CA2137564A1 - Polymers of haloperfluoro and perfluoro ethers - Google Patents

Polymers of haloperfluoro and perfluoro ethers

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CA2137564A1
CA2137564A1 CA002137564A CA2137564A CA2137564A1 CA 2137564 A1 CA2137564 A1 CA 2137564A1 CA 002137564 A CA002137564 A CA 002137564A CA 2137564 A CA2137564 A CA 2137564A CA 2137564 A1 CA2137564 A1 CA 2137564A1
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copolymer
alkyl radical
och3
polymer
group
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Nobuyuki Ishibe
Charles W. Martin
Tien K. Tran
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Dow Global Technologies LLC
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    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08FMACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F16/00Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical
    • C08F16/12Homopolymers and copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical by an ether radical
    • C08F16/32Monomers containing two or more unsaturated aliphatic radicals
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/20Manufacture of shaped structures of ion-exchange resins
    • C08J5/22Films, membranes or diaphragms
    • C08J5/2206Films, membranes or diaphragms based on organic and/or inorganic macromolecular compounds
    • C08J5/2218Synthetic macromolecular compounds
    • C08J5/2231Synthetic macromolecular compounds based on macromolecular compounds obtained by reactions involving unsaturated carbon-to-carbon bonds
    • C08J5/2237Synthetic macromolecular compounds based on macromolecular compounds obtained by reactions involving unsaturated carbon-to-carbon bonds containing fluorine
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25BELECTROLYTIC OR ELECTROPHORETIC PROCESSES FOR THE PRODUCTION OF COMPOUNDS OR NON-METALS; APPARATUS THEREFOR
    • C25B13/00Diaphragms; Spacing elements
    • C25B13/04Diaphragms; Spacing elements characterised by the material
    • C25B13/08Diaphragms; Spacing elements characterised by the material based on organic materials
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/10Fuel cells with solid electrolytes
    • H01M8/1016Fuel cells with solid electrolytes characterised by the electrolyte material
    • H01M8/1018Polymeric electrolyte materials
    • H01M8/102Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer
    • H01M8/1023Polymeric electrolyte materials characterised by the chemical structure of the main chain of the ion-conducting polymer having only carbon, e.g. polyarylenes, polystyrenes or polybutadiene-styrenes
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/10Fuel cells with solid electrolytes
    • H01M8/1016Fuel cells with solid electrolytes characterised by the electrolyte material
    • H01M8/1018Polymeric electrolyte materials
    • H01M8/1039Polymeric electrolyte materials halogenated, e.g. sulfonated polyvinylidene fluorides
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00Fuel cells; Manufacture thereof
    • H01M8/10Fuel cells with solid electrolytes
    • H01M8/1016Fuel cells with solid electrolytes characterised by the electrolyte material
    • H01M8/1018Polymeric electrolyte materials
    • H01M8/1069Polymeric electrolyte materials characterised by the manufacturing processes
    • H01M8/1086After-treatment of the membrane other than by polymerisation
    • H01M8/1088Chemical modification, e.g. sulfonation
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08JWORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2327/00Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers
    • C08J2327/02Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment
    • C08J2327/12Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a halogen; Derivatives of such polymers not modified by chemical after-treatment containing fluorine atoms
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30Hydrogen technology
    • Y02E60/50Fuel cells
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50Manufacturing or production processes characterised by the final manufactured product

Abstract

Homopolymers prepared from diunsaturated mono- or polyhaloperfluoro or perfluoro ethers, and copolymers prepared from two or more of such ethers, or one or more of such ethers and one or more other ethylenically unsaturated monomers; and articles fabricated from such polymers.

Description

~- 2137~6~ -Polymers of Haloperfluoro-and Perfluoro Ethers This invention relates to polymers of haloperfluoro and perfluoro ethers, and to the preparation, fabrication and crosslinking of such polymers.

Haloperfluoro and perfluoro mono- and polyethers which are ethylenically unsaturated can be homopolymerized or can be copolymerized with other ethylenically unsaturated monomers to form a melt processible, thermoplastic polymer.

An advantageous feature of such ethers which contain two sites of unsaturation, both a vinyl and an allyl group for example, is that they can be polymerized through one bond to form a melt processible, thermoplastic polymer, while the other bond remains unreacted in a side chain. This unreacted bond is then available to participate in a crosslinking reaction which converts the thermoplastic polymer to a thermoset.

