WO2001025196A2 - Slurry preparation of bis(halophthalimides) and of polyether polymers - Google Patents

Slurry preparation of bis(halophthalimides) and of polyether polymers Download PDF

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WO2001025196A2
WO2001025196A2 PCT/US2000/027183 US0027183W WO0125196A2 WO 2001025196 A2 WO2001025196 A2 WO 2001025196A2 US 0027183 W US0027183 W US 0027183W WO 0125196 A2 WO0125196 A2 WO 0125196A2
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radical
bιs
slurry
salt
mixture
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PCT/US2000/027183
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French (fr)
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WO2001025196A3 (en
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Farid Fouad Khouri
Ganesh Kailasam
Joseph John Caringi
Peter David Phelps
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General Electric Company
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Priority to JP2001528144A priority Critical patent/JP2003511365A/en
Priority to AT00968594T priority patent/ATE265434T1/en
Priority to DE60010305T priority patent/DE60010305T2/en
Priority to EP00968594A priority patent/EP1222168B1/en
Publication of WO2001025196A2 publication Critical patent/WO2001025196A2/en
Publication of WO2001025196A3 publication Critical patent/WO2001025196A3/en

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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07D—HETEROCYCLIC COMPOUNDS
    • C07D209/00—Heterocyclic compounds containing five-membered rings, condensed with other rings, with one nitrogen atom as the only ring hetero atom
    • C07D209/02—Heterocyclic compounds containing five-membered rings, condensed with other rings, with one nitrogen atom as the only ring hetero atom condensed with one carbocyclic ring
    • C07D209/44—Iso-indoles; Hydrogenated iso-indoles
    • C07D209/48—Iso-indoles; Hydrogenated iso-indoles with oxygen atoms in positions 1 and 3, e.g. phthalimide
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
    • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
    • C08G65/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols
    • C08G65/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group
    • C08G65/4012—Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones
    • C08G65/4031—(I) or (II) containing nitrogen
    • C08G65/4037—(I) or (II) containing nitrogen in ring structure, e.g. pyridine group
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
    • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
    • C08G65/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols
    • C08G65/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group
    • C08G65/4012—Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones
    • C08G65/4043—(I) or (II) containing oxygen other than as phenol or carbonyl group
    • C08G65/405—(I) or (II) containing oxygen other than as phenol or carbonyl group in ring structure, e.g. phenolphtalein
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
    • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
    • C08G65/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols
    • C08G65/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group
    • C08G65/4093—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group characterised by the process or apparatus used
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G73/00—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups C08G12/00 - C08G71/00
    • C08G73/06—Polycondensates having nitrogen-containing heterocyclic rings in the main chain of the macromolecule
    • C08G73/10—Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
    • C08G73/12—Unsaturated polyimide precursors
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G75/00—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen, or carbon in the main chain of the macromolecule
    • C08G75/20—Polysulfones
    • C08G75/23—Polyethersulfones

Definitions

  • This invention relates to the preparation of polyether polymers and intermediates therefor. More particularly, it relates to the preparation of b ⁇ s(halophthal ⁇ m ⁇ des), their isolation as a slurry and their use in slurry form for the preparation of poiyethe ⁇ mides.
  • Va ⁇ ous types of aromatic polyethers particularly poiyethe ⁇ mides but also including polyethersulfones, polyetherketones, and polyetheretherketones, have become important as enginee ⁇ ng resins by reason of their excellent properties.
  • These polymers are typically prepared by the reaction of salts of dihydroxyaromatic compounds, such as bisphenol A disodium salt, with dihaloaromatic molecules
  • dihydroxyaromatic compounds such as bisphenol A disodium salt
  • dihaloaromatic molecules such as bisphenol A disodium salt
  • poiyethe ⁇ mides are conveniently prepared by the reaction of salts of dihydroxyaromatic compounds with b ⁇ s(halophthahm ⁇ des) as illustrated by l,3-b ⁇ s[N-(4-chlorophthahm ⁇ do)]benzene (hereinafter sometimes "C1PAMI”), which has the structure
  • polysulfones and polyetherketones b ⁇ s(4-fluorophenyl) sulfone, b ⁇ s(4- chlorophenyl) sulfone and the analogous ketones are typically employed.
  • the preparation of aromatic polyethers may be conducted m solution in relatively non-polar solvents, using a phase transfer catalyst which is substantially stable under the temperature conditions employed
  • Solvents disclosed in 5,229,482 include o-dichlorobenzene, dichlorotoluene, 1,2,4-t ⁇ chlorobenzene and d ⁇ henyl sulfone
  • monoalkoxybenzenes such as amsole, d ⁇ henylether, or phenetole are employed.
  • Solvents of the same types may be used for the preparation of b ⁇ s(halophthahm ⁇ de) intermediates for poiyethe ⁇ mides.
  • the present invention is based in part on the discovery that b ⁇ s(halophthal ⁇ m ⁇ des) may be prepared in high yield and conversion by the reaction of halophtha c anhyd ⁇ de and diamino compound, even in equimolar amounts, and may be isolated in slurry rather than solid form, if certain reaction conditions are
  • the invention in one of its aspects is a method for prepa ⁇ ng a b ⁇ s(halophthahm ⁇ de) in organic slurry form which comp ⁇ ses effecting contact at a temperature of at least 100°C between the constituents of a mixture comp ⁇ sing at least one diamino compound, at least one halophthahc anhyd ⁇ de, a relatively non-polar organic liquid and an lmidization catalyst, said mixture having a solids content of at least about 5% by weight, thereby producing a slurry of said b ⁇ s(halophthal ⁇ m ⁇ de) in said liquid
  • Another aspect of the invention is a method for prepa ⁇ ng an aromatic polyether polymer which comp ⁇ ses contacting, in at least one relatively non-polar organic liquid as diluent, substantially equimolar amounts of at least one alkali metal salt of a dihydroxy-substituted aromatic hydrocarbon and a slurry in said organic liquid of at least one substituted aromatic compound of the formula
  • Z is an activating radical
  • a 1 is an aromatic radical
  • X 1 is fluoro, chloro, bromo or mtro, in the presence of a catalytically active amount of a phase transfer catalyst
  • Any diammo compound may be employed m the method of this invention.
