CN103314037A - Flame resistant spun staple yarns made from blends of fibers derived from sulfonated polyoxadiazole polymers - Google Patents

Abstract

Described is a flame-resistant spun yarn having: about 50 to about 95 parts by weight of a sulfonated polyoxadiazole based staple fiber comprising repeat units of Formula (I) and one or both of Formula (II) and (I la): wherein M is a cation; and about 5 to about 50 parts by weight of a textile staple fiber having limiting oxygen index of 21 or greater and a tenacity of about 4 grams per denier or greater, based on the total amount of the polymeric fiber and the textile fiber in the yarn.

Description

By the flame resistant spun staple yarns of making derived from the fiber blends of Huangization polyoxadiazole polymers

The cross reference of related application

Present patent application requires in the U.S. Provisional Application Nos.61/423616 of submission on December 16th, 2010 and 61/423620 right of priority, and described full patent texts is incorporated this paper into way of reference.

Technical field

The present invention relates to flame resistant spun staple yarns, contain fabric and clothes and their preparation method of these yarns.Yarn comprises that to contain sulfonation poly-

The blend of the staple fibre of the polymerization of aromatic oxadiozole polymer fa.

Background technology

The worker who is exposed in flame, high temperature and/or the electric arc etc. need wear protective clothing and the goods of being made by heat resistance fiber.Any increase of these protective article effects, or any increase of these goods comfortableness, weather resistance and dyeability when keeping barrier propterty all are welcome.

Poly-

Aromatic oxadiozole polymer fa has particular performances, and can be used in many fields, for example high-performance fiber such as fire-retardant fibre.Improving flammable method is that the preparation sulfonation is poly-

Aromatic oxadiozole polymer fa.These methods have comprised uses sulfonated monomers and back sulfonation.People such as Gomes (US 20098/0318109, US2008/0193652, US2009/0203870) react sulfuric acid hydrazine and aromatic dicarboxylate to form a sulfonation in phosphoric acid poly- The diazole multipolymer is subsequently with described polymkeric substance sulfonation.Another kind method is to use oleum with the prepared polymkeric substance of sulfonation between polymerization period.People such as Lee (US 7,528,216 and US 7,582,721) are by making the reaction of aromatic dicarboxylate and sulfuric acid hydrazine under the finite quantity oleum, and use sulfonated monomers (US 7,528,217) preparation sulfonation random poly- The diazole multipolymer makes random poly-

The diazole multipolymer.

Therefore need a kind of that sulfonation is poly-

Diazole is incorporated in the yarn for use in the method for protective clothing, and it is poly-that described protective clothing utilization has the sulfonation of performance such as the flame retardant resistance of improvement and dyeability

The beneficial effect of diazole fiber.

Summary of the invention

The invention discloses and comprised for about 50 gathering based on sulfonation to about 95 weight parts

The flame resistant spun staple yarns of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I):

Wherein M is positively charged ion; And have 21 or the textiles staple fibre of higher limiting oxygen index(LOI) and about 4 gram/DENIER or higher toughness in the total amount about 5 of textile fiber described in described polymer fiber and the yarn to about 50 weight parts.

The invention also discloses comprise at least about 25 weight parts to about 80 weight parts based on sulfonation poly-two

The flame resistant spun staple yarns of the staple fibre of azoles, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And in the total amount of polymer fiber described in the yarn and described textile fiber about 20 modified acryl fibres to about 75 weight parts.

The invention also discloses and comprised for about 50 gathering based on sulfonation to about 95 weight parts The flame resistant spun staple yarns of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And in the high-modulus staple fibre with 200 gram/DENIER or higher tensile modulus of the total amount of polymer fiber described in the yarn and described textile fiber about 5 to about 50 weight parts.

The invention also discloses and comprised for about 20 gathering based on sulfonation to about 50 weight parts

The flame resistant spun staple yarns of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And with poly-based on sulfonation described in the yarn

The total amount meter about 50 of the fiber of diazole and described textile fiber is to the rigid rod staple fibre of about 80 weight parts.

The invention also discloses the protective clothing, woven fabrics, supatex fabric, band or the long filament that comprise flame resistant spun staple yarns.

Disclosed herein is the method for preparing staple, and described method comprises: a) form about 50 to about 95 weight parts based on poly-

The fibre blend of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And have 21 or the textiles staple fibre of higher limiting oxygen index(LOI) and about 4 gram/DENIER or higher toughness in the total amount of polymer fiber described in the yarn and described textile fiber about 5 to about 50 weight parts; And b) fibre blend is spun to staple.

The invention also discloses the method for preparing staple, described method comprises: a) form at least about 25 weight parts based on poly- The fibre blend of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And in the total amount of polymer fiber described in the yarn and described textile fiber about 20 modified acryl fibres to about 75 weight parts; And b) fibre blend is spun to staple.

The invention also discloses the method for preparing staple, described method comprises: a) form about 50 to about 95 weight parts based on poly-

The fibre blend of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And in the high-modulus staple fibre with 200 gram/DENIER or higher tensile modulus of the total amount of polymer fiber described in the yarn and described textile fiber about 5 to about 50 weight parts; And b) fibre blend is spun to staple.

The invention also discloses the method for preparing staple, described method comprises: a) form about 20 to about 50 weight parts based on poly- The fibre blend of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And in the rigid rod staple fibre of the total amount of polymer fiber described in the yarn and described textile fiber about 50 to about 80 weight parts; And b) fibre blend is spun to staple.

Embodiment

The invention discloses flame resistant spun staple yarns, described flame resistant spun staple yarns comprises:

About 50 gathering based on sulfonation to about 95 weight parts

The staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I):

Wherein M is positively charged ion;

And have 21 or the textiles staple fibre of higher limiting oxygen index(LOI) and about 4 gram/DENIER or higher toughness in the total amount of polymer fiber described in the yarn and described textile fiber about 5 to about 50 weight parts.

In one embodiment, poly-based on sulfonation

The content of the staple fibre of diazole is about 50 to about 85, or about 50 to about 75, or about 60 to about 85, or about 70 to about 80 weight parts, and the content of high-modulus staple fibre is about 15 to about 50, or about 25 to about 40, or about 15 to about 40, or about 20 to about 30 weight parts.

Suitable textile fiber comprises meta-aramid fiber, para-aramid fiber and polyazole fiber.

The invention also discloses comprise at least about 25 weight parts to about 80 weight parts based on sulfonation poly-two

The flame resistant spun staple yarns of the staple fibre of azoles, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And in the total amount of polymer fiber described in the yarn and described textile fiber about 20 modified acryl fibres to about 75 weight parts.

In one embodiment, poly-based on sulfonation

The content of the staple fibre of diazole is about 35 to about 70, or about 50 to about 75 weight parts, or about 45 to about 60, or about 45 to about 70 weight parts, and the content of modified acryl fibre is about 30 to about 65, or about 25 to about 50, or about 40 to about 55, or about 30 to about 55 weight parts.

Suitable denaturing acrylamide acid fiber comprises the acrylonitrile copolymer that mixes with vinylidene chloride.

The invention also discloses comprise at least about 50 to about 95 weight % poly-based on sulfonation

The flame resistant spun staple yarns of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And in the high-modulus staple fibre with 200 gram/DENIER or higher tensile modulus of the total amount of polymer fiber described in the yarn and described textile fiber about 5 to about 50 weight parts.

In one embodiment, poly-based on sulfonation

The content of the staple fibre of diazole is about 50 to about 85, or about 50 to about 75, or about 60 to about 85, or about 70 to about 80 weight parts, and the content of high-modulus staple fibre is about 15 to about 50, or about 25 to about 40, or about 15 to about 40, or about 20 to about 30 weight parts.

Many different fibers can be used as the high-modulus staple fibre, comprise para-aramid fiber, polyazole fiber, carbon fiber and their mixture.In certain embodiments, the para-aramid fiber can be used as the high-modulus staple fibre in described blend.So-called aromatic poly refers to that wherein at least 85% acid amides (CONH-) connects the polymeric amide that base directly links to each other with two aromatic rings.Additive can be used with aromatic poly, and find in fact, can other polymeric material and the aromatic poly blend of 10 weight % will be reached, perhaps can use multipolymer, described multipolymer has nearly other diamines of the diamines of 10% alternative aromatic poly, or other diacid chloride of the diacid chloride of 10% alternative aromatic poly nearly.In certain embodiments, preferred para-aramid is poly-(poly P phenylene diamine terephthalamide).The method for preparing available para-aramid fiber generally is disclosed in for example United States Patent(USP) Nos. 3,869,430; 3,869,429; With 3,767, in 756.Various forms of these type of aromatic poly organic fibres are with trade(brand)name

With Respectively by Wilmington, the E.I.du Pont de Nemours and Company of Delaware; With the Teijin of Japan, Ltd. sells.And, be defined as para-aramid fiber as used herein based on the fiber of copolymerization (to phenylene/3,4 '-phenyl ether terephthaloyl amine).This fibrid of a kind of commercially available acquisition is called as

Fiber derives from Teijin, Ltd equally.

