MIXTURES OF POLYIMIDES AND ELASTOMERS

Abstract: The invention relates to a polymeric blend having a major amount of an elastomeric material and a minor amount of at least one particulate polyimide. Additionally, the polymeric blend may further contain lubricants.

Description: ° MIXTURES OF POLYIMIDES AND ELASTOMERS FIELD OF THE INVENTION The present invention relates to compositions containing a mixture of polyimides and elastomeric 5 materials. BACKGROUND OF THE INVENTION There is a need to extend the wear characteristics imparted by polyimides to more cost effective offerings that could be produced by other 10 manufacturing processes in different geometries. A medium can be chosen that would retain the current strengths of polyimides and enhance other properties such as elongation, noise and vibration dampening and wear resistance. Additionally, there is a need to improve 15 certain properties of polyimides. SUMMARY OF THE INVENTION The present invention relates to compositions containing a mixture of polyimides in particulate form and an elastomeric material. The particulate polyimide can be 20 either green or sintered polyimide resin or can be obtained from either sintered or green ground parts or a combination of any of the above material . Green material is unsintered. Sintering is generally carried at elevated temperature, i.e., for example, at between about 300 and 25 about 450°C. Sintered material of either type is preferred for uniformity. The polyimide is added to the elastomeric material in a known manner such as those which are currently utilized for mixing polymeric and resinous materials. The high temperature properties of the Q polyimides can be approached by proper elastomer selection. Similarly, the properties of polyimides can be enhanced by their admixture with elastomers. The present invention relates to the use of an elastomeric material as a matrix for a polyimide so that « the wear characteristics of the polyimide can be imparted to the elastomer. Furthermore, the present invention relates to imparting the inherent properties of elastomers, such as, for example impact resistance, vibration dampening and possibly noise suppression to the polyimides . DETAILED DESCRIPTION OF THE INVENTION 5 The present invention relates to compositions comprising particulate polyimides and elastomeric materials. It has been found that these compositions yield an improved wear elastomeric material . The elastomer containing the particulate polyimide may 10 optionally contain a lubricant . The particle size of the particulate polyimide can vary from fine to course particle sizes. The polyimide can have a degree of imidization of 90% or greater. The particulate polyimide can be ground scrap or 15 parts from polyimide molding operations as well as particulate in the form of resin or mixtures thereof. Useful polyimides include various known polyimides or mixtures . Typically, the particulate polyimide material is 20 present in an amount of between about 25 and 100 parts per one hundred parts (PPH) of the elastomeric composition by weight . The amount of polyimide in the elastomeric mixture will vary with the particular elastomer or elastomers and the actual application for the 25 elastomer/polyimide mixture . With respect to the particle size of the particulate polyimide, a too fine particle size can cause processing problems in elastomer processing equipment . A too fine material can become airborne during processing. 3Q A too coarse particle size can reduce the level of loading of the polyimide in the composition. The desired particle size for the polyimide resin particles is generally in the range of from about 5 to about 80 microns. The ground polyimide particulate material can be measured by screen g«r mesh and the desired particle size range is from about 40 to about 80 mesh. This mesh size range is from about 400 to about 100 microns. Polyimide particles having a desired particle size can be prepared from polyimides having larger sizes by grinding and classifying the larger sized polyimides. In the grinding process, polyimide parts are rough broken and ground to a size of approximately 0.25 inches in diameter. The ground material is then ground again and screened