CONSOLIDATION AND MOLDING OF POLYBENZAZOLE-CONTAINING MATERIALS

2129522 9315900 PCTABS00024 A process for consolidating/molding a material made of (a) block copolymers of rigid or semi-rigid PBZ with thermoplastic polymers, (b) block copolymers of rigid PBZ with semi-rigid PBZ, (c) molecular composites of rigid or semi-rigid PBZ with thermoplastic polymers, (d) molecular composites of rigid or semi-rigid PBZ with non-rigid PBZ polymers or (d) semi-rigid PBZ polymers which process comprises (1) providing the material in its substantially acid-free, wet coagulated state, and in the form of a plurality of films or film layers, filaments or fibers, powders, or granules, (2) removing substantially all surface water remaining on the material, leaving the material with sufficient water to plasticize the material, (3) subjecting the material to a first pressure (P1) which is sufficient to provide a substantially void-free consolidated material upon molding, and (4) applying heat and a second pressure (P2) to the wet coagulated material in amounts sufficient to fuse the films or film layers, filaments or fibers, powders, or granules into a single entity. The molded material is suitable for use as a structural material or as an electronic substrate or for any other use in which a thermoplastic polymer corresponding to the thermoplastic portion of the block copolymer or molecular composite would have been suitable.