Abstract:
A novel wholly aromatic polyester capable of forming an anisotropic melt phase is provided. Such polyester has been demonstrated to be capable of forming quality molded articles having a combination of excellent heat resistance and mechanical properties. The resulting polyester further is capable of readily being melt processed while using conventional equipment. Four essential recurring units are present in the polyester of the present invention wherein (I) is derived from 2,6-napthalenedicarboxylic acid and/or 4,4&#39;-biphenyldicarboxylicacid; (II) is derived from another dicarboxylic acid (as defined) such as terephthalic acid; and (III) is derived from aromatic diols (as defined) such as 1,4-dihydroxybenzene and 4,4&#39;-dihydroxybiphenyl; and (IV) is derived from another aromatic diol (as defined), such as 4,4&#39;-dihydroxydiphenyl ether. In a preferred embodiment, an inorganic filler is dispersed therein. Molded articles exhibiting highly satisfactory tensile strengths, tensile elongations, and tensile moduli are made possible when melt processing the wholly aromatic polyester.

Description:
The present invention relates to a new optically anisotropic copolyester which can be melt-processed with conventional equipment to form moldings having excellent heat resistance and mechanical properties. 
     BACKGROUND OF THE INVENTION 
     Recently high-performance polymers are demanded by the market. Although liquid-crystal polymers having specific properties such as optical anisotropy, satisfy the demands of the market under these circumstances, they sometimes have problems in that the melting points are excessively high due to their molecular chain structures and they tend to be economically expensive, since special monomers are to be used for producing them. 
     In particular, wholly aromatic polyesters now available on the market are mainly formed from hydroxy acids, particularly p-hydroxybenzoic acid, However, since the melting point of a homopolymer of p-hydroxybenzoic acid is higher than its decomposition point, the melting point must be lowered by copolymerizing it with various components. 
     A wholly aromatic polyester produced by using 1,4-phenylenedicarboxylic acid, 1,4-dihydroxybenzene, 4,4&#39;-dihydroxybiphenyl, etc., as the comonomer components has a melting point off as high as 350° C. or above which is too high to allow melt-processing with an ordinary apparatus. On tile contrary, although a wholly aromatic polyester produced by using 2,6-naphthalenedicarboxylic acid has a melting point of as low as around 300° C. and excellent properties, a special comonomer component is necessitated for producing it. 
     As wholly aromatic polyesters produced without using p-hydroxybenzoic acid, ones produced by using a dihydroxyarylene or dicarboxyarylene as the monomer are described in Japanese Patent Publication-A No. 26681/1989. However, these polymers are economically disadvantageous, since a special monomer having a substituent in the aromatic ring is necessitated for lowering the melting point. 
     SUMMARY OF THE INVENTION 
     After extensive investigations made for the purpose of solving the above-described problem, the present inventors have found that an optically anisotropic polyester having a low melting point and excellent mechanical properties can be produced without using p-hydroxybenzoic acid and a special comonomer component. The present invention has been completed on the basis of this finding. 
     Thus, the present invention relates to an aromatic polyester having an optical anisotropy in the molten state consisting essentially of recurring structural units represented by the following general formulae (I), (II), (III) and (IV) in amounts of 5 to 45, 5 to 45, 10 to 49, and 1 to 40 mole percent, respectively, based on the total structural units where: ##STR1## wherein Ar 1  is selected from the group consisting of 2,6-naphthalene, 4,4&#39;-biphenylene groups, and mixtures thereof; Ar 2  is selected from the group consisting of 1,2-phenylene, 1,3-phenylene, 1,4-phenylene groups and mixtures of two or more of these; Ar 3  is selected from the group consisting of 1,3-phenylene, 1,4-phenylene groups and a residue of a compound comprising at least two phenylene groups bonded to each other at the p-position, and Ar 4  represents 1,4-phenylene, and X represents at least one of ##STR2## and -(O(CH 2 ) n  O)- (n being 2 to 6). 
