3.1. Binary Copolyesters
Unsubstituted and substituted derivatives of hydroxybenzoic acids are widely used for syntheses of TMCPs [
1,
8], however 4-hydroxybenzoic acid itself is not quite suitable as monomer because of the decarboxylation by-process at about 200 °C [
16]. So usually, acetoxybenzoic acids prepared by acetylation of hydroxybenzoic acids are used as the monomers. The general route for binary and ternary copolymer syntheses from acetoxy acids is presented in
Figure 1.
There are three possible ways to synthesize polyesters: solution polycondensation (SP), melt polycondensation (MP), and solid-state polycondensation (SSP). High melting point polyesters, including non-meltable, can be synthesized by SP and SSP procedures. Copolyesters which melting or softening points lower than decomposition point can be synthesized by MP method. Thus, binary copolyesters of VA and HBCA (B1/2, B1/1, and B2/1) were synthesized by solution polycondensation from AVA and ABCA at 300 °C (
Table 1). Thermolan H was used as high temperature solvent representing a mixture of aromatic hydrocarbons with b.p. > 330 °C.
Characterization of the binary copolymers was carried out by FTIR method (
Figure 2) because of its insolubility in common solvent. Very strong band C=O vibration (
νC=O) of ester groups appeared at 1729 cm
-1 for B1/2, shifted to 1731 cm
-1 for B1/1, and to 1732 cm
-1 for B2/1. This shift is entirely consistent with the fact that C=O vibration of ester groups appeared at 1727 cm
-1 for HBCA homopolymer and 1735 cm
-1 for polyvanillate [
32,
38]. Benzene ring stretching vibrations (
νC=С) appeared at about 1600 cm
-1 and 1500 cm
-1. Stretching vibration of C-O (
νC-O) bond in VA units appeared at 1283 cm
-1 and 1028 cm
-1 and their intensity increases with increasing VA/HBCA ratio in the copolymers. Absorption peaks at 763 cm
-1, 749 cm
-1, 713 cm
-1, and 694 cm
-1 are related to in-plane bending vibrations of para- and 1,2,4-substituted phenyl rings.
Thermal properties of binary copolyesters were analyzed by DSC-TGA method. The glass transition points are slightly lowered from 135.5 °C to 132.5 °C with increase of VA content in copolyester (
Figure 3). The
Tg points are higher than that of copolyester Vectra A950 with
Tg = 93 °C composed from 2-hydroxy-6-naphtoic and
p-hydroxybenzoic linear units [
39]. These was explained by effect of bulky substituent –OCH
3 in VA units decreasing chain mobility, that was observed for other TMCPs [
40]. DSC was not shows melting of B1/2-B2/1, i.e., these polymers have very low crystallinity degree.
TGA thermograms (
Figure 4a) demonstrate the decomposition onset temperature (
Ton) and the temperature of 5% weight loss (
T5%) were lowered with increase of VA content in the copolyesters. DTG curves (
Figure 4b) of the binary copolyesters shows two-stage decomposition process with two minimums: the first one is observed at temperature below 500 °C and the second one—higher than 500 °C. The first minimum belongs to VA units’ decomposition and the second one to HBCA decomposition. Thus, increasing molar fraction of VA units results in decreasing thermal stability of copolyesters. Additionally, this is reflected on the amount of mass remaining after decomposition at heating to 1000°C: 30.1% for B1/2 and 23.9% for B2/1. Although B2/1 can be molded with short-time exposition at 350 °C, TGA data indicates that such high temperature for B2/1 rather is not applicable since material darkening is observed.
Copolyesters B1/2 and B1/1 are not processable because of high viscosity while B2/1 was molded at 350 °C in order to visualize the formation of the liquid crystalline phase. Polarized optical microscopy (POM) of B2/1 demonstrated mesophase formation (
Figure 5), but due to the high melt viscosity, it was difficult to obtain a sufficiently thin layer of the microslide.
In general, it can be said that the binary copolyesters of VA and HBCA do not have acceptable characteristics: these polymers have a softening point that is too high, close to the beginning of the decomposition of vanillic acid units. At the same time, despite the ability of polyesters to form a mesophase at a high VA content, such melts are unacceptably viscous for effective processing.
To reduce the softening point, we synthesized ternary copolyesters containing HBA units in addition to VA and HBCA.
