Aromatic polyamides containing ether linkages and process for producing same

Claim 2

An aromatic polyamide polymer produced by polymerization of an aromatic diamine having the general formula: ##STR3## wherein R 1 through R 4 are the same or different, and are members selected from the group consisting of H, Cl and CH 3 , and wherein R 5 and R 6 are the same or different, and are the members selected from the group consisting of H, CH 3 , C 2 H 5 and C 3 H 7 , the total carbon number of R 5 and R 6 being no greater than 4; with an equivalent amount of a mixture of terephthalic acid dichloride and isophthalic acid dichloride in molar proportions of from 80:20 to 20:80, said polymer having a reduced viscosity of 0.3 to 1.5 dl/g, and initial weight loss temperature of 380° C. or above, and an initial flow temperature of at least 80° C. lower than the initial weight loss temperature, whereby said aromatic polyamide polymer has melt moldability, in which said polymer is obtained by reacting said diamine and said mixture in a water-immiscible, chemically inert, organic solvent in the presence of an aqueous solution of an alkali-metal hydroxide or carbonate in an amount sufficient to neutralize an acidic substance generated in the reaction.

Claim 3

An aromatic polyamide according to claim 1, wherein said diamine is at least one member selected from the group consisting of 4,4'-di(p-aminophenoxy)diphenylmethane; 4,4'-di(p-aminophenoxy)-3,3'-dichlorodiphenylmethane; 4,4'-di(p-aminophenoxy)-3,3'-dimethyldiphenylmethane; 4,4'-di(p-aminophenoxy)-3,3',5,5'-tetramethyldiphenylmethane; 4,4'-di(p-aminophenoxy)-diphenylpropane-(2,2); 4,4'-di(p-aminophenoxy)-3,3'-dichlorodiphenylpropane-(2,2); 4,4'-di(p-aminophenoxy)-3,3'-dimethyldiphenylpropane-(2,2); 4,4'-di(p-aminophenoxy)-3,3'-dimethyldiphenylpropane-(2,2); and 4,4'-di(p-aminophenoxy)-3,3'-dichlorodiphenylpentane-(3,3).

Claim 4

An aromatic polyamide polymer according to claim 1, wherein the mixture is an equimolar mixture of terephthalic acid dichloride and isophthalic acid dichloride.

Claim 5

An aromatic polyamide polymer according to claim 2, wherein said diamine is 4,4'-di(p-aminophenoxy)diphenylpropane-(2,2).

Claim 6

A process for preparing an aromatic polymer which comprises: reacting an aromatic diamine having the general formula: ##STR4## wherein R 1 through R 4 are the same or different, and are members selected from the group consisting of H, Cl and CH 3 , and R 5 and R 6 are the same or different, and are members selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , the total carbon number of R 5 and R 6 being no greater than 4, with a mixture of terephthalic acid dichloride and isophthalic acid dichloride in molar proportions of from 80:20 to 20:80 dissolved in a water-immiscible organic solvent which is chemically inert to said diamine and mixture as well as to the polyamide polymer and is capable of dissolving said diamine and mixture in the presence of an aqueous solution of an alkali-metal hydroxide or carbonate in an amount sufficient to neutralize an acidic substance generated in the reaction, under agitation at a temperature of 40° C. or below for a time sufficient to provide the polyamide polymer with a reduced viscosity of 0.3 to 1.5 dl/g, an initial weight loss temperature of 380° C. or above, and an initial flow temperature of at least 100° C. lower than the initial weight loss temperature; and recovering the resulting polyamide polymer from the reaction system, whereby said polyamide polymer has a melt moldability.

Claim 7

A process for preparing an aromatic polymer which comprises: reacting an aromatic diamine having the general formula: ##STR4## wherein R 1 through R 4 are the same or different, and are members selected from the group consisting of H, Cl and CH 3 , and R 5 and R 6 are the same or different, and are members selected from the group consisting of H, CH 3 , C 2 H 5 , C 3 H 7 , the total carbon number of R 5 and R 6 being no greater than 4, with a mixture of terephthalic acid dichloride and isophthalic acid dichloride in molar proportions of from 80:20 to 20:80 dissolved in a water-immiscible organic solvent which is chemically inert to said diamine and mixture as well as to the polyamide polymer and is capable of dissolving said diamine and mixture in the presence of an aqueous solution of an alkali-metal hydroxide or carbonate in an amount sufficient to neutralize an acidic substance generated in the reaction, under agitation at a temperature of 40° C. or below for a time sufficient to provide the polyamide polymer with a reduced viscosity of 0.3 to 1.5 dl/g, an initial weight loss temperature of 380° C. or above, and an initial flow temperature of at least 100° C. lower than the initial weight loss temperature; and recovering the resulting polyamide polymer from the reaction system, whereby said polyamide polymer has a melt moldability.