  • suitable compounds are ethylenediamme, propylenediamme, tnmethylenediamine, dieth enet ⁇ amine, t ⁇ ethylenetetramine, heptamethylenediamine, octamethylenediamine, 1.12-dodecaned ⁇ am ⁇ ne. 1,18-octadecaned ⁇ am ⁇ ne, 3- methv lheptamethylenediamine, 4,4-d ⁇ methylheptamethylened ⁇ am ⁇ ne, 4- methylnonamethylenediamine, 2,5-
  • 2,6-d ⁇ am ⁇ notoluene m-xylylenediamine, p-xylylenediamme, 2- methyl-4,6-d ⁇ ethyl-l,3-phenylened ⁇ am ⁇ ne, 5-methyl-4,6-d ⁇ ethyl-l,3-phenylene- diamine, benzidine, 3,3'-d ⁇ methylbenz ⁇ d ⁇ ne, 3,3'-d ⁇ methoxybenz ⁇ d ⁇ ne, 1,5- diaminonaphthalene, b ⁇ s(4-am ⁇ nophenyl)methane, b ⁇ s(2-chloro- 4-am ⁇ no-3,5-d ⁇ ethylphenyl)methane, b ⁇ s(4-am ⁇ nophenyl)propane, 2,4-b ⁇ s( ⁇ -am ⁇ no-t- butyl)toluene, b ⁇ s(p- ⁇ -methyl-o-ammopentyl)benzene.
  • halophthahc anhydndes may be represented by the formula
  • X is chloro, bromo or fluoro, preferably chloro
  • the substituent X may be on any free valence position of the aromatic ⁇ ng
  • 4-chlorophthalic anhyd ⁇ de Also required according to the invention is a relatively non-polar organic liquid, usually having a substantially lower pola ⁇ ty than that of the dipolar aprotic solvents such as dimethylformamide, dimethylacetamide and N-methylpyrrohdinone.
  • Said non-polar solvent preferably has a boiling point above about 100°C and most preferably above about 150°C, in order to facilitate the reaction which requires temperatures above that temperature
  • Suitable liquids of this type include o- dichlorobenzene, dichlorotoluene, 1,2,4-t ⁇ chlorobenzene, diphenyl sulfone and monoalkoxybenzenes such as amsole, and more gene ⁇ cally liquids whose pola ⁇ ty is no higher than those of the aforementioned liquids Liquids of similar pola ⁇ ty but lower boiling points, such as chlorobenzene, may be employed at super-atmosphe ⁇ c pressures Amsole and o-dichlorobenzene are usually prefe ⁇ ed
  • b ⁇ s(halophthahm ⁇ de) may be produced in slurry form without isolation and separation from reactants and other by-products, with a high degree of conversion to the desired b ⁇ s(halophthahm ⁇ de).
  • an lmidization catalyst to provide a sufficiently fast reaction rate.
  • Suitable lmidization catalysts include salts of organophosphorus acids, particularly phosphinates such as sodium phenylphosphinate and heterocyc c amines such as 4-d ⁇ am ⁇ nopy ⁇ d ⁇ ne Sodium phenylphosphinate is generally preferred
  • the b ⁇ s(halophthahm ⁇ de) preparation method of the invention typically employs temperatures of at least 1 10°C, preferably in the range from 150° to about 225°C, preferably about 175-225°C At temperatures below 1 10°C, reaction rates are for the most part too slow for economical operation. It is within the scope of the invention to employ super-atmosphe ⁇ c pressures, typically up to about 5 atm, to facilitate the use of high temperatures without causing liquid to be lost by evaporation through boiling.
  • solids content in the reaction mixture of at least about 5%, preferably at least about 12% and most preferably about 15-25%, by weight
  • solids content is meant the proportion of reactants (I e , diamine and anhyd ⁇ de) as a percentage of the total weight including liquids
  • reaction mixture preferably include, for reasons already stated, a 2 1 molar ratio of anhyd ⁇ de to diamine While other ratios may be employed, there is generally no advantage in doing so Catalyst is present in an amount effective to accelerate the reaction, usually about 0 1-0 3% by weight based on the total of diamine and anhyd ⁇ de
  • Water removal from the system to d ⁇ ve conversion and drying can be accomplished on a continuous basis in either batch, semi-continuous or continuous processes using means well-known in the art such as a distillation column in conjunction with one or more reactors
  • a mixture of water and non-polar organic liquid distilling from a reactor is sent to a distillation column where water is taken off overhead and solvent is recycled back into the reactor at a rate to maintain or increase the desired solids concentration
  • Other methods for water removal include, but are not limited to, passing the condensed distillate through a drying bed for chemical or physical adsorption of water
  • the product of said method is a slurry containing the desired b ⁇ s(halophthahm ⁇ de) in combination with such by-products as structurally related amic acids, illustrated by that of the formula
  • the carboxylate salts may be generated by reaction of amic acid with bisphenol salt to form bisphenol or its monosodium salt and hence changing the reaction stoichiometry or generating a chain terminating agent, which typically results in a decrease in the polymer molecular weight.
  • halophthahc anhydrides containing measurable proportions of unsubstituted phthalic anhydride as an impurity.
  • m-ClPAMI l-[N-(4-chlorophthalimido)]-3-(N-phthalimido)benzene
  • the bis(halophthalimide) preparation method of this invention is illustrated by the following examples. All percentages in the examples herein are by weight unless otherwise indicated.
  • Example 3 After a first stage, the reaction mixture was transferred to a pressure vessel with addition of amsole and a second stage was performed at about 200°C reaction temperature and 2.4 atmospheres pressure (aim.). Compa ⁇ son was made with a control employing a lower solids proportion
  • the method of the invention affords C1PAMI in a conversion of at least 99.75% after 7 hoars or less.
  • This example illustrates an lmidization reaction run with an initial excess of one reactant.
  • a 50 gallon glass-lined reactor was charged with o-dichlorobenzene (ODCB; 108.9 kilograms [Kg]), 4-chlorophthalic anhyd ⁇ de (C1PA) (9.990 Kg, 54.7217 moles) and m-phenylenediamine (2.9411 Kg, 27.2247 moles) to give a 0.50 mole % excess of C1PA based on 100% pure 4-C1PA.
  • the C1PA contained from 0.5 to 1 mole % impu ⁇ ties.
  • the reaction was slowly heated to about 180°C over 4 hours and kept in this temperature range for 28 hours, du ⁇ ng which time distillate was collected.
  • Example 4 The procedure of Example 4 was repeated except that the initial formulation was 2.5 mole % (based on moles of diamine) deficient in 4-C1PA. Also 0.25% (by weight based on the total of diamine and anhydride) of sodium phenylphosphinate catalyst was added to the formulation. After heating at reflux overnight the 2.5 mol% C1PA withheld was added to consume the residual monoamine. A sample taken 4 hours after this C1PA addition showed no detectable monoamine and high conversion to C1PAMI.
  • the alkali metal salts of dihydroxy-substituted aromatic Hydrocarbons which are employed are typically sodium and potassium salts.
  • Sodium salts are frequently preferred by reason of their availability and relatively low cost.
  • Said salt may be employed in anhydrous or hydrated form; the anhydrous form is usually prefe ⁇ ed.