. ~31 S6 4 PCT/US93/~034 In one aspect, this invention involves a homopolymer or copolymer of one or more of the ethers described by the formula CF2==CF--CF2--Q--0--CF==CF~, where Q is --Ga--(--0--C2J4--)b--(--0--Z--)c--, in which G
is a substantially fluorinated C3-C7 alkyl radical; a is 0 or 1; each J is independently fluorine, chlorine, bromine, or a Cl-C4 substantially fluorinated alkyl radical on which not more than one substituent is chlorine, provided that not more than two J's are non-fluorine halogen atoms; b is 0-6 inclusive; Z is a substantially fluorinated C2-Clo alkyl radical; and c is 0 or 1; provided that sum of a + b + c is greater than 0. In a further aspect, this invention involves a copolymer of one or more of said ethers and one or more other ethylenically unsaturated monomers. This invention also involves a process for crosslinking a polymer as described above, and involves an electrolyric cell containing a membrane prepared from such a polymer.

The polymers of this invention are melt processible, thermoplastic polymers which can be molded, formed or fabricated into finished articles or other goods of virtually any variety, particularly for use in the automotive and electronics industries or for the manufacture of films, such as molded or extruded films used as membranes. The finished articles or other goods can be crosslinked to improve strength, elasticity and tear resistance.
3o The polymers of this invention are either homopolymers or copolymers of a haloperfluoro or perfluoro ether which contains a trifluorovinyl ether group and a perfluoroallyl group which are joined by a radical (i) which contains at least three atoms, and W094/00502 2 1 ~ 7 3 6 g - PCT/US93/060~

(ii) in which all carbon atoms are substantially fluorinated. A group of carbon atoms is substantially fluorinated when, at fifty percent or more, and preferably at sixty percent or more, of the possible sites at which the carbon atoms in the group could be bonded to hydrogen, the bond is to fluorine rather than hydrogen. Most preferably, the molecule is completely fluorinated, and contains no carbon-hydrogen bonds.

A haloperfluoro or perfluoro ether for use in preparation of the polymers of this invention may be generally described by the formulae CF2==CF--CF2--Q--0--CF==CF2, I
where Q i s ~~Ga~~ ( ----C2J4-- ) b-- ( ----Z-- ) c-- ' II

in which G is a substantially fluorinated C3-C7 alkyl radical; a is 0 or 1; each J is independently fluorine, chlorine, bromine, or a C~-C4 substantially fluorinated alkyl radical on which not more than one substituent is chlorine, provided that not more than two J's are non-fluorine halogen atoms; b is 0-6 inclusive;
Z is a substantially fluorinated C2-C10, preferably C2-C~
and more preferably C2-C6, alkyl radical; and c is 0 or 1; provided that sum of a + b + c is greater than 0.

The haloperfluoro and perfluoro ethers described above may be mono- or polyethers, and can be conveniently prepared, in one method, from a 3-haloperfluoropropene oxide. A halide ion may be reacted with a 3-haloperfluoropropene oxide to produce a 2,3-dihaloperfluoroacyl fluoride. This may be accomplished in an inert liquid reaction medium such as the sulfone ~5~ -4-sulfolane or the glycol ether tetràethylene glycol dimethyl ether.

From a 2,3-dihaloperfluorocarbonyl fluoride, pentafluoro-2-propenyl perfluorovinyl ether (perfluorovinylallyl ether) can be prepared by using a fluoride ion to create an alkoxide ion at the carbonyl carbon of a 2,3-dihaloperfluorocarbonyl fluoride. This reactive intermediate is then coupled to additional 3-haloperfluoropropene oxide by reaction of the alkoxideion with the epoxide ring to obtain a 2-(2',3'-dihaloperfluoropropoxy)-3-haloperfluoropropionyl -- fluoride. The 2-(2',3'-dihaloperfluoropropoxy)-3-haloperfluoropropionyl fluoride can then be decarboxylated, using for example sodium carbonate, and can then be dehalogenated, using for example zinc, to obtain perfluorovinylallyl ether (3-oxaperfluorohexa-1,5-diene). "Perfluoro" as used herein means that all the hydrogen atoms on a molecule, except those whose replacement would affect the nature of the characteristic groups present, have been replaced by fluorine atoms.

If the 2-(2',3'-dihaloperfluoropropoxy)-3-haloperfluoropropionyl fluoride is instead treated further with fluoride ion and is then reacted with additional 3-haloperfluoropropene oxide, a coupling reaction [analogous to that by which the 2-(2',3'-dihaloperfluoropropoxy)-3-haloperfluoropropionyl fluoride itself is prepared] occurs, in which the product is a 2-[2'-t2",3"-dihaloperfluoropropoxy)-3'-haloperfluoropropoxy]-3-haloperfluoropropionyl fluoride.
By successive repetition of the steps used to prepare a
2-[2'-(2",3"-dihaloperfluoropropoxy)-3'-W094/00502 2 1 3 7 ~ 6 4 PCT/US93/06034 haloperfluoropropoxy]-3-haloperfluoropropionyl fluoride, a six-membered, or greater, polyether can be prepared by continued conversion of the terminal carbonyl carbon to an alkoxide ion and addition of it to another e~uivalent of 3-haloperfluoropropene oxide.

