THERMOSETTABLE POLYMERS OR PREPOLYMERS PREPARED FROM POLYMETHYLATED PYRAZINES AND AROMATIC POLYALDEHYDES AND CURED PRODUCTS THEREFROM

Abstract: Thermosettable prepolymers or resins are prepared by reacting a pyrazine containing at least two substituent groups which have a hydrogen atom attached to a carbon atom which is attached to the ring, with a material containing at least two aromatic aldehyde groups. These prepolymers or resins are curable to thermoset products having good mechanical and thermal properties. Thermoset polymers having good mechanical and thermal properties are also prepared by homopolymerization in the presence of N,N'-bis-imides or copolymerization of these prepolymers with N,N'-bis-imides. The prepolymers are suitable for preparing composites.

Description: THERMOSETTABLE POLYMERS OR PREPOLYMERS PREPARED FROM POLYMETHYLATED PYRAZI ES AND AROMATIC POLYALDEHYDES AND CURED PRODUCTS THEREFROM The present invention pertains to polymers prepared from polymethylated pyrazines and aromatic polyaldehydes and cured products prepared therefrom. The present invention provides thermosettable polymers or prepolymers which provide cured thermoset products which have good thermal properties as well as good physical properties. Thermoset products with good thermal as well as good physical properties can also be obtained by homopolymerization in the presence of N,N'-bis-imides or copolymerization of these prepolymers with N,N'-bis-imides. Composites can be prepared by impregnating reinforcing materials such as glass or graphite fibers with the prepolymer. One aspect of the present invention pertains to a thermosettable product characterized by resulting from reacting (A) at least one pyrazine compound having at least two substituent groups which have at least one hydrogen atom attached to a carbon atom which is attached to the ring or mixture of such pyrazines and (B) at least one of (1) material having at least two aldehyde groups or (2) a mixture of (a) at least one aldehyde having at least two aldehyde groups and (b) at least one aldehyde having only one aldehyde group; wherein components (A) and (B) are employed in quantities which provide a mole ratio of (A) to (B) of from 0.25:1 to 4:1, preferably from 1:1 to 1.5:1. Another aspect of the present invention pertains to the products resulting from curing the aforementioned thermosettable reaction product by heat or heat and pressure or by homopolymerization in the presence of N,N'-bis-imides or copolymerization with a N,N'-bis-imide. Suitable pyrazines which can be employed herein include any pyrazine which has at least two substituent groups which have at least one hydrogen atom attached to a carbon atom which is attached to the ring. Particularly suitable pyrazines include, di- and trialkyl pyrazines such as, for example, 2,5-dimethyl- pyrazine, 2,6-dimethylpyrazine, 2,3-dimethylpyrazine, 2,6~diamino-3,5-dimethylpyrazine, 3,5-dicyano-2,6- dimeth lpyrazine, 2,3,5-trimethylpyrazine, 6-nitro- -2,3,5-trimethylpyrazine, 2-chloro-3,5,6-trimethyl- pyrazine, 2,3,5,6-tetramethylpyrazine, 2,5-diethyl- pyrazine, 2,5-dipropylpyrazine, 2,6-diethylpyrazine, 2,6-dipropylpyrazine, 2,3-diethylpyrazine, 2,3-dipropyl- pyrazine, 2,3,5-triethylpyrazine, 2,3,5-tripropylpyrazine, and mixtures thereof. 2-Methylpyrazine can be mixed or blended with pyrazine having two or more methyl groups to control the molecular weight of the prepolymer. Other aromatic nitrogen containing hetero- cycles such as pyrazole, pyridazine, pyrimidines, purines, pteridines, imidazole, triazines, quinoline or guinoxalines or a mixture of any two or more such compounds having two or more substituents which have at least one hydrogen atom attached to a carbon atom which is attached to the ring can be substituted for the pyrazines having such substituents. Suitable pyrazoles include 3,5-dimethylpyrazole, l-ethyl-3,5-dimethyl- pyrazole and 3,4,5-trimethylpyrazole. Suitable pyridazines include 3,5-dimethylpyridazine, 4-chloro- -3,5-dimethylpyridazine and 3,4,5-trimeth lpyridazine. Suitable pyrimidines include 2,4-dimethylpyrimidine, 4,5-dimethylpyrimidine, 4,6-dimethylpyrimidine, 2,6- -dimethyl-4-aminopyrimidine and 