CA1124947A - Process for the manufacture of brominated products of polystyrene - Google Patents

Process for the manufacture of brominated products of polystyrene

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Publication number
CA1124947A
CA1124947A CA351,279A CA351279A CA1124947A CA 1124947 A CA1124947 A CA 1124947A CA 351279 A CA351279 A CA 351279A CA 1124947 A CA1124947 A CA 1124947A
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Prior art keywords
polystyrene
iron
bromine
process according
catalyst
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Expired
Application number
CA351,279A
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French (fr)
Inventor
Thomas Kainmuller
Lothar Buxbaum
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Novartis AG
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Ciba Geigy AG
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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
    • C08F8/00Chemical modification by after-treatment
    • C08F8/18Introducing halogen atoms or halogen-containing groups
    • C08F8/20Halogenation
    • C08F8/22Halogenation by reaction with free halogens

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • General Chemical & Material Sciences (AREA)
  • Addition Polymer Or Copolymer, Post-Treatments, Or Chemical Modifications (AREA)
  • Treatments Of Macromolecular Shaped Articles (AREA)
  • Processes Of Treating Macromolecular Substances (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Polyoxymethylene Polymers And Polymers With Carbon-To-Carbon Bonds (AREA)
  • Macromolecular Compounds Obtained By Forming Nitrogen-Containing Linkages In General (AREA)

Abstract

Case 3-12341/CGM 229/1+2 Process for the manufacture of brominated products of polystyrene Abstract of the Disclosure The direct bromination at low temperature, in a partially halogenated hydrocarbon as solvent and in the presence of a divalent and/or trivalent iron salt or iron oxide as catalyst, of polystyrene which has been obtained by radically initiated polymerisation, results in thermally stable, soluble and uncrosslinked polystyrene products with a high bromine content and at most an insignificant natural colour. These brominated polystyrenes are useful in particular as flame retardants for plastics.

Description

11249~7 Case 3-12341/CGM 229/1+2 Process for the manufacture of brominated products of polystyrene The present invention relates to a process for the manufacture, by direct bromination, of brominated products of polystyrene obtained by radically initiated polymerisation, said products having a high bromine content.

The halogenation of polystyrenes is desirable whenever it is intended that the final products should have flame-resistant properties. A relatively low bromine content usually suffices for this purpose. However, if it is desired to incorporate halogenated polystyrene as flame retardant in other plastics, a high bromine content is advantageous in order that only small amounts of flame retardant may be used. For this utility, the halogenated polystyrene should have at most an insignificant natural colour and sufficient thermal stability.

The direct bromination at low temperature,and using relatively short reaction times,of polystyrenes obtain~d by radically initiated polymerisation to produce products having the desired properties, has proved to be an insoluble problem. It is, however, most desirable, as the use of these commercially available polystyrenes would be more economic. The known difficulties which occur in the direct bromination of these polystyrenes in halogen-containing solvents at low temperature and in the presence of a Lewis acid catalyst, are described e.g. in German Auslegeschrift 2 537 385 and German Offenlegungsschrift , 9~

llZ49~7
2 651 435: premature precipitation by gel formation, low bromine content of the products, pronounced natural colour, and thermal instability. These disadvantages are overcome in the prior art by reacting selectively hydrogenated oligomers of styrene,or polystyrene freshly prepared by cationic polymerisation, with bromine.

It is known from Chemical Abstracts77,75 880 k (1972) and 85,6331 k (1976) to carry out the direct bromination of polystyrene in CC14 at elevated temperature in the presence of iron as catalyst. Although a premature gel formation is prevented in this physiologically hazardous solvent, a noticeable and undesirable reduction in the molecular weight of the brominated polystyrene is observed.
It has also been found that, at low temperature, only an insufficient bromine content is obtained.

Accordingly, it is the object of the present invention to provide a process for the direct bromination of commercially available polystyrene, i.e. polystyrene obtained by radically initiated polymerisation, which process overcomes the disadvantages referred to and yields thermally stable brominated products having at most an insignificant natural colour, a high bromine content, and good solubility in the reaction medium.

The present invention therefore relates to a process for the manufacture of brominated products of polystyrene which contain at least 50% by weight of bromine, by direct bromination of polystyrene obtained by radically initiated polymerisation, in solution and in the presence of a Lewis acid catalyst at low temperature, which process comprises carrying out the bromination in a partially halogenated 112494~

hydrocarbon as solvent, in the presence of a divalent and/or trivalent iron salt as catalyst, in the temperature range from -30 to +30C.