In certain embodiments, polyazole fiber can be used as the high-modulus staple fibre in described blend.For example, suitable poly-azoles comprises polybenzoxazole, polypyridine and azoles etc., and can be homopolymer or multipolymer.Additive can use with poly-azoles, and the most nearly 10 weight % other polymeric material can with described poly-azoles blend.Also can use and have nearly 10% or the multipolymer of other monomer of the more monomer that replaces poly-azoles.Suitable poly-azoles homopolymer and multipolymer can be made by known method, such as United States Patent (USP) 4,533,693 (authorize people such as Wolfe, on August 6th, 1985), 4,703,103 (authorizing people such as Wolfe, on October 27th, 1987), 5,089,591 (authorizing people such as Gregory, on February 18th, 1992), 4,772,678 (authorize people such as Sybert, on September 20th, 1988), 4,847,350 (authorize people such as Harris, on August 11st, 1992) and 5, described in 276,128 (the authorizing people such as Rosenberg, on January 4th, 1994) those.

In certain embodiments, preferred polybenzoxazole is that polybenzimidazole, polybenzothiozole and polyphenyl are opened

Azoles.If described polybenzoxazole is polybenzimidazole, then it is preferably poly-([5,5 '-two-1H-benzoglyoxaline]-2,2 '-two bases-1,3-phenylene), and it is called PBI.If described polybenzoxazole is polybenzothiozole, then it is preferably polyphenyl and dithiazole, and its more preferably poly-(benzo [1,2-d:4,5-d '] dithiazole-2,6-two bases-1,4-phenylene), and it is called PBT.If described polybenzoxazole be polyphenyl also Azoles, then it is preferably polyphenyl and two

Azoles, and it more preferably gathers (benzo [1,2-d:4,5-d '] two

Azoles-2,6-two bases-1,4-phenylene), it is called PBO.

In certain embodiments, preferred polypyridine and azoles are rigid rod-like polymer polypyridine and diazole, comprise poly-(pyrido diimidazole), poly-(pyrido dithiazole) and poly-(pyrido two

Azoles).Preferred poly-(pyrido two

Azoles) (it is called PIPD for 1,4-(2,5-dihydroxyl) phenylene-2,6-pyrido [2,3-d:5,6-d '] diimidazole in order to gather.Suitable polypyridine and diazole can be made by known method, such as United States Patent (USP) 5,674, those described in 969.High modulus carbon fiber is well known in the art, and the carbon fiber of commercially available acquisition comprises and derives from Toho Tenax America, Inc's

Fiber.

In some preferred embodiments, the high-modulus staple fibre has 21 or higher limiting oxygen index(LOI) (LOI), means that high-modulus staple fibre or the fabric of only being made by the high-modulus staple fibre will not support airborne burning.In some preferred embodiments, described high-modulus staple fibre has at least 26 or higher LOI.

In certain embodiments, described high-modulus staple fibre has at least 5 gram/DENIER (4.5 gram/dtex) or higher fracture toughness.In some other embodiment, described high-modulus staple fibre has at least 10 gram/DENIER (9 gram/dtex) or higher fracture toughness.Add more that the high-modulus staple fibre of high-tenacity can provide extra intensity to described staple, this will make the final fabric that made by described staple and intensity and the weather resistance of clothing be improved.And, in some cases, according to blend per-cent, it is believed that the extra toughness that is provided to described staple by described high-modulus staple fibre can obtain amplifying in the fabric that is made by described yarn and clothes, cause in described fabric, to obtain to improve than toughness higher in described staple.

The invention also discloses and comprise at least about 20 gathering based on sulfonation to about 50 weight parts

The flame resistant spun staple yarns of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And in the rigid rod staple fibre of the total amount of polymer fiber described in the yarn and described textile fiber about 50 to about 80 weight parts.

In one embodiment, poly-based on sulfonation

The content of the staple fibre of diazole is about 30 to about 40, or about 35 to about 40, or about 30 to about 50, or about 20 to 40 weight parts, and the content of rigid rod staple fibre is about 60 to about 70, or about 60 to about 65, or about 50 to about 70, or about 60 to about 80 weight parts.

With regard to this paper purpose, " rigid rod fiber " refers to be called the fiber that the rigid rod aromatic(based)polymer of rigidity stuffer fragment makes by having this area; These rigid rod fiber also form fibril under friction or friction.Described rigidity comprises another kind of annular unit or functional group's end group at interval usually, such as-NH-,-CO-,-O-,-COO-,-N=N-and/or-CH=CH-.General these rigid rod polymkeric substance have the aryl of height para-orientation, and have high tensile modulus by the fiber of these polymers.Under friction or friction, rigid rod fiber is easy to fibrillation; Be that their form and to have the center fiber handle and by the structure of its extended fibril.Described fiber handle is generally cylindricality, and diameter is 4 to 50 microns, and described fibril is the hair-like unit that links to each other with described fiber handle, and diameter only is several microns of zero points or several microns/one, and long 10 to 100 microns.

Can use different fibers as the rigid rod staple fibre.In certain embodiments, the para-aramid fiber can be used as the rigid rod staple fibre in described blend.So-called " aromatic poly " refers to that wherein at least 85% acid amides (CONH-) connects the polymeric amide that base directly links to each other with two aromatic rings.Additive can be used with aromatic poly, and find in fact, can other polymeric material and the aromatic poly blend of 10 weight % will be reached, perhaps can use multipolymer, described multipolymer has nearly other diamines of the diamines of 10% alternative aromatic poly, or other diacid chloride of the diacid chloride of 10% alternative aromatic poly nearly.In certain embodiments, preferred para-aramid is poly-(poly P phenylene diamine terephthalamide).The method for preparing available para-aramid fiber generally is disclosed in for example United States Patent(USP) Nos. 3,869,430; 3,869,429; With 3,767, in 756.Various forms of these type of aromatic poly organic fibres are with trade(brand)name With

Respectively by Wilmington, the E.I.du Pont de Nemours and Company of Delaware; With the Teijin of Japan, Ltd. sells.And, be defined as para-aramid fiber as used herein based on the fiber of copolymerization (to phenylene/3,4 '-phenyl ether terephthaloyl amine).This fibrid of a kind of commercially available acquisition is called as

Fiber derives from Teijin, Ltd equally.

In certain embodiments, polyazole fiber can be used as rigid rod fiber in described blend.For example, suitable poly-azoles comprises polybenzoxazole, polypyridine and azoles etc., and can be homopolymer or multipolymer.Additive can use with poly-azoles, and the most nearly 10 weight % other polymeric material can with described poly-azoles blend.Also can use and have nearly 10% or the multipolymer of other monomer of the more monomer that replaces poly-azoles.Suitable poly-azoles homopolymer and multipolymer can be made by known method, such as United States Patent (USP) 4,533,693 (authorize people such as Wolfe, on August 6th, 1985), 4,703,103 (authorizing people such as Wolfe, on October 27th, 1987), 5,089,591 (authorizing people such as Gregory, on February 18th, 1992), 4,772,678 (authorize people such as Sybert, on September 20th, 1988), 4,847,350 (authorize people such as Harris, on August 11st, 1992) and 5, described in 276,128 (the authorizing people such as Rosenberg, on January 4th, 1994) those.

In certain embodiments, preferred polybenzoxazole is that polybenzimidazole, polybenzothiozole and polyphenyl are opened

Azoles.If described polybenzoxazole is polybenzimidazole, then it is preferably poly-([5,5 '-two-1H-benzoglyoxaline]-2,2 '-two bases-1,3-phenylene), and it is called PBI.If described polybenzoxazole is polybenzothiozole, then it is preferably polyphenyl and dithiazole, and its more preferably poly-(benzo [1,2-d:4,5-d '] dithiazole-2,6-two bases-1,4-phenylene), and it is called PBT.If described polybenzoxazole be polyphenyl also

Azoles, then it is preferably polyphenyl and two Azoles, and it more preferably gathers (benzo [1,2-d:4,5-d '] two

Azoles-2,6-two bases-1,4-phenylene), it is called PBO.

In certain embodiments, preferred polypyridine and azoles are rigid rod-like polymer polypyridine and diazole, comprise poly-(pyrido diimidazole), poly-(pyrido dithiazole) and poly-(pyrido two

Azoles).Preferred poly-(pyrido two

Azoles) (it is called PIPD for 1,4-(2,5-dihydroxyl) phenylene-2,6-pyrido [2,3-d:5,6-d '] diimidazole in order to gather.Suitable polypyridine and diazole can be made by known method, such as United States Patent (USP) 5,674, those described in 969.

In certain embodiments, described staple comprises also that to have be 21 or the rigid rod staple fibre of higher limiting oxygen index(LOI) (LOI), and this refers to that rigid rod staple fibre or the fabric that is only made by the rigid rod staple fibre will can not keep flame and burn in air.In some preferred embodiments, described rigid rod staple fibre has at least 26 or higher LOI.