     To obtain the above-described structural units (I) to (IV), usual ester-forming compounds are usable. 
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     Now a detailed description will be made on the starting compounds for forming the aromatic polyesters constituting the present invention in order. 
     The dicarboxylic acid component comprises two structural units (I) and (II). The structural unit (I) is derived from one or two kinds of 2,6-naphthalenedicarboxylic acid and 4,4&#39;-biphenylenedicarboxylic acid. The amount of the structural unit (I) is 5 to 45% by mole, preferably 7 to 86% by mole, based on all the structural units of the polymer. When the amount of the structural unit (I) is outside this range, the melting point of the resultant polymer is seriously raised and no satisfactory molecular weight can be easily obtained. 
     The dicarboxylic acid structural unit (II) is derived from one or more kinds of 1,2-phenylenedicarboxylic acid, 1,8-phenylenedicarboxylic acid and 1,4-phenylenedicarboxylic acid. The amount of the structural unit (II) is 5 to 4% by mole based on all the structural units of the polymer. When the amount of the structural unit (II) is outside this range, the melting point of the resultant polymer is seriously raised and the molecular weight is lowered unfavorably. 
     To introduce the dicarboxylic acid unit into the polymer, a dicarboxylic acid or another diesterforming derivative is usable, the dicarboxylic acid being preferred. 
     The diol component comprises two structural units (III) and (IV). In these structural units, the unit (III) is derived from one or more kinds of 1,3-dihydroxybenzene, 1,4-dihydroxybenzene and compounds having at least two phenylene groups bonded to each other at the p-position (such as 4,4&#39;-dihydroxybiphenyl and dihydroxyterphenyls such as 4,4&#39;-dihydroxyterphenyl), preferably from a combination of 1,4-dihydroxybenzene with a dihydroxyaryl compound other than 1,4-dihydroxybenzene. The amount of the structural unit (III) is 10 to 49% by mole based on all the structural units of the polymer. When the amount of the structural unit (III) is below 10% by mole based on all the structural units, the melting point is seriously raised and the molecular weight is lowered unfavorably. 
     The diol constituting unit (IV) represented by the above formula is derived from one or more kinds of 4,4&#39;-dihydroxydiphenyl ether, 4,4&#39;-dihydroxybenzophenone, 4,4&#39;-dihydroxydiphenyl sulfide 4,4&#39;-dihydroxydiphenyl sulfoxide, 4,4&#39;-dihydroxydiphenyl sulfone, 4,4&#39;-dihydroxydiphenylpropane, 4,4&#39;-dihydroxydiphenylhexafluoropropane and 1,2-bis-)phenoxy)alkylene-4,4&#39;-diols. The amount of the structural unit (IV) is 1 to 40% by mole based on all the structural units. When the amount of the structural unit (IV) is outside this range, the melting point of the resultant polymer is seriously raised and the molecular weight is lowered unfavorably. 
     To introduce the above-described diol units into the polymer, the diols and other diester-forming derivatives such as diacetates, dipropionates and dibenzoates are usable. 
     The aromatic polyester of the present invention is produced by direct polymerization or transesterification. The polymerization is conducted usually by solvent polymerization or slurry polymerization. Melt polymerization can be used also. 
     Various catalysts can be used in the polymerization. They are typified by dialkyltin oxides, diaryltin oxides, titanium dioxide, alkoxytitanium silicates, titanium alcoholates and Lewis acid salts such as alkali and alkaline earth metal salts of carboxylic acids and BF 3 . 
     The amount of the catalyst is usually about 0.001 to 1% by weight, particularly about 0.01 to 0.2% by weight, based on all the monomers. 
     The molecular weight of the polymer thus produced by the above-described polymerization method can be further increased by solid phase polymerization wherein the polymer is heated under reduced pressure or in an inert gas. 
