Polyarylene thioether of high crystallizing rate and a process for producing the same

Claim 2

A polyarylene thioether comprising a repeating unit of ##STR19## as the main constituent and having a necessary time for 50% crystallization of not more than 50 seconds upon crystallization of a molten polymer at 350° C., obtained by treating a polyarylene thioether, having an inherent solution viscosity measured at 206° C. with a 1-chloronaphthalene solution having a concentration of the polymer of 0.4 g/dl, of not less than 0.05 and not more than 0.25 dl/g, with an aqueous solution of a non-oxidative strong acid or of a non-oxidative strong-acid-weak-base salt.

Claim 3

The polyarylene thioether according to claim 1, wherein said repeating unit of ##STR20## comprises not less than 60 mol %.

Claim 4

The polyarylene thioether according to claim 1, which comprises a copolymer containing 60 to 95 mol % of said repeating unit of ##STR21## as the main constituent and 40 to 5 mol % of the repeating unit of ##STR22## as the minor constituent.

Claim 5

The polyarylene thioether according to claim 3, wherein said copolymer contains respective repeating unit of ##STR23## and ##STR24## each in a block form.

Claim 6

A polyarylene thioether according to claim 1, wherein said non-oxidative strong-acid-weak-base salt is ammonium chloride.

Claim 7

A process for producing polyarylene thioether with high crystallizing rate, which comprises reacting an alkali metal sulfide and a halo aromatic compound comprising a p-dihalo benzene as the main ingredient in an aprotic organic polar solvent, thereby forming a polyarylene thioether comprising ##STR25## as the main constituent and having an inherent solution viscosity measured at 260° C. with a 1-chloronaphthalene solution having a concentration of the polymer of 0.4 g/dl, of not less than 0.05 and not more than 0.25 dl/g, separating the resulting polymer from the reaction mixture, and treating with a solution with a pH value of not more than 2 containing a non-oxidative strong acid with an ionization constant K measured in an aqueous solution at 25° C., of not less than 10 -3 under a condition not causing curing and at a temperature of 0 to I50° C. and for a time of 5 to 500 minutes, thereby obtaining a polyarylene thioether with a necessary time of 50% crystallization of not more than 50 seconds when formed upon crystallization at 250° C. from the molten polymer.

Claim 8

A process for producing polyarylene thioether with high crystallizing rate, which comprises reacting an alkali metal sulfide and a halo aromatic compound comprising a p-dihalo benzene as the main ingredient in an aprotic organic polar solvent, thereby forming a polyarylene thioether comprising ##STR25## as the main constituent and having an inherent solution viscosity measured at 260° C. with a 1-chloronaphthalene solution having a concentration of the polymer of 0.4 g/dl, of not less than 0.05 and not more than 0.25 dl/g, separating the resulting polymer from the reaction mixture, and treating with a solution with a pH value of not more than 2 containing a non-oxidative strong acid with an ionization constant K measured in an aqueous solution at 25° C., of not less than 10 -3 under a condition not causing curing and at a temperature of 0 to I50° C. and for a time of 5 to 500 minutes, thereby obtaining a polyarylene thioether with a necessary time of 50% crystallization of not more than 50 seconds when formed upon crystallization at 250° C. from the molten polymer.

Claim 9

The process according to claim 6, wherein said non-oxidative strong acid is at least one of the acids selected from the group consisting of hydrochloric acid, diluted sulfuric acid, phosphoric acid, formic acid and halogenated acetic acid.