  • Suitable dihydroxy-substituted aromatic hydrocarbons include those having the formula
  • a 2 is a divalent aromatic hydrocarbon radical.
  • Suitable A 2 radicals include m-phenylene, p-phenylene, 4,4'-b ⁇ phenylene, 4,4'-b ⁇ (3,5-d ⁇ methyl)phenylene, 2,2- bis(4-phenylene)propane, 2,2,2',2'-tetrahydro-3,3,3',3'-tetramethyl-l,r-spirobi[lH- indene]-6,6'-diol, and similar radicals such as those which co ⁇ espond to the dihydroxy-substituted aromatic hydrocarbons disclosed by name or formula (generic or specific) in U.S. Patent 4,217,438.
  • the A 2 radical preferably has the formula
  • each of A 3 and A 4 is a monocyclic divalent aromatic hydrocarbon radical and Y is a bridging hydrocarbon radical in which one or two atoms separate A 3 from A 4 .
  • the free valence bonds in formula IV are usually in the meta or para positions of A 3 and A 4 in relation to Y.
  • Compounds in which A 2 has formula IV are bisphenols, and for the sake of brevity the term "bisphenol” is sometimes used herein to designate the dihydroxy-substituted aromatic hydrocarbons; it should be understood, however, that non-bisphenol compounds of this type may also be employed as appropriate.
  • the A 3 and A 4 values may be unsubstituted phenylene or substituted derivatives thereof, illustrative substituents (one or more) being alkyl, alkenyl, and halogen, particularly bromine. Unsubstituted phenylene radicals are prefe ⁇ ed. Both A 3 and A 4 are preferably p-phenylene, although both may be o- or m-phenylene or one o- or m-phenylene and the other p-phenyler .
  • the bridging radical, Y is one in which one or two atoms, preferably one, separate A 3 from A 4 .
  • radicals are unsaturated radicals.
  • the preferred radical of formula III is the 2.2-bis(4- phenylene)propane radical, which is derived from bisphenol A and in which Y is isopropylidene and A 3 and A 4 are each p-phenylene.
  • Spiro(bis)indane bisphenols may also be employed. They include 2,2,2',2'-tetrahydro- 3,3,3',3'-tetramethyl-l,l'-spirobi[lH-indene]-6,6'-diol and its substituted analogs.
  • the substituted aromatic compounds of formula I which are employed in the present invention contain an aromatic radical A 1 and an activating radical Z
  • the A 1 radical is normally a di- or polyvalent C ⁇ -io radical, preferably monocychc and preferably free from electron-withdrawing substituents other than Z
  • Unsubstituted C6 aromatic radicals are especially preferred
  • the Z radical is usually an electron-withdrawing group, which may be di- or polyvalent to co ⁇ espond with the valence of A 1
  • divalent radicals are carbonyl, carbonylb ⁇ s(arylene), sulfone, b ⁇ s(arylene) sulfone, benzo- l,2-d ⁇ az ⁇ ne and azoxy
  • the moiety -A ⁇ Z-A 1 - may be a b ⁇ s(arylene) sulfone, b ⁇ s(arylene) ketone, t ⁇ s(arylene)b ⁇ s(sulfone), t ⁇ s(arylene)b ⁇ s(ketone), b ⁇ s(arylene)benzo-1.2-d ⁇ az ⁇ ne or b ⁇ s(arylene)azoxy radical and especially one in which A 1 is p-phenylene
  • R 1 is a C6-20 divalent aromatic hydrocarbon or halogenated hydrocarbon radical, a C2-20 alkylene or cycloalkylene radical, a C2-8 b ⁇ s(alkylene-term ⁇ nated) polydiorganosiloxane radical or a divalent radical of the formula
  • R' is at least one of m-phenylene, p-phenylene, 4,4' oxyb ⁇ s(phenylene) and
  • Polyvalent Z radicals include those which, with A 1 , form part of a fused ⁇ ng system such as benzimidazole, benzoxazole, quinoxahne or benzofuran.
  • substituted aromatic compound of formula I are two displaceable X 1 radicals which may be fluoro, chloro, bromo or nitro. In most instances, fluoro and chloro atoms are prefe ⁇ ed by reason of the relative availability and effectiveness of the compounds containing them.
  • the particularly preferred compound of formula I for the purposes of the present invention, is OP AMI.
  • Organic liquids employed in the polyether polymer preparation method of the invention are, in general, the same ones employed in the bis(halophthahn ' ⁇ de) method.
  • the substituted aromatic compound most often a b ⁇ s(halophthahm ⁇ de) is supplied in the form of a slurry in said liquid
  • the bisphenol salt may be supplied by any convenient means, such as a slurry or a solid; a slurry is usually prefe ⁇ ed.
  • phase transfer catalyst preferably one which is substantially stable at the temperatures employed; I e., in the range of about 125- 250°C Va ⁇ ous types of phase transfer catalysts may be employed for this purpose.
  • phase transfer catalysts include quaternary phosphonium salts of the type disclosed in U S. Patent
  • the prefe ⁇ ed phase transfer catalysts by reason of their exceptional stability at high temperatures and their effectiveness to produce high molecular weight aromatic polyether polymers in high yield are the hexaalkylguanidinium and , ⁇ -bis(pentaalkylguanidinium)alkane salts.
  • the bisphenol salt and substituted aromatic compound are typically brought into contact in substantially equimolar amounts.
  • the amounts should be as close as possible to exactly equimolar, but molecular weight control may be achieved by employing one reagent or the other in slight excess.
  • monofunctional reagents such as monohydroxyaromatic compounds or monohalo- or nitroaromatic compounds as chain termination agents.
  • the monohalo- or nitroaromatic compounds may, as previously noted, be prepared, for example, by the reaction of diamino compounds with halophthahc anhydrides containing unsubstituted phthalic anhydride as an impu ⁇ ty.
  • Reaction temperatures are in the range of about 125-250°C, preferably about 130- 225°C.
  • the proportion of phase transfer catalyst is generally about 0.5-10 and preferably about 1-5 mole percent based on bisphenol salt.
  • an intimate mixing method such as vigorous stirring is employed since the rate of the polymerization reaction is typically dependent on efficiency of mixing.
  • the aromatic polyether polymer may be isolated by conventional methods. This typically includes such steps as acid quenching c • neutralization followed by washing, evaporation of solvent, or anti-solve precipitation and/or devolatilization-pelletization.
  • the polyether polymer preparation method of the invention is illustrated by the following examples. All percentages are by weight.
  • the C1PAMI employed was prepared from two sources of 4-chlorophthalic anhydride.
  • Sample A was prepared from distilled anhydride; it contained 0.3% phthalic acid and, upon exposure to moisture, was partially hydrolyzed to a content of 4.6% of the co ⁇ esponding chlorophthalic acid.
