Nomex™ polyaramid O O N H N H n Discovered: 1958, by P.W. Morgan (Du Pont). Commercialised: 1967, in fibre form, by Du Pont. Key properties: Very good thermal resistance (Tm = 371 deg.C, c.f. nylon 66 which melts at 260 deg.C). Essentially flameproof in fabric form. Good resistance to organic solvents (because of crystallinity) but attacked and hydrolysed by strong acids and bases, especially at high temperatures. Excellent dimensional stability. Rated for continuous use in electrical applications (several thousand hours) at 200 deg.C. Very much higher resistance to ! radiation than aliphatic polyamides. 61 Nomex™ polyaramid O O N H N H n Synthesis H3C O2 HOOC CH3 Mn/Co HNO3 COOH O2N NO2 H2 SOCl2 ClOC H2SO4 COCl H2N Ni NH2 DMAc O O N H N H n 62 Nomex™ polyaramid O O N H N H n Fibre production: Fibre-spinning does not require isolation of polymer from the reaction solution. The solution is partially neutralised with ammonia, the NH4Cl filtered off, and neutralisation is completed with CaO (the so-formed CaCl2 helps retain the polymer in solution). This solution is dry-spun into hot air at 200 deg.C, the fibre wound up at ca. 100 m/min, extracted withwater to remove the CaCl2, and finally drawn in steam to 5 or 6 times its original length. 63 Nomex™ polyaramid O O N H N H n Crystal and molecular structure Aromatic rings are parallel but not coplanar. Both acid- and amine-derived rings are tilted some 30 degrees from the plane of the amide group.Networks of H-bonds link molecules in both the a and b directions (perpendicular to the chain axes). 64 Nomex™ polyaramid O O N H N H n Typical applications for Nomex fibre Heat-resistance applications: Filter bags for hotgas filtration (e.g. from steel-making plants). Insulating paper for electric motors and transformers. Braided tubing for wire-insulation. Sewing thread for high-speed machine sewing. Fire-resistance applications: Protective clothing for foundry workers, welders, pilots, racing drivers, and fire-fighters. Carpets, upholstery, and tents. Dimensional-stability applications: Conveyor belts, fire-hoses. Permselectivity applications: Hollow fibres of Nomex are excellent semi-permeable membranes, and are used commercially for desalination of sewater and brackish water. 65 Tenax™ Polyphenylene ether Ph O Ph n Discovered: 1968 by Hay (GE), using oxidative polymerisation of 2,6-diphenylphenol. Commercialised: 1970, by Akzo (Holland). Key properties: Amorphous 'as made' (Tg = 230 deg.C), but crystallises rapidly above Tg. Tm = 480 deg.C, so polymer unprocessable once crystallised. Amorphous polymer soluble in chloroform and benzene. Applications: By far biggest application is as very high temperature adsorbent in gas chromatography. Otherwise, applications remarkably underdeveloped. 66 Tenax™ Polyphenylene ether Ph O Ph n Synthesis: Ph Ph O2, TMED-CuCl2 HO O ODCB, 85oC n Ph Ph Mechanism: Ph OH Ph Ph OH Cu(II) Ph . O Ph Ph O Ph H . Ph OH Ph Cu(I) Cu(II) Cu(I) H+ Ph etc. Ph Ph O Ph Ph OH O H Ph + Ph Ph OH Ph 67 Tenax™ Polyphenylene ether Ph O Ph n Crystal structure: Polymer is helical, with four monomer residues per turn. Unit cell contains two chains, running in opposite directions (the chain has directionality). X-ray fibre diagram of Tenax 68 Part 3 Liquid Crystalline Polymers 69 Basic Concepts Liquid Crystals: Crystals are fully ordered in three dimensions over a long range. Liquids may have shortrange correlations of molecular position, but are essentially disordered. What about long-range order in only one or two dimensions? Many organic compounds display phases ('liquid crystal-' or 'meso-' phases) which have just such degrees of order. Key feature is shape of molecule. It must be highly anisotropic, so that the cumulative intermolecular forces operate strongly in one or two directions, but not three. Strong interaction Weak interaction Mesophases can occur lyotropically (by increasing the concentration of a material in solution), or thermotropically (by raising the temperature of a crystalline solid). 70 Basic Concepts Liquid crystal polymers: Two main classes, side-chain LC polymers and main-chain LC polymers. Only concerned here with main-chain types. Require an essentially rigid-rod structure. Existence predicted by Flory in 1956. At about the same time, Robinson and Ballard (Courtaulds) discovered liquid crystalline solutions of synthetic polypeptides, e.g. poly(g-benzyl-L-glutamate). Rigid, linear, helical structure of such polymers gives rise to lyotropic LC behaviour. 