Process for preparing anisotropic oleum dopes of polyamides by polymerizing in sulfur trioxide

Claim 2

A process for producing an anisotropic oleum dope of an aromatic polyamide comprising reacting substantially equimolar amounts of at least one diamine monomer selected from the group consisting of diamines of the formulas: ##STR10## with at least one monomer of the formula Z--Ar.sub.2 --Z (III) in sulfur trioxide initially containing from 0 to 20% by weight sulfuric acid for a period of time sufficient to obtain in solution a polyamide having an inherent viscosity of at least 0.1, wherein n is 1, 2, 3 or 4, Ar 1 and Ar 2 are each a radical selected from the group consisting of ##STR11## where "a" is a hydrogen, bromine, fluorine or chlorine atom, Z is a radical selected from the group consisting of --COOH, --CCl 3 , and --CBr 3 and wherein said inherent viscosity is measured by dilution at 25° C. of a portion of said dope with 96% sulfuric acid to a polymer concentration of 0.84 g/dl, said process being characterized in that sufficient amounts of monomers are reacted to provide a dope having a polymer concentration above its critical concentration point.

Claim 3

The process of claim 1 wherein Ar 1 is ##STR12## and Ar 2 is ##STR13##

Claim 4

The process of claim 2 wherein said sulfur trioxide contains no sulfuric acid.

Claim 5

A process for producing an anisotropic oleum dope of aromatic polyamide which comprises: (a) forming a monomer solution by dissolving substantially equimolar amounts of a diamine monomer selected from the group consisting of diamines of the formulas ##STR14## and a monomer of the formula Z--Ar.sub.2 --Z (III) in sulfur trioxide containing from 0 to 20% by weight sulfuric acid while maintaining the temperature of the sulfur trioxide below that at which polymerization of the monomers occurs, wherein a sufficient amount of said formula (III) monomer is employed to provide a solution containing from 8.5 to 13.5 moles of sulfur trioxide per mole of formula (III) monomer; (b) polymerizing said monomers by raising the temperature of said monomer solution until polymerization occurs at a desired rate; (c) continuing said polymerization for a period of time sufficient to provide a dope consisting essentially of oleum and polymer having an inherent viscosity of at least 0.1 when measured on a solution thereof having a polymer concentration of 0.84 g/dl and obtained by diluting at 25° C. of a portion of the dope with 96% sulfuric acid; wherein n is 1, 2, 3 or 4, Ar 1 and Ar 2 are each a radical selected from the group consisting of ##STR15## where "a" is a hydrogen, chlorine, bromine or fluorine atom, Z is a radical selected from the group consisting of --COOH, --CCl 3 , and --CBr 3 .

Claim 6

A process for producing an anisotropic oleum dope of aromatic polyamide which comprises: (a) forming a monomer solution by dissolving substantially equimolar amounts of a diamine monomer selected from the group consisting of diamines of the formulas ##STR14## and a monomer of the formula Z--Ar.sub.2 --Z (III) in sulfur trioxide containing from 0 to 20% by weight sulfuric acid while maintaining the temperature of the sulfur trioxide below that at which polymerization of the monomers occurs, wherein a sufficient amount of said formula (III) monomer is employed to provide a solution containing from 8.5 to 13.5 moles of sulfur trioxide per mole of formula (III) monomer; (b) polymerizing said monomers by raising the temperature of said monomer solution until polymerization occurs at a desired rate; (c) continuing said polymerization for a period of time sufficient to provide a dope consisting essentially of oleum and polymer having an inherent viscosity of at least 0.1 when measured on a solution thereof having a polymer concentration of 0.84 g/dl and obtained by diluting at 25° C. of a portion of the dope with 96% sulfuric acid; wherein n is 1, 2, 3 or 4, Ar 1 and Ar 2 are each a radical selected from the group consisting of ##STR15## where "a" is a hydrogen, chlorine, bromine or fluorine atom, Z is a radical selected from the group consisting of --COOH, --CCl 3 , and --CBr 3 .

Claim 7

The process of claim 4 wherein step (a) is accomplished by dissolving said diamine monomer in said sulfur trioxide after dissolution of said formula (III) monomer.

Claim 8

The process of claim 5 wherein said aromatic polyamide is fiber-forming.

Claim 9

The process of claim 6 wherein the process is carried out under anhydrous conditions.

Claim 10

The process of claim 6 wherein said sulfur trioxide contains no sulfuric acid.

Claim 11

The process of claim 6 wherein said formula (III) monomer is terephthalic acid.

Claim 12

The process of claim 9 wherein said diamine monomer is of the formula ##STR16##

Claim 13

The process of claim 10 wherein the temperature of said sulfur trioxide during step (a) is below 80° C.

Claim 14

The process of claim 11 wherein polymerization is carried out at a temperature between 80° C. and 140° C.

Claim 15

The process according to claim 12 wherein said temperature is about 100° C.

Claim 16

The process of claim 10 wherein said diamine monomer is of the formula ##STR17##

Claim 17

The process of claim 10 wherein said diamine monomer is of the formula ##STR18##

Claim 18

The process of claim 10 wherein said diamine monomer is of the formula ##STR19##

Claim 19

The process of claim 9 wherein said diamine monomer is of the formula ##STR20##

Claim 20

The process according to claim 5 wherein up to 30 mole % of said diamine monomer is replaced with hydrazine sulfate in an amount ranging from 0 to 5% excess of the equivalent molar amount of monomer replaced.

Claim 21

The process of claim 18 wherein 10 mole % of said diamine monomer is replaced with hydrazine sulfate.