  • phthalic acid was converted to m-ClPAMI which served as a chain termination agent.
  • Sample B was prepared from anhydride produced by palladium-catalyzed decarbonylation of trimellitic anhydride acid chloride and contained no phthalic acid.
  • the amount of bisphenol A disodium salt employed in each example was an amount calculated as 1.5 mole % in excess with respect to pure CIPAMI.
  • Each example employed a CIPAMI product (sample A or B) in the form of a paste prepared according to Example 2. It was dried by addition of 12 successive 50-ml portions of dry (maximum 5 ppm water) anisole and distillation under a positive argon atmosphere, and finally reduced again to a paste containing about 10 ml of anisole.
  • the weight average molecular weight was determined by gel permeation chromatography; to avoid variations in analysis, it was additionally expressed as "Mw ratio" which is a percentage of the molecular weight of a single sample of commercial polyetherimide whose molecular weight was determined at the same time.
  • Mw ratio is a percentage of the molecular weight of a single sample of commercial polyetherimide whose molecular weight was determined at the same time.
  • the commercial polyetherimide was prepared by a method similar to that described in U.S. Patent
  • polyetherimide preparation method of the invention affords polymers having molecular weights comparable to or approaching that of a product prepared from solid CIPAMI. It is also apparent that amic acid proportions above 0.25%, as illustrated by Example 7, cause a decrease in molecular weight.

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Abstract

Bis(halophthalimides) such as, 3-bis[N-(4-chlorophthalimido)]benzene are prepared in slurry in an organic liquid such as o-dichlorobenzene or anisole, by a reaction at a temperature of at least 150 °C between at least one diamino compound, preferably an aromatic diamine such as m- or p-phenylenediamine, and at least one halophthalic anhydride such as 4-chlorophthalic anhydride, in the presence of an imidization catalyst such as sodium phenylphosphinate. The solids content of the reaction mixture is at least about 5 % and preferably at least about 12 % by weight. The product slurry may be employed directly in the preparation of polyetherimides, and similar slurries may be employed to prepare other polyether polymers.

Description

SLURRY PREPARATION OF BIS(HALOPHTHALIMIDES) AND OF POLYETHER POLYMERS
BACKGROUND OF THE INVENTION
This invention relates to the preparation of polyether polymers and intermediates therefor. More particularly, it relates to the preparation of bιs(halophthalιmιdes), their isolation as a slurry and their use in slurry form for the preparation of poiyetheπmides.
Vaπous types of aromatic polyethers. particularly poiyetheπmides but also including polyethersulfones, polyetherketones, and polyetheretherketones, have become important as engineeπng resins by reason of their excellent properties. These polymers are typically prepared by the reaction of salts of dihydroxyaromatic compounds, such as bisphenol A disodium salt, with dihaloaromatic molecules For example, poiyetheπmides are conveniently prepared by the reaction of salts of dihydroxyaromatic compounds with bιs(halophthahmιdes) as illustrated by l,3-bιs[N-(4-chlorophthahmιdo)]benzene (hereinafter sometimes "C1PAMI"), which has the structure
Figure imgf000002_0001
For polysulfones and polyetherketones, bιs(4-fluorophenyl) sulfone, bιs(4- chlorophenyl) sulfone and the analogous ketones are typically employed. According to US Patents 5,229,482 and 5,830,974, the preparation of aromatic polyethers may be conducted m solution in relatively non-polar solvents, using a phase transfer catalyst which is substantially stable under the temperature conditions employed Solvents disclosed in 5,229,482 include o-dichlorobenzene, dichlorotoluene, 1,2,4-tπchlorobenzene and dφhenyl sulfone In 5,830,974, monoalkoxybenzenes such as amsole, dφhenylether, or phenetole are employed. Solvents of the same types may be used for the preparation of bιs(halophthahmιde) intermediates for poiyetheπmides.
Each of these patents requires introduction into the reaction mixture of the bιs(halophthalιmιde) as a substantially pure, isolated compound This is often difficult, since solid bιs(halophthahmιdes) are typically of very low density and fluffy, making weighing and handling burdensome. It would be desirable, for both technical and cost reasons, to handle such reactants as slurπes in an organic solvent instead of in drv solid form.
In order to isolate bιs(halophthalιmιdes) m slurry form, however, it is often preferred to prepare them by a method which employs the reactants, namely diamino compound and halophthahc anhydπde, in equimolar proportions so as to avoid competing reactions According to such pπor art as US Patent 3,787.364, the employment of substantially equimolar proportions of reactants can result in the necessity for extremely long reaction times, typically up to 3 days. This is true even when such active solvents as glacial acetic acid are employed. When non-polar solvents are employed, it has typically been necessary to employ one reactant, most often the chlorophtha c anhydπde, in excess, whereupon said reactant is still present after completion of the reaction and can cause competing reactions to take place upon synthesis of the polyetheπmide
SUMMARY OF THE INVENTION
.?. The present invention is based in part on the discovery that bιs(halophthalιmιdes) may be prepared in high yield and conversion by the reaction of halophtha c anhydπde and diamino compound, even in equimolar amounts, and may be isolated in slurry rather than solid form, if certain reaction conditions are
maintained These include relatively high reaction temperatures, relatively high solids content and the presence of a suitable catalyst
The invention in one of its aspects is a method for prepaπng a bιs(halophthahmιde) in organic slurry form which compπses effecting contact at a temperature of at least 100°C between the constituents of a mixture compπsing at least one diamino compound, at least one halophthahc anhydπde, a relatively non-polar organic liquid and an lmidization catalyst, said mixture having a solids content of at least about 5% by weight, thereby producing a slurry of said bιs(halophthalιmιde) in said liquid
It has also been discovered that bιs(halophthalιmιdes) and similar dihaloaromatic compounds may be employed in slurry form for the preparation of the coπesponding polyether polymers Another aspect of the invention, therefore, is a method for prepaπng an aromatic polyether polymer which compπses contacting, in at least one relatively non-polar organic liquid as diluent, substantially equimolar amounts of at least one alkali metal salt of a dihydroxy-substituted aromatic hydrocarbon and a slurry in said organic liquid of at least one substituted aromatic compound of the formula
(I) Z(A1-X1)2 ,
wherein Z is an activating radical, A1 is an aromatic radical and X1 is fluoro, chloro, bromo or mtro, in the presence of a catalytically active amount of a phase transfer catalyst
DETAILED DESCRIPTION, PREFERRED EMBODIMENTS Any diammo compound may be employed m the method of this invention. Examples of suitable compounds are ethylenediamme, propylenediamme, tnmethylenediamine, dieth enetπamine, tπethylenetetramine, heptamethylenediamine, octamethylenediamine, 1.12-dodecanedιamιne. 1,18-octadecanedιamιne, 3- methv lheptamethylenediamine, 4,4-dιmethylheptamethylenedιamιne, 4- methylnonamethylenediamine, 2,5-
dimethylhexamethylenediamme, 2.2-dιmethylpropylenedιamιne, N-methyl-bιs(3- amιnopropyl)amιne, 3-methoxyhexamethylenedιamιne, l ,2-bιs(3- amιnopropoxy)ethane, bιs(3-amιnopropyl) sulfide, 1,4-cyclohexanedιamιne, bιs-(4- amιnocyclohexyl)methane, m-phenylenediamine, p-phenylenediamine, 2,4- diamino toluene. 2,6-dιamιnotoluene, m-xylylenediamine, p-xylylenediamme, 2- methyl-4,6-dιethyl-l,3-phenylenedιamιne, 5-methyl-4,6-dιethyl-l,3-phenylene- diamine, benzidine, 3,3'-dιmethylbenzιdιne, 3,3'-dιmethoxybenzιdιne, 1,5- diaminonaphthalene, bιs(4-amιnophenyl)methane, bιs(2-chloro- 4-amιno-3,5-dιethylphenyl)methane, bιs(4-amιnophenyl)propane, 2,4-bιs(β-amιno-t- butyl)toluene, bιs(p-β-methyl-o-ammopentyl)benzene. 1 ,3-dιammo-4- lsopropylbenzene, bιs(4-amιnophenyl) sulfone, bιs(4-amιnophenyl) ether and 1,3- bιs(3-amιnopropyl)tetramethyldιsιloxane Mixtures of these compounds may also be present The preferred diammo compounds are aromatic diamines, especially m- and p-phenylenediamine and mixtures thereof.