71 Basic Concepts Rigid-rod polymers: Wide range of chemical structures give rise to this type of polymer. Total rigidity not necessary, though can be achieved, e.g. in poly(p-phenylenebenzobisthiazole):- N S S N n Forms liquid-crystalline solutions in polyphosphoric acid Low-energy molecular conformations should be linear (i.e. restricted rotations needed), but significant flexibility allowed:O O O X X X (X = NH or O) O X 72 Basic Concepts Fibres: Characterised by anisotropy, both in dimensions and properties. Ratio of l/d for natural fibres (cotton, flax, wool) typically 1000 -2000. Anisotropic properties of many fibres (strength, stiffness etc.) caused by molecular orientation in the long-dimension of the fibre. For conventional synthetic fibres, orientation is achieved mechanically , by drawing: draw direction Perfect alignment very difficult to obtain with flexible polymers, since cannot avoid knots and entanglements. Consequently theoretical fibre performance not even approached. Theoretical tensile strength depends only on strength of covalent bond, since, when perfect alignment achieved, intra-molecular bonds are weaker than sum of inter-molecular forces (!) 73 Kevlar™ polyaramid O O N H H N n Discovered: 1965, by Stephanie Kwolek of Du Pont. Commercialised: 1971, by Du Pont. Key Properties: Forms liquid-crystalline solutions in organic solvents, and a liquid-crystalline complex with sulphuric acid. Such solutions self-orient under shear, so polymer can be spun to give highly ordered fibres without subsequent drawing. Kevlar fibres have extremely high tensile strength (2.64 GPa) and modulus (127.5 GPa) when compared with aliphatic polyamides such as Nylon 66 (0.90 and 5 GPa respectively). Because of low density, Kevlar has highest specific modulus of any known material. Very good thermal stability (to 450 deg.C), and 60% of strength is retained at 300 deg.C. 74 Kevlar™ polyaramid O H N N H O n Typical applications: The extreme tensile strength and lightness of Kevlar® leads to applications including knife-and bullet-proof clothing, boat hulls, racing cars, cut-resistant gloves, fiber-optic cable-sheathing, firefighters! suits, fuel hoses, helmets, aircraft components, radial tyres, spacecraft, bicycles, tennis and squash racquets, golf clubs and skis. Characteristics of fibre dominate composite-materials properties – excellent in tension but poor in compression. 1.5 tension 1.0 COMPOSITE STRESS (GPA) 0.5 compression 0.5 1.0 1.5 COMPOSITE STRAIN (%) 75 Kevlar™ polyaramid O O N H H N n Applications 76 Kevlar™ polyaramid O O H N N H n Synthesis: Original Du Pont process involved:COCl NH2 + RT COCl O HMPA O H N N H n NH2 Toxicity of HMPA required an alternative solvent before commercialisation possible: NMP/CaCl2 found to be usable though less than ideal (low MW oligomers tend to precipitate; problem overcome by use of high-shear reactor-design). Alternative synthesis (Higashi et al.): COOH NH2 + P(OPh)3 NMP/LiCl Py/CaCl2 100oC COOH NH2 O O N H H N n 77 Kevlar™ polyaramid O N H O H N n Mechanism of phosphorylative synthesis COOH NH2 P(OPh)3 NMP/LiCl Py/CaCl2 + COOH NH2 O O 100oC H N N N H n PhOH P ArCOO ArCOOH + P(OPh)3 OPh OPh Ar'NH2 ArCONHAr' O O P H OPh OPh O H P Ar NHAr' OPh OPh 78 Kevlar™ polyaramid O O H N N H n Fabrication: Polymer forms solid complex with 100% H2SO4 in mole ratio 1:10. Complex melts at 70 deg.C to give a liquid crystalline phase which can be spun into water, via an air-gap. Liquidcrystal domains become oriented during spinning:- domain structure spinneret orientation partial deorientation air-gap water reorientation precipitation 79 Kevlar™ polyaramid O O N H H N n Structure: As well as showing liquid-crystalline behaviour in solution, Kevlar has a high degree of 3-dimensional crystallinity in the solid state. X-ray fibre pattern N.B. C=O- - - H-N hydrogen bonds 80 Kevlar™ polyaramid O O N H H N n Crystal Structure: N.B. C=O- - - H-N hydrogen bonds 81 Kevlar™ polyaramid O N H O H N n Supramolecular structure: Molecules form hydrogenbonded sheets which stack radially in the fibre. Nice example of molecular self-organisation. Not previously observed in synthetic fibres, and can even lead to spontaneous growth of Kevlar fibres under gel-type polymerisation conditions. O O O H H H N N O fibre axis O O O O O N N H N H N H O O O 82 Kevlar™ polyaramid O N H O H N n Contrast between (high) tensile- and (low) compressive modulus: Chains are fully extended (all-trans) so very high tensile modulus Compressive