3.2. Ternary Copolyesters
Wilsens and coworkers applied thin film polycondensation with small amount of monomers to study composition of potential melt processable copolyester [
35,
41]. In present study as well as in our previous work [
42] we applied small-scale (about 1 g of monomers) polycondensation in the flask in inert atmosphere in 240-320 °C range. These allowed more thoroughly visually control the polycondensation process and the viscosity evolution. When the viscosity was increased, the polycondensation was stopped and product was evacuated from the flask. Much attention was paid to composition with reduced molar content of ABCA. The results are presented in
Table 2. Additionally, the ternary copolyester T68/21/11 was prepared from AVA, ABCA and 3-acetoxybenzoic acid (3ABA) which is similar to previously described ternary copolyester with composition: HBA (70%), HBCA (20 %) and 3HBA (10%) which was melted at 315 °C [
36]. The copolyester T1/1/1, T2/2/1, T37/37/26 were soften at about 300 °C. The preparation of T68/21/21 was failed because after 15 minutes of polycondensation of the monomers at 280°C, the reaction mass solidified and raising the temperature to 320°C had no effect. This was unexpected since the copolyester HBA (70%), HBCA (20%) and 3HBA (10%) was melt processable. Typically, the introduction of side substituents reduces the melting or softening point of the resulting copolyester. Although VA unit structurally is HBA unit with a bulky substituent, the HBA and VA units play different roles in thermal properties.
The ternary copolymers VA-HBA-HBCA are also non-crystalline. At the same time, they have noticeably lower glass transition temperatures (about 117 °C) even compared to binary copolyesters VA-HBCA (about 135 °C), and especially compared to copolyesters 3HBA-3HBCA (4′-hydroxybiphenyl-3-carboxylic), for which
Tg can reach 190 °C [
42]. As has been repeatedly shown, including in our early works [
17,
36], in polyesters based on aromatic hydroxy acids, a comonomer with biphenyl units, in this case HBCA, makes a large contribution to heat resistance. The ratio of biphenyl and monophenyl comonomer units in binary copolymers VA-HBCA is higher than in ternary copolymers VA-HBA-HBCA, which leads to a decrease
Tg values.
As in the case of binary copolyesters, terpolymers also show a stepwise thermal decomposition pattern (
Figure 6) with two weight loss maxima: around 410-430 °C and 520-530 °C. In addition, ternary copolyesters have noticeably lower temperatures for the onset of weight loss (300-330 °C) and 5% weight loss (390-410 °C). This is probably due to a decrease in the HBCA/VA ratio, since in the series T2/2/1, T37/37/26, T1/1/1, an increase in thermal stability can be noted with an increase in the content of biphenyl HBCA units. However, the weight residue after decomposition is higher for ternary copolyesters, that can be explained by presence of a large portion of HBA units, which themselves have high thermal stability.
Next, a series of high-molecular-weight ternary copolyesters were obtained using the melt polycondensation at 240-320 °C. A traditional method was applied, using a 100 ml three-neck round bottom flask equipped with an overhead glass stirrer, argon inlet and vacuum outlet on a scale of 15-25 g. The temperature was gradually increased from 240°C to 320°C. The final stage was carried out at a temperature of 320 °C in vacuum. The polycondensation was stopped when the desired viscosity was reached. The products prepared are listed in
Table 3. Polymers TM1/1/1 and TM1/2/1 are not dissolved in pentafluorophenol at 80 °C, only swelling was observed.
During the melt polycondensation darkening of the reaction mixture was observed at temperatures above 280 °C. To avoid the destructive processes, a combined method was used. The first stage was carried out in the melt at a temperature of 240-280 °C in argon atmosphere. Then the prepolymers were crushed and polymerized in the solid state at 250-260 °C in vacuum or argon atmosphere for 8-16 hours (
Table 4). Despite the decrease in polycondensation temperature, colored products were still obtained. Copolyester TS1/3/1 with a lower VA content was less colored compared to the others. Thus, the color change was caused by the presence of VA units in the copolyesters. All copolyesters listed in
Table 3 and
Table 4 were relatively ductile and their logarithmic viscosities values were high. Some of the copolyesters were insoluble in pentafluorophenol due to their high molecular weight. In this regard, IR spectroscopy was also used to confirm the structure of copolyesters.
The FTIR spectra of the ternary copolyesters are presented in
Figure 7 and contain all the characteristic absorption bands as the spectra of the binary copolymers. The C=O vibration band (
νC=O) of the ester groups is shifted to 1728 cm
-1. Stretching vibrations of the C-O bond (
νC-O) in VA units appeared at 1283 cm
-1 and 1028 cm
-1 in the form of a shoulder due to the decrease in the number of VA units. Benzene ring stretching vibrations (
νC=С) and the bending vibrations are presented in the same region as in binary copolyesters: 1600, 1500, 763, 749, 713 and 694 cm
-1.