In certain embodiments, described rigid rod staple fibre has at least 5 gram/DENIER (4.5 gram/dtex) or higher fracture toughness.In some other embodiment, described rigid rod staple fibre has at least 10 gram/DENIER (9 gram/dtex) or higher fracture toughness.Add more that the rigid rod staple fibre of high-tenacity can provide extra intensity to described staple, this will make the final fabric that made by described staple and intensity and the weather resistance of clothing be improved.And, in some cases, it is believed that the extra toughness that is provided to described staple by the rigid rod staple fibre can obtain amplifying in the fabric that is made by described yarn and clothing, cause in described fabric, to obtain to improve than toughness higher in described staple.

The invention also discloses and comprise at least about 50 gathering based on sulfonation to about 95 weight parts

The flame resistant spun staple yarns of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I), and wherein M is positively charged ion; And have 21 or the textiles staple fibre of higher limiting oxygen index(LOI) and about 4 gram/DENIER or higher toughness in the total amount of polymer fiber described in the yarn and described textile fiber about 5 to about 50 weight parts.

In one embodiment, poly-based on sulfonation

The content of the staple fibre of diazole is about 50 to about 85, or about 50 to about 75, or about 60 to about 85, or about 70 to about 80 weight parts, and the content of high-modulus staple fibre is about 15 to about 50, or about 25 to about 40, or about 15 to about 40, or about 20 to about 30 weight parts.

In flame resistant spun staple yarns disclosed herein, M is generally the positively charged ion of monovalence, such as H, Li, Na, K or NH ₄In certain embodiments, with poly-based on sulfonation

The total amount meter of the staple fibre of diazole, formula (I) with about 5 moles of % to about 50 moles of %, or about 5 moles of % are to about 40 moles of %, or about 10 moles of % are to about 30 moles of % existence, and formula (II) and (IIa) one or both of all with about 50 moles of % to about 95 moles of %, or about 60 moles of % are to about 95 moles of %, or about 70 moles of % exist to about 90 moles of %.In other embodiments, formula (II) is with about 60 to about 95 moles of %, or about 70 to about 90 moles of % use; And formula (IIa) is with about 0 to about 30 moles of %, or about 0 to about 20 moles of % uses.Also in other embodiments, formula (II) does not exist or formula (IIa) does not exist.

M can be transformed into another M at any time before or after spinning or forming moulded products.When M was H, polymkeric substance can neutralize by contacting with salt, and described salt is such as but not limited to sodium bicarbonate, sodium hydroxide, cesium hydroxide, lithium hydroxide, potassium hydroxide or salt of wormwood.Can implement ion-exchange and/or neutralization by any method as known in the art.

Poly-based on sulfonation

The staple fibre of diazole also can comprise other repeating unit part on polymer chain.These repeating units can comprise formula (III) and formula (IIIa) one or both of:

Poly-based on sulfonation

The staple fibre of diazole can have at least about 2 weight %, 4 weight %, or the sulphur content of 6 weight %.Sulphur content can be passed through sulfonated monomers before polyreaction, or sulfonated polymer improves.

Be used for preparing disclosed herein poly-based on sulfonation The polymkeric substance of the staple fibre of diazole can be by being well known in the art any method or prepared.A kind of suitable method may further comprise the steps:

A. with hydrazine, oleum, 4,4 '-phenyl ether dioctyl phthalate and terephthalic acid and/or m-phthalic acid mix, to form reaction mixture, wherein the add-on of oleum is counted at least about 5 molar equivalent SO with the hydrazine mole number ₃With

B. reaction mixture is heated to about 100 ℃ to about 180 ℃ temperature, until making sulfonation and copolymerization

Aromatic oxadiozole polymer fa.

Other monomer also can be present in the described reaction mixture.

It is poly-that methods described herein can prepare sulfonation

Aromatic oxadiozole polymer fa, described polymkeric substance comprise at least about 2 weight %, 4 weight %, or the sulphur content of 6 weight %.Can improve sulphur content by following additional operation: with 4,4 '-phenyl ether dioctyl phthalate or terephthalic acid and/or m-phthalic acid further sulfonation before polyreaction, and/or will gather

The sulfonation of diazole copolymer products.This sulfonation can be undertaken by any method that can be beneficial to final product known in the art, as contacting with oleum, sulfuric acid or other sulfonated reagent.

Hydrazine can directly use, or uses with solid hydrazonium salt form.A kind of suitable solid salt is sulfuric acid hydrazine [N ₂H ₅] HSO ₄, it also is called as hydrazonium sulfate.

Oleum also is called as oleum, pyrosulfuric acid or pyrosulfuric acid, refers to have various sulphur trioxide (SO ₃) sulphuric acid soln formed.Usually use 20-30%, more typical 30% oleum, this refers to SO in the sulfuric acid ₃Weight %.The add-on of oleum is counted at least about 5 molar equivalents with the hydrazine mole number, or more typical SO at least about 6 molar equivalents ₃

Reagent dosage depends on repeating unit per-cent desired in the final polymkeric substance.In used di-carboxylic acid total amount, 4,4 '-consumption of phenyl ether dioctyl phthalate (OBBa) is that about 1 mole of % is to about 50 moles of %, or about 5 moles of % are to about 50 moles of %, or about 10 moles of % are to about 30 moles of %, and the consumption of terephthalic acid and/or m-phthalic acid is about 50 moles of % to about 99 moles of %, or about 50 moles of % are to about 95 moles of %, or about 70 moles of % are to about 90 moles of %.In another embodiment, terephthalic acid is with about 50 to about 90 moles of %, or about 70 to about 80 moles of % use, and m-phthalic acid is with about 0 to about 30 moles of %, or about 0 to about 20 moles of % uses.In another embodiment, terephthalic acid does not exist, or m-phthalic acid does not exist.Can use the hydrazine of various ratios, but use the di-carboxylic acid of about 1: 1 mol ratio usually: hydrazine.

Composition can any sequential combination, but at first solids component is fully mixed usually, mixes with oleum then.In one embodiment, oleum adds with one step; That is, add with a aliquots containig.In another embodiment, can before adding other di-carboxylic acid and hydrazine, oleum and OBBA be mixed.By stirring or other whipping appts mixture is fully mixed then, until abundant dissolving, at least five minutes usually.This dissolving can be in room temperature to carrying out under about 100 ℃ at the most.

In one embodiment, said method comprising the steps of:

A1) with hydrazine or its salt, 4,4 '-phenyl ether dioctyl phthalate and terephthalic acid and/or m-phthalic acid mix to form pre-composition;

A2) described pre-composition was stirred 5 minutes at least; With

A3) content is counted at least about 5 molar equivalent SO with the hydrazine mole number ₃Oleum join in the described pre-composition, to form reaction mixture.

After the dissolving, make mixture reaction until forming enough polymkeric substance.Usually at about 100 ℃ to about 180 ℃, or about 120 ℃ implemented polyreaction at least about 0.5 hour to about 140 ℃ temperature.Can keep between the reaction period or rising or rank rise described temperature.Temperature can be used for controlling the type of sulfonation repeating unit in amount of sulfonation and the final polymkeric substance.For example, if expect more sulfonation and/or closed loop repeating unit, the temperature that then should raise is usually extremely greater than about 120 ℃.If expect less sulfonation and/or closed loop repeating unit, then temperature should be lower, usually less than about 100 ℃.

Poly-by the sulfonation that the method that above discloses makes

Aromatic oxadiozole polymer fa can neutralize before or after forming moulded products, made the H positively charged ion be substituted by another kind of positively charged ion, was generally monovalent cation such as Li, Na, K or NH ₄This is by making sulfonation poly-

Aromatic oxadiozole polymer fa contact neutralizing agent or other ion-exchanger are implemented, and described neutralizing agent is generally subsalt such as sodium bicarbonate.

The invention also discloses the sulfonation and copolymerization that is made by methods described herein

Aromatic oxadiozole polymer fa, and by its moulded products that makes and fiber.

Polymkeric substance as herein described can form moulded products, such as film, fine strip body, be used for the fiber of floss and be used for the fiber that textiles uses, and is used for protective clothing, woven fabrics, supatex fabric, paper wood, band or filament.It can be via solvent spinning, uses polymkeric substance formed solution in polymerization solvent, or in another kind of polymer solvent formed solution, be spun into fiber.Can realize fiber sprinning by spinnert, to generate multifilament known in the art or tow via dry-spinning silk, wet spinning silk or dry-jet wet-spinning silk (also being called as the air gap spinning).