to a target level of mesh size. Particles which have a size greater than the target level can be reground. Aromatic polyimides, such as those described in U.S. Pat. Nos. 3,179,614 and 4,622,384 can be used. Certain of those polyimides have been found to be particularly satisfactory in the present invention, namely, those having a rigid polymeric structure. Representative of such rigid polymeric materials are those prepared using aromatic diamines and anhydrides such as m- phenylene diamine (MPD) ; bis-4,4'(3 aminophenoxy) biphenyl ; 3, 4-oxydianiline (3,4-ODA); Oxydianiline (ODA) ; p- phenylene diamine (PPD) ; benzophenone-3 , 3 ' , 4 , ' - tetracarboxylic dianhydride (BTDA) ; bis phenol-A- diphthalicanhydride (BPADA) ; pyromellitic dianhydride (PMDA) ; trimellitic anhydride (TMA) ; and 3, 3', 4- biphenyltetracarbocyclic dianhydride (BPDA) . The dianhydride and the aromatic diamine may be reacted in substantially equimolar quantities. However, excesses of dianhydride or diamine can be used to beneficially modify the properties of the final polyimide. The reaction product of the dianhydride and the aromatic diamine is a polyimide precursor resin, containing a limited amount of polyamic acid which can be thermally or chemically converted to polyimide according to known techniques . One or more of known lubricants for polyimide compositions may be used in the compositions of this invention. Illustrative lubricants include for example graphite, molybdenum disulfide or PTFE (polytetrafluoroethylene) . Nonfibrillating tetrafluoroethylene polymers and copolymers such as tetrafluoroethylene/hexafluoro-propylene are also useful and are commercially available in micropowder form. E.I. Du Pont de Nemours and Company sells such materials under 5 its trademark, Teflon ® MP. Preparation of copolymers of tetrafluoroethylene is described in Morgan U.S. Patent No. 4,879,362. By the term elastomer or elastomeric material, what is meant is a material, such as a rubber or plastic, 0 which at room temperature can be stretched under low stress, preferably, to at least twice its original length and, upon immediate release of the stress, will return with force to its approximate original length. The elastomers useful in this invention include, for example 5 natural or synthetic materials. Typical materials include carboxylated and hydrogenated nitriles, neoprenes, silicones, flouropolymers, polyisoprenes, polyurethanes, acrylonitrile/butadiene copolymers, styrene/butadiene copolymers and mixtures thereof. The selection of the 0 particular elastomers for use in the practice of the invention will be a function of the application and the environment which it is applied. The present invention is further illustrated by the following Examples in which parts and percentages are 5 by weight unless otherwise indicated. EXAMPLES Definitions : Falex No. 1 Ring & Block Wear & Friction Tester. This equipment is described in ASTM Test Method D2714. The Q test consists of mounting the polymeric sample against a rotating metal ring and rotating it at a constant speed with a consistent applied load for a standard time length (normally 24 hrs . ) . Wear rate is the amount of material eroded per unit time. * PV (units psi.fpm or MPa-m/sec) P = applied load in psi or MPa, V = velocity in fpm or m/sec . COF is the observed Coefficient of Friction. SP-1: Pure polyimide resin, shapes or parts derived from pyromellitic dianhydride (PMDA) and 4,4' - oxydianiline (ODA) . SP-21: Polyimide resin, shapes, or parts derived from PMDA and ODA, and containing about 15% by weight of graphite . B Resin: As made, milled, non- flowing polyimide resin having a particle size range of approximately 5 to 80 micrometers (μm) . Vespel ® : polyimides, parts and shapes as manufactured by E.I. DuPont de Nemours and Company . D Resin: Flowable polyimide resin having an average particle size of approximately 250 μm, made from B resin by compacting, milling, and screening to size. Examples of Formulations Within the Scope of the Invention are Shown Hereinbelow PARTS Nx 775 (Carboxylated Nitrile Elastomer) 100 Stearic Acid (Activator/Lubricant) 1 617 AC Poly (Polyethylene) 2 11AF (Carbon Black) 50 Agerite Resin D (Anti-oxidant) 2 Zinc Oxide (Activator) 5 DOP (Plasticizer) 6-10 Saret 517 (Monomer-CoAgent for Cure) 10-20 Varox (Peroxide Curing Agent) 3.5 Vespel ® SP21 50-75 Totals 229.5 - 268.5 The Carboxylated nitrile mixtures within the present invention are generally variations of this basic formulation. These formulations can contain other polyimides including series 10187 (ground Vespel ® instead of SP21) and series 11695 polyimide. Data in the tables shown below indicate the physical properties and Wear test data obtained. Effects of Addition of Polyimide on Nitrile Elastomer Properties SAMPLE NO. 10187H 10187G 10187E 10187F SP21 Loading(PPH) 0 80 80 100 N/A SP-21 Particle size - Mixed Fine Fine — Spec. Grav 1.31 1.26 1.26 1.31 1.42 Elongation 101 25 24 20 5.5 Compression Set 39.8 38.6 24.1 24.6 Hardness-Shore A 91 96 97 98 22 hrs. @ 100C Mixed loading of 10187G was a combination of coarse and fine ground materials with particle size ranging from 40 to 60 mesh, fine was primarily 80 mesh. Falex Wear Testing - 10187 Series Loading (PPH) Sample SP-21 PV(psi.fpm) Wear Rate COF 10187 SP-21 In/Hr x 10 4 H 0 25,000 5.00 0.32 (0.875 MPa-m/sec) (12.7 cm/HrxlO "4 ) E 80/Fine 25,000 2.25 0.27 (0.875 MPa-m/sec) (5.72cm/Hrxl0 "4 ) 100,000 5.40 0.175 (3.5 MPa-m/sec) (13.72cm/HrxlO- 4 ) G 80/Mixed 25,000 1.82 0.30 (0.875 MPa-m/sec) (4.62cm/HrxlO "4 ) 100,000 5.70 0.16 (3.5 MPa-m/sec) (M^δcm/HrxlO- 4 ) Loading (PPH) Sample SP-21 PV(psi.fpm) Wear Rate COF F 100/Fine 25,000 1.47 0.30 (0.875 MPa-m/sec) Q^cm/HrxlO- 4 ) 50,000 4.00 0.25-0.33 (1.75 MPa-m/sec) (lO. lόcm/HrxlO- 4 ) 100,000 5.90 0.16 (3.5 MPa-m/sec) (14.99cm/HrxlO "4 ) Note: With the unloaded sample 10187H, the measurements are approximate. These could not be precise since some wear debris adhered to the edge of the block. When this was removed, an unworn piece of block was torn out. The test was shutdown after 4.28 hrs . because of excessive noise. The other 25M & 100 M PV tests were run 8 hrs; the 50M tests run at a later date were 24 hrs. in duration. General Observations on the 10187 Series Addition of polyimide to the elastomer reduces elongation to a great degree, thus the addition provides stiffness to the elastomer. Hardness appears to increase then level off with increased loading of Polyimide . Compression Set is improved by polyimide addition: Test is run by ASTM Method D395. Wear testing gave mixed results but showed a definite positive effect by the Polyimide addition. It indicates that a larger particle may be more beneficial than a finer size. Follow up Series 10238 used sintered SP21 Resin instead of ground Parts; the compound formulation was basically the same as 10187. It was discovered making these batches that 75 PPH of resin appears to be the practical maximum from an elastomer process standpoint. Falex Weai • Testing - 10238 Series Loading Sample (PPH) PV(psi.fpm) Wear Rate COF 10238 SP-21 In/Hr x 10 "4 0.30 F 50 25,000 1.900 0.25 (0.875 MPa-m/sec) (4.83cm/HrxlO- 4 ) 50,000 4.20 (1.75MPa-m/sec) (10.67 cm/HrXlO ) G 75 50,000 5.22 0.25 (1.75MPa-m/sec) (B^όcm/HrxlO- 4 ) Falex Wear Testing - 11695 Series Evaluation of Major Variables Series I - Effect of level of polyimide loading All tests were run at PV of 50,000 psi-fpm (1.75 MPa-m/sec); All polyimide was sintered SP21 "B" Resin. Loading Sample (PPH) Wear Rate Hardness 11695A SP-21 In/Hr xlO" COF Shore D B 25 4.865 0.330 62 (12.36cm/HrxlO- 4 ) C 50 5.275 0.355 67 (13.4cm/HrxlO- 4 ) D 75 5.650 0.360 68 (^JScm/HrxlO- 4 ) Series II - Effect of polyimide particle size All tests were run at PV of 50,000 psi-fpm(1.75 MPa-m/sec; Polyimide was sintered SP21 "B" Resin unless noted. Level of polyimide loading was at 50 PPH. Sample Wear Rate Hardness 11695A In/Hr x 10" COF Shore D Remarks C 5.275 0.355 67 Base line (B^cm/HrxlO- 4 ) E 5.010 0.345 62 Oil added to (12.73cm/HrxlO- 4 ) alter hardness Sample Wear Rate Hardness 11695A In/Hr x 10" COF Shore D Remarks F 4.135 0.315 58 Ground Parts (10.5cm/HrxlO") used as loading J 2.715 0.195 55 "Bulked" D resin (6.9cm/HrxlO") as loading Series Ill- Importance of polyimide type All tests were run at PV of 50,000 psi-fpm(1.75 MPa-m/sec); Polyimide loading was sintered SP1 Resin replacing SP21. Sample Wear Rate Hardness 11695A In/Hr x 10" COF Shore D Remarks