2,4,6-trimeth lpyrimidine. Suitable purines include 2,8-dimethylpurine, 2,8-dimethyl- -6-aminopurine, and 2,6,8-trimeth lpurine. Suitable pteridines include 6,7-dimethylpteridine, 2,6-dimethyl- pteridine, 2,4,7-trimethylpteridine, and 2,4,6,7-tetra- methylpteridine. Suitable imidazoles include 2,5-di- methylimidazole, 2,4-dimethylimidazole and 2,4,5-tri- methylimidazole. Suitable triazines include 3,5-di- methyl-1,2,4-triazine, 3,6-dimethyl-l,2,4-triazine, 2,6-dimethyl-l,3,5-triazine and 2,4,6-trimethyl-l,3,5- -triazine. Suitable guinolines include 2,6-dimethyl- quinoline, 2,7-dimethylguinoline, 2,4-dimethylquino- line, 2,3,6-trimethylquinoline and 2,3,6,7-tetra- methylquinoline. Suitable guinoxalines include 2,5-dimethylquinoxaline, 2,3-dimethylguinoxaline, 2,6-dimethylquinoxaline, 2,3,7-trimethylguinoxaline and 2,3,6,8-tetramethylguinoxaline. Pyrazole, pyridazine, pyrimidine, purines, pteridines, imidazoles, triazines, guinolines and guinoxalines having two or more of such substituents can be mixed or blended with each other or pyrazine having two or more of such substituents. Also, a pyridine having two or more of such substituents can be mixed or blended with pyrazine, pyrazole, pyrid- azine, pyrimidine, purines, pteridines, imidazoles, triazines, guinolines or quinoxalines having two or more of such substituents or their mixtures. Molecular weight control of the polymer can be obtained by the addition of an aromatic nitrogen containing heterocycle having one substituent which has at least one hydrogen atom attached to a carbon atom which is attached to the ring as a chain terminator to an aromatic nitrogen containing heterocycle having two or more substituents which have at least one hydrogen atom attached to a carbon atom which is attached to the ring. For example, pyrazine, pyridine, pyrazole, pyridazine, pyrimidine, purines, pteridines, imidazoles, triazines, guinolines, or quinoxalines or a mixture of any two or more such compounds having at least one such substituent can be blended or mixed with those having more than one such substituent. Suitable aldehydes which can be employed herein include any aldehydes which contain at least two aldehyde groups and no other substituent groups which would tend to interfere with the reaction of the aldehyde groups and the said substituent groups of the pyrazine material. Particularly suitable aldehyde materials include, for example, those of the formula: wherein n = 2 or more, and R is an aromatic groups such as, for example, where Rj . is alkylene, oxygen, sulfur, oxyalkylene, 0 0 0 o O H O R 2 I I II II II II I II I polyoxyalkylene, -S-, -S-, -C-, -C-0-, -C-N-, -C-N-, II 0 - 0 wherein R 2 and R 3 are alkyl, aryl or aralkyl, and substituted groups thereof. Particularly suitable aldehydes include, for example, terephthaldicarboxaldehyde, o-phthalicdicar- boxaldehyde, isophthalaldehyde, glyoxal, dicinnamyl- aldehyde, 2,5-pyrazinedicarboxaldehyde, 2,3,4,5- -pyrazinetetracarboxaldehyde, 1,5-naphthalenedicar- boxaldehyde, 1,2,4,5,7,8-naphthalenehexacarboxaldehyde, l-bromo-2,5-naphthalenedicarboxaldehyde, 2-hydroxy-l,5- -naphthalenedicarboxaldehyde, 2,6-phenanthrenedicar- boxaldehyde, 2,7-pyrenedicarboxaldehyde, 4-chloro-2H- -thiochromene-3,7-dicarboxaldehyde, 2,6-fluorenedicar- boxaldehyde, 10-chloro-3,8-anthracenedicarboxaldehyde, 3,7-quinolinedicarboxaldehyde, 4,4'-bisbenzene-1- -carboxaldehyde, 4,4'-oxy-bisbenzene-1-carboxaldehyde, 4,4'-(2,1-ethanediylbisoxy)-benzene-1-carboxyaldehyde, 4,4'-sulfonylbisbenzene-1-carboxaldehyde, 4,4'-methylene- bisbenzene-1-carboxaldehyde, and mixtures thereof. Monoaldehydes such as benzaldehyde, o-tolualde- hyde, trans-cinnamaldehyde, 3-chlorobenzaldehyde or p-anisaldehyde can be mixed or blended with a dialdehyde or mixture of dialdehydes to control the molecular weight of the prepolymer. Pyrazine, pyrazole, pyridazine, pyrimidine, pyridine, purines, pteridines, imidazole, triazines, quinoline, and quinoxalines or mixtures thereof con¬ taining both a substituent having at least one hydrogen atom attached to a carbon atom which is attached to the ring and an aldehyde substituent can be reacted with itself. For example, suitable pyrazines containing