     The fact that the polymer of the present invention is a liquid crystal polymer having an optical anisotropy in a molten state is an indispensable condition for obtaining high heat stability and good processability. The optical anisotropy in a molten state can be confirmed by an ordinary polarimetric method with crossed nicols. In particular, the optical anisotropy in a molten state can be confirmed by melting a sample on a hot stage (mfd. by Linkam Co.) and observing it under a polarizing microscope (mfd. by Olympus Optical Co., Ltd.) at ×150 magnification in a nitrogen atmosphere. The above-described polymer is optically anisotropic and transmits light when it is sandwiched between crossed nicols. When the sample is optically anisotropic, the polarized light is transmitted even when it is in, for example,.a molten stationary liquid state. 
     As a measure of the processability in the present invention, liquid crystallinity and melting point (liquid crystallinity developing temperature) may be employed. The development of liquid crystallinity highly depends on the fluidity of a molten sample, and it is indispensable that the polyester of the present application develops liquid crystallinity in a molten state. 
     Since the viscosity of a nematic liquid-crystal polymer is seriously reduced above its melting point, the development of liquid crystallinity at the melting point or above usually serves as a measure of the processability of the polymer. From the viewpoint of heat resistance, it is preferable that the melting point (liquid crystallinity developing temperature) be as high as possible. However, taking the thermal deterioration of a polymer during melt processing and the heating capacity of a molding machine into consideration, the melting point is desirably 350° C. or below. The melt viscosity of a resin is preferably 1×10 6  P or less, still preferably 10 4  P or less, above a temperature of at least 10° C. higher than the melting point under a shear stress of 1000 sec -1 . Such a melt viscosity is generally realized when a polymer is endowed with liquid crystallinity. 
     The polyester of the present invention may contain various fibrous, powdery, granular or flaky inorganic or organic fillers depending on the purpose of use. 
     The fibrous fillers include inorganic fibrous materials such as fibers of glass, asbestos, silica, silica/alumina, alumina, zirconia, boron nitride, silicon nitride, boron, and potassium titanate, and fibers of metals such as stainless steel, aluminum, titanium, copper and brass. A particularly preferred fibrous filler is glass fiber. High-melting organic fibrous substances such as polyamides, fluororesins, polyester resins and acrylic resins are also usable. 
     The powdery or granular fillers include carbon black; graphite; quartz powder; glass; bead; milled glass fiber; glass balloons;glass powder; silicates such as calcium silicate, aluminum silicate, kaolin, talc, clay, diatomaceous earth and wollastonite; metal oxides such as iron oxide, titanium oxide, zinc oxide, antimony trioxide and alumina; metal carbonates such as calcium carbonate and magnesium carbonate; metal sulfates such as calcium sulfate and barium sulfate; ferrite; silicon carbide; silicon nitride; boron nitride; and metal powders. 
     The flaky fillers include mica, glass flakes and metal foils. 
     Examples of the organic fillers include heat-resistant high-strength synthetic fibers such as aromatic polyester fibers, liquid-crystalline polymer fibers, and aromatic polyamide and polyimide fibers. 
     These inorganic and organic fillers are usable either singly or in combination of two or more of them. A combination of the fibrous filler with the granular or flaky filler is preferred particularly for obtaining high mechanical strength and dimensional accuracy, electric properties. etc. The amount of the inorganic filler is 95% by weigh% or below, preferably 1 to 80% by weight, based on the whole composition. 
     These fillers are desirably used in combination with a binder or surface treatment, if necessary. 
     The polyester of the present invention may contain other auxiliary thermoplastic resins in such an among as not to impair the object of the present invention. 
     Examples of the thermoplastic resins thus usable herein include polyolefins such as polyethylene and polypropylene, aromatic polyesters comprising an aromatic dicarboxylic acid and a diol such as polyethylene terephthalate and polybutylene terephthalate, polyacetals (homo- and copolymers), polystyrene, polyvinyl chloride, polyamides, polycarbonates, ABS, polyphenylene oxide. polyphenylene sulfide and fluororesins. These thermoplastic resins are usable also in the form of a mixture of two or more of them. 
