Crystallizable Polyetherimides, Method of Manufacture, and Articles Derived Therefrom
A composition is described, which comprises a crystallizable polyetherimide derived from the polymerization of: (a) a dianhydride component, comprising more than 96.8 mole % of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and (b) a diamine component comprising a diamine or a chemical equivalent thereof, wherein the crystallizable polyetherimide has a T m ranging from 250° C. to 400° C. and the difference between the T m and T g of the composition is more than 50° C. Further described are articles, such as fibers, made from the composition, methods for making the composition, methods for making the articles, and methods for using the articles.
1 . A composition comprising a crystallizable polyetherimide derived from:
(a) a dianhydride component, comprising 96.8 mole % or more of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and
(b) a diamine component comprising a diamine or a chemical equivalent thereof;
wherein the crystallizable polyetherimide has a T m from 250° C. to 400° C. and the difference between the T m and T g of the composition is equal to or more than 50° C.
2 . The composition of claim 1 , wherein the diamine component comprises para-phenylenediamine or a chemical equivalent thereof.
3 . The composition of claim 1 , wherein the diamine component consists essentially of para-phenylenediamine or a chemical equivalent thereof.
4 . The composition of claim 1 , wherein the diamine component is p-phenylenediamine and the composition further comprises less than 5.0 mole % of meta-phenylenediamine or a chemical equivalent thereof.
5 . The composition of claim 1 , wherein the diamine component is p-phenylenediamine, and wherein the composition further comprises less than 2.0 mole % of meta-phenylenediamine or a chemical equivalent thereof.
6 . The composition of claim 1 , wherein the diamine component is p-phenylenediamine substantially free of meta-phenylenediamine or a chemical equivalent thereof.
7 . The composition of claim 1 , wherein the diamine is selected from the group consisting of p-phenylenediamine; benzidine; 1,5-diaminonaphthalene; bis(4-aminophenyl)methane; bis(4-aminophenyl)propane; bis(4-aminophenyl)sulfide; bis(4-aminophenyl)sulfone; bis(4-aminophenyl)ether; 4,4′-diaminodiphenylpropane; 4,4′-diaminodiphenylmethane(4,4′-methylenedianiline); 4,4′-diaminodiphenylsulfide; 4,4′-diaminodiphenylsulfone; 4,4′-diaminodiphenylether(4,4′-oxydianiline); 1,5-diaminonaphthalene; 3,3′dimethylbenzidine; 4,3′-diaminodiphenylether; 1,3-bis(4-aminophenoxy)benzene; 4,4′-bis(4-aminophenoxy)biphenyl; chemical equivalents of the foregoing diamines; and combinations thereof.
8 . The composition of claim 1 , wherein the composition further comprises at least one stabilizer.
9 . The composition of claim 8 , wherein the stabilizer is a phosphorous-containing stabilizer.
10 . The composition of claim 1 , having an apparent viscosity, measured at a shear rate of 1000 s −1 , of more than 0 and less than 10,000 poise at a temperature of less than 400° C.
11 . The composition of claim 1 , having a viscosity, measured at a shear rate of 1000 s −1 , of more than 100 and less than 7000 poise at a temperature of less than 400° C.
12 . The composition of claim 1 , wherein a fiber comprising the composition has a tensile strength from 2 to 20 grams per denier.
13 . The composition of claim 1 , wherein a fiber comprising the composition a hot-air shrinkage of less than or equal to 20% after exposure to 260° C. air for 10 minutes.
14 . The composition of claim 1 , wherein a fiber comprising the composition a hot-air shrinkage of less than or equal to 10% after exposure to 260° C. air for 10 minutes.
15 . The composition of claim 1 , wherein the composition further comprises an end-capping agent.
16 . The composition of claim 15 , wherein the endcapping agent is selected from the group consisting of phthalic anhydride, aniline, and combinations thereof.
17 . A fiber comprising
a crystallized polyetherimide composition derived from the polymerization of:
(a) a dianhydride component, comprising more than 96.8 mole % of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and
(b) a diamine component comprising a diamine or a chemical equivalent thereof;
wherein the fiber has a T m from 250° C. to 400° C. and the difference between the T m and T g of the fiber is equal to or more than 50° C.
18 . The fiber of claim 17 , wherein the diamine component comprises para-phenylenediamine or a chemical equivalent thereof.
19 . The fiber of claim 17 , wherein the diamine component consists essentially of para-phenylenediamine or a chemical equivalent thereof.
