Thermally stable phenylacetylene terminated arylether resins

Abstract

Thermally stable resins based on arylether compounds having terminal phenylethynyl groups are provided.

Description

FIELD OF THE INVENTION

This invention relates to thermally stable phenylacetylene-terminated arylether resins.

BACKGROUND OF THE INVENTION

Composite materials have been used extensively as structural materials in aerospace and other applications where high strength, lightweight materials capable of withstanding high temperatures are required. Recently, considerable efforts have been made to extend the thermal stability range of these materials, while retaining their good structural strength and without increasing the weight of these materials. Addition polymers such as epoxy resins may be used in conjunction with fillers or fibers to provide essentially void-free composite structures which exhibit good structural properties and are light in weight. These latter structures are, however, limited to temperature applications below about 150.degree.-175.degree. C. because of the thermal stability characteristics of epoxy resins.

In recent years, a number of polymeric materials having high temperature properties have been developed. Unfortunately, the early thermally stable systems in this class of materials were formed by condensation reactions with the evolution of by-products. In the fabrication of reinforced composite structures, the volatile by-products, which were evolved, formed voids in the structures, thereby weakening such structures.

Later developed polymeric systems included ethynyl end-capped oligomers and polymers which propagate and cure by addition reactions to form high molecular weight, thermally stable compositions. Such end-capping has been accomplished in a variety of ways. Bilow et al, U.S. Pat. No. 3,864,309, disclose polyimide oligomers having terminal acetylenic groups which are prepared by the reaction of aromatic dicarboxylic anhydride with 3-aminophenylacetylene. Evers, U.S. Pat. No. 4,147,858 discloses fluorocarbon ether bibenzoxazole oligomers having terminal acetylenic groups which are prepared by the reaction of certain perfluoroalkylene ether diimidate esters and certain perfluoroalkylene ether bis(o-aminophenols) followed by reaction with 2-amino-4-ethynyl-phenol.

Kovar et al, U.S. Pat. No. 3,975,444 disclose that ethynyl-substituted aromatic ortho-diamines are useful as end-capping agents for certain heterocyclic oligomers. Arnold et al, U.S. Pat. Nos. 4,098,825 and 4,108,926 disclose acetylenic end-capping using 3-ethynyl-p-toluene sulfonate.

More recently, the preferred end-capping agent appears to be a substituted terminal acetylene compound containing at least three carbon atoms and a hydroxy group on the carbon atom adjacent to the acetylene group. Arnold et al, U.S. Pat. No. 4,268,654 employ 2-methyl-3-butyn-2-ol as the end-capping agent.

All the above ethynyl-terminated compounds are useful as or in the preparation of thermosetting resins, particularly resins having improved thermo-oxidative stability.

Accordingly, it is an object of the present invention to provide novel thermally stable resins based on arylether compounds containing terminal phenylethynyl groups.

Other objects and advantages of the present invention will be apparent to those skilled in the art.

SUMMARY OF THE INVENTION

In accordance with the present invention there are provided novel thermally stable resins based on an arylether compound having terminal phenylethynyl groups of the general formula ##STR1## wherein n is an integer having a value of 1-3 and Ar is a divalent aromatic moiety selected from the group consisting of ##STR2## wherein Y is --O--, --S--, --SO.sub.2 --, --C(CH.sub.3).sub.2 --, --C(CF.sub.3).sub.2 --or --CO--, and wherein R is --H, --O--C.sub.6 H.sub.5, --O--C.sub.6 H.sub.5 and --O--C.sub.6 H.sub.4 --SO.sub.2 --C.sub.6 H.sub.5.

BRIEF DESCRIPTION OF THE DRAWING

In the drawing,

FIG. 1 illustrates the results of isothermal aging of two sulfone-containing arylether polyenes; and

FIG. 2 illustrates the results of isothermal aging of two arylether polyenes.

DESCRIPTION OF THE INVENTION

The thermally stable polyene resins of the present invention are prepared by the thermally induced free radical polymerization of the previously described arylether compound having terminal phenylethynyl groups. The resulting resin has a polyene structure, as follows: ##STR3##

Compound I is prepared by reacting a haloarylether and phenylacetylene or a substituted phenylacetylene in the presence of a catalytic amount of a catalyst system consisting of a substituted phosphine, a complex palladium salt containing two halogen moieties and two substituted phosphine moieties, and a cuprous halide. The substituted phosphine may have substituents selected from the group consisting of phenyl, C.sub.1 to C.sub.4 alkyl and C.sub.1 to C.sub.4 alkyl-substituted-phenyl. Examples of suitable phosphines include triphenyl phosphine, triethylphosphine, diphenyl-ethyl phosphine and the like. In the complex palladium salt the halogen is selected from the group consisting of --Br, --Cl and --I, and the substituted phosphine is as defined above. The cuprous halide may be cuprous bromide, cuprous chloride or cuprous iodide.

