a) Field of the Invention

This invention relates to a novel curable polymeric composition, the composition after it has been cured and an article comprising at least one layer of the composition supported on a substrate. The novel com¬ position comprises an aromatic polymer and a reactive component.

b) Background and Invention

Aromatic polymers have many desirable properties, such as good lap shear strength, thermal stability and tensile strength which make them useful for a wide variety of applications. The term aromatic polymer is used herein to mean a polymer which has aromatic groups incorporated in the repeat unit of their backbone chain. Such polymers include for example poly(imides) , poly(etherimides) , poly(sulfones) , ^' ol (ether sulfones), poly(aryl ether ketones), poly(carbonates) , poly(arylates) and the like.

Aromatic polymers can be used as adhesives, coatings, matrix resins for fiber reinforced composite structures and numerous other uses where a relatively thin layer of the polymer is placed on a substrate. One of the problems that has been encountered in the use of aromatic polymers is the tendency of the poly¬ mers to crack. Further, when used as adhesives and

coatings the adhesion between the polymer and various substrates can be less than that required for high per¬ formance applications.

I have now discovered that solvent cracking resistance, adhesive properties, high temperature pro¬ perties and tensile strength of aromatic polymers can be significantly improved by adding a reactive aromatic component to the aromatic polymer and then curing the resulting composition.

SUMMARY OF THE INVENTION

It has been discovered that novel curable com¬ positions comprising (a) a first component comprising an aromatic polymer having a first preponderant repeat unit and (b) a second reactive component which is com- patible with the aromatic polymer, said second com¬ ponent comprising an aromatic, organic material having a second preponderant repeat unit from 1 to 300 repeat units, the second preponderant repeat units being dif¬ ferent from the first preponderant repeat unit and being substantially free of elemental sulfur and reac¬ tive divalent sulfur wherein said second component is present in an amount effective to substantially cure the composition, and the compositions which have been cured are surprisingly improved as adhesives, are capable of forming free standing films, are melt fusible, exhibit improved creep resistance, are not brittle, exhibit increased tensile strength, show

improved resistance to cracking. Even further, it has been discovered that the compositions are useful as the matrix resin for reinforced composites. The com¬ position is also useful in making an article comprising a substrate having on a surface thereof at least one layer of a cured, aromatic polymer-based composition of this invention. Of particular interest are articles containing a plurality of layers, each comprising a cured composition of this invention, with a conductive layer interposed between two adjacent layers. Such articles can be used as packaging-interconnect devices for integrated circuits.

In another embodiment, the invention relates to a method of bonding comprising 1) heating a composition to predetermined temperature; 2) positioning the com¬ position between two substrates; 3) applying pressure; and 4) curing the bonded substrates for a predetermined time and temperature.

In a still further embodiment, the invention rela- tes to a method of preparing an article a) depositing on a surface of said substrate a first layer of a com¬ position comprising a solution of a composition in a solvent therefor; b) evaporating said solvent; and c) curing said composition.

In the curable composition of this invention, it is preferred that the aromatic polymer component comprises from about 99% to about 1% by weight of the composition

and the reactive component comprises from about 1% to about 99% by weight to the composition. It is further preferred that the aromatic polymer component comprise at least 20%, more preferably at least 40% and most preferably at least 50% by weight of the composition.

It is further preferred that the reactive aromatic com¬ ponent comprise from about 5% to about 35% by weight of the composition. It is further surprisingly found that some of the compositions of the invention are molecu- larly compatible forming molecularly compatible blends.

By preponderant repeat unit we mean that repeat unit which forms the largest fraction by weight of the repeat units present in either the first or second com¬ ponent.

The second reactive component of the composition of the invention comprises an aromatic organic material. The reactive component is selected such that it is com¬ patible with the first component. The material may be a monomer, oligomer or polymer as desired having a second preponderant repeat unit of from 1 to 300 repeat units in the backbone. Preferably the material will have from 1 to 30 repeat units and more preferably from 1 to 10 repeat units. The reactive component is selected such that the second preponderant repeat unit is different from the first preponderant repeat unit selected for the aromatic first component. For example, where an acetylene terminated poly(imide) of a specific repeat unit is selected the reactive second

component, the first component will not be a poly(imide) having the same specific repeat unit as the second preponderant repeat unit although a poly(imide) of different repeat unit could be selected. The reac- tive component further is substantially free of elemen¬ tal sulfur and reactive divalent sulfur. This includes free sulfur, sulfide and all other forms of reactive divalent sulfur. The term "substantially free" is used herein to mean that relatively minor amounts of sulfur may be present, but in amounts which are insufficient to effect substantial cure of the composition without addition of a second reactive component in accordance with this invention.

The second reactive component is present in an amount such that on reacting it will substantially cure the composition. The term "substantially cure" is used herein to mean the composition on curing will have a gel percent as measured by the percent insolubles in chloroform of at least about 10%, preferably at least about 30% and more preferably at least about 50%. The exact mechanism by which curing of the composition takes place is not fully understood. It is believed that one or more of the following reactions takes place. The reactive component may crosslink with itself entrapping portions of the aromatic first com¬ ponent. The reactive component may crosslink with two or more sites on the first component forming a "bridge" crosslink. This bridge crosslink may be between sites on the same molecule or between sites on different

olecules of the first component. Preferred reactive components which will cure the composition are poly(imides) with reactive groups such as aromatic poly(imides) , poly(isoimides) and polymeric precursors thereof which are terminated with acetylene, maleimide or vinyl groups.