Claim 8

A process for preparing an aromatic polyamide polymer according to claim 5, wherein said aromatic diamine is at least one member selected from the group consisting of 4,4'-di(p-aminophenoxy)-diphenylmethane, 4,4'-di(p-aminophenoxy)-3,3'-dichlorodiphenylmethane, 4,4'-di(p-aminophenoxy)-3,3'-dimethyldiphenylmethane, 4,4'-di(p-aminophenoxy)-3,3',5,5'-tetramethyldiphenylmethane, 4,4'-di(p-aminophenoxy) diphenylpropane-(2,2),4,4'-di(p-aminophenoxy)-3,3'-dichlorodiphenylpropane-(2,2),4,4'-di(p-aminophenoxy)-3,3'-dimethyldiphenylpropane-(2,2), 4,4'-di(p-aminophenoxy)-3,3', 5,5'-tetramethyldiphenylpropane-(2,2), and 4,4'-di(p-aminophenoxy)-3,3'-dichlorodiphenylpentane-(3,3).

Claim 9

A process for preparing an aromatic polyamide polymer according to claim 5, wherein the mixture is an equimolar mixture of terephthalic acid dichloride and isophthalic acid dichloride.

Claim 10

A process for preparing an aromatic polyamide polymer according to claim 5, wherein said solvent is a member selected from the group consisting of cyclohexanone, diisobutylketone, acetophenone, p-methylacetophenone, p-methoxyacetophenone, methylene dichloride, dichloroethane, chloroform and nitrobenzene.

Claim 11

A process for preparing an aromatic polyamide polymer according to claim 5, wherein up to 50% of said diamine is replaced by at least one member selected from the group consisting of p-phenylenediamine, m-phenylenediamine, 4,4'-diaminodiphenylmethane, 4,4'-diaminodiphenyl ether, 4,4'-diaminodiphenylsulfone, 4,4'-diaminodiphenyl sulfide, 4,4'-diaminodiphenylpropane-(2,2), and 1,5-diaminonaphthalene.

Claim 12

A melt-moldable aromatic polyamide polymer, which is a polycondensation product of an aromatic diamine selected from the group consisting of 4,4'-di(p-aminophenoxy)diphenylpropane-(2,2), 4,4'-di(p-aminophenoxy)-3,3',5,5'-tetramethyldiphenylmethane, 4,4'-di(p-aminophenoxy)-3,3'-dichlorodiphenylpropane-(2,2), and 4,4'-di(p-aminophenoxy)-3,3'-dimethyldiphenylpropane-(2,2), with an equivalent amount of a mixture of terephthalic acid dichloride and isophthalic acid dichloride in molar proportions of from 80:20 to 20:80, said polycondensation product having a reduced viscosity of 0.55 to 0.9, an initial weight loss temperature of 380° C. or above, and an initial flow temperature of at least 100° C. lower than the initial weight loss temperature.

Claim 13

A melt-moldable aromatic polyamide polymer, which is a polycondensation product of an aromatic diamine selected from the group consisting of 4,4'-di(p-aminophenoxy)diphenylpropane-(2,2), 4,4'-di(p-aminophenoxy)-3,3',5,5'-tetramethyldiphenylmethane, 4,4'-di(p-aminophenoxy)-3,3'-dichlorodiphenylpropane-(2,2), and 4,4'-di(p-aminophenoxy)-3,3'-dimethyldiphenylpropane-(2,2), with an equivalent amount of a mixture of terephthalic acid dichloride and isophthalic acid dichloride in molar proportions of from 80:20 to 20:80, said polycondensation product having a reduced viscosity of 0.55 to 0.9, an initial weight loss temperature of 380° C. or above, and an initial flow temperature of at least 100° C. lower than the initial weight loss temperature.

Claim 14

A melt-moldable aromatic polyamide polymer according to claim 10, wherein up to 50% of said diamine is replaced by a member selected from the group consisting of m-phenylene diamine and 4,4'-diaminodiphenylether.

Claim 15

A melt-moldable polyamide polymer according to claim 10, wherein the mixture of said terephthalic acid dichloride and isophthalic acid dichloride is an equimolar mixture.

Claim 16

A melt-molded article consisting of the polyamide polymer as defined in claim 11.

Claim 17

A melt-molded article consisting of the polyamide polymer as defined in claim 12.