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Polyarylene composition and articles made therefrom

Polyarylene composition and articles made therefrom description/claims

The present application claims the benefit of (i) PCT application no. PCT/EP2006/060535 filed Mar. 7, 2006, and (ii) U.S. application No. 60/842,367 filed Sep. 6, 2006, the whole content of both being herein incorporated by reference.

The present invention relates to a new polyarylene composition comprising polyarylenes of two different specific types, and to articles made therefrom.

Polyarylenes exhibit some outstanding performance properties, including exceptionally high strength, stiffness, hardness, scratch resistance, dimensional stability, great friction and wear properties, high solvent resistance and exceptional low temperature performance.

Polyarylenes are notably commercially available as PRIMOSPIRE™ self-reinforced polymers (SRPs), formerly marketed as PARMAX®. The standard commercial grade is PRIMOSPIRE™ PR-120 (formerly market as PARMAX® 1200), a kinked rigid-rod polyphenylene, i.e. one containing about 85 mole % of rigid rod-forming recurring units and 15 mole % of kink-forming recurring units. Kink-forming recurring units provide an increased fusability and machinability to this polyphenylene; thus, while shaped articles made from unkinked polyphenylenes of the first generation such as PARMAX® 1000 were often manufactured by a solution process, PRIMOSPIRE™ PR-120 polyphenylene can be extruded and compression molded into various shaped articles.

The latest generation of polyarylenes is represented by PRIMOSPIRE™ PR-250 (formerly PARMAX® 1500) kinked rigid-rod polyphenylene material, which is still a developmental injection molding grade. These polyarylenes contain a higher amount of kink-forming recurring units (about 50 mole %). They have lower viscosity and consequently better flow performance at high temperature making them especially well-suited for parts requiring injection molding capabilities.

All the so far known polyarylenes, while offering an exceptionally high level of strength and stiffness (which often even exceeds the needs of the applications wherein they are used) suffer irremediably from limitations in toughness-related properties: they have limited elongability; they have limited impact resistance (as typically characterized by standard notched and unnotched Izod tests).

Further, while being generally acknowledged as materials having a high fire resistance, kinked rigid-rod polyarylenes with a low amount of kink-forming recurring units, a representative thereof being PRIMOSPIRE™ PR-120 polyphenylene, do not yet offer the needed level of fire-resistance in certain especially demanding applications, as may be found in aircraft and other civil transportations. On the other hand, as far as the Applicant knows, the fire-resistance properties of kinked rigid-rod polyarylenes with a high amount of kink-forming recurring units, a representative thereof being PRIMOSPIRE™ PR-250 polyphenylene, have not been investigated so far.

There is a need for a polymer material which, while offering an exceptionally high level of strength and stiffness (similar to that provided by PRIMOSPIRE™ PR-120 and PRIMOSPIRE™ PR-250 polyphenylenes) provide further at least one, preferably at least two and still more preferably all the following advantages:

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