The halophthahc anhydndes may be represented by the formula
Figure imgf000005_0001
wherein X is chloro, bromo or fluoro, preferably chloro The substituent X may be on any free valence position of the aromatic πng Especially prefeπed is 4-chlorophthalic anhydπde Also required according to the invention is a relatively non-polar organic liquid, usually having a substantially lower polaπty than that of the dipolar aprotic solvents such as dimethylformamide, dimethylacetamide and N-methylpyrrohdinone. Said non-polar solvent preferably has a boiling point above about 100°C and most preferably above about 150°C, in order to facilitate the reaction which requires temperatures above that temperature Suitable liquids of this type include o- dichlorobenzene, dichlorotoluene, 1,2,4-tπchlorobenzene, diphenyl sulfone and monoalkoxybenzenes such as amsole, and more geneπcally liquids whose polaπty is no higher than those of the aforementioned liquids Liquids of similar polaπty but lower boiling points, such as chlorobenzene, may be employed at super-atmospheπc pressures Amsole and o-dichlorobenzene are usually prefeπed
In conventional methods for the production of bιs(halophthahmιdes), as disclosed, for example, in the aforementioned US Patent 3,787,364, the halophthahc anhydπde is present in slight excess to dπve the reaction to completion. A pπncipal advantage of the present invention, however, is the fact that such an excess is not necessary Rather, it is possible to employ stoichiometπc proportions of the reagents, or to begin with an excess of one reagent and subsequently introduce the other to the stoichiometπc amount, depending on analytical data for the concentration of one or both reagents. Thus, bιs(halophthahmιde) may be produced in slurry form without isolation and separation from reactants and other by-products, with a high degree of conversion to the desired bιs(halophthahmιde). For this purpose it is required to employ an lmidization catalyst to provide a sufficiently fast reaction rate. Suitable lmidization catalysts are known in the art; they include salts of organophosphorus acids, particularly phosphinates such as sodium phenylphosphinate and heterocyc c amines such as 4-dιamιnopyπdιne Sodium phenylphosphinate is generally preferred
The bιs(halophthahmιde) preparation method of the invention typically employs temperatures of at least 1 10°C, preferably in the range from 150° to about 225°C, preferably about 175-225°C At temperatures below 1 10°C, reaction rates are for the most part too slow for economical operation. It is within the scope of the invention to employ super-atmospheπc pressures, typically up to about 5 atm, to facilitate the use of high temperatures without causing liquid to be lost by evaporation through boiling.
- A further feature, for the same reason, is a solids content in the reaction mixture of at least about 5%, preferably at least about 12% and most preferably about 15-25%, by weight By "solids content" is meant the proportion of reactants (I e , diamine and anhydπde) as a percentage of the total weight including liquids It is further within the scope of the invention to change the solids content duπng the reaction, for such reasons as to effectuate transfer of the reaction mixture from one vessel to another
Other constituent proportions in the reaction mixture preferably include, for reasons already stated, a 2 1 molar ratio of anhydπde to diamine While other ratios may be employed, there is generally no advantage in doing so Catalyst is present in an amount effective to accelerate the reaction, usually about 0 1-0 3% by weight based on the total of diamine and anhydπde
Water removal from the system to dπve conversion and drying can be accomplished on a continuous basis in either batch, semi-continuous or continuous processes using means well-known in the art such as a distillation column in conjunction with one or more reactors In one embodiment, a mixture of water and non-polar organic liquid distilling from a reactor is sent to a distillation column where water is taken off overhead and solvent is recycled back into the reactor at a rate to maintain or increase the desired solids concentration Other methods for water removal include, but are not limited to, passing the condensed distillate through a drying bed for chemical or physical adsorption of water
The product of said method is a slurry containing the desired bιs(halophthahmιde) in combination with such by-products as structurally related amic acids, illustrated by that of the formula
Figure imgf000007_0001
It is within the scope of the invention to further decrease the proportion of organic liquid in the slurry, reducing it to the consistency of a paste, and for the purpose of the invention such a paste is deemed to be a slurry, the only variation being in amount of liquid.
Since the yield in the imidization reaction is essentially quantitative, bis(halophthalimide) and amic acids are the only significant products of the reaction of diamino compound with halophthahc anhydride. To ensure subsequent formation of polyetherimide at an acceptable rate to a high molecular weight product, it is highly prefeπed for the conversion to bisimide (i.e., the proportion of bisimide as a percentage of total bisimide and related amic acids) to be at least 99.75% and the invention is capable of producing conversions at this level. If amic acids are present in amounts larger than 0.25%, they may be incorporated in the polymer in the form of their carboxylate salt resulting in decreased thermal stability of the final resin. The carboxylate salts may be generated by reaction of amic acid with bisphenol salt to form bisphenol or its monosodium salt and hence changing the reaction stoichiometry or generating a chain terminating agent, which typically results in a decrease in the polymer molecular weight.
