WO1990014366A1

WO1990014366A1 - Cyano-containing perfluoropolymers having iodine curesites

Info

Publication number: WO1990014366A1
Application number: PCT/US1990/002602
Authority: WO
Inventors: Anestis Leonidas Logothetis
Original assignee: E.I. Du Pont De Nemours And Company
Priority date: 1989-05-19
Filing date: 1990-05-14
Publication date: 1990-11-29
Also published as: US4972038A; JPH05500070A; DE69013915D1; EP0475959A4; JP2888971B2; DE69013915T2; EP0475959B1; EP0475959A1

Abstract

Perfluoropolymers prepared from tetrafluoroethylene, perfluro (alkyl vinyl) ether and cyano-cure site monomer, and further comprising iodo moieties, and cured elastomers prepared from the perfluoropolymers.

Description

TITLE

CYANO-CONTAINING

PERFLUOROPOLYMERS HAVING IODINE CURESITES

BACKGROUND OF THE INVENTION

Perfluoroelastomers have long been used in a variety of applications that require excellent

resistance to high temperature and chemical attack. One particualrly outstanding fluoropolymer that has been used in elastomeric applications is that prepared from tetrafluoroethylene (TFE) and perfluoro (alkyl vinyl) ether, and particularly perfluro (methyl vinyl) ether (PMVE). To facilitate the crosslinking in these copolymers that is essential to good elastomeric properties, a small percentage of termonomer is generally incorporated, such as the cyano- or

nitrile-containing fluoroolefins described in

Breazeale, U.S. Patent 4,281,092.

While these cyano-perfluoroelastomers have exhibited outstanding thermal and oxidative stability, continuing effort has been directed to further

modification of these polymers to broaden the areas in which they can be used. Particular attention has been paid to the rate and thoroughness of the curing reaction that has been used with perfluoroelastomers. Specifically, the perfluoropolymers previously made from TFE, PMVE and a cure site monomer typically exhibit a high concentration of ionic end groups, such as carboxylic or sulfonic acid moieties, which are introducted from the initiating system. Conventional chain transfer agents can be used to lower the

concentration of the ionic end groups and also lower the polymer viscosity. However, the physical properties of these polymers are generally depreciated with such chain transfer agents.

SUMMARY OF THE INVENTION

The instant invention relates to improved perfluoropolymer compositions which, when compounded and cured as elastomers, exhibit an excellent

combination of curing and mold release characteristics.

Specifically, the present invention provides, in a perfluoropolymer having randomly copolymerized units of tetrafluoroethylene, perfluro (alkyl vinyl) ether and fluorinated curesite monomer containing nitrile groups, the improvement wherein the

perfluoropolymer further comprises iodo moieties present in an amount of least about 0.05 percent, by weight of the perfluoropolymer.

DETAILED DESCRIPTION OF THE INVENTION

The basic components of the present perfluoropolymers, the tetrafluoroethylene and the perfluoro (alkyl vinyl) ether, and their

polymerization, are desribed in Harris et al, U.S.

Patent 3,132,123, which is hereby incorporated by reference. Of the perfluoro (alkyl vinyl) ethers, perfluoro (methyl vinyl) ether (PMVE) has been found to be particularly satisfactory. Other perfluoro (alkyl vinyl) ethers which can be used in the present

invention include perfluoro (alkoxy alkyl vinyl) ethers, such as those described in Fritz et al., U.S. Patent 3,291,843, also hereby incorporated by

reference. Of those perfluoro (alkoxy alkyl vinyl) ethers, perfluoro (5-methyl-3,6-dioxa-l-nonene) has been found to be particularly satisfactory.

A wide variety of cyano- cure sites can be incorporated into these polymers, including those described in Breazeale, U.S. Patent 4,281,092, hereby incorporated by reference. The polymers of this invention preferably contain such curesites randomly distributed along the backbone of the perfluoropolymer.

A central aspect of the present invention is that the perfluoropolymer comprise iodine moieties.

The iodo moieties in the present compositions can be incorporated by conducting the radical copolymerization of the basic monomers noted above in the presence of an iodine-containing compound represented by the formula RI_X, where R is a hydrocarbon or saturated fluorocarbon or chlorofluorocarbon residue having 1 to 8 carbon atoms and x is an integer of 1 or 2 , corresponding to the valence of the residue R.

In the course of the radically initiated copolymerization, the iodo compound acts as a chain transfer agent, resulting in a telomerization

polymerization process in which a labile, iodinecontaining chain end is formed, and the haloalkyl residue of the iodo compound is attached to the other end of the polymer chain. If the iodo compound has two iodo groups, the fluoropolymer chain may therefore have iodine groups at each end, and the telomerization polymerization process will occur at each end of the polymer chain.

