4769436	Beck et al.	Sep 1988
4772722	Lukacs, III	Sep 1988
4774282	Qureshi	Sep 1988
4777208	Hefner	Oct 1988
4778830	Streu et al.	Oct 1988
4778859	Ai et al.	Oct 1988
4778898	Vonlanthen et al.	Oct 1988
4786669	Dewhirst	Nov 1988
4786685	Takida et al.	Nov 1988
4786713	Rule et al.	Nov 1988
4798685	Yangier	Jan 1989
4798686	Hocker et al.	Jan 1989
4798882	Petri	Jan 1989
4801676	Hisgen et al.	Jan 1989
4801677	Eckhardt et al.	Jan 1989
4804722	Hesse et al.	Feb 1989
4804724	Harris et al.	Feb 1989
4806407	Skinner et al.	Feb 1989
4808717	Saito et al.	Feb 1989
4812518	Haubennestel et al.	Mar 1989
4812534	Blakely	Mar 1989
4812552	Cliffton et al.	Mar 1989
4812588	Schrock	Mar 1989
4814416	Poll	Mar 1989
4814417	Sugimori	Mar 1989
4814421	Rosenquist	Mar 1989
4814472	Lau	Mar 1989
4816503	Cunningham et al.	Mar 1989
4816526	Bristowe et al.	Mar 1989
4816527	Rock	Mar 1989
4816556	Gay et al.	Mar 1989
4820770	Schleifstein	Apr 1989
4826927	Schmid et al.	May 1989
4826997	Kirchhoff	May 1989
4827000	Schwartz	May 1989
4829138	Barthelemy	May 1989
4835197	Mercer	May 1989
4837256	Gardner et al.	Jun 1989
4839378	Koyama et al.	Jun 1989
4845150	Kovak et al.	Jul 1989
4845167	Alston et al.	Jul 1989
4845185	Teramoto et al.	Jul 1989
4845278	Erhan	Jul 1989
4851280	Gupta	Jul 1989
4851287	Hartsing, Jr.	Jul 1989
4851494	Eldin et al.	Jul 1989
4851496	Poll et al.	Jul 1989
4851505	Hayes	Jul 1989
4861855	Bockrath et al.	Aug 1989
4861882	Hergenrother et al.	Aug 1989
4861915	Clendinning et al.	Aug 1989
4871475	Lubowitz et al.	Oct 1989
4874834	Higashi et al.	Oct 1989
4876325	Olson et al.	Oct 1989
4876330	Higashi et al.	Oct 1989
4891167	Clendinning et al.	Jan 1990
4891408	Newman-Evans	Jan 1990
4891460	Ishii	Jan 1990
4895892	Satake et al.	Jan 1990
4895924	Satake et al.	Jan 1990
4897527	Cripps et al.	Jan 1990
4902335	Kume et al.	Feb 1990
4902440	Takeyama et al.	Feb 1990
4902769	Cassidy et al.	Feb 1990
4902773	Bodnar et al.	Feb 1990
4916210	Jackson	Apr 1990
4916235	Tan et al.	Apr 1990
4919992	Blundell et al.	Apr 1990
4923752	Cornelia	May 1990
4927899	Michaud et al.	May 1990
4927900	Michaud et al.	May 1990
4931531	Tamai et al.	Jun 1990
4931540	Mueller et al.	Jun 1990
4973662	Odagiri et al.	Nov 1990
5066776	Russeler et al.	Nov 1991
5075537	Lorenzen et al.	Dec 1991
5086154	Camberlin et al.	Feb 1992
5111026	Ma	May 1992
5112936	Okamoto	May 1992
5134421	Boyd et al.	Jul 1992
5151487	Lubowitz et al.	Sep 1992
5230956	Cole et al.	Jul 1993
5254605	Kim et al.	Oct 1993

Foreign Referenced Citations (23)

Number	Date	Country
1269576	May 1990	CAX
0152372	Jan 1985	EPX
0175484	Mar 1986	EPX
0266662	Nov 1988	EPX
0292434	Nov 1988	EPX
71.00975	Jan 1971	FRX
1951632	Jun 1971	DEX
27 22 513	Nov 1978	DEX
47-51116	Dec 1972	JPX
48-78299	Oct 1973	JPX
1453625	Dec 1973	JPX
50-22091	Mar 1975	JPX
56-71068	Jun 1981	JPX
58059-219	Oct 1981	JPX
58-76425	May 1983	JPX
58-215450	Dec 1983	JPX
59-170122	Sep 1984	JPX
60-250030	Dec 1985	JPX
1210-4088-A	Feb 1988	JPX
1099096	Jan 1968	GBX
2002378A	Mar 1982	GBX
8101855	Jul 1981	WOX
8404313	Nov 1984	WOX

Non-Patent Literature Citations (20)