Acetylene terminated aromatic pol (imides) , pol (isoimides) , and polymeric precursors thereof and their preparation are described in Landis et al, Polym. Prepr., Am. Chem. Soc, Div. Polym. Chem., Vol. 15, No. 2, Jan 9, 1974, pp 537-41; U.S. Patent Nos. 3,845,018 (1974), 3,864,309 (1975) and 3,879,349 (1975) all to Bilow et al; and U.S. Patent No. 4,307,220 to Lucarelii et al (1981), incorporated herein by reference. These addition curable compounds crosslink and cure without offgassing to produce low void moldings and structural composites of high strength which are stable up to 370°C.

Preferred poly ⁽ imides) and pol (isoimides) are the terminal acetylenic-capped aromatic poly(imide) and poly(isoimide ⁾ oligomers from National Starch (Thermid) having repeat units as follows:

wherein n is from 1 to about 300 but preferably from 1 to about 30 and more preferably from 1 to about 10.

The poly(imides) and pol (isoimides) used in the curable composition of the invention may be formed in situ by forming the composition with a precursor of said poly(imide) or pol (isoi ide). Said precursors may be con- erted to said poly(imidβ) or poly(isoimides) during cure or use of the composition as an adhesive or the like. Precursors of the poly(imides) and poly(isoimides) are known and described in, for example, the references cited above. Precursors that are preferred include the acetylenic- capped aromatic polyamic acid:

-8-

wherein n is from 1 to about 300 but preferably from 1 to about 30 and more preferably from 1 to about 10 and the acβtylenic-cappβd aromatic imidβ monome ic mixture of:

wherein n is froa 2 to 300.

Maleimide and vinyl terminated poly(imides) may be made similarly to the acetylene terminated poly(imides) above or, for example, see Examples 9 to 11. See U.S. Patents Nos.* 3,576,691 (1971) to Meyers; 3,380,964 (1964) to Grundshober et al; and 4,251,419 (1981) to Hβilman et al.

Other preferred acetylene, maleimide and vinyl ter¬ minated pol (imides) include

wherein n is 1 to 300 and i is 0 to 4,

wherein n is 1 to 300,

wherein n is 1 to 300 and m is 0 to 4

and wherein X and Y is the same as described for the non-reactive aromatic poly(imides) described supra.

The first component of the composition comprises an aromatic polymer having a first preponderant repeat unit. It will be understood that references to aroma¬ tic polymers mean polymers which have aromatic groups incorporated in the repeat unit of their backbone chain, not merely appended as side groups to the claim

as for example in the case of polystyrene. Preferably the aromatic polymers will have no two adjacent methy- lene groups in the repeat unit. More preferably any methylene groups in the monomer unit are linked to quarternary carbon atoms (i.e. aliphatic carbon atoms not linked to hydrogen). Most preferably, any alipha¬ tic carbon atom in the monomer unit linked to one or two hydrogen atoms is also linked to at least two quar¬ ternary carbon atoms. Preferred aromatic polymers include:

a ⁾ poly(etherimide); b) poly(au one); c) poly(aryl ether ketonβ); d) poly(carbonate); β poly(arylate); f) aromatic poly(imides); g) poly(bensimidaaopyrolonβs); or h) polyimide isoindoloquinasolinedione.

_*

The poly(etherimides) suitable for use in this invention are well known in the art and described in, for example, U.S. Patent Nos. 3,847,867, 3,838,097 .and 4,107,147 incorporated herein by reference. A pre¬ ferred poly(ethe iaide) has the structure

where n is greater than 1 but preferably from about 10 to about 10,000 or more and is available as, for example, ϋltem D-1000 from General Electric, a high molecular weight, amorphous and melt processable polymer. See also Ma Kaomol. Chem., Rapid Co mun. 1, pages 667-670 (1980).

Poly ⁽ sulfones) suitable for use in the invention are well known and are linear thermoplastic ρoly ⁽ arylenβ ⁾ poly(ethers) wherein the arylβne units are interspersed with a sulfonβ linkage. These poly¬ mers may be obtained by reaction of an alkali metal double salt of a dihydric phenol and a dihalobensenoid or dinitrobenzenoid compound either or both which con¬ tain a sulfone linkage, i.e. -SO2-, -between arylenβ groupings, to provide sulfonβ units in the polymer chain. Polymers of this sort are further described in US Patent 4,293,670, incorporated herein by reference. Preferred poly(sulfones) are of the formula:

where n is greater than 1 but preferably from about 10 to about 10,000 or more and the poly(ether sulfone) having the formula:

where n is great than 1 but preferably from about 10 to about 10,000 or more.

Poly(aryl ether ketones) suitable for use in this invention have the repeat units of the formula

-CO-Ar-CO-Ar'-

wherein Ar and Ar' are aromatic moieties at least one of which contains a diaryl ether linkage forming part of the polymer backbone and wherein both Ar and Ar' are covalently linked to the carbonyl groups through aroma- tic carbon atoms.

