Aromatic Polysulfone Copolymers High Glass Transition Temperature

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Solution Overview

Problem

Current polysulfone copolymers made with bis(4-chlorophenyl)sulfone have limited applications due to relatively low glass transition temperatures and poor mechanical properties, which restrict their use in high-temperature environments and require expensive raw materials like cesium carbonate.

Innovation Solution

A three-step synthesis method involving the reaction of 2H-benzimidazol-2-one with bis(4-chlorophenyl)sulfone, followed by the addition of a difluoro aromatic ketone to form mono-fluoro aromatic ketone end-capped oligomers, and subsequent reaction with bisphenol to produce polysulfone copolymers with improved thermal stability and flame resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional polysulfone copolymers are made with bis(4-chlorophenyl)sulfone, then good mechanical properties and chemical resistance are achieved, but glass transition temperature is limited to around 220°C restricting high-temperature applications

Engineering Contradiction:

Improveglass transition temperatureVSAvoidapplication range

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The patent changes the chemical structure parameters of the polysulfone copolymer by introducing aromatic ketone units with specific molecular weights and configurations. This structural parameter change directly increases the glass transition temperature from 220°C to above 250°C while maintaining the base polysulfone framework for mechanical properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite polymer structure by combining bis(4-chlorophenyl)sulfone units with aromatic ketone units containing 6-12 aromatic rings. This composite approach integrates the mechanical benefits of polysulfone with the thermal stability of extended aromatic ketone structures.

Inventive Principle:

Principle #40Composite materials

2Temperature

If cesium carbonate is used as raw material to produce polysulfone copolymers, then improved thermal stability is achieved, but production cost increases significantly

Engineering Contradiction:

Improvethermal stabilityVSAvoidproduction cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The patent replaces expensive cesium carbonate with more economical alkali metal carbonates such as potassium carbonate or sodium carbonate. This substitution maintains the necessary alkaline conditions for polymerization and thermal stability while dramatically reducing raw material costs.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention uses alkali metal carbonate as an intermediary base catalyst in the polymerization reaction. This intermediary provides the necessary alkaline environment for forming polysulfone copolymers with improved thermal stability without requiring the expensive cesium carbonate, achieving the same functional effect at lower cost.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Temperature

If polysulfone copolymers are designed for high-temperature applications above 210°C, then heat resistance is improved, but mechanical properties and processability deteriorate

Engineering Contradiction:

Improveheat resistanceVSAvoidmechanical properties

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent introduces aromatic ketone units with specific local structural characteristics (6-12 aromatic rings) at controlled proportions (5-50 mol%) within the polysulfone copolymer chain. This local structural enhancement provides heat resistance at the molecular level while the overall copolymer composition maintains mechanical integrity and processability.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The resulting polysulfone copolymers exhibit higher glass transition temperatures and enhanced thermal stability, expanding their application range without compromising chemical resistance, and can be produced economically using commercially available materials.

Implementation Method 1

Poly(aryl ether sulfone)s are conventionally made by the nucleophilic polycondensation of bisphenol (such as, bisphenol-A, bis(4-hydroxyphenyl)sulfone, and 4,4′-biphenol) with bis(4-chlorophenyl)sulfone

Methodology Applied

Scientific EffectNucleophilic polycondensation: Chemical Bonding

Implementation Method 2

The resulting polysulfone copolymers exhibit higher glass transition temperatures and enhanced thermal stability, expanding their application range without compromising chemical resistance

Methodology Applied

Scientific EffectNucleophilic substitution: Chemical Bonding

Data Source

PatentUS11851532B2Aromatic polysulfone copolymers

Publication Date: 2023.12.26 HT MATERIALS CORP

AI summary

Compositions and methods for aromatic polysulfone copolymers are described herein. The polysulfone copolymers have advantageous properties, particularly in terms of high glass transition temperatures (Tg), improved thermal stability, improved flame resistance, good mechanical properties, chemical resistance and dimensional stability at elevated temperature. The polysulfone copolymers are suitable for manufacturing high temperature molded systems and other articles of manufacture via injection molding, extrusion, compression molding, coating, blow molding, thermoforming, rotational molding and additive manufacturing.