Moulded products as described herein comprises to be extruded or blow mold or film, moulded parts etc.Film can be made by any already known processes, is cast on the flat surfaces as spinning liquid, will spin liquid and extrude by forcing machine forming film, or extrude and blowing is spun liquid film to form the extrusion-blown modling film.Spin those similar methods that typical process that liquid film extrudes comprises and be used for fiber, wherein solution enters air gap by spinning nozzle or mould, enters precipitation bath subsequently.The more details of extruding and being orientated that liquid film is spun in description are found in people's such as Pierini (U.S. Patent No. 5,367,042); (4,898,924) of Chenevey; People's such as Harvey (4,939,235); (4,963,428) with people such as Harvey.Usually preferably to be no more than about 250 mils (6.35mm) thick for the liquid film that spins that makes, and it more preferably about 100 mils (2.54mm) are thick at the most.

" fiber " is defined as the pliable and tough relatively urstoff that has high aspect ratio at the cross-sectional area perpendicular to its length.In this article, term " fiber " exchanges with term " long filament " or " yarn " or " continuous filament yarn " and uses.The cross section of long filament described herein can be Any shape, as circle or beans shape, but generally is circular usually, and is solid and non-hollow basically usually.Spinning fiber on the bobbin in the package is called continuous fibre.Fiber can be cut into short length, is called staple fibre.Fiber can be cut into littler length, is called floss.Yarn, multifilament or tow comprise plurality of fibers.Yarn can be tangled and/or be pooled capital.

Can adopt any method by the solution spinning fibre, yet wet spinning and air gap spinning are known most.In wet spinning, spinning nozzle directly is expressed into fiber in the liquid of precipitation bath, and usually with the spinning nozzle submergence or be positioned at the precipitation bath lower face.In air gap spinning (also being called " doing spray " wet spinning sometimes), spinning nozzle at first is expressed into fiber in gas such as the air in the very short time length, immediately fiber is incorporated in the liquid precipitation bath then.Usually, spinning nozzle is positioned at the precipitation bath surface, produces between spinning nozzle face and precipitation bath surface " air gap ".The general arrangement of spinning nozzle and bath is known in this area, United States Patent(USP) Nos. 3,227, the description of drawings in 793,3,414,645,3,767,756 and 5,667,743 be used for this spinning technique of high-strength polymer.

" dry-spinning " refers to remove solvent, stay the solid long filament, and prepare the method for long filament by solution being squeezed in the hot cell with gas atmosphere.Described solution is included in the polymkeric substance that forms fiber in the solvent, extrudes by one or more orifices so that the polymer molecule orientation with Continuous Flow.This is different from " wet spinning " or " air gap spinning ", and wherein polymers soln is expressed in liquid precipitation or the condensed medium with the regenerated polymer long filament.In other words, in dry-spinning, gas is main solvent extraction medium, and in wet spinning, liquid is main solvent extraction medium.In dry-spinning, after the solid long filament forms, can use the liquid treatment long filament subsequently, with cooling long filament or washing long filament, with the remaining solvent of further extraction.

Then on demand, the fiber after the employing routine techniques processing spinning in multifilament or the tow with described fiber neutralization, washing, drying or thermal treatment, makes stable and available fiber.Fiber by polymer formation described herein can be used in the multiple application.They are colourless, or colourless to white, yet impurity may cause variable color, and especially can be used as fire-retardant fibre, because described polymkeric substance has about 24 or higher, or about 26 or higher, or about 28 or higher, or about 30 or higher limiting oxygen index(LOI).

In one embodiment, can adopt the spinning nozzle with 5-50 hole, by the sulphuric acid soln spinning fibre in 5 to the 25 weight % polymer concentration scopes, described hole has 0.003 " or 0.008 " diameter.The volumetric flow rate of spinning solution is generally 0.3-2mL/min.Then fiber directly is expressed in the precipitation bath, described precipitation bath is filled room temperature or high temperature or is lower than the solution of envrionment temperature, and described solution comprises sulfuric acid, saturated salt solution or the alkaline aqueous solution of 0-70 weight %.

Can change number, size, shape and the configuration in hole, to obtain desired fiber product.No matter before whether by non-condensable fluid layer, the liquid of extruding that spins is fed in the precipitation bath.Non-condensable fluid layer is generally air, but can be any other rare gas element or be not the liquid that spins the liquid peptizer.

Fiber and/or film can comprise common additives, as dyestuff, pigment, antioxidant, delustering agent, static inhibitor and ultra-violet stabilizer, described additive is added into spinning solution, spins in liquid or the precipitation bath, or at spinning duration or be applied on the fiber afterwards.

When comparing with long filament, as used herein, the fiber that term " staple fibre " refers to be cut into desired length or broken, or naturally occurring fiber or the fiber that makes, described fiber have the length of low ratio and cross-sectional area width ratio perpendicular to this length direction.The staple fibre that manually makes is cut into or makes the length that is suitable for processing treatment on cotton, wool or botany spinning equipment.Described staple fibre can have (a) uniform length substantially, (b) variation or random length, or (c) a part of staple fibre has substantially length uniformly, and the staple fibre in the other parts has different length, the staple fibre in the described part is mixed formation distribute uniformly substantially.

In certain embodiments, Shi Yi staple fibre has the length of about 0.25 centimetre (0.1 inch) to about 30 centimetres (12 inches).In certain embodiments, staple length is about 1 centimetre (0.39 inch) to about 20 centimetres (8 inches).In some preferred embodiments, the staple fibre that is made by staple process has about 1 centimetre (0.39 inch) extremely staple length of about 6 centimetres (2.4 inches).

Described staple fibre can be made by any method.For example, staple fibre can adopt rotor or guillotine cutter to be got by continuous fibers straight cutting, obtain straight (namely unconvoluted) staple fibre, or also can be got by the curling continuous fibre cutting with saw-tooth crimp along the staple length direction, (or repeated flex) frequency of curling preferably is no more than 8 curls/centimetre.

Staple fibre also can form by continuous fibre is broken, thereby obtains to have the staple fibre of crushed element, and described crushed element is as curling.The formula staple fibre of breaking can be by operating period pricks one or a branch of continuous filament yarn is broken to make breaking, described breaking operated the zone of breaking with one or more distance to a declared goal, thereby form the fibrous mass of random variation, described fiber has and can regulate the average cutting length of controlling via breaking the zone.

Can use conventional macrofiber well known in the art and staple fibre ring spinning process to make staple by staple fibre.With regard to staple fibre, adopt the cotton system spinning fiber length of about 1.9 to 5.7 centimetres (0.75 inches to 2.25 inches) usually.With regard to macrofiber, adopt the spinning or woolen system fiber of about 16.5 centimetres (6.5 inches) at most usually.Yet this is not intended to be limited to ring spinning, because also can use air-flow to spray spinning, open-end-spinning and the Yarn spinning method that staple fibre changes into many other types of available yarn is spinned.

Also can adopt and break the tow-to-top method and directly make staple by breaking.The staple fibre of being broken in the yarn that method forms by tradition has the long length of about 18cm (7in) at the most usually.Yet by the method described in the PCT patent application WO 0077283 for example, the staple that is made by the method for breaking also can have maximum length and be the staple fibre of about 50cm (20in) at the most.The formula staple fibre of breaking does not need to curl usually, because the method for breaking has been given curling to a certain degree to described fiber.

Staple fibre also can form by continuous fibre is broken, thereby obtains to have the staple fibre of crushed element, and described crushed element is as curling.The formula staple fibre of breaking can be by operating period pricks one or a branch of continuous filament yarn is broken to make breaking, described breaking operated the zone of breaking with one or more distance to a declared goal, thereby form the fibrous mass of random variation, described fiber has and can regulate the average cutting length of controlling via breaking the zone.

The term continuous filament yarn refers to have than minor diameter and its length those length longer pliable and tough fiber more specified than staple fibre.The multifilament of continuous filament fibers and continuous filament yarn can be made by method well known to those skilled in the art.

Can use multiple different fiber as the weaving staple fibre.In certain embodiments, Kevlar can be used as the weaving staple fibre in described blend.In some preferred embodiments, meta-aramid fiber can be used as the weaving staple fibre in described blend.So-called aromatic poly refers to that wherein at least 85% acid amides (CONH-) connects the polymeric amide that base directly links to each other with two aromatic rings.Meta-aramid is that position configuration or position orientation connect a class polymeric amide of base between comprising in polymer chain.Meta-aramid fiber is at present with trade(brand)name

By Wilmington, the E.I.du Pont de Nemours of Delaware sells.Additive can be used with aromatic poly, and find in fact, can other polymeric material and the aromatic poly blend of 10 weight % will be reached, perhaps can use multipolymer, described multipolymer has nearly other diamines of the diamines of 10% alternative aromatic poly, or other diacid chloride of the diacid chloride of 10% alternative aromatic poly nearly.In certain embodiments, preferred meta-aramid fiber be poly-(mpd-i) (MPD-I).Can use several different methods to spin this fiber by dry-spinning or wet spinning; United States Patent(USP) Nos. 3,063,966 and 5,667,743rd, the illustration of methods availalbe.