Preferably, Ar and Ar' are independently selected from substituted and unsubstituted phenylene and substituted and unsubstituted polynuclear aromatic- moieties. The term polynuclear aromatic moieties is used to mean aromatic moieties containing at least two aromatic rings. The rings can be fused, joined by a direct bond or by a linking group. Such linking groups include for example, carbonyl, ether sulfone, sulfide, amide, imide, azo, alkylene, perfluoro-alkylene and the like. As mentioned above, at least one of Ar and Ar ¹ contains a diaryl ether linkage.

The phenylene and polynuclear aromatic moieties can contain substituents on the aromatic rings. These

substi-tuents should not inhibit or otherwise interfere with the polymerization reaction to any significant extent. Such substituents include, for example, phe- nyl, halogen, nitro, cyano, alkyl, 2-alkynyl and the like.

Poly(aryl ether ketones) having the following repeat units (the simplest repeat unit being designated for a given polymer) are preferred:

Poly(aryl ether ketones) can be prepared by known methods of synthesis. Preferred poly(aryl ether keto¬ nes) can be prepared by Friedel-Crafts polymerization of a monomer system comprising:

I) (i) phosgene or an aromatic diacid dihalide together with

(ii) a polynuclear aromatic comonomer comprising:

(a) H-Ar-O-Ar-H

(b) H-(Ar-0) _n -Ar-H wherein n is 2 or 3

(c) H-Ar-0-Ar-(CO-Ar-0-Ar) _m -H wherein m is 1, 2 or 3 f or

II) an acid halide of the formula:

H-Ar"-0-[ (Ar"-CO) _p - (Ar"-0 ) _q (AR"-CO) _r ] _k -Ar"-CO-Z wherein Z is halogen, k is 0, 1 or 2, p is 1 or 2, q is 0, 1 or 2 and r is 0, 1 or 2;

or

III) an acid halide of the formula: H-(Ar"-0) _n -Ar"-Y wherein n is 2 or 3 and Y is CO-Z or CO-Ar"-CO-Z

where Z is halogen;

wherein each Ar" is independently selected from substituted or unsubstituted phenylene, and substi¬ tuted and unsubstituted polynuclear aromatic moieties free of ketone carbonyl or ether oxygen groups, in the presence of a reaction medium comprising:

A) A Lewis acid in an amount of one equivalent per equivalent of carbonyl groups present, plus one equivalent per equivalent of Lewis base, plus an amount effective to act as a catalyst for the polymerization;

B) a Lewis base in an amount from 0 to about 4 equivalents per equivalent of acid halide groups present in the monomer system;

C) a-non-protic diluent in an amount from 0 to about 93% by weight, based on the weight of the total reaction mixture.

The aromatic diacid dihalide employed is pre- ferably a dichloride or dibromide. Illustrative diacid dihalides which can be used include, for example

wherein a is 0-4.

Illustrated polynuclear aromatic comonomers which can be used with such diacid halides are:

(a) H-Ar ^π -0-Ar"-H, which includes, for example:

(b) H-(Ar"-0) _n -Ar"-H, which include, for example:

and

(c) H-Ar"-0-Ar"-(CO-Ar"-0-Ar") _m -H, which includes, for example:

and

(d) H-(Ar"-0) _n -Ar"-CO-Ar"-(O-Ar ^B ) _m -H which includes, for example:

Monomer systems II and III comprise an acid halide. (The term acid halide is used herein to refer to a monoacid monohalide.) In monomer system II, the acid halide is of the formula:

H-Ar"-0-[(Ar"-CO) _p -(Ar"-0) _q -(Ar"-CO) _r ] _K -Ar"-CO-Z

Such monomers include for example, where k = 0

-©—©- ^« '

and wherein k=l

In monomer system III, the acid halide is of the formula

H-(Ar"-0) _n -Ar"-Y

Examples of such acid halides include

and

It is to be understood that combinations of mono- mers can be employed. Por example, one or more diacid dihalides can be used with one or more polynuclear aro¬ matic comonomers as long as the correct stoichiometry is maintained. Further, one or more acid halides can be included. In addition monomers which contain other linkages such as those specified above, can be employed as long a one or more of the comonomers used contains at least one ether oxygen linkage. Such comonomers include for example:

0— -1-0—0 ® ®

which can be used as the sole comonomer with an ether containing diacid dihalide or with phosgene or any diacid dihalide when used in addition to a polynuclear aromatic comonomer as defined in I(ii)(a), I(iiHb), KiiMc) or I(ii)(d). Similarly

0

can be used as a comonomer together with an ether- containing polynuclear aromatic acid halide or as an additional comonomer together with a monomer system as defined in I.

The monomer system can also contain up to about 30 mole % of a comonomer such as a sulfonyl chloride which polymerizes under Friedel-Crafts conditions to provide ketone/sulfone copolymers.

Further details of this process for producing poly (aryl ether ketones) can be found in commonly assigned co-pending U.S. application Serial No. 594,503, filed 31 March 1984, the disclosure of which is incorporated herein by reference.

Other processes for preparing these polymers can be found in U.S. Patent Nos. 3,953,400, 3,956,240, 3,928,295, 4,176,222 and 4,320,220.