If the 2-[2'-(2",3"-dihaloperfluoropropoxy)-3'-haloperfluoropropoxy]-3-haloperfluoropropionyl fluoride, or corresponding higher polyether, is then decarboxylated and dehalogenated, as described above, a
3,6-dioxa-5-halodifluoromethylperfluoronona-1,8-diene, or corresponding higher, diunsaturated polyether, is obtained. A 3,6-dioxa-5-halodifluoromethylperfluoronona-1,8-diene may be represented by the formula F F F F F F

III

where T is a fluorine, chlorine, bromine or iodine atom.
Higher diunsaturated polyethers, prepared by the method described above, may be represented by the formula ~3156 4 -6-F F F F F F F

n where T is as set forth above, and n is 2 to 6 inclusive.
A 3,6-dioxa-5-halodifluoromethyl-7-haloperfluoronona-1,8-diene is described by Formulae I
and II when a and c are 0, b is 1, three J's are fluorine, the fourth J is CTF2, and T is as set forth above. A corresponding polyether of Formula IV is described by Formulae I and II when all values are as described in the preceding sentence except that b is 2 to 6 inclusive.

In another method of preparing a polymerizable ethylenically unsaturated perfluoro ether, an unbranched perfluorovinylallyl ether described by the formula CF2==CF--CF2--0--(CF2)m+2--0--CF==CF2~ where m is inclusively an integer of 0-8, preferably 0-6 and more preferably 0-4, may be prepared by (I) the fluoride ion catalyzed coupling of a 3-haloperfluoropropene oxide to one end of a diacyl fluoride of formula W094/00502 2 1375 6~ PCT/US93/060~

F-C(0)-(CF2)m-C(0)-F, where m is as set forth above, and (II) a similar coupling of the other end to a 3-substituted perfluoropropene in which the 3-substituent is a good leaving group such as perfluoroallyl bromide ` or perfluoroallyl fluorosulfate. An unbranched perfluorovinylallyl ether, as described in this paragraph, is also described by Formulae I and II when a and b are 0, c is 1, and Z is (CF,)m+2.

A diunsaturated perfluorovinylalkenylether described by the formula CF2==CF--CF2--(CF,)p--0--CF==CF2, where p is an integer of 3 to 7 inclusive, can be prepared by chlorinating a diene such as 2 CF2 (CF2)p2--CF==CF2 to eliminate the double bond from the CF2==CF--CF2-- group, and then oxidizing the remaining double bond to an epoxide ring. A
carbonyl fluoride is then formed from the epoxide ring by a trialkyl amine catalyzed ring-opening reaction, and an alkoxide ion is then formed from the carbonyl by the application of fluoride ion, which allows coupling of the molecule to a 3-haloperfluoropropene oxide with consequent reformation of a carbonyl at that location.
Decarboxylation and dehalogenation, as described above, yields a diunsatuarated perfluorovinyl ether. Such an ether is described by Formulae I and II when b and c are 0, a is 1, and G is (CF2)p.

An ether described by Formulae I and II when c is 0, a and b are 1, G is CF2, 3 J's are F, and the fourth J is CF2T (where T is as set forth above), can be prepared by the same method set forth above for preparing a 3,6-dioxa-5-halodifluoromethyl-7-haloperfluoronona-1,8-diene except that a 3,4-W O 94/00502 PC~r/US93/06034 3l36~

dihaloperfluoro butanoyl fluoride is used instead of a2,3-dihaloperfluoropropionyl fIuo~'ide.

The polymers of this invention include a homo-or copolymer of one or more of the diunsaturated mono-or poly-, haloperfluoro- or perfluoroethers of Formula I, as described above. Copolymerization can involve two or more of the ethers of Formula I, or one or more of the ethers of Formula I in a monomer mix with one or more other ethylenically unsaturated monomers (those possessing a C=C bond). A copolymer comprising one or more of said ethers and at least one other ethylenically unsaturated monomer is a copolymer which has been prepared by copolymerizing such ether(s) and monomer(s).
The copolymer chain thus prepared may exhibit a monomer sequence which is either random, alternate, block and/or grafted.

It is preferred that the polymers of this invention be linear. Linear as used herein means that each diunsaturated ether, as described above, which participates in the formation of a polymer does so by polymerizing to form the main chain through one double bond while the other double bond remains pendant on a branch chain, and the two double bonds on the same monomer unit do not react with each other to form a cyclic structure.