In certain embodiments, the para-aramid fiber can be used as the weaving staple fibre in described blend, to increase flame resistant intensity and to reduce heat-shrinkable.The para-aramid fiber is at present with trade(brand)name

By E.I.du Pont de Nemours (Wilmington, Delaware) and with (Tokyo Japan) sells by Teijin Ltd..With regard to purpose of the present invention, (Tokyo Japan), is made by copolymerization (to benzene/3,4 ' diphenyl ester paraphenylene terephthalamide) can to derive from Teijin Ltd.

Fiber is regarded as the para-aramid fiber.

In certain embodiments, poly-azoles fiber type can be used as textile fiber in described blend.For example, suitable poly-azoles comprises polybenzoxazole, polypyridine and azoles etc., and can be homopolymer or multipolymer.Additive can use with poly-azoles, and the most nearly 10 weight % other polymeric material can with described poly-azoles blend.Also can use and have nearly 10% or the multipolymer of other monomer of the more monomer that replaces poly-azoles.Suitable poly-azoles homopolymer and multipolymer can be made by known method, such as United States Patent (USP) 4,533,693 (authorize people such as Wolfe, on August 6th, 1985), 4,703,103 (authorizing people such as Wolfe, on October 27th, 1987), 5,089,591 (authorizing people such as Gregory, on February 18th, 1992), 4,772,678 (authorize people such as Sybert, on September 20th, 1988), 4,847,350 (authorize people such as Harris, on August 11st, 1992) and 5, described in 276,128 (the authorizing people such as Rosenberg, on January 4th, 1994) those.

In certain embodiments, preferred polyphenyl azoles be polybenzimidazole, polybenzothiozole and polyphenyl also

Azoles.If described polybenzoxazole is polybenzimidazole, then it is preferably poly-([5,5 '-two-1H-benzoglyoxaline]-2,2 '-two bases-1,3-phenylene), and it is called PBI.If described polyphenyl azoles is polybenzothiozole, then it is preferably polyphenyl and dithiazole, and its more preferably poly-(benzo [1,2-d:4,5-d '] dithiazole-2,6-two bases-1,4-benzene, it is called PBT.If described polybenzoxazole be polyphenyl also

Azoles, then it is preferably polyphenyl and two

Azoles, and it more preferably gathers (benzo [1,2-d:4,5-d '] two

Azoles-2,6-two bases-1,4-phenylene), it is called PBO.In certain embodiments, preferred polypyridine and azoles are rigid rod-like polymer polypyridine and diazole, comprise poly-(pyrido diimidazole), poly-(pyrido dithiazole) and poly-(pyrido two

Azoles).Preferred poly-(pyrido two

Azoles) (it is called PB for 1,4-(2,5-dihydroxyl) phenylene-2,6-pyrido [2,3-d:5,6-d '] diimidazole in order to gather.Suitable polypyridine and diazole can be made by known method, such as United States Patent (USP) 5,674, those described in 969.

In certain embodiments, can use modified acryl fibre.The modified acryl fibre that is preferred among the present invention is the multipolymer of vinyl cyanide and vinylidene chloride combination.In addition, described multipolymer also can comprise one or more weisspiessglanzs to improve fire line.This type of available modified acryl fibre includes but not limited to as U.S. Patent No. 3,193, disclosed fiber with 2 weight % ANTIMONY TRIOXIDE SB 203 99.8 PCT in 602 is as U.S. Patent No. 3,748, disclosed in 302 is the fiber that at least 2 weight % and the various weisspiessglanzs that preferably are not more than 8 weight % make by content, and as United States Patent(USP) Nos. 5,208,105 and 5, disclosed fiber with 8 to 40 weight % antimony compoundss in 506,042.Preferred modified acryl fibre can be commercially available from Kaneka Corporation (Japan) in a variety of forms, and some does not comprise weisspiessglanz, and other it is said those compounds that comprise 10 to 15 weight % such as Protex C.

In some preferred embodiments, various types of staple fibres exist with the staple fiber blends form.So-called fiber blends refers to the combination of any way of two or more staple fibre types.Described staple fiber blends is preferably " closely blend ", and this refers to that the various staple fibres of blend form fibre blend comparatively uniformly.In certain embodiments, described two or more staple fibre types before spinning or in blend intrafascicular so that various staple fibre is uniformly distributed in short yarn.

Fabric can be made by staple, and can include but not limited to weave or knitted fabrics.General Fabric Design and structure are well known to those skilled in the art.So-called " weaving " fabric refers to, usually pass through warp-wise or broadwise interwoven yarns what loom formed, and make yarn fill each other or interweave to form any texture of fabric (such as plain weave, the crowfoot knit, square plain weave, satin face are knitted, twill weave etc.) fabric.It is believed that plain weave and twill weave are the tissues of normal use in the commerce, and be preferred among many embodiment.

So-called " knitting " fabric refers to the fabric by using pin that the yarn coil interconnection is formed usually.In many cases, for making knitted fabrics, staple is fed into yarn is transformed in the knitting machine of fabric.If desired, can provide plying or not many warps or the yarn of plying in the knitting machine; That is, use routine techniques to be fed into a branch of yarn or a branch of doubled yarn in the knitting machine simultaneously and be knitted into fabric, or directly be knitted into clothing item such as gloves.In certain embodiments, wish to lack yarn with one or more other or continuous filament yarns feeds simultaneously by one or more staples that will have the fibre compact blend, thereby add in the knitted fabrics functional.But metering needle is knitted tightness to satisfy any concrete needs.In for example single jersey and pile knit fabric decorative pattern, found the very effective combination of protective clothing performance.

In some especially available embodiment, staple can be used for preparing the flame retardant resistance clothes.In certain embodiments, described clothes have the armored fabric that one deck is basically made by staple.These type of exemplary clothes comprise firefighter or military personnel's company's trousers shirt and coveralls.This type of suit is generally used for covering on outside firefighter's clothes, and enters into certain zone to put out hill fire for parachute jumping.Other clothes can be included in may take place the extreme heat event such as the trousers that can wear under chemical treatment industry or the industrial electric/electric power environmental, shirt, gloves, oversleeve etc.In some preferred embodiments, described fabric has the arc resistance of every square centimeter every ounce every square yard at least 0.8 card.

In one embodiment, described poly-based on sulfonation by making

The staple fibre of diazole and described weaving form the fibre blend of described fiber with the tight blend of staple fibre.If desired, can make the short fibre mixture combination relatively uniformly therewith of other staple fibre.Can obtain described concurrent mixture by multiple methods known in the art, comprise many continuous filament yarn line tubes are placed on the creel, and cut two or more types long filament simultaneously to form the method for cutting staple fiber blends; Or relate to the different staple fibres bundles of shredding, then in opener, blender and carding machine with the method for various fiber openings and blend; Or form various staple fibre strip, and then it is further processed to form the method for mixture, rectangular as in combing, forming fibre blend.Various types of different fibers can adopt other method of preparation fibre compact concurrent mixture, as long as can be distributed in the whole blend more uniformly.If form yarn by described blend, then described yarn has short fibre mixture uniformly equally.In general, in most preferred embodiment, with independent staple fibre shredding or be separated to the normal degree that in fiber process, can make available fabric, make because the fiber knot that the bad shredding of staple fibre causes or fiber joint and other major defect do not exist with the amount that impairs final fabric quality.

In a preferred method, the following intimate blend of staple fibers that makes: staple fibre and any other staple fibre (if additional function is required) that at first will derive from the shredding bundle mix.Use carding machine that fiber blends is combed slivering then.In the fiber industry, use carding machine to come separated fiber usually, adjust fiber, and fibre delivery is delivered in the continuous strand of loose conjugate fiber, significantly do not twine and have, it is commonly called the carded sliver.Usually by but be not limited to the two-step stretch method, the carded sliver is processed ripe bar.

Adopt technology to make staple by ripe then, described technology comprises conventional cotton system or short fiber spinning process, such as open-end-spinning and ring spinning; Or high speed gas spinning technique, spray spinning such as the Murata air-flow, wherein use air that the staple fibre twisted is become yarn.Also can adopt conventional woolen system or long fine spinning process such as combing or half combing RING SPINNING or break the preparation that spinning realizes staple.No matter adopt which kind of system of processing, ring spinning generally is the preferred method of preparation staple.

Example

Except as otherwise noted, example all adopts following method preparation.Reagent rate provides with the mol ratio form.Oleum available from E.I.du Pont de Nemours and Company (Wilmington, DE).Terephthalic acid (TA), m-phthalic acid (IA), 4,4 '-phenyl ether dioctyl phthalate (OBBA), methylsulfonic acid, Tripyrophosphoric acid and d ₆-dimethyl sulfoxide (DMSO) is available from Sigma-

The sulfuric acid hydrazine is available from Acros Organics.Sulfuric acid and sodium bicarbonate are available from EMD Chemicals, Inc..