Also, it is within the scope of the invention to employ halophthahc anhydrides containing measurable proportions of unsubstituted phthalic anhydride as an impurity. In the subsequent polyetherimide-forming reaction, it will be present in the form of a monohalo compound such as l-[N-(4-chlorophthalimido)]-3-(N-phthalimido)benzene (hereinafter "m-ClPAMI"), which serves as a chain termination agent and which can be compensated for by adjusting the stoichiometry of the polyetherimide-forming reagents.
The bis(halophthalimide) preparation method of this invention is illustrated by the following examples. All percentages in the examples herein are by weight unless otherwise indicated.
EXAMPLES 1-3
In each example, a 250 milliliter (ml) three-necked round-bottomed flask fitted with a strrrer and Dean-Stark trap was charged with 1,980.6 milligrams (mg) (18.315 rnillimoles [mmol]) of m-phenylenediamine, 6,687.2 mg (36.63 mol) of 4- chlorophthahc anhydπde and 14 67 mg of sodium phenylphosphinate. Amsole was added to afford the desired solids percentage and the flask was heated for 0.5 hour with stirπng in a 198°C oil bath, a temperature effective to produce gentle refluxing without distillation. The temperature was then raised to a specified temperature and water was collected in the trap until water evolution was complete. The remaining mateπal in the flask was the desired C1PAMI slurry in amsole. Finally, the trap was replaced with a distillation head and the amsole was stπpped to leave a paste that was analyzed by high pressure liquid chromatography
The results are given in Table I. The yield of C1PAMI and corresponding amic acids was quantitative in each example, but conversion to C1PAMI vaπed and is given in the table. In Example 3. after a first stage, the reaction mixture was transferred to a pressure vessel with addition of amsole and a second stage was performed at about 200°C reaction temperature and 2.4 atmospheres pressure (aim.). Compaπson was made with a control employing a lower solids proportion
TABLE I
Figure imgf000009_0001
As shown in Table I, the method of the invention affords C1PAMI in a conversion of at least 99.75% after 7 hoars or less. By contrast, the control afforded C1PAMI at a lower conversion level after a much greater reaction time.
EXAMPLE 4
This example illustrates an lmidization reaction run with an initial excess of one reactant. A 50 gallon glass-lined reactor was charged with o-dichlorobenzene (ODCB; 108.9 kilograms [Kg]), 4-chlorophthalic anhydπde (C1PA) (9.990 Kg, 54.7217 moles) and m-phenylenediamine (2.9411 Kg, 27.2247 moles) to give a 0.50 mole % excess of C1PA based on 100% pure 4-C1PA. The C1PA contained from 0.5 to 1 mole % impuπties. The reaction was slowly heated to about 180°C over 4 hours and kept in this temperature range for 28 hours, duπng which time distillate was collected.
Samples of the reaction slurry were obtained using a 1/4 inch diameter glass tube at 4, 5, 6 and 21 hours after charging the reactor, and analyzed using High Performance Liquid Chromatography (HPLC) At 24 hours additional 4-C1PA (40 g, 0.219 moles) was added to consume residual monoamine that persisted in the reaction. A sample taken at 28 hrs showed that monoamine was consumed. The slurry was suitable for polymenzation to polyetheπmide.
EXAMPLE 5
The procedure of Example 4 was repeated except that the initial formulation was 2.5 mole % (based on moles of diamine) deficient in 4-C1PA. Also 0.25% (by weight based on the total of diamine and anhydride) of sodium phenylphosphinate catalyst was added to the formulation. After heating at reflux overnight the 2.5 mol% C1PA withheld was added to consume the residual monoamine. A sample taken 4 hours after this C1PA addition showed no detectable monoamine and high conversion to C1PAMI.
In the polyether polymer preparatic I method of the invention, the alkali metal salts of dihydroxy-substituted aromatic Hydrocarbons (hereinafter sometimes simply "bisphenol salt" for brevity) which are employed are typically sodium and potassium salts. Sodium salts are frequently preferred by reason of their availability and relatively low cost. Said salt may be employed in anhydrous or hydrated form; the anhydrous form is usually prefeπed.
Suitable dihydroxy-substituted aromatic hydrocarbons include those having the formula
(III) HO-A2-OH ,
wherein A2 is a divalent aromatic hydrocarbon radical. Suitable A2 radicals include m-phenylene, p-phenylene, 4,4'-bιphenylene, 4,4'-bι(3,5-dιmethyl)phenylene, 2,2- bis(4-phenylene)propane, 2,2,2',2'-tetrahydro-3,3,3',3'-tetramethyl-l,r-spirobi[lH- indene]-6,6'-diol, and similar radicals such as those which coπespond to the dihydroxy-substituted aromatic hydrocarbons disclosed by name or formula (generic or specific) in U.S. Patent 4,217,438.
The A2 radical preferably has the formula
(IV) -A -Y-A4- ,
wherein each of A3 and A4 is a monocyclic divalent aromatic hydrocarbon radical and Y is a bridging hydrocarbon radical in which one or two atoms separate A3 from A4. The free valence bonds in formula IV are usually in the meta or para positions of A3 and A4 in relation to Y. Compounds in which A2 has formula IV are bisphenols, and for the sake of brevity the term "bisphenol" is sometimes used herein to designate the dihydroxy-substituted aromatic hydrocarbons; it should be understood, however, that non-bisphenol compounds of this type may also be employed as appropriate.
In formula IV, the A3 and A4 values may be unsubstituted phenylene or substituted derivatives thereof, illustrative substituents (one or more) being alkyl, alkenyl, and halogen, particularly bromine. Unsubstituted phenylene radicals are prefeπed. Both A3 and A4 are preferably p-phenylene, although both may be o- or m-phenylene or one o- or m-phenylene and the other p-phenyler .
The bridging radical, Y, is one in which one or two atoms, preferably one, separate A3 from A4. Illustrative radicals of this type are -C=O, -O-, -S-, -SO-, -SO:-, methylene, cyclohexylmethylene, 2-[2.2.1]-bicycloheptylmethylene, ethylene, isopropylidene, neopentylidene, cyclohexylidene, cyclopentάdεcylidene, cyclododecylidene. adamantylidene; gem-alkylene (alkylidene) radicals are preferred. Also included, however, are unsaturated radicals. For reasons of availability and particular suitability for the purposes of this invention, the preferred radical of formula III is the 2.2-bis(4- phenylene)propane radical, which is derived from bisphenol A and in which Y is isopropylidene and A3 and A4 are each p-phenylene.
