Crystallizable Polyetherimides, Method of Manufacture, and Articles Derived Therefrom

Abstract

A composition is described, which comprises a crystallizable polyetherimide derived from the polymerization of: (a) a dianhydride component, comprising more than 96.8 mole % of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and (b) a diamine component comprising a diamine or a chemical equivalent thereof, wherein the crystallizable polyetherimide has a T m ranging from 250° C. to 400° C. and the difference between the T m and T g of the composition is more than 50° C. Further described are articles, such as fibers, made from the composition, methods for making the composition, methods for making the articles, and methods for using the articles.

What is claimed is: 
     
         1 . A composition comprising a crystallizable polyetherimide derived from:
 (a) a dianhydride component, comprising 96.8 mole % or more of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and   (b) a diamine component comprising a diamine or a chemical equivalent thereof;   wherein the crystallizable polyetherimide has a T m  from 250° C. to 400° C. and the difference between the T m  and T g  of the composition is equal to or more than 50° C.   
     
     
         2 . The composition of  claim 1 , wherein the diamine component comprises para-phenylenediamine or a chemical equivalent thereof. 
     
     
         3 . The composition of  claim 1 , wherein the diamine component consists essentially of para-phenylenediamine or a chemical equivalent thereof. 
     
     
         4 . The composition of  claim 1 , wherein the diamine component is p-phenylenediamine and the composition further comprises less than 5.0 mole % of meta-phenylenediamine or a chemical equivalent thereof. 
     
     
         5 . The composition of  claim 1 , wherein the diamine component is p-phenylenediamine, and wherein the composition further comprises less than 2.0 mole % of meta-phenylenediamine or a chemical equivalent thereof. 
     
     
         6 . The composition of  claim 1 , wherein the diamine component is p-phenylenediamine substantially free of meta-phenylenediamine or a chemical equivalent thereof. 
     
     
         7 . The composition of  claim 1 , wherein the diamine is selected from the group consisting of p-phenylenediamine; benzidine; 1,5-diaminonaphthalene; bis(4-aminophenyl)methane; bis(4-aminophenyl)propane; bis(4-aminophenyl)sulfide; bis(4-aminophenyl)sulfone; bis(4-aminophenyl)ether; 4,4′-diaminodiphenylpropane; 4,4′-diaminodiphenylmethane(4,4′-methylenedianiline); 4,4′-diaminodiphenylsulfide; 4,4′-diaminodiphenylsulfone; 4,4′-diaminodiphenylether(4,4′-oxydianiline); 1,5-diaminonaphthalene; 3,3′dimethylbenzidine; 4,3′-diaminodiphenylether; 1,3-bis(4-aminophenoxy)benzene; 4,4′-bis(4-aminophenoxy)biphenyl; chemical equivalents of the foregoing diamines; and combinations thereof. 
     
     
         8 . The composition of  claim 1 , wherein the composition further comprises at least one stabilizer. 
     
     
         9 . The composition of  claim 8 , wherein the stabilizer is a phosphorous-containing stabilizer. 
     
     
         10 . The composition of  claim 1 , having an apparent viscosity, measured at a shear rate of 1000 s −1 , of more than 0 and less than 10,000 poise at a temperature of less than 400° C. 
     
     
         11 . The composition of  claim 1 , having a viscosity, measured at a shear rate of 1000 s −1 , of more than 100 and less than 7000 poise at a temperature of less than 400° C. 
     
     
         12 . The composition of  claim 1 , wherein a fiber comprising the composition has a tensile strength from 2 to 20 grams per denier. 
     
     
         13 . The composition of  claim 1 , wherein a fiber comprising the composition a hot-air shrinkage of less than or equal to 20% after exposure to 260° C. air for 10 minutes. 
     
     
         14 . The composition of  claim 1 , wherein a fiber comprising the composition a hot-air shrinkage of less than or equal to 10% after exposure to 260° C. air for 10 minutes. 
     
     
         15 . The composition of  claim 1 , wherein the composition further comprises an end-capping agent. 
     
     
         16 . The composition of  claim 15 , wherein the endcapping agent is selected from the group consisting of phthalic anhydride, aniline, and combinations thereof. 
     
     
         17 . A fiber comprising
 a crystallized polyetherimide composition derived from the polymerization of:
 (a) a dianhydride component, comprising more than 96.8 mole % of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and 
 (b) a diamine component comprising a diamine or a chemical equivalent thereof; 
   wherein the fiber has a T m  from 250° C. to 400° C. and the difference between the T m  and T g  of the fiber is equal to or more than 50° C.   
     
     
         18 . The fiber of  claim 17 , wherein the diamine component comprises para-phenylenediamine or a chemical equivalent thereof. 
     
     
         19 . The fiber of  claim 17 , wherein the diamine component consists essentially of para-phenylenediamine or a chemical equivalent thereof. 
     
     
         20 . The fiber of  claim 17 , wherein the diamine component is p-phenylenediamine, and the composition further comprises less than 5.0 mole % of meta-phenylenediamine or a chemical equivalent thereof. 
     