Iodocompounds which can be used in the preparation of the perfluoropolymer of the present invention include, for example, those based on

hydrocarbon residue such as methylene iodide,

1,4-diiodo butane, and butyl iodide, and those based on saturated fluorocarbon or chlorofluorocarbon residue such as monoiodo perfluoromethane, diiodo methane, monoiodo perfluoroethane, monoiodo perfluoro propane, monoiodopropane, 1,3-diiodoperfluoro-n-propane, 1,4- diiodo-n-butane, 1,4-diiodoperfluoro-n-butane,

1,3-diiodo-2-chloroperfluoro-n-propane and

1,5-diiodo-2,4-dichloro-perfluoro-n-pentane. Other iodo-compounds which can be used include those

described in U.S. Patent 4,243,770, hereby incorporated by reference.

The amount of iodo-compound used should be high enough to give extensive chain transfer and result in incorporation of at least about 0.05 weight % of iodine in the perfluoropolymer. High chain transfer efficiency by the alkyl iodide results in a

perfluoropolymer with lower compound viscosity and a relatively narrow molecular weight distribution with a typical value of Mw/Mn of about 2-3, for desirable rheology and processing characteristics.

In general, the concentration of iodine in the polymer should be about from 0.05 to 1.0 weight %, and preferably 0.1-0.5 weight %, based on the

perfluoropolymer composition. The concentration in the fluoropolymer will depend upon the concentration of alkyl iodides in the polymerization medium and upon polymerization conditions, which will effect the chain transfer efficiency. The upper limit on iodine content corresponds approximately to the practical lower limit on polymer viscosity, since higher concentrations of iodine gives polymers with lower molecular weight and viscosity. The iodine concentration in the

perfluoropolymer can be determined by conventional analytical techniques, such as elemental analysis.

The lower limit of iodine incorporation is approximately that at which a significant effect on the cure rate and vulcanizate properties is found when cured by peroxides. The upper limit on iodine content corresponds approximately to the practical lower limit on polymer viscosity, since higher concentrations of iodine gives polymers with lower molecular weight and viscosity. The upper limit on iodine content also relates to the desired highest state of cure, insofar as it relates to the efficiency of formation of chains terminated with iodo groups.

The components of the perfluoropolymers are present in the amounts generally used in the

preparation of copolymers of tetrafluoroethylene, perfluoro (alkyl vinyl) ether and cure site monomer, as described, for example, in the aforementioned U.S.

Patent 4,281,092. Concentrations of about from 0.1 to 5.0 weight % of the cyano- moiety have been found to provide particularly good processing characteristics.

The perfluoropolymers of the present invention can be made by free radical emulsion

polymerization in a continuous stirred tank reactor, as described, for example, in the aforementioned U.S.

Patent 4,281,092, and under the general reaction conditions used in the past for the preparation of perfluoropolymers. Specifically, polymerization temperatures can be in the range of about from 40 to 130°C, and preferably about from 70 to 115°C, at pressures of about from 2 to 8 MPa and residence time

10 to 240 minutes. Free radical generation is effected using a water-soluble initiator such as ammonium persulfate, either by thermal decomposition or by reaction with a reducing agent such as sodium sulfite. The alkyl iodides can be fed into the reactor directly or as a solution. Initiator levels are set low enough so that iodine end groups predominate over those from initiator fragments. This leads to the desired low polymer viscosity and high solubility. The polymer dispersion is stabilized with an inert surface-active agent such as ammonium perfluorooctanoate, usually with addition of a base such as sodium hydroxide or a buffer such as disodium phosphate to control pH in the range 3 to 7. After polymerization, unreacted monomer is removed from the reactor effluent latex by vaporization at reduced pressure. Polymer can be recovered from latex by coagulation, e.g., by reducing pH to about 3 by acid addition and adding a salt solution such as calcium nitrate, magnesium sulfate, or potassium aluminum sulfate in water, followed by separation of serum from polymer, washing with water, and drying of the wet polymer. The iodine concentration in the perfluoropolymer can be determined by conventional analytical techniques, such as elemental analysis.

Perfluoropolymers of the present invention are typically compounded with one or more of the additives known to be useful in perfluoropolymer compositions, such as pigments, fillers, pore-forming agents and plasticizers. It is particularly

advantageous to add carbon black to the fluoroelastomer to increase its modulus. Usually amounts of from 5-50 parts per hundred parts of fluoroelastomer are used, with the particular amount determined from the particle size of the carbon black and the desired hardness and modulus of the cured composition.