The pol (carbonates) suitable for use in the invention are well known and are thermoplastic linear polyesters of carbonic acid, made by the polymeric con¬ densation of bisphenols with a phosgene or its deriva- tives. These polymers are known for their excellent properties of toughness, flexibility, impact strength, optical clarity and heat resistance. More recent representative examples are included in U.S. Patent Nos. 4,469,861, 4,469,833, 4,469,860, 4,469,852,

■ _j _ _Q 4,469,850 and 4,469,838. Preferred poly(carbonates) include any of the Lexan grades available from General Electric which have the general formula:

wherein n is greater than 1 but preferably from about

15 10 to about 10,000 or more.

Poly(arylates) suitable for use in the invention are aromatic polyesters derived from a dihydric phenol, particularly bisphenol A and an aromatic diσarboxylic

20 acid, particularly mixtures of terephthalic and isophthalic acids. See for example and further defini¬ tion U.S. Patent Nos. 4,246,381 and 4,250,279 incor¬ porated herein by reference. A preferred poly(arylate) is of the formula:

25 -O IK -- ¹ -^ ⁾ -^

wherein n is greater than 1 but preferably from about 10 to about 10,000 or more, commercially available from Union Carbide under the trade name of Ardell in a number of grades where average molecular weight varies.

Aromatic pol (imides) can be prepared by any suitable means for example see Journal of Polymer Science, Part A, Vol. 1, pages 3135-3150 (1963) incor¬ porated herein by reference. Especially preferred are the following aromatic poly(imides) :

wherein X is:

wherein Y is

-0- xS^-ø

wherein G and Z each being the same or different are

a) a single bond b) 0 σ) S d) CH ₂ e) 0-Ar-O, wherein Ar is

CH, CF„

CH ₃ CF ₃

~ --Q ^~

f ) -(CCCF3HC5H5)- g ⁾ CO h) S0 ₂ i ) C ⁽ CF ₃ ⁾ ₂ j ⁾ CF ₂

1) '-0-'

m) C(R]_) ₂ wherein R _] _ is H or alkyl of 1 to 6 carbon atoms each R]_ being the same or different n) -CH(OH)-

Other preferred aromatic pol (imides) include poly ⁽ imides) having phenylindane diamine and/or dianhydride moieties incorporated into the poly(imide) backbone are described in U.S. Patent No. 3,856,752, incorporated herein by reference. A preferred such poly(imide) is XU218 from Ciba-Geigy which is of the formula:

wherein n is greater than 1.

Poly(benzimidazopyrrolones) or pyrrones are well known in the art and can be prepared for example by methods taught in J. Macromol, Sci.-Revs. Macromol. Chem, Cll(l), 143-176 (1974) incorporated herein by reference. Preferred pyrrones have the structure

wherein X and Y are the same as the aromatic pol (imides) described above and n is an integer greater than 1.

Polyimide isoindoloquinazolinedione compounds (PIQ) are well known in the art. For example, see Polymer Materials for Electronic Applications, Fell and Wilkins, 1982, pages 123-138 incorporated herein by reference. Particularly preferred are PIQ compounds of the formula

wherein X and Y are the same as the aromatic pol (imides) above and n is greater than 1.

It is understood that one or more reactive com¬ ponent and one or more aromatic polymer can be present

in the composition to provide the desired physical pro¬ perties of the final article. The polymers or co- polymers can be used in any of the ^' various commercial grades which may vary in average molecular weights, molecular weight distributions and may contain minor amounts of comonomer residues and the like.

A preferred embodiment having more than one aroma¬ tic polymer includes compositions comprising

1) an acetylene terminated aromatic poly(imide), poly(isoimide) , or a polymeric precursor thereof;

2) a pol (etherimide) ; and

3) a poly(aryl ether ketone).

It is well known that most polymers are generally incompatible with each other. Most blends of two or more polymers contain the separate polymers as indivi¬ dual component domains or phases. Thus blends of what are termed compatible polymers generally are mechani¬ cally compatible only and exhibit properties which vary

» widely over the concentration range of the polymers. Such blends comprise a matrix polymer containing the other polymer as a dispersed or co-continuous phase. Such dispersed phases can be microscopic in size some¬ times giving the resulting blend of multiple phases the appearance of being a single phase. There are, however, a few pairs of polymers which are molecularly compatible, that is, they form a molecularly dispersed mixture comprising a single amorphous phase when they

are blended together. Not only do such blends not separate into their individual amorphous components, but they are also characterized by having a single glass transition temperature (Tg) and optical transparency. Mechanic-ally compatible blends, on the other hand, exhibit two or more Tg's characteristic of the Tg's of the individual components. By the term glass transition temperature is meant the temperature at which an amorphous polymer or the amorphous regions of a partially crystalline polymer changes to or from a hard and relatively brittle state to a more flexible or rubbery condition. Measurement of glass transition temperatures of polymer systems is described, for example, in Thermal Characterization Techniques, Slade, et al.. Marcel Dekker, Inc., New- York (1970).

It has been surprisingly found that blends of the invention consisting of a acetylene terminated poly(imide) or poly(isoimide) and a poly(ether imide), as described above, are molecularly compatible.

The compositions of the invention can contain various additives, in order to give any desired pro¬ perty to the polymer composition. For example, stabi¬ lizers, flame retardants, pigments, plastiσ-izers, surfactants and the like can be present. Compatible or non-compatible polymers may also be added to give a desired property.