The polymerization to form the polymers of this invention can be conducted in an aqueous system using a water soluble initiator, for example an inorganic peroxide such as ammonium persulfate or an organic peroxide such as disuccinoyl peroxide. An initiator such as a di(perfluoroacyl)peroxide can also be used in W094/00502 2 1 3 7 S 6 l PCT/US93/060~
_9_ an aqueous polymerization. 0.0001 moles to 0.2 moles of initiator is used per mole of the monomer which is present in the greatest quantity. An aqueous polymerization can be carried out at a pH of about 8 or lower, at a temperature of 50C to 110C, and a pressure of 0.01 MPa to 5 MPa. It may also involve use of a hydrogen-containing chain transfer agent. A
fluorocarbon solvent, such as a Cl 4 chlorfluoroalkane may also be used, but if so, the initiator should not be soluble in such solvent. A dispersing agent such as an ammonium salt of a long-chain perfluorocarbon acid such as ammonium perfluorocaprylate may be used if desired.
Aqueous polymerization such as discussed above is described in greater detail in Gresham, U.S.P.
3,635,926.

The polymerization can also be conducted entirely in a perfluorocarbon solvent, for example a perfluoroalkane such as perfluoroheptane, or a perfluorocycloalkane such as perfluorodimethylcyclobutane. A perfluoroinated free radical initiator such as a perfluoroperoxide or a nitrogen fluoride is frequently used. 0.0001 moles to 0.2 moles of initiator is used per mole of the monomer which is present in the greatest quantity. The process may be run at a temperature of -50C to 200C and a pressure of 0.01 MPa to 5 MPa. Polymerization in a perfluorocarbon solvent, such as discussed above, is described in greater detail in Connolly, U.S.P.
3,282,875. The polymerization may also be run in bulk where excess liquid monomer is used as the solvent.

Virtually any ethylenically unsaturated monomer capable of polymerization under the conditions described above can be copolymerized with one or more of the ethers of Formula 1.
Representative monomers suitable for copolymerization with such ethers can be described as F-C(R) = = C-R2, where each R is independently (1) hydrogen;
5 (2) a halogen such as fluorine, chlorine or bromine;
(3) -OCH3;
(4) -OC6F5;
(5) -C(CF3)20H;
(6) -R1-NH-R'-R2, where each R' is independently SO2, CO or PO2, and R2 is a substantially fluorinated C1-C,O alkyl radical, optionally carrying at one or more sites an ionic charge or a precursor group which can be converted to an ionically charged substituent;
(7) a C,-C10 linear or branched alkyl radical, interruptible with one or more oxygen atoms, each independently optionally containing one or more substituents selected from the group consisting of phenyl, -F, -Cl, -Br, -I, -SO2F, -OCH3, -PO(OCH3)2, -COF, -CO2H, -C(CF3)20H, -CO2CH3, -CN and -R'-NH-R'-R2, where R' and R2 are as set forth above;
(8) a phenyl or naphthyl radical, each independently optionally containing one or more substituents selected from the group consisting of -F, -Cl, -Br, -I, -SO2Fl -OCH3, -PO(OCH3)2, -COF, -CO2H, -C(CF3)20H, -CO2CH3, -CN, -R1-NH-R'-R2, where R' and R2 are as set forth above, and a C,-C6 linear or branched alkyl radical [independently optionally also containing one or more of the other substituents set forth in this group (8)]; or
(9) O-R3, S-R3 or CO2R3, where R3 is a C,-C,O linear or branched alkyl radical, interruptible with either oxygen or keto groups, each independently optionally containing one or more substituents selected from the group consisting of phenyl, -F, -Cl, -Br, -SO2F,-OCH3,-OC5-F5, PO(OCH3)2, -COF, -CO2H, -CO2CH3, -CN, -C(CF3)2OH, and-R'-NH-R1-R2, where R' and R2 are as set forth above.
However, it is not required that all of the substituents named above as being represented by R, R' or R2 be utilized, and any one or more of such substituents, or sub-components thereof, may be omitted as desired in the 0 practice of this invention.
One or more of the above described ethylenically unsaturated monomers may carry an ionic charge or a precursor group which can be converted to an ionically charged substituent.

In a preferred embodiment of the polymerizable monomers described by the formula set forth above, each R is independently (1 ) hydrogen; (2) a halogen such as fluorine, chlorine or bromine; (3) a C1-C10 (and more preferable C1-C~) linear or branched alkyl radical, interruptible withone or more oxygen atoms, each independently optionally containing one or 20 more substituents selected from the group consisting of -F, -Cl, -Br, -I, -SO2F, -COF, -OCH3; or (4) O-R' where R' is a C,-C,O linear or branched alkyl radical, each independently optionally containing one or more substituents selected from the group consisting of -F, -Cl, -Br, -I, -SO2F, -COF and -OCH3.
The most preferred monomers are tetrafluoroethylene, chlorotrifluoroethane, 25 vinylidene fluoride (CF2CH2) and an unsaturated perfluoro ether described by 2 l375 6 ~ 12 CF2==CF--o--(--R3--o--)t--R3, where each R3 is independently a substantially perfluorinated Cl-C8 alkyl or C6-Cl2 aryl radical, and t is an integer from 0 to 5 inclusive.