Spiro(bis)indane bisphenols may also be employed. They include 2,2,2',2'-tetrahydro- 3,3,3',3'-tetramethyl-l,l'-spirobi[lH-indene]-6,6'-diol and its substituted analogs. The substituted aromatic compounds of formula I which are employed in the present invention contain an aromatic radical A1 and an activating radical Z The A1 radical is normally a di- or polyvalent Cό-io radical, preferably monocychc and preferably free from electron-withdrawing substituents other than Z Unsubstituted C6 aromatic radicals are especially preferred
The Z radical is usually an electron-withdrawing group, which may be di- or polyvalent to coπespond with the valence of A1 Examples of divalent radicals are carbonyl, carbonylbιs(arylene), sulfone, bιs(arylene) sulfone, benzo- l,2-dιazιne and azoxy Thus, the moiety -A^Z-A1- may be a bιs(arylene) sulfone, bιs(arylene) ketone, tπs(arylene)bιs(sulfone), tπs(arylene)bιs(ketone), bιs(arylene)benzo-1.2-dιazιne or bιs(arylene)azoxy radical and especially one in which A1 is p-phenylene
Also included are compounds in which -A^Z-A1- is a bisimide radical, illustrated by those of the formula
Figure imgf000012_0001
wherein R1 is a C6-20 divalent aromatic hydrocarbon or halogenated hydrocarbon radical, a C2-20 alkylene or cycloalkylene radical, a C2-8 bιs(alkylene-termιnated) polydiorganosiloxane radical or a divalent radical of the formula
Figure imgf000012_0002
in which Q is
Figure imgf000013_0001
CF3
or a covalent bond. Most often, R' is at least one of m-phenylene, p-phenylene, 4,4' oxybιs(phenylene) and
Figure imgf000013_0002
Polyvalent Z radicals include those which, with A1, form part of a fused πng system such as benzimidazole, benzoxazole, quinoxahne or benzofuran.
Also present in the substituted aromatic compound of formula I are two displaceable X1 radicals which may be fluoro, chloro, bromo or nitro. In most instances, fluoro and chloro atoms are prefeπed by reason of the relative availability and effectiveness of the compounds containing them. The particularly preferred compound of formula I, for the purposes of the present invention, is OP AMI.
Organic liquids employed in the polyether polymer preparation method of the invention are, in general, the same ones employed in the bis(halophthahn'<de) method. The substituted aromatic compound, most often a bιs(halophthahmιde), is supplied in the form of a slurry in said liquid The bisphenol salt may be supplied by any convenient means, such as a slurry or a solid; a slurry is usually prefeπed.
Also present in the reaction mixture is a phase transfer catalyst, preferably one which is substantially stable at the temperatures employed; I e., in the range of about 125- 250°C Vaπous types of phase transfer catalysts may be employed for this purpose. They include quaternary phosphonium salts of the type disclosed in U S. Patent
4,273,712, N-alkyl-4-dιalkylamιnopyπdιnιum salts of the type disclosed in U.S. Patents 4.460,778 and 4.595,760, and guanidinium salts of the type disclosed in the aforementioned US Patent 5,229,482 Said patents and application are incorporated by reference herein. The prefeπed phase transfer catalysts, by reason of their exceptional stability at high temperatures and their effectiveness to produce high molecular weight aromatic polyether polymers in high yield are the hexaalkylguanidinium and ,ω-bis(pentaalkylguanidinium)alkane salts.
The bisphenol salt and substituted aromatic compound are typically brought into contact in substantially equimolar amounts. For maximum molecular weight, the amounts should be as close as possible to exactly equimolar, but molecular weight control may be achieved by employing one reagent or the other in slight excess. It is also within the scope of the invention to employ monofunctional reagents such as monohydroxyaromatic compounds or monohalo- or nitroaromatic compounds as chain termination agents. The monohalo- or nitroaromatic compounds may, as previously noted, be prepared, for example, by the reaction of diamino compounds with halophthahc anhydrides containing unsubstituted phthalic anhydride as an impuπty.
Reaction temperatures are in the range of about 125-250°C, preferably about 130- 225°C. The proportion of phase transfer catalyst is generally about 0.5-10 and preferably about 1-5 mole percent based on bisphenol salt. For best results, an intimate mixing method such as vigorous stirring is employed since the rate of the polymerization reaction is typically dependent on efficiency of mixing.
Following completion of the reaction, the aromatic polyether polymer may be isolated by conventional methods. This typically includes such steps as acid quenching c • neutralization followed by washing, evaporation of solvent, or anti-solve precipitation and/or devolatilization-pelletization.
The polyether polymer preparation method of the invention is illustrated by the following examples. All percentages are by weight. The C1PAMI employed was prepared from two sources of 4-chlorophthalic anhydride. Sample A was prepared from distilled anhydride; it contained 0.3% phthalic acid and, upon exposure to moisture, was partially hydrolyzed to a content of 4.6% of the coπesponding chlorophthalic acid. During the C1PAMI formation reaction, phthalic acid was converted to m-ClPAMI which served as a chain termination agent. Sample B was prepared from anhydride produced by palladium-catalyzed decarbonylation of trimellitic anhydride acid chloride and contained no phthalic acid. The amount of bisphenol A disodium salt employed in each example was an amount calculated as 1.5 mole % in excess with respect to pure CIPAMI.
EXAMPLES 6-10
Each example employed a CIPAMI product (sample A or B) in the form of a paste prepared according to Example 2. It was dried by addition of 12 successive 50-ml portions of dry (maximum 5 ppm water) anisole and distillation under a positive argon atmosphere, and finally reduced again to a paste containing about 10 ml of anisole.
A 250 ml three-necked round-bottomed flask, fitted with a stiπer and male joint, was charged with bisphenol A disodium salt and 100 ml of dry anisole. The mixture was dried by distillation under a positive argon atmosphere with removal of about 65 ml of anisole. It was then quantitatively transfeπed under argon pressure through an oven- dried adapter into the CIPAMI slurry. The combined mixture was heated in an oil bath at 170°C, and 3.5 mole percent (based on bisphenol A salt) of hexaethylguanidinium chloride dissolved in anisole was added, also under argon. The mixture was heated under reflux for 4 hours to yield the desired polyetherimide. In each example the weight average molecular weight was determined by gel permeation chromatography; to avoid variations in analysis, it was additionally expressed as "Mw ratio" which is a percentage of the molecular weight of a single sample of commercial polyetherimide whose molecular weight was determined at the same time. The commercial polyetherimide was prepared by a method similar to that described in U.S. Patent
3,838.097.
The results are given in Table II, in comparison with a control in which a solid isolated CIPAMI reagent was employed.
TABLE II
Figure imgf000015_0001
Figure imgf000016_0001
ure m- a e e ore po ymeπzation
It can be seen that the polyetherimide preparation method of the invention affords polymers having molecular weights comparable to or approaching that of a product prepared from solid CIPAMI. It is also apparent that amic acid proportions above 0.25%, as illustrated by Example 7, cause a decrease in molecular weight.
