The present disclosure relates to methods for preparing polyimide resins and polyimides made therefrom by monitoring reaction conditions.
Organic films are high in flexibility as compared to glass, difficult to break, and lightweight. Recently, study has been performed with the aim of developing a flexible display using organic film as the substrate of a flat panel display.
Generally, resins used in organic film include polyester, polyamide, polyimide, polycarbonate, polyether sulfone, acrylic, and epoxy. Of these, polyimide resin is high in heat resistance, mechanical strength, abrasion resistance, dimensional stability, chemical resistance, insulation capability, and accordingly in wide use in the electric/electronic industries.
For use as an alternative to the glass substrate in display elements, polyimide resin is required to have high transparency and low birefringence. These properties are necessary to obtain clear images. However, manufacturing methods provide inconsistencies in resins leading to variation in performance properties. Accordingly, there is a need for devising and improving processes that lead to performance consistency.
Various aspects and embodiments contemplated herein may include, but are not limited to one or more of the following.
In a first aspect, a method for preparing a polyimide includes placing a tetracarboxylic compound and a solvent in a reaction vessel. The method can include adding a first amount of a diamine, wherein the first amount is not more than 99.5 mol % of the tetracarboxylic compound to the reaction vessel to form a mixture. In one embodiment, the method can include adding not more than 99 mol %, not more than 98 mol %, not more than 97 mol %, not more than 96 mol %, or not more than 95 mol % of the tetracarboxylic compound to the reaction vessel to form a mixture. The method can further include agitating the mixture. The method can further include determining a viscosity of the mixture. The method includes adding a second amount of the diamine. The method can further include repeating the determining of the viscosity and the adding of a second amount of the diamine until the viscosity increases to a target value.
In a second aspect, the present disclosure includes a polyimide resin or a polyimide formed by the foregoing method.
In a third aspect, the present disclosure includes a polyimide material made from a diamine and a tetracarboxylic compound. The diamine can be selected from
any combination thereof. The polyimide material has at least one property selected from the following property group A:
The polyimide material has at least one property selected from the following property group B:
In a fourth and fifth aspect, the present disclosure includes an optical stack or an electronic device comprising a polyimide material as described herein.
The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
In the following specification, the concepts have been described with reference to specific embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of invention.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
Also, the use of “a” or “an” are employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise. Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
After reading the specification, skilled artisans will appreciate that certain features are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, references to values stated in ranges include each and every value within that range.
As described above, in a first aspect, a method for preparing a polyimide includes placing a tetracarboxylic compound and a solvent in a reaction vessel. The method can include adding a first amount of a diamine, wherein the first amount is not more than 99.5 mol % of the tetracarboxylic compound to the reaction vessel to form a mixture. In one embodiment, the method can include adding not more than 99 mol %, not more than 98 mol %, not more than 97 mol %, not more than 96 mol %, or not more than 95 mol % of the tetracarboxylic compound to the reaction vessel to form a mixture. The method can further include agitating the mixture. The method can further include determining a viscosity of the mixture. The method includes adding a second amount of the diamine. The method can further include repeating the determining of the viscosity and the adding of a second amount of the diamine until the viscosity increases to a target value. In one embodiment, the tetracarboxylic compound can be selected from:
any tetracarboxylic acid thereof, or any combination thereof.
In one further embodiment, the tetracarboxylic compound can be selected from 4,4′-oxydiphthalic acid dianhydride, 3,3′,4,4′-benzophenone tetracarboxylic acid dianhydride, 2,2′,3,3′-Benzophenonetetracarboxylic dianhydride, 3,3′,4,4′-biphenyltetracarboxylic dianhydride (BPDA), 2,2′,3,3′-Biphenyltetracarboxylic dianhydride, 3,3′,4,4′-diphenylsulfone tetracarboxylic dianhydride, 2,2-bis(3,4-dicarboxyphenyl)propane dianhydride, 2,2-bis(2,3-dicarboxyphenyl)propane dianhydride, 2,2-bis(3,4-dicarboxyphenoxyphenyl)propane dianhydride, 4,4′-(hexafluoroisopropylidene)diphthalic acid dianhydride (6FDA), 1,2-bis(2,3-dicarboxyphenyl)ethane dianhydride, 1,1-bis(2,3-dicarboxyphenyl)ethane dianhydride 1,2-bis(3,4-dicarboxyphenyl)ethane dianhydride, 1,1-bis(3,4-dicarboxyphenyl)ethane dianhydride, bis(3,4-dicarboxyphenyl)methane Dianhydride, bis(2,3-dicarboxyphenyl)methane dianhydride, 4,4′-(p-phenylenedioxy)diphthalic acid dianhydride, 4,4′-(m-phenylenedioxy)diphthalate. An acid dianhydride is mentioned. Examples of monocyclic aromatic tetracarboxylic dianhydrides include 1,2,4,5-benzenetetracarboxylic dianhydride, and condensed polycyclic aromatic tetracarboxylic dianhydrides. Examples thereof include 2,3,6,7-naphthalenetetracarboxylic dianhydride. These can be used alone or in combination of two or more.