both a substituent having at least one hydrogen atom attached to a carbon atom which is attached to the ring and an aldehyde substituent include 2-methyl-5-pyrazine- carboxaldehyde, 2-methyl-6-pyrazinecarboxal-dehyde, 2-methyl-3,5-pyrazinedicarboxaldehyde, 2,3-dimethyl-5- -pyrazinecarboxaldehyde and 2,3-dimethyl-5,6-pyrazine- dicarboxaldehyde. The reaction can be conducted in the absence or presence of suitable catalysts such as, for example, acids, Lewis acids, bases or salts. Particularly suitable acids include, for example, sulfuric, hydro¬ chloric or p-toluene-sulfonic acid. Particularly suitable bases include, for example, hydroxides of alkali or alkaline earth metals or of quaternary ammonium. Particularly suitable Lewis acids include, for example, boron trifluoride. Particularly suitable salts include, for example, zinc chloride or aluminum chloride. The use of such catalysts is not indispens¬ able but it reduces the time required for the reaction. When employed, the amount of the catalyst is typically from 0.1 to 10 mole percent with respect to the aromatic dialdehyde. If desirable, larger or lesser quantities can be employed. The reaction can also be accelerated by certain substances such as, for example, methyl iodide, methyl sulfate, or benzyl chloride capable of forming with the pyrazinic base quaternary ammonium derivatives, such substances being usable in catalytic amounts or higher proportions. Addition of a dehydrating agent such as acetic anhydride can also promote the reaction and its action can be sufficient to render superfluous the incorporation of a catalyst. The reaction is usually conducted in an inert atmosphere such as, for example, nitrogen, helium, neon, zenon, argon, or mixtures thereof. Volatile emission during cure can be limited by subjecting the thermosettable prepolymers or resins of the present invention to sublimation, distillation or solvent extraction to remove reactants, catalyst and solvents. Suitable solvents for extraction include, for example, ketones, alcohols, ethers, hydrocarbons, or chlorinated solvents. Particularly suitable sol¬ vents include acetone, methanol, ethanol, or mixtures thereof. The thermosettable prepolymers or resins of the present invention can be cured as is with the application of heat and pressure, or they can be dissolved in a suitable solvent or mixture of solvents and employed to saturate various reinforcing materials so as to prepare composites therefrom through the application of heat and pressure. Suitable solvents which can be employed for preparing these composites include, for example, ketones, acetates, alcohols, ethers, or hydrocarbons. Partic- ularly suitable solvents include, for example, acetone, methylethylketone, ethyl acetate, methylene chloride, trichloroethylene, tetrahydrofuran, chlorobenzene, ethanol, n-propanol, N-methyl-pyrrolidinone, dimethyl- formamide, dimethylacetamide, nitrobenzene, or mixtures thereof. Suitable reinforcing materials include any synthetic or natural fiber materials, for example, glass fibers, aramid fibers, carbon or graphite fibers in any form such as, for example, woven, matt, roving or random fibers. The thermosettable prepolymers can be used according to various conventional techniques applicable to thermosetting resins. Powdered prepolymers are especially adapted for shaping by pressure-molding, but they can also be dissolved in a solvent or be employed in molten form. They can be used in the preparation of laminates or composites, molded articles, films, coat¬ ings and the like. The prepolymer is advantageously cured to a thermoset condition by heating at a temperature of from 100° to 350°C, preferably by compression molding at a temperature of from 150°C to 350°C and at a pressure of up to 10,000 psig (6.89 MPa gage). Finally there is obtained a non-fusible and non-soluble polymer. Said polymer has a good thermal stability. The prepolymer can be homopolymerized in the presence of a N,N'-bis-imide or copolymerized with a N,N'-bis-imide of the formula: in which X represents a divalent radical containing a carbon-carbon double bond and A is a divalent radical having at least 2 carbon atoms. Preferred N,N'-bis- -i