The haloarylether has the general formula ##STR4## wherein Ar and n are as previously defined and X is a halogen. These haloarylethers may be prepared by an Ullmann ether synthesis, if not otherwise readily available. A suitable preparation is described by Unroe et al, U.S. patent application Ser. No. 522,940, filed Aug. 12, 1983, which is incorporated herein by reference, and involves reacting an aromatic diphenol with a dihalobenzene compound in the presence of cuprous oxide in an Ullman-type condensation in 2,4,6-collidine.

The haloarylether compound and the phenylacetylene or substituted phenylacetylene are reacted in approximately stoichiometric amounts, although an excess of up to about 15 mol% of the acetylenic compound may be employed.

The catalyst system, described previously, is employed in an amount ranging from about 1 to about 10 weight percent of the total weight of reactants. In the catalyst system the relative molar amounts of the Pd complex salt, the substituted phosphine and the cuprous halide can range from about 5:10:1 to 20:25:1, respectively.

The reaction of the bis-haloarylether with the acetylene terminated compound can be carried out under relatively mild conditions, including a temperature in the approximate range of 20.degree. to 200.degree. C., preferably about 50.degree. to 125.degree. C. Normal reaction pressure is atmospheric, although increased reaction pressures of up to about 250 psig can be employed. The reaction time to employ is somewhat dependent on the particular charge stock and catalyst system chosen and the reaction temperature. In general the reaction time can be from 1 to 150 hours, but is more usually from 3 to 24 hours.

The above reaction is carried out in the presence of a suitable amine solvent. Suitable solvents include dimethylamine, trimethylamine, diethylamine, triethylamine, ethylpropylamine, ethylbutylamine, dibutylamine and the like.

The resins of this invention are cured by heating the compound I to about 250.degree. to 350.degree. C. either in air or under an inert atmosphere such as nitrogen, argon, xenon or the like, for about 30 minutes to about 24 hours, although 1 to 2 hours is generally sufficient. The compositions are particularly suitable for use in the fabrication of reinforced composite structures, and for use as high temperature adhesives and coatings.

The following examples illustrate the invention:

EXAMPLE I

1,3-bis-m-(phenylethynyl)phenoxybenzene

A mixture of 6.24 g (0.015 mole) of 1,3-bis-(m-bromophenoxy)benzene and 3.27 g (0.032 mole) of phenylacetylene in 80 ml. of triethylamine was deaerated for 20 minutes by bubbling N.sub.2 through the solution. To the deaerated solution was added 0.03 g (0.042 mmol) bis-triphenylphosphine palladium dichloride, 0.30 g (1.14 mmol) of triphenylphosphine and 0.12 g (0.624 mmol) of cuprous iodide. The resulting suspension was heated at reflux for 24 hours under nitrogen. The reaction mixture was cooled to room temperature, then filtered. The triethylamine was removed under reduced pressure to give a brown oil. The oil was purified by column chromatography on silica gel using hexane as the eluent to give 5.1 g of a white solid, mp 78-79. Yield 73.5%.

Analysis: Calc'd for C.sub.34 H.sub.22 O.sub.2 : C, 88.29; H, 4.79. Found: C, 88.58; H, 4.91.

EXAMPLE II

4,4'-bis(3-phenylethynylphenoxy)diphenylsulfone

A solution of 4.0 g (7.1 mmol) of 4.4'-bis(3-bromo-phenoxy)diphenylsulfone and 1.64 g (16.0 mmol) of phenylacetylene in 100 ml of triethylamine was deaerated for 20 minutes by bubbling nitrogen through the solution. To the deaerated solution was added 0.02 g (0.028 mmol) of bis(triphenylphosphine)Pd dichloride, 0.15 g (0.57 mmol) of triphenyl-phosphine, and 0.05 g (0.26 mmol) of cuprous iodide. The resulting mixture was heated at reflux for 16 hours. The mixture was cooled at RT, filtered and the triethylamine removed under reduced pressure. The resulting oil was purified by column chromatography using 2:1 hexane:methylene chloride as the eluent. The second fluorescent band was collected and the solvent removed under high vacuum to give 2.75 g (64.4%) of a light yellow solid, mp 55.degree. C. (DSC).

Analysis: Calc'd for C.sub.40 H.sub.26 SO.sub.4 : C, 79.71; H, 4.35; S, 5.32. Found: C, 79.91; H, 4.40; S, 5.14.

EXAMPLE III

2,2-bis[([([3-phenoxy]-3-phenoxy)-3-phenylethynyl]-3-phenoxy)-4-phenyl]-propane

A mixture of 3.73 g (6.93 mmol) of 2,2-[4,4'-bis(3-bromophenoxy)]diphenylpropane and 4.22 g (14.77 mmol) of 1-phenoxy-3-(m-3-ethynylphenoxy)benzene and 0.30 g (1.14 mmol) of triphenylphosphine were dissolved in 75 ml of triethylamine. The solution was stirred under a nitrogen atmosphere for 10 minutes at RT. 0.12 g of cuprous iodide and 0.03 g of bis(triphenylphosphine)Pd dichloride were added to the reaction mixture. The resulting mixture was heated at reflux for 24 hours. The mixture was cooled to RT and the triethylamine was removed under reduced pressure. The residue was washed with methylene chloride and filtered. The filtrate was extracted with 15% HCl (2.times.100 ml) and washed with water (2.times.200 ml). After drying over anhydrous magnesium sulfate the solvent was removed to provide a dark brown solid. The crude product was chromatographed on silica gel using 4:1 hexane:methylene chloride. The product was dried in vacuo at 40.degree. C. to afford a light yellow amorphous solid (3.65 g. Yield 56%).