stress however leads to buckling of the supramolecular sheet structure O O O H H H N N O O O O O O N N H N H N H O O O 83 Vectra™ thermotropic polyester O O O 0.7n O 0.3n Discovered: 1974, by Calundann of Celanese. Commercialised: 1985, by Hoechst-Celanese. Key Properties: Melts at ca. 275 deg.C, to form a liquid crystal phase which can be processed in similar fashion to conventional thermoplastic, i.e. by injection moulding, extrusion, or fibre-spinning. Major differences however are 1) the mesophase has very much lower viscosity than a conventional polymer melt, and 2) molecular orientation occurs under shear, so that anisotropic mouldings and extrusions are abtained. Have very high modulus in shear direction, but can be much weaker in other diections. Orientation leads to fibrillar wood-like texture. Materials are tough, with good impactresistance, and retain useful strength up to 200 deg.C. Thermochemically stable, with continuous service temperatures up to 220 deg.C. 84 Vectra™ thermotropic polyester O O O 0.7n O 0.3n Typical applications: Low mesophase viscosity allows very complex and finely detailed mouldings to be obtained (e.g. for microelectronic applications). Transparency to microwaves, coupled with thermal stability, means material suitable for microwave cookware. Orientation under shear allows meltspinning of high-modulus fibre, c.f. Kevlar. 85 Vectra™ thermotropic polyester O O O O 0.7n 0.3n Synthesis: COOH O H3C + O COOH O H3C O 200oC, N2 purge Clear melt 250 - 280oC CH3COOH Turbid dispersion 280 - 340oC O O O 0.7n O 0.3n Opalescent polymer "melt" 86 Vectra™ thermotropic polyester O O O 0.7n O 0.3n Q. Why a co-polymer? A. Because the homopolymers are intractable. The homopolymer of 4-hydroxybenzoic acid is in fact manufactured, as 'Ekonol', but it can only be fabricated via powder-metallurgy techniques such as high-energy-rate forging and plasma-spraying. O O PhOH Ph O HO n O Ekonol 'Ekonol' undergoes a thermal transition at 350 deg.C, to give an as yet incompletely characterised phase which may or may not be liquid crystalline. Copolymerisation with 2,6-HNA however produces materials with a crystal-to-mesophase transition as low as 250 deg.C (60:40, HBA:HNA) 87 Vectra™ thermotropic polyester O O O 0.7n O 0.3n Sructure: The detailed structure of liquid crystal polyesters is still a matter of debate. 13C NMR of Vectra indicates the polymer-sequence is fully random, and yet it shows a relatively high degree of crystallinity. One possible explanation is based on formation of non-periodic layer crystallites :- ababbababbababaababababbbabaab ababbaababbabaababbababaababba aababbaababababababaabaaabbaba abbbbabbabbabababbbaaabaabbaba aababbabbabababaabbababbabbaab Essentially involves matching of sequences in adjacent chains. Limited length of matches results in low melting point, but overall can still achieve significant crystallinity. 88 Vectra™ thermotropic polyester O O O 0.7n O 0.3n Non-periodic layer crystallites: Very remarkable theory, and increasing evidence appearing in the literature, but still controversial idea. Best seen via computational simulation:- 89 Chain Rigidity and Polymer Crystal Melting We have seen that crystalline polymers with rather rigid and inflexible chains (e.g. aromatic polyamides and aromatic polyesters) have extremely high crystal melting points, generally above their decomposition temperatures. Unless a thermotropic liquid-crystalline phase can be obtained, e.g. by copolymerisation, such polymers cannot be processed in the melt, and must be fabricated from solution or by using solid-state techniques such as powder-sintering. The close relationship between chain rigidity and polymer crystal melting point can be explained as follows: "Gm = "Hm - Tm"Sm, but for a phase transition "G = 0, so that: 0 = "Hm - Tm"Sm and therefore: Tm = "Hm / "Sm For a flexible chain, the entropy of melting "Sm, will be large as the chain can take up only one conformation in the crystal but very many in the melt state.Thus Tm will be low. For a rigid chain however, "Sm will be small, as the number of different chain conformations available in the melt is very small, and Tm will be very much higher. (This assumes that "Hm, which depends mainly on intermolecular attractive forces, is not greatly different in the two cases). As an example, the aliphatic polyamide Nylon 6,6 melts at 280 °C, whereas the much more rigid aromatic polyamide, Kevlar, does not melt below its decomposition temperature of ca. 450 °C. 90