The compounds are generally cured by a free radical process. A curable composition comprises polymer and a peroxide to generate free radicals at curing temperatures. A dialkyl peroxide which

decomposes at a temperature above 50°C is especially preferred when the composition is to be processed at elevated temperatures before it is cured. A

di-tertiarybutyl peroxide having a tertiary carbon atom attached to peroxy oxygen may be particularly

beneficial in many cases. Among the most useful peroxides of this type are 2,5- dimethyl-2,5-di(tertiarybutylperoxy) hexyne-3 and 2,5- dimethyl-2,5-di (tertiarybutylperoxy) hexane. Other peroxides can be selected from such compounds as dicumyl peroxide, dibenzoyl peroxide, tertiarybutyl perbenzoate, and di[1,3-dimethyl-3-(t-butylperoxy) butyl]carbonate, and the like.

The resulting perfluoroelastomers exhibit particularly good processing characteristics, including curing and mold release properties.

Perfluoroelastomers of TFE, PMVE and cure site monomer have typically been difficult to process in milling, extrusion and molding operations, because of their high bulk viscosities. While the superior performance of the present compositions is not fully understood, it is believed that the selection of iodo compounds, which function as chain transfer agents, results in iodo end groups for the polymer chains, and these end groups are reactive to crosslinking agents. When used in

conjunction with the known cyano- cure sites, the iodides permit the curing of relatively low molecular weight polymers with peroxides to give parts with very good properties. The polymers can be cured with greater ease and with high yields. In addition, complicated parts which could not be made with

previously available perfluoroelastomers can be

fabricated with the present perfluoroelastomers using transfer and injection molding techniques.

The perfluoropolymers of the present invention react with peroxide curing agents and

crosslinking coagents to give unique polymer networks in which crosslinks are formed both at random points along the polymer chain and at the ends of the chains. Such polymers have excellent strength and compression set properties, as well as good processing

characteristics. The perfluoropolymers per se, without fillers or curing, can also be used in a wide variety of applications. In addition to the usual applications for which perfluoroelastomers have previously been found to provide particular benefits, the present compositions have been found to be particularly useful as antireflective coatings for pellicles, for example, in the protection of printed circuits. Specifically, a coating of perfluoroelastomers of the present invention of about from 0.2 to 1.0 microns, on a substrate of nitrocellulose, provides a pellicle material having an outstanding combination of adhesion to both the

nitrocellulose film and to the pellicle frame as well as excellent optical transmittance.

The present invention is further illustrated by the following specific examples.

Examples 1-5 and Control Example A

In representative Example 2,

perfluoroelastomer was prepared from TFE, PMVE, and perfluoro-(8-cyano-5-methyl-3,6-dioxa-1-octene)

(8CNVE), with perfluoroalkyl iodides (Rfl or IRfl), which provided iodo moieties on the ends of some of the polymer chains. This polymer had 8CNVE cure sites randomly dispersed in the backbone.

The polymers were prepared in a 1 liter mechanically agitated, waterjacketed, stainless-steel autoclave operated continuously at 90°C and 4800 KPa into which was pumped, at a rate of 250 ml/hr an aqueous polymerization medium/initiator solution comprising of 8 liters of water, 32 g. ammonium

persulfate, 260 g. of disodium hydrogen phosphate heptahydrate, and 280 g. of ammonium perfluoroctanoate ("Fluorad" FC-143, 3M Co.). At the same time, a

separate solution of 8CNVE in F-113 "Freon" at the rate of 5.6 ml/hr (the solution contained 3.0g of 8CNVE, the rest being F-113) and another separate solution of 3.4 ml/hr of 1,4-diiodoperfluorobutane in F-113 (0.67 g. the rest being F-113) were being pumped in. A gaseous stream of tetrafluoroethylene (70 g/hr) and

perfluoro(methyl vinyl) ether (85 g/hr) was also fed simultaneously to the autoclave at a consant rate by means of a diaphragm compressor.

