High-molecular weight polymers and methods of manufacture

Abstract

A composition comprises a solid-stated block copolymer of an aromatic polyester and a caprolactone, wherein the copolymer has been solid state polymerized such that intrinsic viscosity increases at least 20%, the caprolactone content decreases no more than 1.2% absolute and the transesterification increases no more than 3.5% absolute, and wherein the solid-stated copolymer has an intrinsic viscosity of at least 0.82. Particularly preferred chain extension reactions are performed at a temperature of less than 175° C., and even more preferably at less than 165° C. In further aspects of the inventive subject matter, yarns and methods of producing a fiber include contemplated solid-stated block copolymers.

1 . A composition comprising: 
 a solid state polymerized block copolymer comprising an aromatic polyester and a caprolactone, wherein the copolymer has been polymerized in the solid state at a temperature sufficient to achieve an increase in intrinsic viscosity of at least 20%, a decrease in caprolactone content of no more than 1.2% absolute, and an increase in transesterification of no more than 3.5% absolute; and    wherein the solid-stated block copolymer has an intrinsic viscosity of at least 0.82, a caprolactone content of less than 15 wt % and less than 6% transesterification.    
     
     
         2 . The composition of  claim 1  wherein the aromatic polyester comprises a compound selected from the group consisting of a poly(alkylene terephthalate), a poly(alkylene naphthalate), and a poly(cycloalkylene naphthalate).  
     
     
         3 . The composition of  claim 1  wherein the copolymer has been solid-state polymerized at a temperature of no more than 175° C.  
     
     
         4 . The composition of  claim 1  wherein the copolymer has been solid-state polymerized at a temperature of no more than 165° C.  
     
     
         5 . The composition of  claim 4  wherein the aromatic polyester comprises poly(ethylene terephthalate).  
     
     
         6 . The composition of  claim 5  wherein the decrease in caprolactone content is no more than 0.1% absolute.  
     
     
         7 . The composition of  claim 6  wherein the increase in transesterification is no more than 0.2% absolute.  
     
     
         8 . The composition of  claim 3  wherein the increase in intrinsic viscosity is at least 35%, and wherein the aromatic polyester comprises poly(ethylene terephthalate).  
     
     
         9 . The composition of  claim 8  wherein the increase in transesterification is no more than 0.6% absolute.  
     
     
         10 . The composition of  claim 1  wherein the caprolactone content is no more than 30 mol %.  
     
     
         11 . The composition of  claim 1  wherein the caprolactone content is no more than 15 mol %.  
     
     
         12 . A chip comprising the composition of  claim 1 .  
     
     
         13 . A Film comprising the composition of  claim 1 .  
     
     
         14 . A yarn comprising a fiber produced from the composition of  claim 1 .  
     
     
         15 . A yarn comprising a fiber produced from the composition of  claim 6 .  
     
     
         16 . A yarn comprising a fiber produced from the composition of  claim 7 .  
     
     
         17 . A yarn comprising a fiber produced from the composition of  claim 8 .  
     
     
         18 . A webbing comprising the composition of  claim 1 .  
     
     
         19 . A seat belt comprising the webbing of  claim 18 .  
     
     
         20 . (Canceled)  
     
     
         21 . (Canceled)  
     
     
         22 . (Canceled)  
     
     
         23 . (Canceled)  
     
     
         24 . (Canceled)