Polyethersulfone prepregs, composites, and blends

Claim 2

A prepreg comprising an oligmer formed by reacting: (1) 2 moles of A--OH (2) n+1 moles of a dihalogen of the general formula x--R--X and (3) n moles of a bisphenol of the general formula HO--R'--OH, wherein A is selected from the group consisting of: Y i --φ--i=1 or 2; Y= ##STR17## φ=phenyl; R 1 =lower alkyl, aryl, substituted alkyl, substituted aryl, lower alkoxy, aryloxy, or mixtures thereof; G=--SO 2 --, --S--, --CH 2 --, or --O--; J=1 or 2; R=an aromatic radical; R'=an aromatic radical; n=an integrer such that the oligomer has an average formula weight of between about 1,000 to about 40,000; Me=methyl; and T=allyl or methallyl and a additive in fiber or particulate form.

Claim 3

An oligomer formed by the condensation of: (a) 2 moles of a crosslinkable imidophenol having at least two crosslinking functionalities; (b) n+1 moles of an aromatic dihalogen; and n moles of an aromatic bisphenol.

Claim 4

An oligomer formed by the condensation of: (a) 2 moles of a crosslinkable imidophenol having at least two crosslinking functionalities; (b) n+1 moles of an aromatic dihalogen; and n moles of an aromatic bisphenol.

Claim 5

The oligomer of claim 2 wherein the imidophenol is selected from the group consisting of: ##STR18## wherein Y is selected from the group consisting of: ##STR19## R 1 =lower alkyl, aryl, substituted alkyl, substituted aryl, lower alkoxy, aryloxy, or mixtures thereof; G=--SO 2 --, --S--, --CH 2 --, or --O--; j=0, 1 or 2; Me=methyl; and E=allyl or methallyl.

Claim 6

The oligomer of claim 3 wherein the dihalogen is selected from the group consisting of: ##STR20## wherein q=--SO 2 --, --S--, --CO--, --(CH 3 ) 2 C--, or --(CF 3 ) 2 C--.

Claim 7

The oligomer of claim 3 wherein the bisphenol is selected from the group consisting of: hydroquinone; bisphenol A; p, p'-biphenol 4, 4'-dihydroxydiphenylsulfide; 4, 4'-dihydroxydiphenylether; 4, 4'-dihydroxydiphenylisopropane; 4, 4'-dihydroxydiphenylhexafluoropropane; HO--AR--OH; HO--Ar--L--AR'--L--AR--OH; HO--Ar'--Ar--L--AR'--OH; wherein L=--CH 2 --, --(CH 3 ) 2 C--, --(CH 3 ) 2 C--, --O--, --S--, --SO 2 -- or --CO--; Ar'= ##STR21## Ar= ##STR22## T and T 1 =lower alkyl, lower alkoxy, aryl, aryloxy, substituted alkyl, substituted aryl, or mixtures thereof; q=0-4; k=0-3; and j=0, 1, or 2; a dialcohol having a Schiff base segment, the radical being selected from the group consisting of: ##STR23## wherein R is selected from the group consisting of: phenyl; biphenyl; naphthyl; or a radical of the generally formula: ##STR24## wherein W=--CH 2 -- or --SO 2 ; or a dialcohol selected from the group: ##STR25## wherein L is as defined above; Me=CH-- 3 ; m=an integer, generally less than 5; and D=any of --CO--, --SO 2 --, or --(CF 3 ) 2 C--.