X-ray diffraction patterns were obtained for a number of ternary polyesters with different comonomer ratios in the 2
θ range from 5 to 60° (
Figure 8). All ternary copolyesters do not show sharp reflections of crystalline phases, but only a broad halo with a maximum of about 20°, which indicates their low degree of crystallinity. All three comonomers (VA, HBA, HBCA) are structurally similar and have similar XRD patterns. The peak at 20° is characteristic of both structural fragments of HBCA [
17,
43] and HBA [
44]. At the same time, a sharper peak is usually observed for biphenyl fragments of HBCA, and a broadened one for HBA. Thus with an increase in the HBCA/HBA ratio from TS1/3/1 to TS37/37/26, a narrowing of the reflex at 20° can be noted. According to [
32], for structural fragments of vanillic acid peaks are observed in the region of 15-20° and at 25°, but when the ratio of VA with other comonomers is equalized, all peaks disappear. This explains the absence of additional peaks in the XRD patterns for terpolymers, especially considering the low content of VA compared to other comonomers.
Terpolymers obtained by melt polycondensation and using a solid-state process demonstrates similar thermal characteristics. They have a relatively low glass transition temperature in the region of 110-120 °C (
Table 3 and
Table 4) and a stepwise behavior of thermal decomposition (
Figure 9 and
Figure 10). For all samples, the typical temperature for the onset of mass loss lies in the range of 330-350 °C, the temperature of 5% mass loss is in the range of 390-410 °C, the weight residue at 1000 °C is about 40%.
The ternary copolyesters with the same composition, but obtained by different methods (in solution, in the melt, in solid phase) evidently possessing different molecular weights, no significant differences in thermal characteristics were showed.
Table 5 shows the results for different VA/HBA/HBCA copolyester samples with a ratio of 1/1/1, so no significant difference was found in the thermal stability of copolyesters subjected to solid-state polycondensation for different times (8 and 16 hours). This fact is not unexpected: for example, in papers [
45,
46] is shown, that for similar copolyesters in a wide range of molecular weights, the thermal characteristics differ insignificantly.
In general, the introduction of VA into macromolecule backbone drastically reduces their thermal stability. TGA showed that the decomposition started at 330 °C, so visual observations at 280 °C. Therefore, VA copolymers preferably should additionally contain aliphatic comonomers to reduce the processing temperature less than 280 °C.
The existence of a liquid crystalline phase of ternary copolyesters VA/HBA/HBCA with various comonomer compositions - 1/1/1, 1/2/1, 1/3/1 (
Figure 11) was confirmed by polarization optical microscopy (POM). Generally, TMCPs exhibit a schlieren texture typical for nematic melts. Similar results were obtained for copolyesters based on hydroxy acids, aromatic diols / diacids of various structures [
17,
41,
47,
48].
The ternary copolyesters do not demonstrated isotropization up to 375 °C, which is apparatus limit and higher than decomposition temperature. After cooling liquid crystalline (LC) melts saved the texture, thus the formation of LC glasses was observed. As an example,
Figure 12 shows micrographs obtained by heating copolyester T1/1/1 from a temperature below the glass transition to the temperature of mesophase formation throughout the entire volume of the melt. It can be noted that when the glass transition temperature is exceeded and as the viscosity of the melt decreases, the formation, growth and coalescence of LC phase droplets occur.
The mechanical characteristics of ternary polyesters (tensile strength, relative elongation at break, elasticity modulus) were measured by tensile testing of film samples. The copolyesters thin film (thickness 100 μm) were molded by hot pressing at 300 °C.
Tests were carried out for polyesters: TM1/1/1, TM1/2/1, TS37/37/26 and TS1/3/1. Unfortunately, it was not possible to achieve high strength characteristics for these copolymers. Average values of mechanical characteristics are as follows: tensile strength is 39 MPa, elastic modulus is 125 MPa and relative elongation at break of 4%. These characteristics are close to those for semi-aromatic copolyesters of polyethylene terephthalate and HBCA [
17], but are much lower than typical values for fully aromatic thermotropic polymers. We assume that this problem is associated with a fairly high softening temperature of the copolyesters, which lies close to the region of thermal degradation. In this regard, VA should be used for copolyesters with moderate thermal stability and additional comonomers reducing processing point should be included into macromolecular backbone of the copolyesters.
Wilsens and coworkers used VA as comonomers for TMCPs in amount of 10 and 16 molar %. [
13,
23,
49,
50]. On the other hand, ternary copolyester of HBA/HNA/VA with 5 % molar content of VA demonstrated lowered melting point, increased glass transition temperature, good thermal stability, and excellent spinnability [
51]. In combination with the results obtained in our research, it can be stated that vanillic acid can be used as additive comonomer for TMCPs synthesis with content not exceeding 10-20 mol. % and do not considered as the major comonomer. The higher amount of VA in TMCPs results in decreased thermal stability and increased of melt viscosity due to the presence of bulky –OCH
3 hindering chain mobility.