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Kevlar-like Aramid Polymers from Mixed PET Waste

This work describes the synthetic approaches, spectroscopic and thermal characterization of aramid polymers prepared from waste polyethylene terephthalate (PET) via sustainable and scalable processes. Direct depolymerization of PET with aliphatic diamines under melt conditions resulted in decomposition without substantial formation of any aramid polymer. The Higashi–Ogata methodology or direct polycondensation of terephthalic acid (TPA) derived from PET waste and p-phenylenediamine, resulted in oligomerization and formation of aramids with a low degree of polymerization. The highest molecular weight polymers were obtained via the acid chloride of TPA, the traditional method. A proprietary solvent enabled the dissolution of most polymers and subsequent size exclusion chromatography analysis in the same solvent. We emphasize that although the soluble polymer compounds are prepared via the traditional route, they are novel. The apparent molecular weights of the soluble polymers ranged between 10–35 kDa (Mn) and 28–81 kDa (Mw). All analogues were prepared with commercially available diamines and diamine combinations. The obtained solid powders were dissolved in D2SO4 and analyzed spectroscopically to qualitatively evaluate the degrees of polymerization, while the solids were characterized via thermogravimetric analysis and differential scanning calorimetry. Many reaction conditions were employed to improve the solution polycondensation reaction, and it was found that addition of pyridine (2 eq) to the NMP reaction medium was crucial in preventing the precipitation of the polymer. Contrary to conventional wisdom, CaCl2 did not play a crucial role in the molecular weight increase of the polymer when oxydianiline was used. Our data indicated that the temperature and absence of CaCl2 provided a boost in molecular weight. Both room temperature and 0 °C reactions generated similar polymers as suggested by nuclear magnetic resonance; however, the cold conditions enhanced gel formation, an important attribute in the future processing of these materials to obtain fibers. All analogues had a high degradation temperature at 5 and 10% weight loss (5% and T10%), above 400 °C, along with high percent char values. A glass transition (Tg) was not detected in any of the analogues prepared.