The compositions of the invention are melt fusible. By melt fusible is meant that the material can be

heated without significant decomposition above its glass transition temperature, if it is amorphous or above its crystalline melting point if it has crystallinity, and coalesced under pressure. See e.g. U.S. Patent No. 4,485,140 to DuPont.

The compositions can be prepared by any convenient technique. For example, the components can be mixed on a two-roll mill, in an internal mixer such as a Brabender mixer or Banbury mixer, or in a twin-screw extruder. They may also be prepared by precipitation from a solvent, or cast from solution or the like.

The composition generally can be substantially cured preferably at elevated temperature i.e. 250-350°C for 30 min. to 3 hours. Where appropriate, the composition may also be cured by radiation or other means as appropriate to the ^" reactive compo,nent ■selected.

A shaped article of the composition can be formed before or after cure by known techniques depending on the desired shape. Films or coatings of the com¬ position can be formed by extrusion, spraying, spin coating or casting especially using solvents, and fibers formed fibers by melt spinning or the like. Other articles may be injection molded, compression molded, pour molded, blow molded or the like with or without additives as previously described.

The compositions of the invention are especially useful as improved adhesives and as coatings such as semiconductor coatings including alpha particle barriers, coatings for passivation and mechanical pro- tection.

The compositions of this invention are particularly advantageous in the preparation of a layered article, in particular a multi-layered article for use in electronic systems. The article comprises a substrate, for example of glass or ceramic material, with at least one layer comprising a cured, aromatic polymer-based composition of this invention deposited on a surface thereof. Generally a plurality of layers are suc¬ cessively deposited on the substrate and cured. One or more layers of conductive material can be interposed between two adjacent layers of the aromatic polymer- based composition. The conductive layer is generally not continuous or coextensive with the adjacent poly¬ meric layers and typically forms a plurality of electrically conductive pathways. The conductive layer is preferably of metal but can comprise a semi- conductive element.

In preparing such articles, the composition used is preferably highly resistant to hydrolysis and has a water absorption of less than about 2%, preferably less than about 1% when contacted with water at 90°C for 960 minutes. The composition preferably also is a dielectric having a dielectric constant less than about 5, preferably less than about 3.

The article is prepared by coating the aromatic polymer in the form of a solution, preferably by a spin coating technique, onto the substrate. The solvent is evaporated and the composition is cured at elevated temperatures. Typically, the thickness of the coating is about 5 to 40 microns. The conductive layer is applied over the polymeric layer using, for example, a sputtering technique with appropriate areas masked to create the desired conductive pathways. The next poly- meric layer is applied in the same manner as the first. These two steps can be repeated until the desired multi-layered article is produced. The multi-layered article can be used, for example, as a packaging- interconnect device for integrated circuits.

The invention also relates to a reinforced com¬ position or matrix comprising the blend of the inven¬ tion either cured or uncured and a reinforcing component e.g. carbon or glass fibers or other poly¬ meric fibers or the like such as poly(amides) (e.g. poly(aramide) sold by DuPont under the trade name Kevla ) forming a high strength composite.

The following examples are representative of the invention but not intended to be limiting. Substitution of additives materials, polymers, and con- ditions which are obvious from this disclosure are within the contemplation of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

In Example 1, Thermid resins MC-600, IP-600, IP-603, IP-615, and IP-630 obtained from National Starch in powder form were blended with Ultem 1000, (poly(ether imide)), Victrex PEEK (poly(aryl ether ketone) from ICI), Victrex PES(Poly(ether sulfone) from ICI), Udel (pol (sulfone) from Union Carbide), Lexan (pol (carbonate) from General Electric), and XU-218 (poly(imide) from Ciba-Geigy).

Example 1 - Processing

Sample A

To 100ml of methylene chloride was added 18 grams of poly(ethersulfone) Victrex PES 200P (available from ICI, Ltd.) and 2 grams of Thermid IP-600. The solution was stirred until all the solids dissolved. The mix¬ ture was precipitated by adding 100 ml of isopropyl alcohol and stirring rapidly. The resulting powder was dried in air for 4 hours and at 125°C for 4 hours. The dry powder was pressed at 315°C at 1000 psi for 30 minutes to yield a transparent brown film.

Sample B

The procedure for Sample A was repeated but 16 grams of poly(ethersulfone) and 4 grams of Thermid IP-600 were used. The resulting yellow powder was

pressed at 315°C at 1000 psi for 30 minutes to yield a transparent brown film.

Sample C

The procedure for Sample A was repeated except 18 grams of pol (etherimide) (Ultem 1000 available from General Electric) and 2 grams of Thermid IP-600 were used. A light yellow powder resulted. The powder was pressed at 300°C at 100 psi for 30 minutes to yield a transparent yellow film.

Sample D

The procedure for Sample A was repeated but 20 grams of Ultem 1000 poly(etherimide) and 10 grams of Thermid IP-603 were used. A yellow powder resulted.

Sample E

The procedure for Sample A was repeated but 18 grams of poly(carbonate) (Lexan 143 available from General Electric) were used. A light yellow powder resulted.

Sample F

The procedure Sample A was repeated except 16 grams of XU-218 poly(imide) (available from Ciba-Geigy) and 4 grams of Thermid IP-600 were used. The resulting

dark yellow powder was pressed at 300°C at 1000 psi for 30 minutes to yield a transparent brown film which was insoluble in methylene chloride.