Specific examples of representative monomers which can be copolymerized with an unsaturated haloperfluoro or perfluoro ether as described above are a polyhaloolefin such as a monohaloperfluoroolefin, a vinylidene halide or dihalide, or the perfluoroolefin hexafluoropropylene; or a perhaloethylene such as a monohalotrifluoroethylene, bromotrifluoroethylene, chlorotrifluoroethylene or tetrafluoroethylene; or 2-perfluorovinyloxyethanesulfonyl halide.
In a copolymer of a diunsaturated haloperfluoro or perfluoro ether as described above with monomers such as those named above, the ether can constitute from 0.1 mole percent to 99 mole percent, preferably from 0.2 mole percent to 50 mole percent, more preferably from 0.3 mole percent to 25 mole percent, and most preferably from 0.5 mole percent to 15 mole percent of the copolymer, with the other ethylenically unsaturated monomers as described above constituting from 99.9 mole percent to 1 mole percent, preferably from 99.8 mole percent to 50 mole percent, more preferably from 99.7 mole percent to 75 mole percent, and most preferably from 99.5 mole percent to 85 mole percent of the copolymer.

In several exemplary runs, a 3,6-dioxa-5-halodifluoromethylperfluoronona-1,8-diene is polymerized with other ethylenically unsaturated monomers as follows:

W094/00502 2 1 3 7 5 6 4 PCT/US93/060~

Examplel. Tetrafluoroethylene was fed into an emulsified mixture of 3,6-dioxa-5-trifluoromethylperfluoronona-1,8-diene (2.4g), ammonium persulfate (0.16g), ammonium perfluorooctanoate (1.66g), sodium dihydrogen phosphate (1.03g) and disodium monohydrogen phosphate (1.25g) in deionized water (300 ml). The pressure and temperature of the reaction mixture were kept at lO0 psi (689 kPa) and 60C, respectively. After 15g of tetrafluoroethylene were introduced over 60 minutes, the reaction mixture was cooled to ambient temperature (23.5-26C) and discharged to atmospheric pressure. Diluted hydrochloric acid (50 ml) was added to coagulate the polymer particles, which were collected by filtration. Washing with deionized water and methanol and drying under vacuum gave 12g of colorless polymer particles. The infrared spectrum of the copolymer did not show the perfluorovinyl C=C double bond absorption at 1,840 cm-l, but does show the perfluoroallyl C=C double bond absorption at 1,800 cm-1, indicating that the perfluorovinyl group was incorporated in the main chain of the copolymer, while the perfluoroallyl group remained as a pendant, side chain.

~ xample2. 2-Chlorotetrafluoroethyl trifluorovinyl ether (47 g) and 3,6-dioxa-5-trifluoromethylperfluoronona-1,8-diene (5 g) were emulsified with an aqueous mixture (300 ml) of ammonium perfluorooctanoate (1.66 g), ammonium persulfate (0.32 g), sodium dihydrogen phosphate (1.03 g), and disodium monohydrogen phosphate (1.25 g). After degassing under vacuum, tetrafluoroethylene was fed into the reaction mixture, and the pressure and temperature of the mixture ~ 6 ~ _14_ were maintained at 100 psi (689 kPa) and 60C, respectively. After 40 g of tetrafluoroethylene were introduced over 2 hours, the reaction mixture was cooled to ambient temperature (23.5-26C) and was discharged to atmospheric pressure. Diluted hydrochloric acid was added to the reaction mixture to coagulate the copolymer particles, which were collected by filtration. Washing with deionized water and drying under vacuum gave 55 g of colorless copolymer particles. The infrared spectrum of the terpolymer exhibited the perfluoroallyl C=C
stretching band at 1,795 cm-l. The differential scanning calorimetry of the terpolymer showed neither exothermic nor endothermic activity from ambient temperature to 350C, indicating that the terpolymer was amorphous.

~ r~ple3. 2-Fluorosulfonyltetrafluoroethyl trifluorovinyl ether (22g) and 3,6-dioxa-5-trifluoromethylperfluoronona-1,8-diene (2.3g) were emulsified with a mixture of sodium dihydrogenphosphate (1.03g), sodium monohydrogenphosphate (1.25g), ammonium persulfate (0.32g) and a FC-143 surfactant, ammonium perfluorooctanoate (1.66g), in deionized water (300 ml).
The mixture was stirred at 55C, and tetrafluoroethylene was charged thereto at a pressure of 100 psi (689 kPa).
The reaction mixture was kept at this pressure until l9g of tetrafluoroethylene was absorbed over 81 minutes.
The reaction mixture was released to atmospheric pressure. Diluted hydrochloric acid (50 ml) was added to the reaction mixture to coagulate white fine powder, which was collected by centrifugation and was dried.
Yield of the polymer was 35g. Titration of the terpolymer gives the sulfonyl fluoride equivalent weight of 636 g/eq. The infrared spectra of the terpolymer W094/00502 2I37~6g PCI/USg3/06034 exhibited the C=C stretching at 1,793 cm-1, the S02F
stretching at 1,467 cm-1 and the CF2-0 at 1,107 cm-1 before curing, while the C=C stretching absorption disappeared on curing.