     The aromatic polyester and the composition thereof according to the present invention comprising the specified structural units and having anisotropy in a molten stage have a high fluidity in a molten state and an excellent thermal stability and, in addition, it can be molded at a temperature which is not so high. Therefore, they can be molded into various three-dimensional moldings, fibers and films by injection molding, extrusion molding or compression molding. 
     Since these aromatic polyesters and compositions have well-balanced thermal stability, they are suitable for use as the material of precision parts, particularly connectors having a narrow pitch, thin parts, electric wire coating materials, etc. 
    
    
     The following Examples will further illustrate the present invention, which by no means limit the invention. 
     EXAMPLE 1 
     As shown in Table 1, 89.50 g (25% by mole) of 2,6-naphthalenedicarboxylic acid, 68.77 g (25% by mole) of terephthalic acid, 51.05 g (28% by mole) of 1,4-dihydroxybenzene, 37.00 g (12% by mole) of 4,4&#39;-dihydroxybiphenyl, 33.48 g (10% by mole) of 4,4&#39;-dihydroxydiphenyl ether, 174.28 g of acetic anhydride and 0.05% by weight, based on the total feed, of potassium acetate were fed into a reactor provided with a stirrer, nitrogen-inlet tube and distillation tube. After purging the reactor with nitrogen, the resultant mixture was reacted at 140° C. For 1 h. Then the temperature was gradually elevated to 250° C. during a period of 1.5 h. During this period, about 100 g of acetic acid was distilled off. The temperature was gradually elevated from 250° C. to 300° C. during a period of 1.5 h and then to 340° C. during  1 h. The reaction mixture was stirred at 340° C. for 0.5 h. More than 90% of the theoretical amount of acetic acid distillate had been distilled off by then. Thereafter, the pressure in the reactor was slowly reduced to 20 mmHg at 340° C. after 0.5 h and then to 1 mmHg or below after additional 0.2 h. The reaction was conducted under this pressure for 1 h. A small amount of acetic acid was distilled off during the pressure reduction. After the completion of the reaction, nitrogen was blown into the reactor and the contents were taken out. The resultant polymer was pale yellowish milk white and had a melting point of 294° C. as determined with DSC (mfd. by Perkin-Elmer Corporation). The polymer was heated and observed under crossed nicols on a hot stage (mfd. by Linkam Co.) under a polarizing microscope mfd. by Olympus Optical Co. to find a nematic liquid crystal pattern at the melting point or above. The melt viscosity of the polymer was 780 P (320° C.,  1000 sec -1 ) as determined with a Capirograph (mfd. by Toyo Seiki Seisaku-Sho). 
     Then tensile test pieces were prepared from this polymer on a Mini Shot 2 machine (mfd. by Tsubaco Yokohama Co., Ltd.) and tested with a tensile tester mfd. by Toyo Baldwin Co., Ltd. to find that they have a tensile strength of 1630 kg/cm 2 , a tensile elongation of 2.0% and a tensile modulus of 7.9×10 4  kg/cm 2 . 
     EXAMPLES 2 TO 10 
     The polymerization was conducted in the same manner as that of Example 1 except that the proportion of the constituents was altered as specified in Table 1, and the resultant polymer was evaluated also in the same manner as that of Example 1 except that the melting point was determined with a melting point apparatus mfd. by Yanagimoto Mfg. Co., Ltd., since the data obtained with DSC were unreliable because of a small quantity of heat transfer depending on the proportion of the constituents. 
     EXAMPLE 11 
     The polymer obtained in Example 1 was mixed with 30% by weight of glass fibers and extruded on an extruder mfd. by Haake Buchler Instruments Inc., and the test pieces were prepared therefrom in the same manner as that of Example 1 and evaluated. 
     The test results are summarized in Table 1. 