In another embodiment, the diamine can be selected from:
and any combination thereof.
In one embodiment, the solvent can be selected from ethylene glycol methyl ether, ethylene glycol butyl ether, 1-methoxy-2-propanol, 2-butoxyethanol, propylene glycol monomethyl ether, phenol, o-cresol, m-cresol, p-cresol, cresols, ethyl acetate, butyl acetate, ethylene glycol acetate, γ-butyrolactone, γ-valerolactone, propylene glycol acetate, ethyl lactate, acetone, methyl ethyl ketone, cyclopentanone, cyclohexanone, 2-heptanone, methyl isobutyl ketone, pentane, hexane, heptane, ethylcyclohexane, toluene, xylene, acetonitrile, tetrahydrofuran, dimethoxyethane, chloroform, chlorobenzene, N,N-dimethylacetamide, N,N-dimethylformamide, dimethyl sulfone, dimethyl sulfoxide, or any combination thereof.
In another embodiment, the method can include adding a catalyst before or after the adding of the first amount of diamine. The catalyst can be selected from N-ethylpiperidine, N-propylpiperidine, N-butylpyrrolidine, N-butylpiperidine, N-propylhexahydroazepine, azabicyclo[2.2.1]heptane, azabicyclo[3.2.1]octane, azabicyclo[2.2.2]octane, azabicyclo[3.2.2]nonane, 2-methylpyridine (2-picoline), 3-methylpyridine (3-picoline), 4-methylpyridine (4-Picoline), 2-ethylpyridine, 3-ethylpyridine, 4-ethylpyridine, 2,4-dimethylpyridine, 2,4,6-trimethylpyridine, 2,3-cyclopentenopyridine, 3,4-cyclopentenopyridine, 5,6,7,8-Tetrahydroisoquinoline, isoquinoline, or any combination thereof.
In one further embodiment, the agitating step includes heating the mixture to a temperature of at least 40° C., at least 60° C., at least 80° C., at least 100° C., at least 110° C., at least 120° C., at least 130° C., at least 140° C., at least 150° C., or at least 160° C. In one embodiment, determining the viscosity of the reaction mixture can include the viscosity being determined by a rotational viscometer, a vibrational viscometer, an oscillating viscometer, or by measuring torque of an impeller.
In one embodiment, the adding of the second amount of diamine can be done in increments of containing at least 0.001 mol %, 0.01 mol %, 0.02 mol %, 0.03 mol %, 0.04 mol %, 0.05 mol %, 0.06 mol %, 0.07 mol %, 0.08 mol %, 0.09 mol %, 0.1 mol %, 0.15 mol %, 0.2 mol %, 0.25 mol %, 0.3 mol %, 0.35 mol %, 0.4 mol %, 0.45 mol %, 0.5 mol %, or 0.55 mol % per increment, wherein the mol % is relative to the amount of the tetracarboxylic acid. For example, if the 2 mol of tetracarboxylic acid are present in the reaction vessel and an increment of 0.15 mol % is chosen, each increment of diamine addition is 2×0.0015=0.003 mol of diamine. Increments can be added either neat or in solution.
In another embodiment, the method can further include correlating the viscosity to a weight-averaged molecular weight of a polyimide. For any reaction mixture system, samples can be withdrawn at various viscosities to determine the weight-averaged or number-averaged molecular weight of the formed polyimide using size exclusion chromatography. In later repetitions of the runs, the viscosity is an indicator of the achieved molecular weight.
