Process for the production of molded polybenzimidazole articles and the resultant articles

Claim 2

A process for the production of shaped polybenzimidazole articles comprising: (a) preparing a solvent solution of a polybenzimidazole polymer wherein the inherent viscosity of the polybenzimidazole polymer is in the range of about 0.25 to 0.7; (b) forming a film from the solvent solution; (c) removing sufficient solvent from the film such that the film retains from about 10 to about 30 percent by weight of the solvent; (d) forming the film having retained solvent into particulates of sufficiently small size to be used in a molding process; and (e) molding the particles into a shaped article.

Claim 3

A process for the production of shaped polybenzimidazole articles comprising: (a) preparing a solvent solution of a polybenzimidazole polymer wherein the polybenzimidazole polymer exhibits an inherent viscosity of about 0.25 to 0.7 and wherein the solvent is selected from the group consisting of N,N-dimethylacetamide, N,N-dimethyl formamide, dimethyl sulfoxide and N-methyl-2-pyrrolidone; (b) forming a polybenzimidazole polymer film from the solvent solution; (c) removing sufficient solvent from the film such that the film retains about 15 to about 25 percent by weight of the solvent; (d) forming the film with retained solvent into particulates to a size from about 40 to about 100 mesh; and (e) compression molding the particulates with retained solvents, into shaped articles at a temperature from about 180° C. to about 260° C., using a compression mold.

Claim 4

A process for the production of shaped polybenzimidazole articles comprising: (a) preparing a solvent solution of a polybenzimidazole polymer wherein the polybenzimidazole polymer exhibits an inherent viscosity of about 0.25 to 0.7 and wherein the solvent is selected from the group consisting of N,N-dimethylacetamide, N,N-dimethyl formamide, dimethyl sulfoxide and N-methyl-2-pyrrolidone; (b) forming a polybenzimidazole polymer film from the solvent solution; (c) removing sufficient solvent from the film such that the film retains about 15 to about 25 percent by weight of the solvent; (d) forming the film with retained solvent into particulates to a size from about 40 to about 100 mesh; and (e) compression molding the particulates with retained solvents, into shaped articles at a temperature from about 180° C. to about 260° C., using a compression mold.

Claim 5

A process for the production of shaped polybenzimidazole articles comprising: (a) forming a solvent solution of a polybenzimidazole polymer wherein the polybenzimidazole polmyer exhibits an inherent viscosity of about 0.25 to 0.7 and wherein the solvent is selected from the group consisting of N,N-dimethylacetamide, N-N-dimethyl formamide, dimethyl sulfoxide and N-methyl-2-pyrrolidone; (b) forming a polybenzimidazole polymer film from the solvent solution; (c) removing sufficient solvent from the film such that the film retains about 10 to about 30 percent by weight of the solvent; (d) forming the film into a polybenzimidazole polymer particulate; and (e) molding the particulate into a shaped article employing a compression molding process.

Claim 6

A process for the production of shaped polybenzimidazole articles comprising: (a) forming a solvent solution of a polybenzimidazole polymer wherein the polybenzimidazole polmyer exhibits an inherent viscosity of about 0.25 to 0.7 and wherein the solvent is selected from the group consisting of N,N-dimethylacetamide, N-N-dimethyl formamide, dimethyl sulfoxide and N-methyl-2-pyrrolidone; (b) forming a polybenzimidazole polymer film from the solvent solution; (c) removing sufficient solvent from the film such that the film retains about 10 to about 30 percent by weight of the solvent; (d) forming the film into a polybenzimidazole polymer particulate; and (e) molding the particulate into a shaped article employing a compression molding process.

Claim 7

The process of claim 1 wherein the film formed in step (c) is crushed prior to molding.

Claim 8

The process of claim 1 wherein the film formed in step (c) is milled to form a polybenzimidazole polymer particulate prior to molding into the shaped article.

Claim 9

The process as in any of claims 1, 2, 3, 4 or 5 wherein sufficient solvent is removed from the deposited film such that the film retains about 15 to about 25 percent by weight of the solvent.

Claim 10

The process as in any of claims 1, 2, 3, 4 or 5 wherein the film is deposited upon the support to a wet film thickness of about 0.2 to 30.0 mils.

Claim 11

The process of claim 7 wherein the film is deposited on the support to a wet film thickness of about 5.0 to about 10.0 mils.

Claim 12

The process as in claims 1, 2, 3, 4 or 5 wherein the polybenzimidazole product is mixed with a filler, extender or reinforcing agent prior to molding.

Claim 13

The process as in any of claims 1, 2, 3, 4 or 5 wherein the polybenzimidazole product is mixed with graphite prior to molding.

Claim 14

The process as in any of claims 1, 2, 3, 4 or 5 wherein a reinforcing means is placed between two layers of the polybenzimidazole film prior to molding.

Claim 15

The process of claim 9 wherein the reinforcing means is a reinforcing fabric.

Claim 16

The process as in any of claims 1, 2, 3, 4 or 5 wherein the polybenzimidazole polymer consists essentially of recurring units of the formula: ##STR4## wherein R is a tetravalent aromatic nucleus, with the nitrogen atoms forming the benzimidazole rings paired upon adjacent carbon atoms of said aromatic nucleus, and R' is selected from the group consisting of (1) an aromatic ring, (2) an alkylene group having from four to eight carbon atoms, and (3) a heterocyclic ring selected from the group consisting of (a) pyridine, (b) pyrazine, (c) furan, (d) quinoline, (e) thiophene, and (f) pyran.

Claim 17

The process as in any of claims 1, 2, 3, 4 or 5 wherein the polybenzimidazole polymer consists essentially of recurring units of the formula: ##STR5## wherein Z is an aromatic nucleus having the nitrogen atoms forming the benzimidazole rings paired upon adjacent carbon atoms of said aromatic nucleus.

Claim 18

The process as in any of claims 1, 4 or 5 wherein the polybenzimidazole polymer is poly-2,2'-(m-phenylene)-5,5'-bibenzimidazole.

Claim 19

The process as in any of claims 1, 4 or 5 wherein the solvent for the polybenzimidazole polymer is selected from the group consisting of N,N-dimethylacetamide, N,N-dimethylformamide, dimethyl sulfoxide and N-methyl-2-pyrrolidone.

Claim 20

The process as in any of claims 1, 2, 3, 4 or 5 wherein the solvent is N,N-dimethylacetamide.

Claim 21

The product produced in accordance with the process as in any of claims 1, 2, 3, 4 or 5.

Claim 22

The product produced in accordance with the process of claim 6.

Claim 23

The product produced in accordance with the process of claim 9.

Claim 24

The product produced in accordance with the process of claim 10.

Claim 25

The product produced in accordance with the process of claim 11.

Claim 26

The product produced in accordance with the process of claim 12.

Claim 27

The product produced in accordance with the process of claim 13.

Claim 28

The product produced in accordance with the process of claim 14.

Claim 29

The product produced in accordance with the process of claim 15.