Polymer latex was removed by means of a let-down valve and unreacted monomers were vented. The latex from 14 hrs operations was added with stirring to a preheated (95°C) coagulating solution consisting of 1840 g MgSO₄.7H₂O in 40 liters of water. The

coagulated crumb was filtered off, washed repeatedly with water and dried by heating in an 80°C oven for 48 hrs in the presence of air. The dried polymer weighed 1825 gs. and had the composition, as weight % of the polymer, of tetrafluoroethylene 55.6, perfluoro(methyl vinyl) ether 42.6, 8CNVE 1.4 and iodine 0.32. The inherent viscosity of the polymer was determined at

30°C using 0.2 g. of polymer per deciliter of a solvent mixture comprising (by volume) 60 parts

2,2,3-trichloro-heptafluorobutane, 40 parts

perfluoro (butyltetrahydrofuran) and 3 parts diethylene glycol dimethyl ether. The Mooney viscosity of the polymer was measured after 10 minutes as 42 at 100°C and 12 at 121°C. The resulting polymer was mixed on a 2-roll rubber mill with (phr) 15 MT black, 3 triallyl isocyanurate, and 5 Luperco 101XL (Lubrizol Co)

peroxide, and shaped and cured at 177°C and postcured at 232°C unrestrained under nitrogen for 26 hrs. The results are shown in Table 1.

In the remaining Examples, the above general procedure was repeated. In Control Example A, in which no iodine was incorporated, the cure rate was slowest. and the vulcanizate properties were inferior to those of Examples 1-5. The operating conditions for these Examples are summarized below.

Example A 1 2 2 4 5

TFE g/hr 70 70 70 70 70 70

PMVE g/hr 74 85 85 85 85 85

8CNVE g/hr 4.8 0 3.0 1.6 2.0 2.4

I(CF₂)4I g/hr 0 1.1 0.67 0.64 0.64 0.64

APS g/hr 1.0 0.4 0.4 0.4 0.4 0.4

Phosphate g/hr 3.5 3.2 3.2 3.2 3.2 3.2

FC-143 g/hr 4.5 4.0 4.0 4.0 4.0 4.0

Temp. °C 80 90 90 90 90 90 The resulting polymers were compounded, cured and tested tested as before, and the results are shown in Table 1.

Examples 6-8 and Control Example B

In Examples 6-8, TFE/PMVE/8CNVE

perfluoroelastomers were prepared with hydrocarbon alkyl iodides (RI or IRI), which provided iodo moieties on the ends of some of the polymer chains. The 8CNVE cure sites in these polymers were randomly dispersed in the backbone.

The polymerization conditions were identical to those of Examples 1-5, except as reported below:

Example Control 6 2 8

TFE g/hr 70 60 60 60

PMVE g/hr 74 75 75 75

8CNVE g/hr 4.8 3.2 3.2 3.2

ICH₂I g/hr 0 0.12 0.10 0.83

Phosphate g/hr 3.5 4.0 4.0 4.0

FC-143 4.5 3.6 3.6 3.6

Temp. °C 80 90 90 90

The methylene iodide was dissolved in t-butanol as a 10% solution because it was not soluble in F113. The compounding and curing were identical to the conditions used in Examples 1-5, and the results are shown in Table 2. The iodo-containing polymers exhibit faster cure rates when compared to Control Example B as well as improved vulcanizate properties.

Claims

I CLAIM:

1. In a perfluoropolymer having randomly copolymerized units of tetrafluoroethylene, perfluro

(alkyl vinyl) ether and fluorinated curesite monomer containing nitrile groups, the improvement wherein the perfluoropolymer further comprises iodo moieties present in an amount of least about 0.05 percent, by weight of the perfluoropolymer.

2. A perfluoropolymer of Claim 1 wherein the iodo moieties are present in an amount of about from 0.05 to 1.0 weight percent.

3. A perfluoropolymer of Claim 2 wherein the iodo moieties are present in an amount of about from 0.1 to 0.5 weight percent.

4. A perfluropolymer of Claim 1 wherein the iodo moieties are substantially all positioned on the ends of the polymer chains .

5. A perfluoropolymer of Claim 1 wherein the cyano-containing curesites comprise at least about 0.3%, by weight of the perfluorσolymer, and are

randomly distributed along the backbone of the

perfluoropolymer.

6. A perfluoropolymer of Claim 5 wherein the cyano-moieties comprise about from 1 to 2% by weight of the perfluqpolymer.

7. A perfluoropolymer of Claim 1 wherein the perfluoro (alkyl vinyl) ether consists essentially of perfluoro (methyl vinyl) ether.

8. A perfluoropolymer of Claim 1 wherein the perfluoro (alkyl vinyl) ether is a perfluoro (alkoxy alkyl vinyl) ether.

9. A perfluoropolymer of Claim 8 wherein the perfluoro (alkoxy alkyl vinyl) ether consists

essentially of perfluoro (5-methyl-3,6-dioxa-1-nonene).

10. A cured perfluoroelastomer prepared from the perfluoropolymer of Claim 1.