In several exemplary runs, the copolymer prepared in Example 2 was cured as follows:
Example4. A mixture of the terpolymer prepared in Example 2 (6 g), 1,6-diiodoperfluorohexane (0.5391 g), 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane (0.3361 g), and calcium hydroxide (0.31 g) was slurried in 1,1,2-trichloro-1,2,2-trifluoroethane (150 ml). The mixture was evacuated using a rotary~evaporator to strip the solvent. The dry powder obtained was placed in a mold (1.25 x 2.5 cm2) and pressed at 175F (79.4C). The preform obtained therefrom was preheated at 350F
(176.7C) for 2 minutes and was procured at the same temperature by pressing at a pressure of 5 tons (4,536 kg) for 15 minutes. The procured preform was post-cured at 450F (232.2C) for 2 hours. Dynamic mechanical properties of the cured polymer were measured with a Rheometrics Mechanical Spectrometer Model 605 in the torsional rectangular mode from -175C to 330C. The storage modulus, G', of the terpolymer showed a rubbery plateau extending from a glass transition temperature at 15C to 340C, which indicates crosslinking. The cured copolymer was transparent and possessed a rubbery resilience.
Example5. The terpolymer prepared in Example 2 (6 g) and 2,5-dimethyl-2,5-di(tert-butylperoxy)hexane (0.3356 g) were added to 1,1,2-trichloro-1,2,2-trifluoroethane (150 ml). The mixture was evacuated using a rotary evaporator to give a colorless fine WO 94/00502 PCr/US93/06034 31~64 -16-powder. The polymer mixture was added to a mold (1.25 x2.5 cm2) and was pressed at 175F (79.4C). The preform obtained thereby was preheated at 3~0F (176.7C) for 2 minutes and was procured at 350F (176.7C) by pressing at a pressure of 5 tons (4,536 kg) for 15 minutes. The procured preform was post-cured at 450F (232.2C) for 2 hours under nitrogen. The mechanical properties of the cured polymer were measured with a Rheometrics Mechanical Spectrometer Model 605 and showed a rubbery
10 plateau above a glass transition temperature at 15C to 300C in the storage modulus, which indicated crosslinking. The cured polymer was transparent and possesses a rubbery resilience.

Example6. The terpolymer prepared in Example 2 (6 g) was ground in a ball mill and was placed in a mold (1.25 x 2.5 cm2). The mold was covered with a metal plate. A preform was prepared by curing at 270C for 20 hours under nitrogen. The mechanical properties were 20 measured with a Rheometrics Mechanical Spectrometer Model 605. The storage modulus showd a rubbery plateau extending from a glass transition temperature at 15C to 350C, which indicated crosslinking. The cured polymer 25 was transparent and possesses a rubbery resilience. The cured polymer showd no perfluoroallyl C=C absorption in the infrared spectrum.

In another exemplary run, the copolymer of 30 Example 3 was cured as follows:

Example 7. The copolymer of Example 3 was cured and subjected to a hydration test as follows: Polymer powder was added to a circular disk (diameter of about 24 mm and thickness of about 2.4 mm) and was pressed at W094/00502 PCT/US93/060~
--1 ~! 1 3 7 5 6~

0.5 ton (453.6 kg) and 210C. The preform disk was cured under nitrogen at 270C for 20 hours. Each disk before or after curing was dried under vacuum at 100C
for 24 hours, and was immersed in 25 percent NaOH with stirring at 60C for 3 days. The disk was washed with deionized water, kept in boiled deionized water for 2 hours, and dried under vacuum at 80C for 2~ hours. A
change of weight and volume was measured before and after alkali hydration for the uncured and cured disks.
The results of such testing were shown in Table I as follows:
Table I

Uncured Disk Cured Disk Weight before 2.3693 2.2960 hydration, grams Weight after 4.1078 3.7020 hydration, gr~ms Percent change + 73.4 + 65.5 Volume before 1.065 1.099 hydration, cm3 25Volume after 2.812 2.255 hydration, cm3 Percent change + 164 + 105 3 The results of these examples and tests show the value of having two sites of unsaturation, such as both a vinyl and ally group, in ethylenically diunsaturated ethers which are used to prepare the polymers of this invention. When there is sufficient separation between the two double bonds in the molecule, ~ 6 4 -18-such as the allyl and vinyl groups in a 3,6-dioxa-5-halodifluoromethyl-7-haloperfluoronona-1,8-diene or a corresponding multiple ether, their differing reactivity allows one unsaturated group-to``join in formation of the polymer while the other remains pendant in a side chain.
The unsaturated side chain is thereafter free to participate in a dimerization reaction with such side chains on other polymer molecules, thereby crosslinking the polymer molecules. The benefits of crosslinking may be observed in Example 8 where the disk which has been cured, and thereby crosslinked, gains almost as much weight by water adsorption as the uncured disk. but does not gain nearly as much volume, which indicates that the cured polymer molecules are more resistant to chage of shape because of the strength of the crosslinking bonds holding them together.