Conventional polymerization process

Except as otherwise noted, each example uses conventional polymerization process, but by specified change monomer ratio.Via powder funnel, add sulfuric acid hydrazine (0.015 mole, 1 molar equivalent) and one or more di-carboxylic acid of totally 1 molar equivalent in the 100mL dry glass reactor that glass machinery agitator, nitrogen inlet and reagent adds entrance to being equipped with.Except as otherwise noted, di-carboxylic acid: the molar ratio of sulfuric acid hydrazine is 1: 1.The concrete mol ratio of every kind of di-carboxylic acid is specified in example.In nitrogen, with solids component fully blend 15 minutes together.At room temperature in the solid mixture of this blend, add 19.028g (0.0712 mole of SO ₃) 30% oleum (oleum, the 30 weight % SO that dissociates ₃Content), stir simultaneously.Reactor seals fully and does not have and splits leakage (comprising stirrer shaft), to prevent gas phase composition effusion still.At room temperature with mixture mechanical stirring some minutes.Then with the reactor submergence in oil bath, and be heated to 130 ℃.Polyreaction was carried out under 130 ℃ 4 hours.During polyreaction, too high if the viscosity of polymeric reaction solution becomes, reduce stir speed (S.S.) usually or stop stirring.

In some instances, use 4,4 of pre-reaction '-phenyl ether dioctyl phthalate (OBBA).OBBA is dissolved in 30% oleum, and makes to be reflected at and carried out under 130 ℃ 6.5 hours.Sulfuric acid hydrazine from ratio same as above to reactor and other di-carboxylic acid of adding.Add 4,4 then '-solution of phenyl ether dioctyl phthalate.Mixture comprises many solid chunks, and it is not admixed in the reaction mixture well, after experiencing about 200 minutes under 130 ℃.Polyreaction was carried out under 130 ℃ 4 hours.

Conventional fibre formation method

Adopt three kinds of methods to prepare fiber.Fiber among the example 1-19 is following to be made.With sulfuric acid (95-98%) diluted polymer reaction mixture.Add the sulfuric acid of capacity, make soltion viscosity enough high, so that thin continuous flow can be added drop-wise in the blender that comprises water, described blender with the given pace rotation, is not drawn back with the fiber of guaranteeing to solidify simultaneously.To each polyreaction, determine the optimal conditions of this method.For coagulated fibre, rubber sheet gasket is added in blender blade top, this makes fiber to be wound and to collect.Usually by hand fiber is rewound on the vial then, washes with water, be soaked in then in the sodium bicarbonate of dilution, until neutralization fully.Then fiber is washed with water and soak, to remove the sodium bicarbonate of any remnants.Make fiber dry under envrionment conditions.In some instances, with fiber samples high vacuum dry at room temperature, with in methylsulfonic acid via size exclusion chromatography, (SEC) determining molecular weight.

Fiber in the example 20 and 21 is prepared by following method.By the sulphuric acid soln spinning fibre of polymer concentration in 6-9 weight % scope.Via toothed gear pump solution is sent by having the spinning nozzle in 10 holes, described hole has the diameter of 0.005 " or 0.008 ".The volumetric flow rate of spinning solution is 0.3-2mL/min.Fiber directly is expressed in the precipitation bath, and solution at room temperature is filled in described precipitation bath, and described solution is the sulfuric acid of 0-20 weight %.The residence time of fiber in precipitation bath is between 15 to 60 seconds.Leave the fiber of precipitation bath via the water-bath of ceramic guide inlet chamber temperature laundering.In washing bath, fiber is reeled around two fast controlled driving rolls, and 50-100% then stretches.Center on each in these rollers, make three volumes usually.Fiber is wrapped on the resol core.In a series of intermittence step, the fiber bobbin of winding is neutralized in 0.5 weight % sodium hydrogen carbonate solution then, in deionized water, wash, and at room temperature air-dry.

Also can prepare fiber by following method.By the sulphuric acid soln spinning fibre of polymer concentration in 4-14 weight % scope.Via toothed gear pump solution is sent by having the spinning nozzle in 10-20 hole, described hole has 0.003 " or 0.008 " diameter.The volumetric flow rate of spinning solution is 0.3-2mL/min.Fiber directly is expressed into the precipitation bath top, and described precipitation bath is filled room temperature, high temperature or is lower than the solution of envrionment temperature, and described solution is 0-70 weight % sulfuric acid.Fiber is apart from precipitation bath 1/8 " to 6 inches.The residence time of fiber in precipitation bath is between 15 to 60 seconds.The fiber that leaves precipitation bath enter room temperature, high temperature via ceramic guide or be lower than the washing water-bath of envrionment temperature, acidic aqueous solution is bathed or alkaline aqueous solution is bathed.In washing bath, fiber is reeled around two fast controlled driving rolls, and 0-500% then stretches.Center on each in these rollers, make three volumes usually.Fiber is wrapped on the resol core.Then in a series of intermittence step, the fiber bobbin that twines neutralizing in the basic solution slightly, is washed in deionized water, and air-dry under room temperature or high temperature, or dry in room temperature or vacuum high temperature furnace.

Conventional curtain coating membrane preparation method

Polymeric reaction solution makes it possible to be poured on the uniform film of acquisition on the sheet glass with sulfuric acid (95-98%) dilution until gained viscosity.This viscosity is usually less than the required viscosity of coagulated fibre.Polymkeric substance and sheet glass are immersed in the water-bath so that film solidifies.Wash the film that solidifies with water, be soaked in then in the sodium bicarbonate of dilution, until neutralization fully.Then film is washed with water and soak, to remove the sodium bicarbonate of any remnants.Film is suppressed repeatedly, until touching up substantially dry between paper handkerchief with pressure in various degree.Then film is placed between the aluminium foil, and under 10,000lb, suppressed 5 minutes.With gained film high vacuum dry 24 hours at room temperature.

Conventional paste membrane preparation method

The casting films that water will as above make in blender is slurried into small-particle.Solid filters by fritted glass filter, and the water repetitive scrubbing.,, filter by fritted glass filter until neutralization solid pulp in blender again with the sodium hydrogen carbonate solution that dilutes, and the water repetitive scrubbing.Water until neutralization, filters solid pulp in blender again by fritted glass filter, and the water repetitive scrubbing.Repeat slurring method then.Solid film is dry on fritted glass filter, can take off lightly with a slice until it.Film is suppressed repeatedly, until touching up substantially dry between paper handkerchief with pressure in various degree.Then film is placed between the aluminium foil, and under 10,000lb, suppressed 30 minutes.With film high vacuum dry at room temperature.

LOI measures

Limiting oxygen index(LOI) (LOI) is the oxygen represented with volume percent and the minimum oxygen concn in the nitrogen mixture, and described mixture just can be kept the material flaming combustion under the initial room-temperature under ASTM G125/D2863 condition.Adopt improved ASTM method (ASTM D 2863) to measure LOI, with can the rapid screening sample.Film is installed on the sample clamping device, described sample clamping device is inserted in the LOI equipment, and covers with lens.Oxygen content in the digital control lens.Make film contact flame, and increase the oxygen content in the lens, burn until sample.At the time point that can keep the burning of candle shape, measure the LOI of any appointment sample.Sampled data and the results are summarized in the table 1.

(1) the comparative example oleum replaces with Tripyrophosphoric acid, and sulfuric acid replaces with phosphoric acid

(2) OBBA of use pre-reaction

(3) comparative example

(4) comparative example of fairly large enforcement is by mixing 86.885 gram (0.6677 moles hydrazine) solid sulphuric acid hydrazines, 105.12 gram (0.6327 mole) solid terephthalic acid and 9.000 gram (0.0333 mole) solid m-phthalic acids and blend 30 minutes together the preparation polymkeric substance in agitator.Add 30% oleum (534 gram oleums, 2.001 moles of SO down at 25 ℃ ₃) the first time reinforced, 25 ℃ of following mechanical stirring 15 minutes, under mechanical stirring, be heated to 120 ℃ then, until observe constant moment of torsion (60 minutes) at agitator.Add 30% oleum (611 gram oleums, 2.290 moles of SO down at 130 ℃ then ₃) the second time reinforced.Temperature was kept 2 hours down at 130 ℃, reach stable until soltion viscosity, be cooled to room temperature then.

(5) use sulfuric acid hydrazine (1.005 molar equivalent), terephthalic acid, 4,4 '-phenyl ether dioctyl phthalate and 20% oleum, with fairly large (2L) embodiment.By adding water, the amber mixture of cancellation gained utmost point thickness, and be diluted to 9.42 weight %.

Example 22

4,4 '-sulfonation of phenyl ether dioctyl phthalate proves

With 4,4 '-phenyl ether dioctyl phthalate (87mg, Aldrich 99%) joins in 0.9mL 30% oleum.At ambient temperature material was stirred＜1 minute, and be transferred to immediately in the test tube that is suitable for nucleus magnetic resonance (NMR) Spectroscopy Study of 5mm external diameter (o.d).Before the sealed hair tubule was inserted in the NMR pipe, comprised the dimethyl sulfoxide (DMSO)-d for locking deuterium and chemical shift location in the described kapillary ₆Described test tube is inserted in the NMR probe that remains on 30 ℃ immediately.Through the brief time in homogenize (" coarse adjustment ") magnetic field, collect sample automatically ¹H NMR spectral series.