It is preferred to use bromine or bromine chloride as brominating agent in the direct bromination. The bromine chloride can be obtained in known manner, e.g. by continuously adding bromine and passing a flow of chlorine gas through the reaction solution. This procedure may also result in the formation to an insignificant degree of chlorinated final products.

The process of the invention affords the particular advantage that it is possible to use essentially polystyrene which is ready prepared and commercially available. The brominated polystyrenes obtained in the process of this invention have a bromine content of preferably at least 55% by weight, most preferably of at least 60% by weight.
The degree of polymerisation of the polystyrene employed is preferably at least 100 and is especially between 500 and 2500, most preferably between 1000 and 2500. Partially halogenated hydrocarbons are used as solvents. These can have aromatic and especially aliphatic or cycloaliphatic character and additionally contain at least one hydrogen atom in the molecule. Preferred halogens are bromine, fluorine and especially chlorine. The use of readily volatile halogenated hydrocarbons is also advantageous, as they are easiest to remove from the products obtained.
Examples of such solvents are: chloroform, methylene chloride, dibromomethane, chloroethane, bromoethane, dibromoethane, chlorobenzene, hexafluorobenzene, as well as correspondingly mixed halogenated hydrocarbons or mixtures of partially halogenated hydrocarbons. Preferred solvents are methylene chloride and 1,2-dichloroethane.

llZ4947 The amount of polystyrene is not crucial for the process. It is advantageous to employ an amount of 5 to 60% by weight, based on the reaction solution.

Divalent and/or trivalent iron salts or oxides are used as catalysts. These can be both salts of inorganic and organic acids and complex salts. Examples are: iron fluoride, iron chloride, iron bromide, iron sulfate, iron nitrate, iron phosphate, iron oxalate, iron acetate or iron benzoate, as well as hexacyanoferrate and iron oxides such as Fe304. When using an iron bromide, it is especially advantageous to form this in situ by reacting iron with bromine. Iron is therefore used in this case, and the catalytically active iron bromide is formed during the bromination. The catalyst is normally used in an amount of 0.05 to 20V/o by weight, with the preferred amount being from 0.5 to 5% by weight, based on the polystyrene employed.

Preferred catalysts are iron halides, especially FeC13, and iron. However, very good results are also obtained by substituting other iron salts for these catalysts in the process of the invention.

The bromination is preferably carried out in the temperature range from 0 to 25C in apparatus ordinarily used for the purpose. To avoid secondary reactions, it is advantageous to perform the reaction while excluding light.

The reaction can be performed e.g. by dissolving the polystyrene in the partially halogenated hydrocarbon, then adding the catalyst, e.g. iron powder. Then, while excluding light and with stirring and cooling, the required amount of bromine, if desired dissolved in the same solvent, 11~4947 is slowly added dropwise. The reaction mixture can be stirred for a time in order to bring the reaction to completion.

The reaction mixture is worked up by conventional methods. Excess bromine can be removed by a reducing agent, e.g. an aqueous hydrogen sulfite solution. The reaction solution is then washed free of bromide with water. The brominated polystyrene can then be isolated by removing the solvent e.g. by distillation. However, it is also possible to precipitate the brominated polystyrene from the solution by addition of a polar solvent e.g. an alcohol. The isolated brominated polystyrene can then be dried at elevated temperature and in vacuo in order to remove the solvent more completely.

The brominated polystyrenes obtained by the process of this invention are soluble, uncrosslinked thermoplastic products which are distinguished by a high bromine content, an insignificant natural colour, and very good thermal stability. Surprisingly, these products are obtained by the process o~f the invention using radically polymerised polystyrene as simple starting material. These brominated polystyrenes are useful flame retardants for plastics, especially for thermoplastics.

The invention is illustrated in more detail by the following Examples.

11~4947 Example 1: 26 g of commercially available polystyrene (Hostyren N 5000) are dissolved in 600 ml of methylene chloride. After addition of 0.5 g of iron powder, 99.8 g of bromine are slowly added dropwise at 0C while excluding light and with stirring and cooling. After stirring for 6 hours at 0C, the methylene chloride solution is stirred at room temperature with 100 ml of 3% sodium hydrogen sulfite solution and then washed free of bromide with water (S x 500 ml). The methylene chloride solution is then poured into lS00 ml of methanol with stirring.
The precipitated product is filtered with suction and dried for 12 hours at 60C/1 mbar, affording 59 g of brominated polystyrene in the form of a colourless powder with a bromine content of 64.9%. The product starts to decompose at 315C (determination by thermogravimetric analysis).