The polymers of this invention, when first manufactured, are not crosslinked, or are substantially uncrosslinked, which means they are still processible as a thermoplastic, and may have, for example, a glass transition temperature less than 25C. As is shown in Example 8, however, there are often product enhancements, or other reasons, which make it desirable to crosslink the polymers of this invention.
Crosslinking may be defined as the attachment of two chains of different polymer molecules by bridges composed of either an element, a group or a compound which join carbon atoms of the chains by primary chemical bonds. Crosslinking can be effected by thermal cure (forexample heating at a temperature of 250-350C
for a period of 1 minute to 20 hours, and preferably a temperature of 270-330C for a period of 5 minutes to 20 hours), exposure to high energy radiation, or a combination thereof with the activity of a crosslinking co-agent such as an organic peroxide, an azo compound, a diiodo compound, a diphenate salt, or, in general, a free radical generator. When a co-agent is used, crosslinking typically occurs at lower temperature, for example 150-200C. Crosslinking in a polymer may be shown by the presence of a rubbery plateau in the dynamic mechanical spectrum of the polymer.

Crosslinking typically results in polymer molecules which have increased strength and heat and solvent resistance, and creates what is known as a thermoset. It will therefore be seen that the polymers of this invention are characterized by an advantageous versatility which allows them to be fabricated as a thermoplastic at a temperature, for example, of less than 22~C, after which, because of the presence of pendant, unreacted double bonds, they can be cured to a thermost by crosslinking at a temperature, for example, 2~ of 250-350C. In one preferred embodiment, for instance, one or more diunsaturated ethers, as described above, is copolymerized with one or more other ethylencially unsaturated monomers (as described above) carrying an ionic charge or a precursor group which can be converted to an ionically charged substituent, for example by hydrolysis with an aqueous alkaline solution.
The copolymer thus prepared is fabricated into a membrane which, after being cured to crosslink the polymers, is well suited for use in an electrolytic cell, chlor-alkali cell or fuel cell. Such a membrane may further be hydrolyzed with an aqueous alkaline solution.

W O 94/00502 PC~r/US93/06034 ~31~36 ~ -20-A diunsaturated vinyl allyl ether may also be polymerized with other ethylenically un-c~turated monomers as follows: Tetrafluoroethylene is fed into a mixture of perfluoroallylvinyl ether (17.6g) and 2-perfluorovinyloxyethanesulfonyl fluoride (32.4g) emulsified in water (300 ml), which mixture contains ammonium perfluorooctanoate (1.66g), sodium dihydrogen phosphate (1.03g), disodium monohydrogen phosphate (1.25g), and ammonium persulfate (0.25g) under nitrogen.
10 The pressure and temperature-of the reaction mixture are kept at 175 psi (1205.75 kPa) and 60C, respectively.
After 64g of tetrafluoroethylene are introduced. the reaction mixture is cooled to ambient temperature (23-26.5C) and is discharged to atmospheric pressure.
15 Diluted hydrochloric acid (50 ml) is added to coagulate the copolymer particles, which are collected by filtration. Washing with deionized water and drying under vacuum gives colorless copolymer particles. The copolymer is titrated with caustic to give an equivalent 20 weight of 1,137. The copolymer is readily pressed at 280C to give a colorless clear film.

It is within the skill in the art to practice 25 this invention in numerous modifications and variations in light of the above teachings It is, therefore, to be understood that changes may be made in the various described embodiments of this invention without departing from the spirit and scope of this invention as 30 defined by the appended claims.