Claim 8

The oligomer of claim 4 wherein the disphenol is selected from the group consisting of: hydroquinone; bisphenol A; p, p'-biphenol 4, 4'-dihydroxydiphenylsulfide;

Claim 9

4'-dihydroxydiphenylether; 4, 4'-dihydroxydiphenylisopropane; 4, 4'-dihydroxydiphenylhexafluoropropane; HO--Ar--OH; HO--Ar--L--AR'--L--AR--OH; HO--Ar'--L--AR--L--Ar'--OH; ##STR26## wherein L=--CH 2 --, --(CH 3 ) 2 C--, --(CH 3 ) 2 C--, --O--, --S--, --SO 2 -- or --CO--; Ar'= ##STR27## AR= ##STR28## T and T 1 =lower alkyl, lower alkoxy, aryl, aryloxy, substituted alkyl, substituted aryl, or mixtures thereof; q=0-4; k=0-3; and j=0, 1, or 2; or a dialcohol having a Schiff base segment, the radical being selected from the group consisting of: ##STR29## wherein R is selected from the group consisting of: phenyl; biphenyl; naphthyl; or a radical of the general formula: ##STR30## wherein W=--CH 2 -- or --SO 2 --.

Claim 10

4'-dihydroxydiphenylether; 4, 4'-dihydroxydiphenylisopropane; 4, 4'-dihydroxydiphenylhexafluoropropane; HO--Ar--OH; HO--Ar--L--AR'--L--AR--OH; HO--Ar'--L--AR--L--Ar'--OH; ##STR26## wherein L=--CH 2 --, --(CH 3 ) 2 C--, --(CH 3 ) 2 C--, --O--, --S--, --SO 2 -- or --CO--; Ar'= ##STR27## AR= ##STR28## T and T 1 =lower alkyl, lower alkoxy, aryl, aryloxy, substituted alkyl, substituted aryl, or mixtures thereof; q=0-4; k=0-3; and j=0, 1, or 2; or a dialcohol having a Schiff base segment, the radical being selected from the group consisting of: ##STR29## wherein R is selected from the group consisting of: phenyl; biphenyl; naphthyl; or a radical of the general formula: ##STR30## wherein W=--CH 2 -- or --SO 2 --.

Claim 11

The prepreg of claim 1 wherein R= ##STR31## wherein w=--SO 2 --, --S--, or --(CF 3 ) 2 C--; and R'=phenyl, biphenyl, naphthyl, or ##STR32## wherein y=--SO 2 --, --S--, --(CF 3 ) 2 C--, --O--, or --(CH 3 ) 2 C--.

Claim 12

A cured, solvent resistant, thermoplastic composite formed by cured the prepreg of claim 1.

Claim 13

A composite formed by curing the oligomer of claim 2.

Claim 14

A prepreg the oligomer of claim 2 and a reinforcing additive in fiber or particulate form.

Claim 15

A prepreg comprising the oligomer of claim 3 and a reinforcing additive in fiber or particulate form.

Claim 16

A prepreg comprising the oligomer of claim 6 and a reinforcing additive in fiber or particulate form.

Claim 17

The oligomer of claim 2 further comprising a suitable coreactant.

Claim 18

A prepreg comprising the oligomer of claim 13 and a reinforcing additive in fiber or particulate form.

Claim 19

The oligomer of claim 13 wherein the coreactant is selected from the group consisting of p-phenylenediamine, benzidine, 4,4'-methylenedianiline, an alkyl diamine having from 2-6 carbon atoms in the alkyl chain, or mixtures thereof, and the oligomer includes an imidophenol having maleic crosslinking functionalities.

Claim 20

The oligomer of claim 13 wherein the coreactant is selected from the group consisting of: ##STR33## wherein R 1 =lower alkyl, aryl, substituted aryl, lower alkoxy, or mixtures thereof; j=0, 1 or 2; and R=alkyl having 2-6 carbon atoms or an aromatic radical selected from the group consisting of phenyl, biphenyl, and --φ--CH 2 --φ--, and the oligomer includes an imidophenol having norborene crosslinking functionalities.

Claim 21

The oligomer of claim 13 wherein the coreactant is selected from the group consisting of: ##STR34## wherein R=alkyl having 2-6 carbon atoms or an aromatic radical selected from the group consisting of phenyl, biphenyl, and --φ--CH 2 --φ-- and the oligomer includes acetylenic crosslinking functionalities.

Claim 22

A composite formed by during the oligomer of claim 13.