ides which may be employed, are maleic N,N'-ethylene- -bis-imide, maleic N,N'-hexamethylene-bis-imide, maleic N,N'-metaphenylene bis-imide, maleic N,N'-par phenylene- -bis-imide, maleic N,N'-4,4'-diphenylmethane-bis-imide, maleic N,N'-4,4*-diphenylether-bis-imide, maleic N,N'-4,- 4'-diphenylsulfone-bis-imide, maleic N,N'-4,4'-dicyclo- hexylmethane-bis-imide, maleic N,N'-metaxylylene-bis- -imide, and maleic N,N'-4,4'-diphenylcyclohexane-bis- -i ide. The following examples are illustrative of the present invention, but are not to be construed as to limiting the scope thereof in any manner. EXAMPLE 1 2,5-Dimethylpyrazine (100 g, 0.92 mole) and terephthaldicarboxaldehyde (104.9 g, 0.78 mole) were heated with stirring in a 500 ml reactor in a nitrogen atmosphere. Zinc chloride (2.67 g, 0.0196 mole) was added after complete dissolution which was apparent at 128°C. The temperature was maintained between 162° and 186°C. The reaction was stopped after two hours (7200 s). The infrared spectrum of the brown resin showed a band of 970 cm " which indicates the presence of trans unsaturation. Gel permeation chro atography indicated the weight average molecular weight of the N,N-dimethyl- formamide soluble portion of the prepolymer was 6200. The weight average molecular weight is based upon polystyrene standards. The resin was crushed and formed an orange powder. The powder was cured at <200°C for 2 hours (7200 s) and 250°C for 21 hours (76,500 s) under vacuum. Thermogravimetric analysis of the cured resin showed it lost between 30 and 35 weight percent at 940°C in nitrogen, 5 weight percent at 390°C in air and 60 weight percent at 700°C in air. The cured product showed no apparent glass transition temperature (Tg) in differential scanning calorimetry (DSC) analyses up to 400°C. EXAMPLE 2 2,3,5-Trimethylpyrazine (100 g, 0.82 mole) and terephthaldicarboxaldehyde (93.5 g, 0.70 mole) were heated with stirring in a 500 ml resin kettle in a nitrogen atmosphere. After complete dissolution which was apparent at 110°C, ' zinc chloride (2.37 g, 0.017 mole) was added to the reactor contents. The tem¬ perature was maintained between 133° and 188°C for 11 hours and 43 minutes (42,180 s). The infrared spectra of the dark brown solid indicated the presence of trans unsaturation. Gel permeation chromatography indicated the weight average molecular weight of the N,N-dimethyl- formamide soluble portion of the prepolymer was 7200. The resin was crushed forming a red-orange powder. The powder was cured at <200°C for 4 hours (14,400 s) and 250°C for 27 hours (97,200 s) in a vacuum oven. Thermo¬ gravimetric analysis of the cured resin showed it lost 5 weight percent at 380°C and 69 weight percent at 700°C in air. Differential scanning calorimetry sug¬ gested the cured product had no apparent glass transi¬ tion temperature up to 400°C. 11 EXAMPLE 3 2,3,5,6-Tetramethylpyrazine (100 g, 0.73 mole) and terephthaldicarboxaldehyde (83.7 g, 0.62 mole) were heated with stirring in a 500 ml reactor in a nitrogen atmosphere. After complete dissolution at 80°C, zinc chloride (2.13 g, 0.16 mole) was added to the reactor contents. The reaction temperature was maintained between 166° and 195°C for 32 minutes (1920 s). The infrared spectra supported the presence of trans unsaturation. Gel permeation chromatography indicated the weight average molecular weight of the N,N-dimethylformamide soluble portion of the prepolymer was 5700. The resin was crushed to give a red powder with a mortar and pestle. The red powder was cured at <200°C for 4 hours (14,400 s) and 250°C for 27 hours (97,200 s) in a vacuum oven. Thermogravimetric ana¬ lysis of the cured polystyrylpyrazine indicated it lost 5 weight percent at 360°C and 98 weight percent at 700°C in air. Differential scanning calorimetry sug- gested the cured product had no apparent glass transi¬ tion temperature up to 400°C. EXAMPLE 4 2,5-Dimethylpyrazine (597 g, 5.5 moles) and terephthaldicarboxaldehyde (629 g, 4.7 moles) were added to a 2 liter resin kettle equipped with a molecular sieve trap, immersion thermometer, mechanical stirrer, nitrogen purge system and Brookfield viscometer. A reflux condenser was attached to the molecular