Claims (23)

1. A linear copolymer having pendent unsaturated groups, said copolymer comprising (a) one or more ethers described by the formula CF2= =CF--CF2--Q--O--CF = = CF2, where Q is --Ga--(--O--C2J4--)b--(--O--Z--)c--, in which G is a substantially fluorinated C3-C7 alkyl radical; a is 0 or 1; each J is independently fluorine, chlorine, bromine, or a C1-C4 substantially fluorinated alkyl radical on which not more than one substituent is chlorine, provided that not more than two J's are non-fluorine halogen atoms; b is 0-6 inclusive; Z is a substantially fluorinated C2-C10 alkyl radical; and c is 0 or 1;
provided that sum of a + b + c is greater than 0; and (b) one or more other ethylenically unsaturated monomers.
2. The copolymer of Claim 1 wherein b and c in component (a) are both 1.
3. The copolymer of Claim 1 wherein one or more of said ethylenically unsaturated monomers in component (b) is described by the formula F-C(R)= =C-R2, where each R is independently (1) hydrogen;
(2) halogen;
(3) -OCH3;
(4) -OC6F5;
(5) -C(CF3)2OH;
(6) -R1-NH-R1-R2, where each R1 is independently SO2, CO

or PO2, and R2 is a substantially fluorinated C1-C10 alkyl radical, optionally carrying at one or more sites an ionic charge or a precursor group which can be converted to an ionically charged substituent;
(7) a C1-C10 linear or branched alkyl radical, interruptible with one or more oxygen atoms, each independently optionally containing one or more substituents selected from the group consisting of phenyl, -F, -Cl, -Br, -l, -SO2F, -OCH3, -PO(OCH3)2, -COF, -CO2H, -C(CF3)2OH, -CO2CH3, -CN and -R1-NH-R1-R2, where R1 and R2 are as set forth above;
(8) a phenyl or naphthyl radical, each independently optionally containing one or more substituents selected from the group consisting of -F, -Cl, -Br, -l, -SO2F, -OCH3, -PO(OCH3)2, -COF, -CO2H, -C(CF3)2OH, -CO2CH3, -CN and -R1-NH-R1-R2, where R1 and R2 are as set forth above, and a C1-C6 linear or branched alkyl radical [indepedently optionally also containing one or more of the other substituents set forth in this group (8)]; or (9) O-R3, S-R3 or CO2R3, where R3 is a C1-C10 linear or branched alkyl radical, interruptible with either oxygen or keto groups, each independently optionally containing one or more substituents selected from the group consisting of phenyl, -F, -Cl, -Br, -SO2F,-OCH3,-OC6-F5, PO(OCH3)2, -COF, -CO2H, -CO2CH3, -CN, -C(CF3)2OH, and -R1-NH-R1-R2, where R1 and R2 are as set forth above.
4. The copolymer of Claim 1 wherein one of said ethylenically unsaturated monomers in component (b) is tetrafluoroethylene.
5. The copolymer of Claim 1 of which about 0.1 to about 99 mole percent is comprised of said ether or said ethers in component (a).
6. The copolymer of Claim 1 which is thermoplastic.
7. The copolymer of Claim 6 which has been thermally crosslinked after fabrication into an article.
8. The copolymer of Claim 7 which has been thermally crosslinked at 250-350°C.
9. The copolymer of Claim 3 wherein at least one of said ethylenically unsaturated monomers in component (b) carries an ionic charge or a precursor group which can be converted to an ionically charged substituent.
10. The copolymer of Claim 9 wherein another of said ethylenically unsaturated monomers in component (b) is tetrafluoroethylene.
11. The copolymer of Claim 9 or 10 which has been thermally crosslinked after fabrication into an membrane.
12. The copolymer of Claim 11 which has been thermally crosslinked at 250-350°C.
13. The copolymer of Claim 9 or 10 in which the precursor group is converted to an ionic group.
14. An electrolytic cell, chlor-alkali cell or fuel cell comprising the copolymer of Claim 11.
15. The copolymer of Claim 9 or 10 which has been hydrolyzed with an aqueous alkaline solution.
16. The copolymer of Claim 11 which has been hydrolyzed with an aqueous alkaline solution after crosslinking.
17. A linear homopolymer or copolymer having pendent unsaturated groups, said copolymer comprising one or more of the ethers described by the formula CF2= =CF--CF2--Q--O--CF= =CF2, where Q is --Ga--(--O--C2J4--)b--(--O--Z--)c--, in which G is a substantially fluorinated C3-C7 alkyl radical; a is 0 or 1; each J is independently fluorine, chlorine, bromine,or a C1-C4 substantially fluorinated alkyl radical on which not more than one substituent is chlorine, provided that not more than two J's are non-fluorine halogen atoms; b is 0-6 inclusive; Z is a substantially fluorinated C2-C10 alkylradical; and c is 0 or 1; provided that sum of a + b + c is greater than 0.
18. The polymer of Claim 17 wherein b and c are both 1.
19. The polymer of Claim 17 which is thermoplastic.
20. The polymer of Claim 17 wherein at least one of said ethers is an ether of the formula F F F F F F F

F C C C O C C O C C F

n where T is a fluorine, chlroine, bromine or iodine atom, and n is an integer from 1 to 6 inclusive.
21. The polymer of Claim 17 which has been crosslinked.
22. The polymer of Claim 19 which has been thermally crosslinked after fabrication into an article.
23. The polymer of Claim 22 which has been thermally crosslinked at 250-350°C.
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