While typical embodiments have been set forth for the purpose of illustration, the foregoing descriptions should not be deemed to be a limitation on the scope of the invention. Accordingly, various modifications, adaptations, and alternatives may occur to one skilled in the art without departing from the spirit and scope of the present invention.

Claims

WHAT IS CLAIMED IS
1 A method for prepaπng a bιs(halophthahmιde) in organic slurry form which compπses effecting contact at a temperature of at least 100°C between the constituents of a mixture compπsing at least one diamino compound, at least one halophthahc anhydπde, a relatively non-polar organic liquid and an imidization catalyst, said mixture having a solids content of at least about 5% by weight, thereby producing a slurry of said bιs(halophthahmιde) in said liquid
2 The method according to claim 1 wherein the diamino compound is at least one aromatic diamine
3 The method according to claim 2 wherein the solids content is at least about
12%) by weight
4 The method according to claim 3 wherein the temperature is at least 150°C
5 The method according to claim 4 wherein the molar ratio of anhydπde to diamine is 2 1 or is adjusted to that value
6 The method according to claim 4 wherein the organic liquid has a polaπty no higher than that of o-dichlorobenzene, dichlorotoluene, 1,2,4-tπchlorobenzene, diphenyl sulfone and anisole
7 The method according to claim 6 wherein the organic liquid is o- dichlorobenzene or amsole
8 The method according to claim 4 wherein the aromatic diamine is m- or p- phenylenediamine or a mixture thereof
9 The method according to claim 4 wherein the halophthahc anhydπde is 4- chlorophthahc anhydπde
10 The method according to claim 4 wherein the temperature is in the range of about 175-225°C
11 The method according to claim 4 wherein the imidization catalyst is a salt of an organophosphorus acid or a heterocyc c amine 12 The method according to claim 1 1 wherein the imidization catalyst is sodium phenylphosphinate
13 The method according to claim 4 wherein the solids content is in the range of about 15-25%
14 The method according to claim 13 wherein a mixture of water and non-polar organic liquid distilling from a reactor is sent to a distillation column where water is taken off overhead and solvent is recycled back into the reactor at a rate to maintain or increase the solids content
15 The method according to claim 1 wherein the reaction is performed under super-atmospheπc pressure
16 A method for prepaπng l,3-bιs[N-(4-chlorophthalιmιdo)]benzene in orgamc slurry form which compπses effecting contact at a temperature in the range of about 175-225°C between the constituents of a mixture compπsing at least m- phenylenediamine or a mixture thereof with p-phenylenediamine, 4-chlorophthalic anhydπde, an imidization catalyst and o-dichlorobenzene or anisole, said mixture having a solids content in the range of about 15-25% by weight, thereby producing a slurry of said bιs(halophtha mιde) said o-dichlorobenzene or anisole
17 A method for prepaπng an aromatic polyether polymer which compπses contacting, in at least one relatively non-polar organic liquid as diluent, substantially equimolar amounts of at least one alkali metal salt of a dihydroxy-substituted aromatic hydrocarbon and a slurry in said organic liquid of at least one substituted aromatic compound of the formula
(I) Z(Al-Xl)2 ,
wherein Z is an activating radical, A1 is an aromatic radical and X1 is fluoro, chloro, bromo or nitro, in the presence of a catalytically active amount of a phase transfer catalyst
18. The method according to claim 17 wherein the organic liquid is o- dichlorobenzene or anisole.
19. The method according to claim 17 wherein the phase transfer catalyst is a quaternary phosphonium salt, an alkylaminopyridinium salt or a guanidinium salt.
20. The method according to claim 19 wherein the phase transfer catalyst is a hexaalkylguanidinium or an α,ω-bis(pentaalkylguanidinium)alkane salt.
21. The method according to claim 17 wherein the dihydroxy-substituted aromatic hydrocarbon has the formula HO-A3-Y-A -OH, wherein each of A3 and A4 is a monocyclic divalent aromatic hydrocarbon radical and Y is a bridging hydrocarbon radical in which one or two atoms separate A3 from A4.
22. The method according to claim 17 wherein A1 is p-phenylene.
23. The method according to claim 17 wherein -A^Z-A1- is a bisimide radical of the formula
Figure imgf000019_0001
wherein R1 is a C6-20 divalent aromatic hydrocarbon or halogenated hydrocarbon radical, a C2-20 alkylene or cycloalkylene radical, a C2-8 bis(alkylene-terminated) polydiorganosiloxane radical or a divalent radical of the formula
Figure imgf000020_0001
in which Q is
Figure imgf000020_0002
CF3
or a covalent bond.
24. The method according to claim 23 wherein said substituted aromatic compound contains no more than 0.25% by weight of amic acids.
25. The method according to claim 24 wherein R1 is m-phenylene or a mixture thereof with p-phenylene.
26. The method according to claim 22 wherein X1 is chloro.
27. The method according to claim 17 wherein the dihydroxy-substituted aromatic hydrocarbon is bisphenol A.
28. The r .ethod according to claim 17 wherein the reaction temperature is in the range of about 130-225°C
29. The method according to claim 17 wherein the phase transfer catalyst is a guanidinium salf.
30. The method according to claim 29 wherein the proportion of phase transfer catalyst employed is about 1-5 mole percent based on the dihydroxy-substituted aromatic hydrocarbon salt.
31. A method for preparing a polyetherimide which comprises contacting, in o- dichlorobenzene or anisole as diluent, substantially equimolar amounts of bisphenol A disodium salt and a slurry in said o-dichlorobenzene or anisole of l,3-bis[N-(4-chlorophthalimido)]benzene, in the presence of a catalytically active amount of a hexaalkylguanidinium chloride as a phase transfer catalyst; said l,3-bis[N-(4-chlorophthalimido)]benzene containing no more than 0.25% by weight of amic acids.
PCT/US2000/027183 1999-10-06 2000-10-02 Slurry preparation of bis(halophthalimides) and of polyether polymers WO2001025196A2 (en)

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US7981996B2 (en) 2004-12-22 2011-07-19 Sabic Innovative Plastics Ip B.V. Method of making bisimides
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EP1222168B1 (en) 2004-04-28
ATE456555T1 (en) 2010-02-15
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DE60043790D1 (en) 2010-03-18
EP1426358A3 (en) 2006-03-08
WO2001025196A3 (en) 2001-10-18
DE60010305T2 (en) 2005-05-12
EP1222168A2 (en) 2002-07-17
DE60010305D1 (en) 2004-06-03
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ATE265434T1 (en) 2004-05-15
US6235866B1 (en) 2001-05-22
JP2003511365A (en) 2003-03-25
ES2338872T3 (en) 2010-05-13
EP1426358A2 (en) 2004-06-09

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