8.11 and the resonance at 6.98ppm place is defined as the unsulfonated ring ¹H nuclear, and 8.47,8.18 and the resonance at 7.06ppm place be defined as those of the sulfonation ring that replaces on the ehter bond ortho position.During kinetics spectra collection process, the strength of resonance that is defined as the unsulfonated ring weakens, and is defined as those enhancings of sulfonation ring, the sulfonation of surface ring.30 ℃ the half-life of this process is 52 minutes down.

Example 23

Sulfonation 4,4 '-proof of phenyl ether dioctyl phthalate structure

Comprise to 40mL and add 4,4 in the bottle of magnetic stirring bar '-phenyl ether dioctyl phthalate (6.0g) and 30% oleum (39.6g).Mixture was heated 3 days in 130 ℃ of hot-cast pieces.Water cancellation gained transparent brown solution sample (1mL), and vortex mixed then.With the solid filtering that is settled out and with the washing of frozen water appropriateness.Remaining solid is mainly the sulfone product of a sulfonation, and contains the sulfone that filter liquor mainly comprises two sulfonation.Carry out ¹H NMR wave spectrum or LC/MS detect, and show sulfonation and sulfonylation product that formation is desired.

Comprising trace 3-trimethyl silyl Sodium Propionate-d ₄Water-d as the chemical shift indicator ₂The saturated solution of middle preparation one sulfonation sulfone product.Solution is inserted in the NMR probe, and is heated to 60 ℃ to guarantee dissolving.Implement the experiment of a series of NMR two-dimensional correlation, to illustrate described material structure.These experiments can be determined the fen of primary product 4-sulfo group Thiophene-2,8-di-carboxylic acid 10, the 10-dioxide ¹H resonance. ¹H ownership (be unit with the ppm with respect to 0.00ppm place chemical shift indicator) is shown in hereinafter.

Example 24

The demonstration of polymkeric substance sulfonylation and sulfonation

Under 50 ℃, will gather (phenylene-copolymerization-4,4 '-phenyl ether dioctyl phthalate disulfonate

Diazole) (34.4mg) be dissolved in 30% oleum (1.384g), wherein terephthalic acid and 4,4 '-phenyl ether diformate mono body unit exists with 70: 30 mol ratios.This substance transfer is applicable in the cylindrical tube of NMR spectrum to having 3mm external diameter (o.d).Then this pipe is frozen in the liquid nitrogen, finds time and the flame sealing.The pipe of sealing is inserted in 5mm external diameter (o.d) the NMR pipe, and the void space between the pipe is filled dimethyl sulfoxide (DMSO)-d ₆Then pipe is inserted in the NMR probe, and is heated to 130 ℃.After reaching temperature, use the quantitative collection condition to begin automatically ¹H NMR spectra collection series is with the research reaction kinetics.Observe 4,4 '-phenyl ether dioctyl phthalate ring sulfonylation, as mentioned described in the example.

Via formed material in the NMR analysis example 9 and use above the spectrum ownership, find that 17.65% OBBA monomer is two sulfonation forms, 7.35% is a sulfonation sulfone form, and trace is two sulfonation sulfone forms, it is the S of 5.34 weight %:

Material to example 6 is implemented ultimate analysis, and finds 43.26%C, 3.07%H, 30.06%O, 10.18%N, and 6.50%S.

Example 25

Comprise 80: 10: 10 terephthalic acids: 4,4 '-the phenyl ether dioctyl phthalate: the 5-sulfoisophthalic acid poly-(

Diazole) (POD) synthetic

Add in the 100mL dry glass reactor of entrance to being equipped with glass machinery agitator, nitrogen inlet and reagent, add (0.015 mole of sulfuric acid hydrazine via powder funnel, 1.007 molar equivalent) and the amount di-carboxylic acid of totally 1 molar equivalent (terephthalic acid (1.994g, 0.8 molar equivalent), 4,4 '-phenyl ether dioctyl phthalate (0.387g, 0.1 molar equivalent) and 5-sulfoisophthalic acid (0.402g, 0.1 molar equivalent)).In nitrogen, with solids component fully blend 15 minutes together.At room temperature in the solid mixture of this blend, add 28.5g 20% oleum (oleum, the 20 weight % SO that dissociates ₃Content), stir simultaneously.Reactor seals fully and does not have and splits leakage (comprising stirrer shaft), to prevent gas phase composition effusion still.At room temperature with mixture mechanical stirring some minutes.Then with the reactor submergence in oil bath, and be heated to 130 ℃.Polyreaction was carried out under 130 ℃ 4 hours.During polyreaction, too high if the viscosity of polymeric reaction solution becomes, reduce stir speed (S.S.) usually or stop stirring.

Example 26

The 25%OBBA-POD fiber with orchil #29 dyeing with benzylalcohol carrier

In the round-bottomed flask that comprises magnetic stirring bar and fiber (0.037g), add solution (82g), described solution by 10 weight %MERPOL HCS (Aldrich, 1.25g), TSPP (Aldrich, tetrasodium pyrophosphate, 0.25g) and DI water (248.50g) form.Described mixture is positioned in 29 ℃ of oil baths, and is heated to 85 ℃ with about 3 ℃/min speed, under this temperature, kept 20 minutes then.Use the hot wash fiber, wash with room temperature water then.Wet fiber is returned in the round-bottomed flask that comprises magnetic stirring bar.In flask, add 0.1 weight %MERPOL HCS (0.005g) solution and comprise benzylalcohol (Aldrich, solution 3.75g) (55.00g) and DI water (121.25g).Mixture was heated 15 minutes in 46 ℃ of body lotions.Then, orchil #29 (Aldrich, 0.0032g is in fiber 7.96 weight % dyestuffs) is dissolved in the solution and DI water (121.25g) that 10.00g comprises benzylalcohol (3.75g), and joins in the reaction mixture.46 ℃ of following reheat 10 minutes, red solution became baby pink then with mixture, and fiber is scarlet.Mixture is taken out from heating bath, and pH is 6.3.By adding acetic acid (1,0.85 weight %), with pH regulator to 3.9.Then mixture was heated 15 minutes in 74 ℃ of body lotions, and dye solution becomes colourless.Mixture was refluxed 60 minutes in 130 ℃ of body lotions again.Use the hot wash fiber, and then wash with room temperature water.Wet fiber is returned in the round-bottomed flask that comprises magnetic stirring bar.In flask, add 0.1 weight %MERPOL HCS (0.04g) and DI water (50.00g).Mixture was heated 20 minutes down at 85 ℃.Use the hot wash fiber, and then wash with room temperature water.It is blotted in paper handkerchief, in 82 ℃ of baking ovens, placed 3 hours then.Adopt the cross section optical microscopy to guarantee that dyestuff takes in fully.

Example 27

The OBBA-POD fiber that this example shows flame resistant spun staple yarns and derives from example 24 with have 21 or the textiles staple fibre of higher limiting oxygen index(LOI) and about 4 gram/DENIER or higher toughness, such as with trade mark

Fiber is available from E.I.duPont de Nemours﹠amp; Poly-(mpd-i) of Company be the fabric of the tight blend of fiber (MPD-I).

By the preparation of conventional cotton system equipment with process the OBBA-POD staple fibre of 50 weight % and the scutching cotton blending bar of the MPD-I staple fibre of 50 weight %, and use ring spinning frame to be spun into to have about 4.0 twist multiplier and the flame resistant spun staple yarns of about 21 spies (28 yarn count) one-ply yarn size.On buncher, two these type of single thread are pooled capital then, make the bifilar yarn of flame retardant resistance, to be used as the fabric warp thread.Use identical blend and similar method, comprise the identical twist and blending ratio, make the single thread of 24 spies (24 yarn count), and two strands of quilts in these one-ply yarns pool capital to form bifilar flame-retardant yarn as the fabric weft yarn.These doubled warps and bifilar weft yarn all have the toughness greater than the toughness of the bifilar 100%OBBA-POD short fiber yarn that makes under conditions of similarity, that is, described bifilar yarn has the toughness of at least 3 gram/DENIER (2.7 gram/dtex).

Warp thread and weft yarn that ring spins are woven into fabric at fly-shuttle loom, obtain to have 2 * 1 twill weave and 26 through * 17 latitudes/centimetre (72 through * 52 latitude/inches) structure and about 215g/m ²(6.5oz/yd ²) nature fabric of basic weight.In hot water, clean the true qualities twilled fabric then, and dry under low-tension.The fabric jet dyeing of using basic dyestuff to clean then.The gained fabric has about 231g/m ²(7oz/yd ²) basic weight and surpass 28 LOI.

The part of fabric is cut into different shape, and different shape is sewn to together fabric is changed into those situations that the individual layer protective clothing is used for being exposed to hot dangerous matter sources.

