Polyarylsulfones,synthesis and properties,

A new class of high molecular weight polyarylsulfones is described. Polymer synthesis and structure–property relationships are discussed. The polymers are prepared by Friedel-Crafts type polycondensation of aromatic sulfonyl chlorides with aromatic hydrocarbons. A number of Lewis acids in small quantities are useful as catalysts for the polymerization. The polymerization reaction is carried out at elevated temperatures in the melt or in solution. Inert, nonbasic solvents which are compatible with the Lewis acid catalysts such as nitrobenzene and dimethyl sulfone are useful for conducting the polymerization. Many of the polyarylsulfones are amorphous, rigid thermoplastics with unusually high softening points, having glass transition temperatures in the range of 200–350°C. Outstanding resistance to air oxidation at high temperatures is derived from incorporation of the deactivating sulfone groups in the aromatic polymer backbone. Melt stability and solubility in selected solvents are emphasized as basis for processibility by conventional solution casting and molding techniques. The combination of properties, which in addition to thermal stability includes a high level of mechanical and electrical properties, chemical inertness, and hydrolysis resistance makes these new arylsulfone polymers useful over a wide temperature range and in severe and corrosive environments.