Example 2: 26 g of commercially available polystyrene are dissolved in 600 ml of methylene chloride. After addition of 1 g of iron powder, 99.8 g of bromine are added slowly dropwise at 15-20C while excluding light and with stirring and cooling. After stirring for 6 hours at 15-20C, the reaction mixture is washed free of bromide as in Example 1. The methylene chloride solution is concentrated and the residue is kept for a further hour at 250C/10 mbar, affording 61 g of slightly yellowish brominated polystyrene with a bromine content of 64.4 % by weight. The product starts to decompose at 325C
(determination by thermogravimetric analysis).

Example 3: 26 g of commercially available polystyrene are dissolved in 600 ml of dichloroethane. After addition of 1 g of iron powder, 99.8 g of bromine are slowly added 11~4947 dropwise at 15-20C while excluding light and with stirring and cooling. After atirring for 6 hours at 15-20C, the reaction mixture is washed free of bromide as in Example 1. Precipitation of the polymer solution in methanol yields 58 g of almost colourless polystyrene with a bromine content of 64.3% by weight. The product starts to decompose at 305C (determination by thermogravimetric analysis).

Example 4: 26 g of commercially available polystyrene are dissolved in 600 ml of methylene chloride. After addition of 0.5 g of iron powder, 79.9 g of bromine are slowly added dropwise at -10C while excluding light and with stirring and cooling. After stirring for 24 hours at -10C, the reaction mixture is washed free of bromide as in Example 1. Precipitation of the polymer solution in methanol yields 55 g of almost colourless brominated polystyrene with a bromine content of 61.6% by weight.
The product starts to decompose at 325C (determination by thermogravimetric analysis).

Example 5: 26 g of commercially available polystyrene are dissolved in 300 ml of methylene chloride. After addition of 4 g of FeP04, 79.9 g of bromine are slowly added dropwise at 0C while excluding light and with stirring and cooling. After stirring for 24 hours at 0C, the reaction mixture is washed free of bromide as in Example 1. Precipitation yields 62 g of brominated polystyrene in the form of a yellowish powder with a bromine content of 62.4% by weight. The product starts to decompose at 318C(determination by thermogravimetric analysis).

11~4947 Example 6: 26 g of commercially available polystyrene are dissolved in 300 ml of methylene chloride. After addition of 2 g of dried Fe(II) oxalate (10 hours/140C/l mbar), 51.3 g of bromine and 21.3 g of chlorine are added at 0C
in the course of 4 hours while excluding light and with stirring and cooling. The addition of the halogens is made as follows: first only bromine (1 hour), later bromine and chlorine simultaneously (2 hours) and finally only chlorine (1 hour). The reaction mixture is stirred for 18 hours, then washed free of bromide as in Example 1 and worked up, affording 69.6 g of brominated polystyrene in the form of a yellowish powder with a bromine content of 63.3% by weight and a chlorine content of 0.9% by weight.
The product starts to decompose at 349C (determination by thermogravimetric analysis).

Example 7: 26 g of commercially available polystyrene are dissolved in 300 ml of methylene chloride. After addition of 2 g of finely powdered Fe304, 51.3 g of bromine and 21.3 g of chlorine are added in the manner described in Example 6. The reaction mixture is stirred for 18 hours and worked up as in Example 1, affording 72.6 g of bromin-ated polystyrene in the form of a yellowish powder with a bromine content of 64.0% by weight and a chlorine content of 1.2% by weight. The product starts to decompose at 334C (determination by thermogravimetric analysis).

Comparison Example: 26 g of commercially available polystyrene are brominated as described in Example 1 using CCl4 as solvent. The brominated polystyrene has a bromine content of only 45% by weight.

Claims (9)

What is claimed is:
1. A process for the manufacture of brominated products of polystyrene,said products containing at least 50% by weight of bromine, by direct bromination of polystyrene obtained by radically initiated polymerisation, in solution and in the presence of a Lewis acid catalyst at low temperature, which process comprises carrying out the bromination in a partially halogenated hydrocarbon as solvent, in the presence of a divalent and/or trivalent iron salt or oxide as catalyst, in the temperature range from -30° to +30°C.
2. A process according to claim 1, wherein the solvent is a partially chlorinated aliphatic hydrocarbon.
3. A process according to claim 2, wherein the solvent is 1,2-dichloroethane or methylene chloride.
4. A process according to claim 1, wherein the iron salt is used in an amount of 0.05 to 20% by weight, based on the polystyrene.
5. A process according to claim 1, wherein an iron halide is used as catalyst.
6. A process according to claim 1, wherein the reaction temperature is in the range from 0° to 25°C.
7. A process according to claim 1, wherein the direct bromination is carried out with bromine or bromine chloride.
8. A process according to claim 1, wherein an iron salt is used as catalyst.
9. A process according to claim 1, wherein the catalyst is iron(II) oxalate, iron(III) phosphate or iron(III) oxide.
CA351,279A 1979-05-07 1980-05-05 Process for the manufacture of brominated products of polystyrene Expired CA1124947A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
CH4256/79-0 1979-05-07
CH425679 1979-05-07