sieve trap. The molecular sieve trap was designed to trap water on molecular sieves but return 2,5-dimethyl- pyrazine and other organics back to the reactor. The reactor contents were heated with stirring. After complete dissolution, sulfuric acid (11.92 g, 0.122 mole) was added to the reactor contents. The tempera¬ ture was maintained between 163° and 176°C. After 7 hours and 46 minutes (27,960 s) the viscosity reached 758 centipoise (0.758 Pa-s). The reactor contents were cooled to room temperature resulting in a brown viscous liquid. The brown viscous liquid was stirred in metha- nol for an hour (3600 s). The methanolic solution of prepolymer was vacuum filtered using a sintered funnel of medium porosity. The prepolymer was washed with methanol, acetone and then dried in a vacuum oven between 80 and 120°C giving a yellow powder. The infrared spectra of the yellow powder showed a band at 970 cm " which indicates the presence of trans unsatura- tion. The prepolymer exhibited a distinct softening point between 232° and 240°C. The yellow prepolymer was compression molded between 250 and 260°C and 4300 psi (29648 kPa) for 2 hours (7200 s) with a Carver Laboratory press, employing a silicone mold release agent. Thermogravimetric analysis of the cured polymer in nitrogen showed 5 percent weight loss at 380°C and. 31percent weight loss at 950°C. In air, the polymer lost 5 percent weight at 385°C and 62 percent weight at 700°C. Differential scanning calorimetry indicated no glass transition temperature (Tg) was present up to 400°C. The compressed molded polymer was post cured at 270°C for 24 hours (86,400 s). Thermogravimetric analysis in nitrogen showed 5 percent weight loss at 470°C and 29 percent weight loss at 950°C. In air, the post cured polymer lost 5 percent weight at 460°C and 58 percent weight loss at 700°C. EXAMPLE 5 2,3,5,6-Tetramethylpyrazine (600 g, 4.4 moles) and terephthaldicarboxaldehyde (502 g, 3.7 moles) were added to a resin kettle of the type described in Example 4. After complete dissolution, sulfuric acid (9.78 g, 0.096 mole) was added to the reactor contents. The temperature was maintained between 174° and 182°C. After 1 hour and 22 minutes (4920 s), the viscosity reached 3670 centipoise (3.670 Pa*s). A dark red, hard, glassy solid was obtained after the reactor contents were cooled to room tempera¬ ture. The solid was crushed with a mortar and pestle to give a red powder. The powder was stirred in methanol for an hour (3600 s). The methanolic solution of prepolymer was vacuum filtered using a sintered funnel of medium porosity. The prepolymer was washed with methanol, acetone and then dried in a vacuum oven between 80° and 120°C giving an orange powder. The infrared spectra of the orange powder was consistent with the infrared spectra described in Example 4. The orange prepolymer had a broad softening point ranging from 190° to 219°C. The prepolymer was compression molded between 250 and 290°C and 7000 psi (48264 kPa) for 2 hours (7200 s) with a Carver Laboratory press as described in Example 4. Thermogravimetric analysis of the cured polymer in nitrogen showed 5 percent weight loss at 460°C and 39 percent weight loss at 950°C. The polymer lost 5 percent weight at 475°C and 76% weight at 700°C in air. Differential scanning calorimetry revealed no apparent glass transition temperature up to 400°C. Dynamic mechanical analyses showed no glass transition temperature up to 400°C, a gamma transition (T, ) temperature at -105°C, and storage modulus (G' ) of 1.355 x 10 10 dynes/cm≥ (1.355 GPa) at 25°C. The polymer exhibited the following mechanical properties at room temperature: Mechanical Properties (R.T.) ASTM Method Tensile Stress 1 , psi 4,298 D-638-27 , kPa 29,634 Flexural Stress 2 , psi 6320 D-790-27 , kPa 43,575 Tensile Modulus 1 , psi 363,600 D-638-27 , kPa 2,506,949 % Elongation 1 1.5 D-638-27 1 average of three samples 2 average of four samples The red compression molded polymer was post cured at 270°C for 24 hours (86,400 s). Thermogravi- metric analysis in nitrogen showed 5 percent weight loss at 495°C and 35 percent weight loss at 950°C. The post cured red polymer lost 5 percent by weight at 500°C