     
         21 . The fiber of  claim 17 , wherein the diamine component is p-phenylenediamine, and the composition further comprises less than 2.0 mole % of meta-phenylenediamine or a chemical equivalent thereof. 
     
     
         22 . The fiber of  claim 17 , wherein the diamine is selected from the group consisting of p-phenylenediamine; benzidine; 1,5-diaminonaphthalene; bis(4-aminophenyl)methane; bis(4-aminophenyl)propane; bis(4-aminophenyl)sulfide; bis(4-aminophenyl)sulfone; bis(4-aminophenyl)ether; 4,4′-diaminodiphenylpropane; 4,4′-diaminodiphenylmethane(4,4′-methylenedianiline); 4,4′-diaminodiphenylsulfide; 4,4′-diaminodiphenylsulfone; 4,4′-diaminodiphenylether(4,4′-oxydianiline); 1,5-diaminonaphthalene; 3,3′dimethylbenzidine; 4,3′-diaminodiphenylether; 1,3-bis(4-aminophenoxy)benzene; 4,4′-bis(4-aminophenoxy)biphenyl; chemical equivalents of the foregoing diamines; and combinations thereof. 
     
     
         23 . The fiber of  claim 17 , wherein the composition further comprises at least one stabilizer. 
     
     
         24 . The fiber of  claim 23 , wherein the stabilizer is a phosphorous-containing stabilizer. 
     
     
         25 . The fiber of  claim 17 , wherein the composition further comprises an end-capping agent. 
     
     
         26 . The composition of  claim 17 , wherein the endcapping agent is selected from the group consisting of phthalic anhydride, aniline, and combinations thereof. 
     
     
         27 . The fiber of  claim 17 , wherein the fiber has a tensile strength from 2 to 20 grams per denier. 
     
     
         28 . The fiber of  claim 17 , wherein the fiber has a hot-air shrinkage of less than or equal to 20% after exposure to 260° C. air for 10 minutes. 
     
     
         29 . The fiber of  claim 17 , wherein the fiber has a hot-air shrinkage of less than or equal to 10% after exposure to 260° C. air for 10 minutes. 
     
     
         30 . An article comprising a plurality of the fibers of  claim 17 . 
     
     
         31 . The article of  claim 30 , wherein article is a non-woven fabric. 
     
     
         32 . The article of  claim 30 , wherein article is a woven fabric. 
     
     
         33 . A method of making a fiber, comprising
 extruding, through an orifice under conditions sufficient to form at least one fiber, a crystallizable polyetherimide composition derived from the polymerization of:
 (a) a dianhydride component, comprising more than 96.8 mole % of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and 
 (b) a diamine component comprising a diamine or a chemical equivalent thereof; 
 wherein the crystallizable polyetherimide has a T m  ranging from 250° C. to 400° C. and the difference between the T m  and T g  of the composition is equal to or more than 50° C. 
   
     
     
         34 . The method of  claim 33  wherein the method further comprises drawing the at least one fiber. 
     
     
         35 . The method of  claim 33 , wherein the method further comprises heat-treating the at least one fiber under a constraint effective to crystallize the polyetherimide. 
     
     
         36 . The method of  claim 33 , wherein the method further comprises weaving fiber into a fabric. 
     
     
         37 . The method of  claim 33 , wherein the method further comprises combining a plurality of the fibers into a yarn and then weaving a fabric from the yarn. 
     
     
         38 . A crystallizable polyetherimide composition derived from the polymerization of:
 (a) a dianhydride component, comprising more than 96.8 mole % of 4,4′-bisphenol A dianhydride or a chemical equivalent thereof; and   (b) a diamine component comprising p-phenylene diamine or a chemical equivalent thereof, and having less than 5 mole % meta-phenylenediamine or a chemical equivalent thereof;   wherein the crystallizable polyetherimide composition has
 a T m  from 250° C. to 400° C.; 
 a viscosity, measured at a shear rate of 1000 s −1 , of more than 100 and less than 10,000 poise at a temperature of less than 400° C., and further 
   wherein the difference between the T m  and a T g  of the crystallizable polyetherimide composition is equal to or greater than 50° C.   
     
     
         39 . The composition of  claim 38 , wherein the diamine component consists essentially of para-phenylenediamine or a chemical equivalent thereof. 
     
     
         40 . The composition of  claim 38 , wherein the diamine component is p-phenylenediamine and the composition further comprises less than 5.0 mole % of meta-phenylenediamine or a chemical equivalent thereof. 
     
     
         41 . The composition of  claim 38 , wherein the composition has a viscosity, measured at a shear rate of 1000 s −1 , of more than 100 and less than 10,000 poise at a temperature of less than 400° C. 
     
     
         42 . The composition of  claim 38 , wherein the composition further comprises an end-capping agent. 
     
     
         43 . The composition of  claim 42 , wherein the endcapping agent is selected from the group consisting of phthalic anhydride, aniline, and combinations thereof.