In a similar fashion, the ring yarn is made as contrast with relevant fabric and clothes by the 100%OBBA-POD staple fibre.

Table 2 shows the performance of fabric and the clothes of gained."+" expression is than the performance of those excellent performances of contrast, and mark " 0 " expression contrast performance, or the performance suitable with the contrast performance.

Table 2

Example 28

This example shows flame resistant spun staple yarns and derives from OBBA-POD fiber and the modified acryl fibre of example 24, such as by Kaneka Corporation with trade mark Protex The fabric of the tight blend of the modified acryl fibre of making.

By the preparation of conventional cotton system equipment with process the OBBA-POD staple fibre of 65 weight % and the scutching cotton blending bar of the modacrylic staple fibre of 35 weight %, and use ring spinning frame to be spun into to have about 4.0 twist multiplier and the flame resistant spun staple yarns of about 21 spies (28 yarn count) one-ply yarn size.On buncher, two these type of single thread are pooled capital then, make the bifilar yarn of flame retardant resistance, to be used as the fabric warp thread.Use identical blend and similar method, and the identical twist and blending ratio, make the single thread of 24 spies (24 yarn count), and two strands of quilts in these one-ply yarns pool capital to form bifilar flame-retardant yarn as the fabric weft yarn.These doubled warps and bifilar weft yarn all have the toughness greater than the toughness of the bifilar 100%OBBA-POD short fiber yarn that makes under similar condition, that is, bifilar yarn has the toughness of at least 3 gram/DENIER (2.7 gram/dtex).

Warp thread and weft yarn that ring spins are woven into fabric at fly-shuttle loom, obtain to have 2 * 1 twill weave and 26 through * 17 latitudes/centimetre (72 through * 52 latitude/inches) structure and about 215g/m ²(6.5oz/yd ²) nature fabric of basic weight.In hot water, clean the true qualities twilled fabric then, and dry under low-tension.The fabric jet dyeing of using basic dyestuff to clean then.The gained fabric has about 231g/m ²(7oz/yd ²) basic weight and surpass 28 LOI.

The part of fabric is cut into multiple shape, and described multiple shape is stitched into together fabric is transformed into the individual layer protective clothing, for those situations that are exposed to hot dangerous matter sources.

In a similar fashion, the ring yarn is made as contrast with the fabric and the clothes that are associated by the 100%OBBA-POD staple fibre.

Table 3 shows the performance of fabric and the clothes of gained."+" expression is than the performance of those excellent performances of contrast, and mark " 0 " expression contrast performance, or the performance suitable with the contrast performance.

Table 3

Example 29

The OBBA-POD fiber that this example shows flame resistant spun staple yarns and derives from example 24 with have high-modulus, particularly, the fiber of 200 gram/DENIER or higher tensile modulus is such as with trade mark

Fiber is available from E.I.duPont de Nemours﹠amp; The fabric of the tight blend of the PPTA of Company (PPD-T) fiber.PPD-T is known as the rigid rod polymkeric substance in the art.

By the preparation of conventional cotton system equipment with process the OBBA-POD staple fibre of 85 weight % and the scutching cotton blending bar of the PPD-T staple fibre of 15 weight %, and use ring spinning frame to be spun into to have about 4.0 twist multiplier and the flame resistant spun staple yarns of about 21 spies (28 yarn count) one-ply yarn size.Use identical blend and similar method, comprise the identical twist and blending ratio, then two strands of these type of one-ply yarns are used as the fabric warp thread at the buncher plying to make bifilar flame-retardant yarn, make the single thread of 24 spies (24 yarn count), and two strands of quilts in these one-ply yarns pool capital to form bifilar flame-retardant yarn as the fabric weft yarn.These doubled warps and bifilar weft yarn all have the toughness greater than the toughness of the bifilar 100%OBBA-POD short fiber yarn that makes under similar condition, that is, bifilar yarn has the toughness of at least 3 gram/DENIER (2.7 gram/dtex).

Warp thread and weft yarn that ring spins are woven into fabric at fly-shuttle loom, obtain to have 2 * 1 twill weave and 26 through * 17 latitudes/centimetre (72 through * 52 latitude/inches) structure and about 215g/m ²(6.5oz/yd ²) nature fabric of basic weight.In hot water, clean the true qualities twilled fabric then, and dry under low-tension.The fabric jet dyeing of using basic dyestuff to clean then.The gained fabric has about 231g/m ²(7oz/yd ²) basic weight and surpass 28 LOI.

The part of fabric is cut into multiple shape, and described multiple shape is stitched into together fabric is transformed into the individual layer protective clothing, for those situations that are exposed to hot dangerous matter sources.

In a similar fashion, the ring yarn is made as contrast with relevant fabric and clothes by the 100%OBBA-POD staple fibre.

Table 4 shows the performance of fabric and the clothes of gained."+" expression is than the performance of those excellent performances of contrast, and mark " 0 " expression contrast performance, or the performance suitable with the contrast performance.

Table 4

Example 30

Repeat example 29, except scutching cotton blending bar comprises the PPD-T staple fibre of the OBBA-POD staple fibre of 40 weight % and 60 weight %.As in example 29, the ring yarn is made as contrast with relevant fabric and clothes by the 100%OBBA-POD staple fibre.

Table 5 shows the performance of fabric and the clothes of gained."+" expression is than the performance of those excellent performances of contrast, and mark " 0 " expression contrast performance, or the performance suitable with the contrast performance.

Table 5

Claims (12)

1. flame resistant spun staple yarns comprised for about 50 gathering based on sulfonation to about 95 weight parts

The staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I):

Wherein M is positively charged ion;

With in the total amount about 5 of the described polymer fiber in the described yarn and the described textile fiber textiles staple fibre to about 50 weight parts, described textiles staple fibre has 21 or higher limiting oxygen index(LOI) and about 4 gram/DENIER or higher toughness.

2. the protective clothing, woven fabrics, supatex fabric, band or the long filament that comprise the described flame resistant spun staple yarns of claim 1.

3. flame resistant spun staple yarns comprised at least about 25 weight parts gathering based on sulfonation to about 80 weight parts

The staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I):

Wherein M is positively charged ion;

With total amount about 20 modified acryl fibres to about 75 weight parts in the described polymer fiber in the described yarn and described textile fiber.

4. the protective clothing, woven fabrics, supatex fabric, band or the long filament that comprise the described flame resistant spun staple yarns of claim 3.

5. flame resistant spun staple yarns comprised for about 50 gathering based on sulfonation to about 95 weight parts The staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) or the repeating unit of the two and formula (I):

Wherein M is positively charged ion;

With in the total amount about 5 of the described polymer fiber in the described yarn and the described textile fiber high-modulus staple fibre with 200 gram/DENIER or higher tensile modulus to about 50 weight parts.

6. the protective clothing, woven fabrics, supatex fabric, band or the long filament that comprise the described flame resistant spun staple yarns of claim 5.

7. flame resistant spun staple yarns comprised for about 20 gathering based on sulfonation to about 50 weight parts

The staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I):

Wherein M is positively charged ion;

Described poly-based on sulfonation with in the described yarn

The fiber of diazole and described textile fiber

Total amount meter about 50 is to the rigid rod staple fibre of about 80 weight parts.

8. the protective clothing, woven fabrics, supatex fabric, band or the long filament that comprise the described flame resistant spun staple yarns of claim 7.

9. the method for preparing staple, comprise a) form about 50 to about 95 weight parts based on poly-

The fibre blend of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I):

Wherein M is positively charged ion;

With in the total amount about 5 of the described polymer fiber in the described yarn and the described textile fiber textiles staple fibre to about 50 weight parts, described textiles staple fibre has 21 or higher limiting oxygen index(LOI) and about 4 gram/DENIER or higher toughness; And

B) described fibre blend is spun into staple.

10. the method for preparing staple, comprise a) form at least about 25 weight parts based on poly- The fibre blend of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I):

Wherein M is positively charged ion;

With total amount about 20 modified acryl fibres to about 75 weight parts in the described polymer fiber in the described yarn and described textile fiber, and

B) described fibre blend is spun into staple.

11. prepare the method for staple, comprise a) form about 50 to about 95 weight parts based on poly-

The fibre blend of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I):

Wherein M is positively charged ion;

With in the total amount about 5 of the described polymer fiber in the described yarn and the described textile fiber high-modulus staple fibre with 200 gram/DENIER or higher tensile modulus to about 50 weight parts; And

B) described fibre blend is spun into staple.

12. prepare the method for staple, comprise a) form about 20 to about 50 weight parts based on poly-

The fibre blend of the staple fibre of diazole, described staple fibre comprise formula (II) and (IIa) one or both of and the repeating unit of formula (I):

Wherein M is positively charged ion;

With in the total amount about 50 of the described polymer fiber in the described yarn and the described textile fiber rigid rod staple fibre to about 80 weight parts; And

B) described fibre blend is spun into staple.