Entry
Additives Lower Pickup of Moisture by Polyimides, NASA Tech Briefs, 80-81, Apr. 1989.
Heidemann, "Oligomers", Encyclopedia of Polymer Science and Technology vol. 9 Molding to Petroleum Resins 485-506, 1968, (The month of the publication date is not available).
Second-generation polyimide raises continuous-use temperatures, Advanced Composites, May/Jun., 1988.
Vanucci et al., 700.degree. F Properties of Autoclave Cured PMR-II Composities, NASA Tech. Memo 100923, Sep., 1988.
Vanucci, PMR Polyimide Compositions for Improved Performance at 371.degree. C, NTIS N87-16071, Apr., 1987.
Elsenbaumer et al., Highly Conductive Meta Derivatives of Poly(phenylene Sulfide), J. Polymer Sci: Polymer Phys. Ed., vol. 20, 1781-1787, 1982, (The month of the publication date is not a available).
Patel et al., Poly-Schiff Bases, I. Preparation of Poly-Schiff Bases from 4,4'-Diacetyl Diphenyl Ether (DDE) with Various Diamines, J. of Polymer Sci: Polymer Chem. Ed., vol. 20, 1985-1992, 1982 (The month of the publication date is not available).
Walton, A New Network Polymer as an Electrical Conductor and Thermally Stable Plastic, Am. Chem, Soc. Org. Coat Plast. Chem. vol. 42, 595-599, 1980 (The month of the publication date is not available).
Lubowitz et al., Novel High Temperature Matrix Materials.
Serafini et al., Thermally Stable Polyimides from Solutions of Monomeric Reactants, Journal of Applied Polymer Science, vol.16, pp. 905-915, 1972 (The month of the publication date is not available).
Southcott et al., The Development of Processable, Fully Imidized, Polyimides for High-Temperature Applications, High Perform. Polym. 6 1-12, 1994 (The month of the publication date is not available).
Spillman et al., Copolymers of Poly(Para-Phenylene Terephthalamide) Containing a Thermally Activated Cross-Linking Agent, PMSW vol. 68, Spring Meetings 1993, Denver, CO, 1993 (The month of the publication is not available).
Falcone, Recent Advances in Polyimides and other High Performance Polymers, Symposium sponsored by Polymer Chemistry, Inc. American Chemical Society, Jan. 22-25, 1990.
Radlmann, et al., New Synthesis of Poly(ether Ketones). (44195h), Chemical Abstracts vol. 72, 1970, p. 44187, 1970, (The month of the publication date is not available).
Bryant, et al.,Synthesis and Properties of Phenylethynyl-Terminated Polyimides, Polymer PrePrints, vol. 34, No.1, Mar., 1993, Denver, CO, 1993, (The month of the publication date is not available).
Crivello et al., Polyimidothioether-Polysulfide Block Polymers, Journal of Polymer Science, Polymer Chemistry Ed., vol. 13, pp. 1819-1842 (1975), 1975, (The month of the publication date is not available).
Frazer, High Temperature Resistant Polymers, Interscience Publishers, Copyright 1968 by John Wiley & Sons, Inc., pp. 139-213, (The date of publication is not available).
Mittal (ed), Polyimides, Plenum Press, NY, vol. 1 & 2, (The date of publication is not available).
Mittal (ed), Polyimides--Synthetic's Characteristics, Plenum Press, NY, vol. 2, pp. 907-1041, The date of publication is not available).
Mittal (ed), Polyimides--Synthetic's Characteristics, Plenum Press, NY, vol. 1, pp. 89-95, (The date of publication is not available.

Related Publications (40)

	Number	Date	Country
	137493	Dec 1987
	167656	Mar 1988
	168289	Jun 1988
	176518	Apr 1988
	212404	Jun 1988
	241997	Sep 1988
	460396	Jan 1990
	619677	Nov 1990
	639051	Jan 1991
	43824	Apr 1993
	79999	Jun 1993
	159823	Nov 1993
	161164	Dec 1993
	232682	Apr 1994
	269297	Jun 1994
	280866	Jul 1994
	137493
	167656
	168289
	176518
	212404
	241997
	460396
	619677
	639051
	43824
	79999
	159823
	161164
	232682
	269297
	280866
	726259	Apr 1985
	673229	Nov 1984
	536350	Sep 1983
	505348	Jun 1983
	651862	Sep 1994
	673229
	536350
	505348

Divisions (13)

	Number	Date
Parent	327942	Oct 1994
Parent	43824
Parent	831145	Jan 1992
Parent	16703	Feb 1987
Parent	831145
Parent	181013	Apr 1988
Parent	934768	Aug 1992
Parent	345062	Apr 1989
Parent	886960	May 1992
Parent	353588	May 1989
Parent	980109	Nov 1992
Parent	46376	May 1987
Parent	167656

Continuations (3)

	Number	Date
Parent	576790	Feb 1984
Parent	223308	Jul 1988
Parent	568911	Aug 1990

Continuation in Parts (24)

	Number	Date
Parent	92740	Sep 1987
Parent	773381
Parent	726258	Apr 1985
Parent	726259
Parent	810817	Dec 1985
Parent	726258
Parent	519394	Aug 1983
Parent	519394
Parent	321119	Nov 1981
Parent	519394
Parent	810817
Parent	726258
Parent	773381
Parent	786364	Oct 1985
Parent	167604	Mar 1988
Parent	92740
Parent	181013
Parent	46376	May 1987
Parent	715801	Mar 1985
Parent	536264	Sep 1983
Parent	176518
Parent	810818	Dec 1985
Parent	715801	Mar 1985
Parent	536264	Sep 1983

Method for making multiple chemically functional oligomers

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

US Classifications

Field of Search

US

International Classifications

Abstract