Sample G

To 100 ml of l-methyl-2-pyrrolidinone was added 16 grams of Ultem 1000 poly(etherimide) and 4 grams of Thermid IP-630. After the solids dissolved the solu¬ tion was poured into a rapidly stirring solution of isopropyl alcohol to precipitate the solids. The solids were filtered, washed with ethanol, and dried.

The resulting yellow powder was pressed at 300°C at 100 psi for 30 minutes to yield a transparent yellow film. The blend had a single Tg of 189.3°C.

Sample H

The procedure for Sample G was repeated except 20 grams of Ultem 1000 poly(etherimide) and 10 grams of Thermid IP-615 were used. The resulting yellow powder was pressed at 300°C at 100 psi for 30 minutes to yield a transparent yellow film. The blend had a single Tg of 191.2°C.

Sample I

The procedure for Sample G was repeated except 16 grams of pol (ethersulfone) (Victrex PES) and 4 grams of Thermid IP-630 were used. A yellow powder resulted.

Sample J

A mixture containing 90 weight percent poly(arylether ketone) power (Victrex PEEK 45G available from ICI) and 10 weight percent Thermid IP-630 powder were added to a Brabender mixer. The mix temperature was about 380°C. The resulting solid was pressed at 400°C at 1000 psi for 5 minutes to yield a transparent material.

Sample K

The procedure for Sample J was repeated except a mixture containing 50 weight percent Victrex PEEK poly(aryletherketone) powder and 50 weight percent Thermid IP-630 were used. A transparent brown material was obtained.

Sample L

A mixture of 90 weight percent poly(aryletherketone) (Victrex PEEK 45G) powder and 10 weight percent of Thermid MC--600 powder was extruded on a Brabender twin screw extruder. The melt temperature was about 380°C. A brown extrudate was obtained and pelletized.

Example 2 - Blend Morphology

Certain of the compositions were examined by scanning electron microscopy (SEM). Blends of Ultem 1000 poly(ether imide) with Thermid IP-600 and Thermid IP-630 at ratios of 80/20 and 65/35 and blends of poly(ether sulfone) with Thermid MC-600 at ratios of 80/20 and 67/33, respectively have been examined. No phase separation could be observed in any of the samples evaluated either before or after curing, which indicates continuous, sub-microscopic phase domains.

Example 3 - Mechanical Properties

The mechanical properties of Ultem poly(etherimide) and a 90/10 blend of Ultem/Thermid IP-600 (tested at 200°C) before and after aging at 200°C are listed in Table 1. Before aging Ultem has a tensile strength of 4110 psi and 83% elongation versus 3238 psi and 58% elongation for the Ultem/Thermid IP-600 blend. After 7 days aging at 200°C the Ultem/Thermid IP-600 blend has an almost 100% increase in tensile strength to 6418 psi with a drop in elonga¬ tion to 10%. The Ultem shows a 10% increase in tensile strength to 4533 psi and a drop in elongation to 3% after 7 days aging at 200°.C. Clearly the Ultem/Thermid IP-600 blend has much better performance at elevated temperatures than does pure Ultem.

Example 4 - Cure Conditions

Tables 2, 3, 4, and 5 list the gel levels for various cure conditions for Ultem/Thermid IP-600, Victrex PES/Thermid IP-600, Thermid IP-603 blends, and Thermid IP-630 blends, respectively. Gel levels were determined as percent insolubles in chloroform.

TABLE 1

THERMAL STABILITY OF ULTEM/THERMID IP-600 (90/10) RESIN* TESTED AT 200°C

AGING TIME TENSILE STRENGTH % ULTIMATE

MATERIAL (DAYS) (PSI) ELONGATION

ULTEM 0 4,110 83

ULTEM/IP-600 0 3,238 58

ULTEM 7 4,533 3

ULTEM/IP-600 7 6,418 10

ULTEM/IP-600 14 6,070 5

*ALL SAMPLES PRESSED AT 315°C (600°F)