Once a target viscosity is achieved, the reaction can be stopped by ceasing the heating and agitating and letting the reaction mixture cool.
In one embodiment, the method further comprises adding a precipitation agent to form a precipitate. The precipitation agent can be selected from water, methanol, ethanol, propanol, butanol, pentanol, acetic acid, ammonia, or any combination thereof.
As stated above, in one aspect, a polyimide material can be made from a diamine and a tetracarboxylic compound, The diamine can be selected from
or any combination thereof. The polyimide material has at least one property selected from the following property group A:
The polyimide material has at least one property selected from the following property group B:
In one embodiment, the polyimide material can have at least two, at least three, or at least four properties of property group A. In another embodiment, the polyimide material can have at least two, at least three, or at least four properties of property group B.
Into a 3 neck flask equipped with under nitrogen with a reflux condenser and an overhead stirrer with thermometer and torque display, 4,4′-(Hexafluoroisopropylidene)diphthalic anhydride (6-FDA) (44.42 g, 100 mmol, 1 eq), 190 mL m-cresol, and a catalytic amount of about 130 mg (˜1 mol %) of isoquinoline were combined. Then, 95 mmol (8.15 g, 95 mol %) of 1,4-diaminobutane were added. A 0.5 M solution of 1,4-diaminobutane (DAB) in m-cresol (12 mL) was placed in a dropping funnel under nitrogen atmosphere and connected to one neck of the reaction flask. The flask contents were stirred and heated to 155° C. minutes. Then, DAB from the dropping funnel was added at a rate of approximately 0.1 mL/min and the torque was monitored. After 2 hours, the reaction was stopped, allowed to cool to about 70° C. and quenched with about 650 mL of ethanol that provided a colorless powder of the polyimide.
By monitoring the viscosity, the degradation of high molecular weight can be avoided, thereby providing control of the average molecular weight of the resulting polyimide.
This experiment is a repetition of Experiment 1 with smaller amounts of addition of DAB over a longer time. Into a 3 neck flask equipped with under nitrogen with a reflux condenser and an overhead stirrer with thermometer and torque display, 6-FDA (44.42 g, 100 mmol, 1 eq), 190 mL m-cresol, and 130 mg isoquinoline were combined. Then, 98 mmol (8.65 g, 98 mol %) of DAB were added. A 0.2 M solution of (DAB) in m-cresol (12 mL) was placed in a dropping funnel under nitrogen atmosphere and connected to one neck of the reaction flask. The flask contents were stirred and heated to 155° C. minutes. Then, DAB from the dropping funnel was added at a rate of approximately 0.05 mL/min and the torque was monitored.
After 3.5 hours, the reaction was stopped, allowed to cool to about 70° C. and quenched with about 650 mL of ethanol that provided a colorless powder of the polyimide.
This experiment is a repetition of Experiment 2 with even smaller amounts of addition of DAB and an intermittent cease of addition. Into a 3 neck flask equipped with under nitrogen with a reflux condenser and an overhead stirrer with thermometer and torque display, 6-FDA (44.42 g, 100 mmol, 1 eq), 190 mL m-cresol, and 130 mg of isoquinoline were combined. Then, 99 mmol (8.73 g, 99 mol %) of DAB were added. A 0.1 M solution of (DAB) in m-cresol (12 mL) was placed in a dropping funnel under nitrogen atmosphere and connected to one neck of the reaction flask. The flask contents were stirred and heated to 155° C. minutes. Then, DAB from the dropping funnel was added at a rate of approximately 0.025 mL/min and the torque was monitored. The addition of DAB was stopped after addition of approximately 3 mL and kept at reaction temperature and agitation for one hour, then resumed. After 4 hours an instantaneous shot of 3 mL was added to the reaction mixture. During the course of the experiment, 50 microliter samples of the reaction mixture were taken throughout the course of the experiment, quenched and the molecular weight of the polyimides formed determined by size exclusion chromatography.
This application claims the benefit of U.S. provisional application No. 62/706,293, filed Aug. 7, 2020, which is incorporated herein by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2020/054322 | 10/5/2020 | WO |
Number | Date | Country | |
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62706293 | Aug 2020 | US |