and 70.5 percent by weight at 700°C in air. EXAMPLE 6 Maleic N,N'-4,4'-diphenylmethane-bis-imide (or 1,1'-(methylenedi-4,l-phenylene)bismaleimide) was oven cured under full vacuum at 180°C and sieved with U.S.A. Standard Testing Sieve No. 40 (425 μm). The resulting N,N'-bis-imide prepolymer softened between 200°and 250°C. 1,1'-(methylenedi-4,l-phenylene)bis- maleimide (10 g) and the sieved orange prepolymer described in Example 5 were mixed to give an orange powder. This powder was compression molded between 270° and 293°C and 6200 psi (42,749 kPa) for 2 hours with a Carver Laboratory press as described in Example 4. The infrared spectrum of the molded polymer was nearly the superposition of the infrared spectra of the cured polymer described in Example 5 and the infrared spectra of cured 1,1'-(methylenedi-4,l-phenylene)bis- maleimide. The major difference noted was a decrease in the 690 cm " band with respect to cured 1,1'- (methylenedi-4,1-phenylene)bismaleimide. Dynamic mechanical analyses showed no glass transition tem- perature up to 400°C, a gamma transition (T. ) temper¬ ature at -107°C and storage modulus (G 1 ) of 1.152 x 10 10 dynes/cm 2 (1.152 GPa) at 25°C. Modulus retention at 200° and 300°C with respect to the storage modulus at 30°C was 81 and 75%, respectively. Thermogravi- metric analysis in nitrogen showed 5 percent weight loss at 458°C and 46.5 percent weight loss at 950°C. In air, the polymer lost 5 percent weight at 453°C. EXAMPLE 7 2,3,5,6-Tetramethylpyrazine (554 q, 4.1 moles) and terephthaldicarboxaldehyde (471 g, 3.5 moles) were added to a 2-liter resin kettle equipped with a immersion thermometer, mechanical stirrer, nitrogen purge system and Brookfield viscometer. The reactor contents were heated with stirring. After complete dissolution, sulfuric acid (8.46 g, 0.089 moles) was added to the reactor contents. The tempera¬ ture was maintained between 155° and 179°C. After 1 hour 39 minutes (5940 s) the viscosity reached 500 centipoise (0.500 Pa-s). The reactor contents was a wet red-orange solid at room temperature. The solid (204 g) was stirred in methanol (468 g) for an hour (3600 s). The methanolic solution of prepolymer was vacuum filtered. The resultant prepolymer was washed twice with a mixture of 50 volume percent methanol and 50 volume percent acetone, washed once with methanol and dried for 1 hour 50 minutes (6600 s) at 130°C and 18 inches vacuum (40.4 kPa). The dried orange pre- polymer was sieved with a U.S.A. Standard Testing Sieve No. 40. (425 μm). The prepolymer soften between 150°and 223°C. EXAMPLE 8 1,1'-(Methylenedi-4,l-phenylene)bismaleimide was oven cured under full vacuum between 113°-150°C for 1 hour 49 minutes (6540 s) and sieved as described in Example 6. The resulting N,N'-bis-imide prepolymer melted between 146°-150°C. 1,1'-(methylenedi-4,1- -phenylene)bismaleimide (12 g) and the orange prepolymer described in Example 7 were mixed to give an orange powder. This powder was compression molded between 187° and 192°C and 4650 and 5000 psi (32062 and 34475 kPa) for 2 hours (7200 s) with a Carver Laboratory press as described in Example 4. Dynamic mechanical analyses showed no glass transition temperature up to 400°C, a gamma transition (T λ ) at -102°C and storage modulus (G') of 1.362 x 10 10 dynes/cm 2 (1.362 GPa) at 25°C. Thermogravimetric analysis in nitrogen showed 5 percent weight loss at 412°C and 51.5 percent weight loss at 950°C. In air, the polymer lost 5 percent weight at 412°C and 97.5 percent weight at 700°C in air. EXAMPLE 9 The sieved orange prepolymer (100 g) described in Example 5 and N-methylpyrrolidinone (100 g) were mixed in a beaker. This solution was painted onto a 14" x 14" (356 x 356 mm) woven graphite fiber mat (Hercules AP193 dry cloth) clamped to a frame. The graphite fiber mat preimpregnate was allowed to dry over night at room temperature. Then it was dried in an oven under full vacuum between 142° and 145°C for 46 minutes (2760 s). Finally the graphite fiber mat preimpregnate was dried in a convection oven between 175° and 182°C for 68 minutes (4080 s). Six 4" x 6" (101 x 152 mm) sections were cut from the graphite fiber mat preimpregnate, layed up on top