FOR 1 HOUR BEFORE AGING AT 200°C

TABLE 2

PERCENT GEL FORMATION FOR ULTEM/THERMID IP600 BLENDS

ULTEM/THERMIC IP-600 CURE TEMP , °C CURE TIME (MIN ) %GEL

95/5 287 900 60

95/5 315 900 40

90/10 260 30 20

90/10 260 60 38

90/10 260 120 47

90/10 287 10 30

90/10 287 30 45

90/10 287 45 48

90/10 287 60 52

90/10 315 30 52

90/10 315 120 62

80/20 315 900 100

80/20 350 20 61

TABLE 3

PERCENT GEL FORMATION FOR POLYETHERSULFONE/THERMID IP-600 BLENDS

VICTREX PES/THERMID IP-600 CURE TEMP (°C) CURE TIME (MIN) % Gel

90/10 315 30 21

80/20 315 10 70

80/20 315 30 78

80/20 315 900 100

80/20 343 60 66

80/20 350 20 41

80/20 350 120 100

TABLE 4

PERCENT GEL FORMATION FOR THERMID IP-603 BLENDS

BLEND RATIO CURE CONfDITION PERCENT GEL

Ultem/IP-603 90/10 30 min. 287°C 38

Ultem/IP-603 90/10 60 min. 287°C 42

Ultem/IP-603 80/20 30 min. 287°C 56

Ultem/IP-603 80/20 60 min. 287°C 61

Ultem/IP-603 67/33 30 min. 287°C 81

Victrex PES/IP- -603 90/10 30 min. 315°C 21

Victrex PES/IP- -603 90/10 60 min. 315°C 10

Victrex PES/IP- -603 80/20 10 min. 315°C 70

Victres PES/IP- -603 80/20 30 min. 315°C 78

Victrex PES/IP- -603 80/20 60 min. 315°C 66

TABLE 5

PERCENT GEL FORMATION FOR THERMID IP-630 BLENDS

BLEND RATIO CURE CONDITIONS PERCENT GEL

Ultem/IP-630 80/20 30 min. 300°C 71

Victrex PES/IP-630 80/20 30 min. 315°C 90. ,5

Victrex PES/IP-630 67/33 30 min. 300°C 98

The most significant finding here is that addition of approximately 20% Thermid IP-600 or MC-600 to Ultem or Victrex PES leads to 100% gel formation. Fully cured blends (80/20 ratios) do not dissolve or swell significantly when exposed to methylene chloride

(solvent for both Ultem and PES). Even the addition of only 10% Thermid IP-600 can lead to gel levels greater than 60%. Therefore, much improved solvent resistance is achieved.

Example 5 - Adhesive Properties

Table 6 lists the lap shear strengths for stainless steel to stainless steel adhesive bonds using Thermid blends as hot melt thermosetting adhesives. At 200°C the blends show much higher bond strengths than pure Ultem. Addition of 10% or 20% Thermid IP-600 to

Ultem leads to a 25% increase in the lap shear strength at 200°C. The lap shear increase from 1240 psi to about 1540 psi. At 35% Thermid IP-600/65% Ultem the lap shear increases to 1697 psi (37% increase). Victrex PES/Thermid MC-600 blends can also be used as adhesive but they had much lower lap shear strengths than the Ultem/Thermid IP-600 blends at room tem¬ perature.

Example 6 - Composite Matrix Application

One of the applications of blends of the invention is as a matrix resin in fiber reinforced composites. The blends will offer improved thermal stability, creep resistance, solvent resistance, and high continuous use temperature.

Ultem/Thermid IP-600 and Victrex PES/Thermid IP-600 blends have been impregnated on both Kevlar poly(amide) fiber produced by duPont and carbon fibers.

A high modulus carbon fiber (Celion 6000 ANS available from Celanese Corporation) was impregnated with an Ultem 1000/Thermid IP-600 (95/5) blend in the following fashion: The continuous fiber was passed through a solution of 95 grams Ultem 1000 and 5 grams Thermid IP-600 in 380 grams chloroform at a rate of 10 feet per minute. Immediately after leaving the solu¬ tion, the wet fiber was passed through a drying tower at 60°C and a second drying tower at 120°C. The dry prepreg tow was passed between 2 hot rollers to smooth and flatten the tow. The prepreg (60% by volume carbon fiber) was woven into a 2 inch by 2 inch sample, con¬ solidated at 290°C, 100 psi for 30 minutes and post cured at 280°C for 24 hours in air. The consolidated sample showed an 8% weight loss and no delamination after 24 hour immersion in either chloroform or dich- loromethane. A similarly prepared sample using Ultem 1000 as the matrix resin completely delaminated and the

matrix resin dissolved when immersed 24 hours in chloroform or dichlormethane.

«

Example 7 - Ultem/Thermid Adhesive Film Preparation

To 100 ml of dichloromethane was added 18 grams of Ultem 1000 and 2 grams of Thermid IP-600. The solution was stirred until the solids dissolved. The mixture was precipitated by adding 100 ml of isopropyl alcohol and stirring rapidly. The resulting powder was dried in air for 12 hours and at 125°C for 4 hours. The dry 1 _Q powder was pressed at 275°C at 1000 psi for 1 minute to yield an amber film.

The above procedure was repeated using 16 grams of Ultem 1000 and 4 grams of Thermid IP-600. An amber film was also obtained.

• _j _5 The above procedures were repeated 'using Thermid IP-603 in place of Thermid IP-600. Amber films were obtained.

TABLE 6

LAP SHEAR STRENGTHS FOR STAINLESS STEEL ADHESIVE BONDS (1/2" OVERLAP)

LAP SHEAR (PSI ) LAP SHEAR (PSI ) MATERIAL RATIO § ROCM TEMP. 8 200 °C

Ultem 100 1887 1240

Ultem/Thermid TP-600 90/10 - 1547

Ultem/Thermid IP-600 80/20 2880 1526 mtan/Thermid MC-600 65/35 - 1697 Ultar Thermid IP-603 90/10 - 1723* mta Thermid IP-603 80/20 2340 1698*

Victrex PES/Thermid MC-600 80/20 1905

Victr-sx PES/Thermid MC-600 67/33 1630

Ultaπ/Thermid TP-615 80/20 2375 Ultem/Thermid IP-630 80/20 2829

Ultan Thermid IP-630 80/20 1821

Cure Conditions: 25 minutes, 315 °C, 100 psi

*Ulteπ</Thermid IP-603 adhesives cured at 275 °C, 20 minutes, at 100 psi pressure. The .adhesive films were prepared in the same manner described in Example 1 but Thermid IP-603 was substituted for Thermid IP-600. All samples had a single Tg.