     Comparative Examples 1 to 4 
     Polymerization was conducted in the same manner as that of Example 1 except that the proportion of the constituents was altered as specified in Table 2, but the viscosity of the reaction mixture began to seriously increase at around 300° C. When the temperature was elevated finally to 390° C., the reaction mixture was solidified and could not be taken out of the reactor. 
     The test results are summarized in Table 2. 
     
                                           TABLE 1__________________________________________________________________________                         Melt Tensile                                   Tensile                                         TensileMonomer compn. (% by mole) Tm viscosity                              strength                                   elongation                                         modulus(I)      (II) (III)              (IV)    (°C.)                         (P)  (kg/cm.sup.2)                                   (%)   (kg/cm.sup.2)__________________________________________________________________________Ex.1  NDA 25    TPA 25         HQ 28              DHDPE 10                      294                         750  1630 2.0   7.9 × 10.sup.4          BP 122  NDA 25    TPA 25         HQ 28              DHBP  10                      333                         360  1750 1.8   9.2 × 10.sup.4          BP 123  NDA 25    TPA 25         HQ 28              DHDPSO.sub.2                    10                      312                         1500 1210 2.0   7.1 × 10.sup.4          BP 124  NDA 25    TPA 25         HQ 28              DHDPP 10                      278                         3100 1370 2.7   7.3 × 10.sup.4          BP 125  NDA 25    TPA 25         HQ 28              DHDPPF                    10                      267                         3800 1160 3.1   6.8 × 10.sup.4          BP 126  BPDA  30     IPA 20         HQ 20              DHDPE 10                      273                         830  1350 2.3   7.2 × 10.sup.4          BP 207  BPDA  20     IPA 30         HQ 20              DHDPE 10                      335                         560  1710 2.0   7.7 × 10.sup.4          BP 208  NDA 25    TPA 25         HQ 35              DHDPE 15                      325                         670  1580 1.8   7.5 × 10.sup.49  BPDA  25    TPA 25         HQ 25              DHDPE 25                      332                         890  1430 1.9   8.1 × 10.sup.410 BPDA  25    TPA 25          BP 25              DHDPE 25                      341                         910  1590 2.0   7.9 × 10.sup.411 mixture of polymer of Example 1 with 30%                      -- --   1850 1.8   8.5 × 10.sup.4   by wt. of glass fibers.__________________________________________________________________________ 
    
     
                                           TABLE 2__________________________________________________________________________                        Melt Tensile                                  Tensile                                        TensileMonomer compn. (% by mole)                     Tm viscosity                             strength                                  elongation                                        modulus(I)       (II) (III)               (IV)  (°C.)                        (P)  (kg/cm.sup.2)                                  (%)   (kg/cm.sup.2)__________________________________________________________________________Comp.Ex.1   --    TPA 25          HQ 28               DHDPE 10                     N/A                        N/A  N/A  N/A   N/A           BP 122   NDA 50     --   HQ 28               DHDPE 10                     N/A                        N/A  N/A  N/A   N/A           BP 123   BPDA   25     TPA 25          --   DHDPE 50                     N/A                        N/A  N/A  N/A   N/A4   BPDA   25     TPA 25           BP 50               --    N/A                        N/A  N/A  N/A   N/A__________________________________________________________________________ (Note to Tables 1 and 2) *NDA: 2,6naphthalenedicarboxylic acid, BPDA: 4,4biphenyldicarboxylic acid, TPA: terephthalic acid, IPA: isophthalic acid, HQ: 1,4dihydroxybenzene (1,4phenylenediol), BP: 4,4dihydroxybiphenyl, DHDPE: 4,4dihydroxydiphenyl ether, DHBP: 4,4dihydroxybenzophenone, DHDPP: bisphenol A,  DHDPSO.sub.2 : 4,4dihydroxydiphenyl sulfone, DHDPPF: 4,4dihydroxydiphenylhexafluoropropane, N/A: solidifed and could not be taken out of the reactor.