20 . The fiber of claim 17 , wherein the diamine component is p-phenylenediamine, and the composition further comprises less than 5.0 mole % of meta-phenylenediamine or a chemical equivalent thereof.
21 . The fiber of claim 17 , wherein the diamine component is p-phenylenediamine, and the composition further comprises less than 2.0 mole % of meta-phenylenediamine or a chemical equivalent thereof.
22 . The fiber of claim 17 , wherein the diamine is selected from the group consisting of p-phenylenediamine; benzidine; 1,5-diaminonaphthalene; bis(4-aminophenyl)methane; bis(4-aminophenyl)propane; bis(4-aminophenyl)sulfide; bis(4-aminophenyl)sulfone; bis(4-aminophenyl)ether; 4,4′-diaminodiphenylpropane; 4,4′-diaminodiphenylmethane(4,4′-methylenedianiline); 4,4′-diaminodiphenylsulfide; 4,4′-diaminodiphenylsulfone; 4,4′-diaminodiphenylether(4,4′-oxydianiline); 1,5-diaminonaphthalene; 3,3′dimethylbenzidine; 4,3′-diaminodiphenylether; 1,3-bis(4-aminophenoxy)benzene; 4,4′-bis(4-aminophenoxy)biphenyl; chemical equivalents of the foregoing diamines; and combinations thereof.
23 . The fiber of claim 17 , wherein the composition further comprises at least one stabilizer.
24 . The fiber of claim 23 , wherein the stabilizer is a phosphorous-containing stabilizer.
25 . The fiber of claim 17 , wherein the composition further comprises an end-capping agent.
26 . The composition of claim 17 , wherein the endcapping agent is selected from the group consisting of phthalic anhydride, aniline, and combinations thereof.
27 . The fiber of claim 17 , wherein the fiber has a tensile strength from 2 to 20 grams per denier.
28 . The fiber of claim 17 , wherein the fiber has a hot-air shrinkage of less than or equal to 20% after exposure to 260° C. air for 10 minutes.
29 . The fiber of claim 17 , wherein the fiber has a hot-air shrinkage of less than or equal to 10% after exposure to 260° C. air for 10 minutes.
30 . An article comprising a plurality of the fibers of claim 17 .
31 . The article of claim 30 , wherein article is a non-woven fabric.
32 . The article of claim 30 , wherein article is a woven fabric.
33 . A method of making a fiber, comprising
extruding, through an orifice under conditions sufficient to form at least one fiber, a crystallizable polyetherimide composition derived from the polymerization of:
(a) a dianhydride component, comprising more than 96.8 mole % of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and
(b) a diamine component comprising a diamine or a chemical equivalent thereof;
wherein the crystallizable polyetherimide has a T m ranging from 250° C. to 400° C. and the difference between the T m and T g of the composition is equal to or more than 50° C.
34 . The method of claim 33 wherein the method further comprises drawing the at least one fiber.
35 . The method of claim 33 , wherein the method further comprises heat-treating the at least one fiber under a constraint effective to crystallize the polyetherimide.
36 . The method of claim 33 , wherein the method further comprises weaving fiber into a fabric.
37 . The method of claim 33 , wherein the method further comprises combining a plurality of the fibers into a yarn and then weaving a fabric from the yarn.
38 . A crystallizable polyetherimide composition derived from the polymerization of:
(a) a dianhydride component, comprising more than 96.8 mole % of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and
(b) a diamine component comprising p-phenylene diamine or a chemical equivalent thereof, and having less than 5 mole % meta-phenylenediamine or a chemical equivalent thereof;
wherein the crystallizable polyetherimide composition has
a T m from 250° C. to 400° C.;
a viscosity, measured at a shear rate of 1000 s −1 , of more than 100 and less than 10,000 poise at a temperature of less than 400° C., and further
wherein the difference between the T m and a T g of the crystallizable polyetherimide composition is equal to or greater than 50° C.
39 . The composition of claim 38 , wherein the diamine component consists essentially of para-phenylenediamine or a chemical equivalent thereof.
40 . The composition of claim 38 , wherein the diamine component is p-phenylenediamine and the composition further comprises less than 5.0 mole % of meta-phenylenediamine or a chemical equivalent thereof.
41 . The composition of claim 38 , wherein the composition has a viscosity, measured at a shear rate of 1000 s −1 , of more than 100 and less than 10,000 poise at a temperature of less than 400° C.
42 The composition of claim 38 , wherein the composition further comprises an end-capping agent.
43 . The composition of claim 42 , wherein the endcapping agent is selected from the group consisting of phthalic anhydride, aniline, and combinations thereof.