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CA1124947A true CA1124947A (en) 1982-06-01

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EP (1) EP0020294B1 (en)
JP (1) JPS55151007A (en)
AT (1) ATE1781T1 (en)
BR (1) BR8002787A (en)
CA (1) CA1124947A (en)
DE (1) DE3061057D1 (en)
ES (1) ES491190A0 (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4879353A (en) * 1987-01-28 1989-11-07 Great Lakes Chemical Corporation Bromination of polystyrene using bromine as the reaction solvent
US7632893B2 (en) 2005-06-30 2009-12-15 Albemarle Corporation Brominated styrenic polymers and their preparation

Families Citing this family (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0611856B2 (en) * 1983-10-25 1994-02-16 三菱瓦斯化学株式会社 Flame-retardant polyphenylene ether resin composition
EP0201411A3 (en) * 1985-05-03 1989-02-08 The Dow Chemical Company Brominated polymers of alkenyl aromatic compounds
JPH02215807A (en) * 1989-02-17 1990-08-28 Nippon Kayaku Co Ltd Preparation of brominated polystyrene
US5637650A (en) 1996-06-14 1997-06-10 Ferro Corporation Brominated polysytrene having improved thermal stability and color and process for the preparation thereof
US6518368B2 (en) 1996-06-14 2003-02-11 Albemarle Corporation Brominated polystyrene having improved thermal stability and color and process for the preparation thereof
US6235844B1 (en) 1996-09-26 2001-05-22 Albemarle Corporation Brominated polystyrenic resins
US6232408B1 (en) 1996-09-26 2001-05-15 Albemarle Corporation Brominated polstyrenic resins
US6326439B1 (en) 1996-09-26 2001-12-04 Albemarle Corporation Process for brominating polystyrenic resins
US6133381A (en) * 1996-09-26 2000-10-17 Albelmarle Corporation Brominated polystyrenic flame retardants
JP4328388B2 (en) 1996-09-26 2009-09-09 アルベマール・コーポレーシヨン Method for brominating styrene polymers
US6521714B2 (en) 1996-09-26 2003-02-18 Albemarle Corporation Brominated polystyrenic resins
US5767203A (en) * 1996-09-26 1998-06-16 Albemarle Corporation Process for brominated styrenic polymers
US6235831B1 (en) 1996-09-26 2001-05-22 Albemarle Corporation Polymer compositions containing brominated polystyrenic resins
US6232393B1 (en) 1996-09-26 2001-05-15 Albemarle Corporation Polymers flame retarded with brominated polystyrenic resins
CN105504106A (en) * 2015-12-24 2016-04-20 深圳爱易瑞科技有限公司 Brominated polystyrene with high thermal stability and preparation method of brominated polystyrene

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2651435C3 (en) * 1976-11-11 1980-11-27 Basf Ag, 6700 Ludwigshafen Process for the preparation of brominated styrene polymerization products
DE2800012B2 (en) * 1978-01-02 1981-08-13 Chemische Werke Hüls AG, 4370 Marl Process for the production of heat-resistant, core-brominated polystyrenes

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4879353A (en) * 1987-01-28 1989-11-07 Great Lakes Chemical Corporation Bromination of polystyrene using bromine as the reaction solvent
US7632893B2 (en) 2005-06-30 2009-12-15 Albemarle Corporation Brominated styrenic polymers and their preparation
US8168723B2 (en) 2005-06-30 2012-05-01 Albemarle Corporation Brominated styrenic polymers and their preparation

Also Published As

Publication number Publication date
EP0020294A1 (en) 1980-12-10
BR8002787A (en) 1980-12-16
ATE1781T1 (en) 1982-11-15
ES8104339A1 (en) 1981-04-16
DE3061057D1 (en) 1982-12-16
ES491190A0 (en) 1981-04-16
JPS55151007A (en) 1980-11-25
EP0020294B1 (en) 1982-11-10

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