Claim 10

A process for producing polyarylene thioether with high crystallizing rate, which comprises reacting an alkali metal sulfide and a halo aromatic compound comprising a p-dihalo benzene as the main ingredient in an aproptic solvent, thereby forming a polyarylene thioether comprising ##STR26## as the main constituent and having an inherent solution viscosity, measured at 206° C. with a 1-chloronaphthalene solution having a concentration of the polymer of 0.4 g/dl, of not less than 0.05 and not more than 0.25 dl/g, separating the resulting polymer from the reaction mixture, and treating with a solution containing 0.1 to 30% by weight of a salt composed of a non-oxidative strong acid with an ionization constant K of not less than 10 -3 and a weak base with an ionization constant K of not more than 10 -4 , both measured in an aqueous solution of 25° C., under a condition not causing curing and at a temperature of 0° to 150° C. and for a time of 5 to 500 minutes, thereby obtaining a polyarylene thioether with a necessary time for 50% crystallization of not more than 50 seconds when formed upon crystallization from the molten polymer at 250° C.

Claim 11

A process for producing polyarylene thioether with high crystallizing rate, which comprises reacting an alkali metal sulfide and a halo aromatic compound comprising a p-dihalo benzene as the main ingredient in an aproptic solvent, thereby forming a polyarylene thioether comprising ##STR26## as the main constituent and having an inherent solution viscosity, measured at 206° C. with a 1-chloronaphthalene solution having a concentration of the polymer of 0.4 g/dl, of not less than 0.05 and not more than 0.25 dl/g, separating the resulting polymer from the reaction mixture, and treating with a solution containing 0.1 to 30% by weight of a salt composed of a non-oxidative strong acid with an ionization constant K of not less than 10 -3 and a weak base with an ionization constant K of not more than 10 -4 , both measured in an aqueous solution of 25° C., under a condition not causing curing and at a temperature of 0° to 150° C. and for a time of 5 to 500 minutes, thereby obtaining a polyarylene thioether with a necessary time for 50% crystallization of not more than 50 seconds when formed upon crystallization from the molten polymer at 250° C.

Claim 12

The process according to claim 8, wherein said strong acid is at least one of the acids selected from the group consisting of hydrochloric acid, diluted sulfuric acid, phosphoric acid, formic acid and halogenated acetic acid; and said weak base is at least one of the bases selected from the group consisting of ammonia and pyridine.

Claim 13

A process for producing a polyarylene thioether having a crystallizing rate higher than that of commercially available polyarylene thioether, wherein the polyarylene thioether according to claim 1 is mixed in an amount of not less than 5% by weight into said commercially available polyarylene thioether.

Claim 14

A polyarylene thioether composition containing not less than 20% by weight of the polyarylene thioether according to claim 1 and comprising one or more of fibrous fillers, inorganic powdery fillers, synthetic resins or elastomers.

Claim 15

The polyarylene thioether composition according to claim 11, wherein said fibrous fillers comprise glass fibers, carbonaceous fibers, silica fibers, alumina fibers, silicon carbide fibers, zirconia fibers, calcium titanate fibers, wollastonite, calcium sulfate fibers, aramide fibers or the mixture thereof.

Claim 16

The polyarylene thioether composition according to claim 11, wherein said inorganic powdery fillers comprise talc, mica, clay, kaolin, calcium carbonate, magnesium carbonate, calcium silicate, magnesium silicate, silica, alumina, titanium white, carbon black, calcium sulfate, iron oxide, zinc oxide, copper oxide or the mixture thereof.

Claim 17

The polyarylene thioether composition according to claim 9, wherein said synthetic resins comprise polyolefin, polyester, polyamide, polyimide, polyether imide, polycarbonate, polyphenylene ether, polysulfone, polyether sulfone, polyether ether ketone, polyether ketone, polyarylene, polyacetal, polyvinylidene fluoride, polyethylene tetrafluoride, polystyrene, acrylonitrile-butadiene-styrene resin epoxy resin, urethane resin, silicone resin, phenol resin or the mixture thereof.

Claim 18

The polyarylene thioether composition according to claim 11, wherein said elastomers comprise polyolefin rubber, fluorine rubber, silicone rubber, hydrogenated styrene-bytadiene-rubber, butyl rubber, polyester rubber, polyamide rubber or the mixture thereof.