of one another, and then compression molded between 270° and 293°C and 2500 and 2800 psi (17238 and 19306 kPa) for 3 hours (10,800 s) with a Carver Laboratory press. Dynamic mechanical analyses showed no glass transition temperature up to 400°C, a gamma transition (T, ) tem¬ perature at -102°C and storage modulus (G' ) of 2.26 x 10 10 dynes/cm 2 (2.26 GPa) at 25°C. Modulus retention at 200° and 300°C with respect to the storage modulus at 30°C was 99 and 111 percent, respectively. Thermo¬ gravimetric analysis of the graphite composite in nitro¬ gen showed 5% weight loss at 437°C and 34 percent weight loss at 950°C. The composite lost 5% weight at 446°C and 80 percent weight at 700°C in air. EXAMPLE 10 The sieved orange prepolymer (50 g) described in Example 7 and N-methylpyrrolidinone (50 g) were mixed in a beaker to give an orange paste. The orange paste was warmed and stirred for ten minutes (600 s) and then painted onto a 14" x 14" (356 x 356 mm) woven graphite fiber mat (Hercules AP193 dry cloth) clamped to a frame. The graphite fiber mat preimpregnate was allowed to dry over night at room temperature. Then it was dried in an oven under full vacuum at 160°C for 30 minutes (1800 s). Prepolymer scraped off the graphite fiber mat preimpregnate soften between 220° and 236°C. Six 4" x 6" (101 x 152 cm) sections were cut from the graphite fiber mat preimpregnate, layed up on top of one another, and then compression molded between 222° and 224°C and 500 and 1000 psi (3448 and 6895 kPa) for 1 hour (3600 s) and at 250°C and 500 psi (3448 kPa) for 2 hours (7200 s). The finished composite had thoroughly fused giving a flexible sample after trimming.

Claims: 1. A thermosettable product characterized by resulting from reacting (A) at least one pyrazine compound having at least two substituent groups which have at least one hydrogen atom attached to a carbon atom which is attached to the ring or mixture of such pyrazines and (B) at least one of (1) at least one material having at least two aldehyde groups or (2) a mixture of (a) at least one aldehyde having at least two aldehyde groups and (b) at least one aldehyde having only one aldehyde group; wherein components (A) and (B) are employed in quantities which provide a mole ratio of (A):(B) of from 0.25:1 to 4:1. 2. The thermosettable product of Claim 1 characterized in that component (A) a pyrazine, pyrazole, pyridazine, pyrimidine, purine, pteridine, imidazole, triazine, quinoline or quinoxaline, or a mixture of any two or more such compounds having two or more substituents which have at least one hydrogen atom attached to a carbon atom which is attached to the ring is substituted for the pyrazine compound. 3. The thermosettable product of Claim 2 characterized in that component (A) additionally contains a pyridine having two or more substituents which have at least one hydrogen atom attached to a carbon atom which is attached to the ring. 4. A cured product characterized by being prepared by subjecting the thermosettable product of Claim 1 to a temperature of from 100° to 350°C to effect curing to a thermoset condition. 5. The cured product of Claim 4 characterized by being prepared by subjecting the thermosettable product of Claim 1 to compression molding at a temperature of from 150° to 350°C and at a pressure up to 10,000 psig (6.89 MPa gage). 6. The cured product of Claim 5 charac¬ terized in that the composition before curing addi¬ tionally contains an N,N'-bis-imide. 7. The cured product of Claim 6 charac¬ terized in that the N,N'-bis-imide has the formula 0 0 0 0 in which X represents a divalent radical containing a carbon-carbon double bond and A is a divalent radical having at least 2 carbon atoms. 8. The cured product of Claim 5 charac¬ terized by additionally containing a reinforcing material. 9. The cured product of Claim 8 charac¬ terized in that the reinforcing material is woven, mat, roving or random fibers of natural or synthetic materials.

Inventors: SWEARINGEN LOREN L, TREYBIG DUANE S, SWEARINGEN, LOREN, L., TREYBIG, DUANE, S.
Applicants: DOW CHEMICAL CO, THE DOW CHEMICAL COMPANY
Application year: 1985
Main classification: C08G16
IPC codes: C08G16, C08J5, C08L61