Example 8 - Ceramic Coating

S-ample A

To 100 ml of dry l-methy-2-pyrrolidinone was added 15 grams of XU-218 and 5 grams of Thermid IP-600. The solution was stirred until the solids dissolved. The solution was poured on to a 4 inch x 4 inch ceramic substrate which was spinning at 2000 rpm. After 30 seconds the ceramic was stopped and placed in an oven at 80°C for 1 hour, 125°C for 1 hour, 200°C for 30 min. and 250°C for 30 minutes. A light yellow coating resulted. The bond strength of the coating to the ceramic at room temperature was 1673 psi.

Sample B

The above experiment was repeated but 16 grams of Ultem and 4 grams of Thermid IP-600 were used. A light yellow coating resulted. Bond strength of the coating to ceramic was greater than 9700 psi.

Sample C

To a solution of 85.0 g (0.207 moles) 2,2-bis[4(4-aminophenoxy)phenyl] propane and 120.0 g

Thermid LR-600 in 300 g 2-methoxyethyl ether was added dropwise a solution of 66.75 g (0.207) moles 3,3' ,4,4'-benzophenone tetracarboxylic dianhydride (BTDA) in 260 g l-methyl-2pyrrolidinone. External

cooling was used to keep the reaction temperature below 20°C. After addition of the BTDA solution was complete, the mixture was stirred an additional 3 hours. A 5 ml sample of the solution was spin coated on to a 4 inch by 4 inch ceramic substrate (1000 rpm for 15 seconds) and dried and cured under the following conditoins: 15 minutes at 90°C, 25 minutes at 150°C, 15 minutes at 200°C, 30 minutes at 350°C, and 30 minu¬ tes at 200°C. A second 5 ml of solution was applied, dried and cured as described above. No cracks in the first or second layers of cured polyimide could be detected when the sample was examined with an optical microscope (50X).

To a solution of 0.85 g (0.00207 moles) 2,2-bis[4- (4--aminophenoxy)-phenyl] propane mixture of 2.5 g

2-methox ethyl ethe.r and 0.5 g l-methyl-2-pyrrolidinone (NMP) was added a solution of 0.667 g (0.00207 moles) BTDA in 2.6 g NMP. The solution was stirred for an additional 3 hours. A 2.5 ml sample was spin coated on to a 4 inch by 4 inch ceramic substrate (1000 rpm for 15 seconds) and dried and cured as described above. A second 2.5 ml of solution was applied, dried and cured as described above. The cured polyimide was examined with an optical microscope (50X) and sever cracking in the first layer of polyimide was observed.

The following three examples disclose a method for making other reactive second components where the reac¬ tive end group is a maleimide or vinyl group.

Example 9

To a solution of 5.0 g (0.0122 moles) 2,2-bis[4-(4- amino-phenoxy)-phenyl] propane in 75 ml of dry l-methyl-2-pyrrolidinone was added 2.0 g (0.0062 moles) of BTDA and 1.2 g (0.0122 moles) maleiσ anhydride.

After stirring under nitrogen for 45 minutes at room temperature, 4.1 g 4,4'-bis(4-aminophenoxy)biphenyl followed by 4.9 g (0.0.11 moles) 2,2-bis(3,4-dicarboxyphenyl) hexafluoropropane dianhydride was added. After 25 minutes, the mixture was coated on to a ceramic substrate, dried and cured (10 minutes at 100°C, 10 minutes at 200°C, and 20 minu¬ tes at 325°C). A light brown, pin hole free coating resulted.

Example 10

To a solution of 1.5 g (0.0075 moles) 4,4'-diaminodiphenyl ether and 1.4 g (0.015 moles) 3-aminostyrene in 15 ml of dry l-methyl-2-pyrrolidinone is added 4.8 g (0.015 moles) of BTDA. After stirring 24 hours at room temperature, 10 ml acetic anhydride and 3 ml pyridine is added to imidize the vinyl ter¬ minated amic acid oligomer. Coagulation in methanol affords 7.1 g vinyl terminated polyimide oligomer (VTPO).

To a solution of 3.0 g Victrex PES

(polyethersulphone) in a mixture of 14 g

N,N-dimethylformamide and 1 g m-xylene is added 1.0 g VTPO. The solution is coated on to a metal substrate, dried and cured (10 minutes at 100°C, 10 minutes 15 200°C, and 20 minutes at 325°C).

Example 11

To a solution of 1.5 g (0.0036 moles) 2,2-bis[4-(4-aminophenoxy)-phenyl] propane in 15 ml dry l-methyl-2-pyrrolidinone is added 0.59 g (0.0018 moles) BTDA and 0.36 g (0.0036 moles) maleic anhydride. After stirring 24 hours at room temperature, 10 ml acetic anhydride and 3.0 ml pyridine is added to imidize the amic acid oligomer. Coagulation in methanol affords 2.3 g maleimide terminated polyimide oligomer (MTPO).

To a solution of 4.0 g Ultem 1000 in 17 g l-methyl-2-pyrrolidinone is added 1.0 g MTPO. The solution is coagulated using a non-solvent, such as isopropyl alcohol, and dried to yield a granular powder. The dry powder is pressed at 250°C at 1000 psi for 1 minute to yield an amber film.