G 2.955 0.19 57 42.5 (7.5cm/HrxlO") PPH of SP1 H 2.715 0.175 50 50 PPH (6.9cm/HrxlO") Total SP1 + added Graphite Comments The 11695 series was compounded to evaluate as many variables as possible with minimal formulation changes and is not necessarily the optimum formulation that would be used in commercial applications. In Series II, the larger particle size of both ground parts and the "bulked" D resin indicate a possible beneficial effect on both wear rate and COF. It also shows the use of normal elastomer additives such as oils can alter both hardness and wear properties. Bulking (the D Resin Process) increases the average particle size to 250 microns. In Series III, the SP21 resin was replaced with SP1 at the same level of Polyimide; SP21 is SP1 with encapsulated Graphite, 42.5 PPH of SP1 is an equivalent level to 50PPH of SP21 loading. Series III shows that the polyimide is the major contributor to wear improvement as both the wear rate and COF results were the best obtained. It was postulated that the improvement may have been because of the Graphite, this series would seem to disprove that . While the invention has been illustrated and described in the preferred embodiments of the invention, it is to be understood that these embodiments are capable of variation and modification, and, therefore, the invention is not to be limited to the precise details set forth. The inventors avail themselves of such changes and alterations as falling within the purview of the appended claims .

Claims: o WHAT IS CLAIMED IS: 1. A polymeric blend comprising a major amount of an elastomeric material and a minor amount of at least one particulate polyimide. 2. The polymeric blend of claim 1, further comprising a lubricant. 3. The polymeric blend of claim 1 or claim 2, wherein the at least one particulate polyimide is at least about 90% imidized. 4. The polymeric blend of claim 1 or claim 2, comprising from about 60 to about 95% by weight of the elastomeric material and about 5 to about 40% by weight of the at least one particulate polyimide. 5. The polymeric blend according to claim 2, wherein the lubricant is present in an amount of up to about 40% by weight. 6. The polymeric blend according to claim 1 or claim 2 wherein the particulate polyimide is green or sintered polyimide resin and is obtained from molded sintered or green ground polyimide parts or a combination of any of the above . 7. The polymeric blend according to claim 1 or claim 2, wherein the particulate polyimide is green or sintered polyimide resin. 8. The polymeric blend according to claim 1 or claim 2, wherein the particulate polyimide is obtained from molded sintered or green ground polyimide parts. 9. The polymeric blend according to claim 7, wherein the at least one particulate polyimide has a mean particle size of from about 8 to about 80 microns. 10. The polymeric blend according to claim 8, wherein the mean particle size is from about 40 mesh to about 80 mesh. 11. The polymeric blend according to claim 1 or claim 2, comprising about 8 to about 24% by weight of the at least one particulate polyimide and about 76 to about 92% by weight of the elastomeric material. 12. The polymeric blend according to claim 1 or claim 2, wherein the elastomeric material is a carboxylated and hydrogenated nitriles, neoprenes, silicones, fluoropolymers, polyisoprenes, polyurethanes, acrylonitrile butadiene copolymers styrene/butadiene copolymer and mixtures thereof. 13. The polymeric blend of claim 2, wherein the lubricant is graphite, molybdenum disulfide, polytetrafluoroethylene , nonfibrillating tetrafluoroethylene polymers or a tetrafluoroethylene copolymer. 14. The polymeric blend according to claim 1 or claim 2, wherein the at least one particulate polyimide is derived from the reaction of an aromatic diamine and a dianhydride . 15. The polymeric blend according to claim 1 or claim 2, wherein the particulate polyimide is present in an amount of between about 25 and about 100 parts per hundred of the elastomeric material by weight .

Inventors: MCNAMARA JAMES FRANCIS, MCNAMARA, JAMES, FRANCIS
Applicants: DU PONT, E.I. DU PONT DE NEMOURS AND COMPANY
Application year: 1998
Main classification: C08L21
IPC codes: C08L13, C08L21