Analysis: Calc'd for C.sub.67 H.sub.48 O.sub.6 : C, 84,81; H, 5.06. Found: C, 85.00; H, 5.29.

EXAMPLE IV

2,2-bis[([([3-phenoxy]-3-phenoxy)-3-phenylethynyl]-3-phenoxy)-4-phenyl]-hexafluoropropane

To 125 ml of triethylamine was added 4.9 g (7.6 mmol) of 2,2-bis[3-bromophenoxy)-4-phenyl]hexafluoropropane, 6.5 g (22.8 mmol) of 1-phenoxy-3-(m-ethynylphenoxy)benzene and 0.4 g of triphenylphosphine. The solution was stirred under nitrogen for 10 minutes at RT. 0.2 g of cuprous iodide and 0.2 g of bis(triphenylphosphine)Pd dichloride were added to the reaction mixture. The resulting solution was heated to reflux for 6 hours under a nitrogen atmosphere. The reaction mixture was cooled to RT. The volume of the reaction mixture was reduced and the product was then isolated by filtration. The filtrate was extracted with 15% HCl (2.times.100 ml) then washed with water (2.times.200 ml), then dried over anhydrous magnesium sulfate. Removal of the residual solvent afforded 10.35 g of crude product. The product was purified by column chromatography on silica gel using 4:1 hexane:methylene chloride. The product was dried under reduced pressure at 50.degree. C. (5.4 g, Yield 68%)

Analysis: Calc'd for C.sub.67 H.sub.42, O.sub.6 F.sub.6 : C, 76.13; H, 3.98. Found: C, 75.93; H, 4.14.

EXAMPLE V

The uncured and cured glass transition temperatures of each of the compounds prepared in Examples I-IV are shown in the following Table. The uncured Tg was determined by DSC at a heating rate of 20.degree. C./min. The cured Tg was determined by TMA at a heating rate of 20.degree. C./min. These compounds were cured by heating at 300.degree.-312.degree. C. for 8-16 hours.

TABLE______________________________________Resin(Example No.) Tg (.degree.C.) Uncured Tg (.degree.C.) Cured______________________________________I -1 246II 35 177III 48 105IV 16 127______________________________________

EXAMPLE VI

Samples of the compounds prepared according to Examples I and II were cured in air at 300.degree. C. for 8 hours. Isothermal aging studies were carried out to determine the thermooxidative stabilities of the cured polymers by exposing the cured samples to air flowing at 40 cc/min. at 600.degree. F. for 200 hours. For comparison, compounds having the same backbone structures but having immediately terminal acetylenic groups were prepared.

Referring to the drawing, in FIG. 1 the thermooxidative stability of a cured sample of 1,3-bis-m-(phenylethynyl)-phenoxybenzene is compared to that of 1,3-bis-(m-ethynylphenoxy)benzene. It can be seen that the resin of this invention has vastly improved stability.

In FIG. 2 the thermooxidative stability of 4,4'-bis(3-phenylethynylphenoxy)diphenylsulfone is compared to that of 4,4'-bis(ethynyl-phenoxy)-diphenylsulfone. It can be seen that the resin of this invention has vastly improved stability.

Various modifications of the present invention may be made in view of the foregoing disclosure without departing from the spirit and scope of the invention.

Claims

1. A thermally stable resin of the general formula ##STR5## wherein Ar is a divalent aromatic moiety, n is an integer in the range of 1 to 3, and R is --H, --O--C.sub.6 H.sub.5, --O--C.sub.6 H.sub.5 or --O--C.sub.6 H.sub.4 --SO.sub.2 --C.sub.2 H.sub.5.

2. The resin of claim 1 wherein Ar is selected from the group consisting of ##STR6## wherein Y is --SO.sub.2 --, --C(CH.sub.3).sub.2 --, --C(CF.sub.3).sub.2 -- --S--, --O-- or --CO--.

3. The resin of claim 2 which is the cured product of 1,3-bis-m-(phenyl-ethynyl)phenoxy benzene.

4. The resin of claim 2 which is the cured product of 4,4'-bis-3-(phenyl-ethynyl)phenoxy diphenylsulfone.

5. The resin of claim 2 which is the cured product of 2,2-bis[([([3-phenoxy]-3-phenoxy)-3-phenylethynyl]-3-phenoxy)-4-phenyl]-propane.

6. The resin of claim 2 which is the cured product of 2,2-bis[([([3-phenoxy]-3-phenoxy)-3-phenylethynyl]-3-phenoxy)-4-phenyl]-hexafluoropropane.