Classifications

• • 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

• the invention relates to a process for the preparation of aromatic polyethersulfones and to the polyethersulfones obtainable in the process.
• Aromatic polyethersulfones are usually prepared by condensing a dichlorodiphenylsulfone component with a bisphenol component as monomers in the presence of alkali metal carbonates. Usually, the polycondensation is carried out in a solvent such as N-methylpyrrolidone (NMP). Such a method has the disadvantage that a toxic solvent must be handled, which must be separated from the product after the reaction, optionally purified and recycled to the reaction.
• DE-A-27 49 645 relates to a process for preparing polyethers in which substantially equivalent amounts of a bisphenol and a dihalobenzene compound are condensed in the absence of solvents or diluents and in the presence of anhydrous alkali carbonate.
• the object of the present invention is to provide a process for the preparation of aromatic polyethersulfones by reacting a dichlorodiphenylsulfone component with a bisphenol component as monomers in the presence of alkali metal carbonate in the melt in the absence of solvents or diluents, high molecular weights to be accessible and the aromatic polyethersulfones should discolour as little as possible.
• the object is achieved according to the invention by a process for the preparation of aromatic polyethersulfones by reacting a dichlorodiphenylsulfone component with a bisphenol component as monomers in the presence of alkali metal carbonate in the melt in the absence of solvents or diluents, the reaction being carried out in a mixer. ter operated with a shear rate in the range of 5 to 500 s _1 .
• the degree of filling of the mixing kneader according to the invention is preferably in the range from 0.2 to 0.8, preferably 0.22 to 0.7, in particular 0.3 to 0.7, especially 0.35 to 0.64.
• degree of filling indicates what proportion of the free volume in the kneader, which can be filled with monomers and permits thorough mixing, is filled by the starting monomers, thus indicating a degree of filling in the range from 0.2 to 0.8 that 20 to 80% of the Filling with monomers and their mixing available free volume in the process of filling with monomers and alkali carbonate can be used.
• the shear rate is in the range of 5 to 500 s -1 , preferably 10 to 250 s -1 , in particular 20 to 100 s -1 .
• the shear rate is in the range of 5 to 500 s _1, preferably 25 to 100 S "1, in particular 35 to 70 s _1.
• Suitable mixing kneaders can be used, which allow heating to above the melting point of the monomers and allow the discharge of gaseous condensation products.
• Suitable mixing kneaders usually have one or preferably at least two axially parallel rotating shafts, of which the main shaft can have disc surfaces with kneading bars arranged on their circumference.
• Suitable mixing kneaders are, for example, in
• the mixing kneader has a rotor which is operated at a speed in the range of 5 to 50 revolutions per minute, particularly preferably 7.5 to 40 revolutions per minute and in particular 10 to 30 revolutions per minute.
• the mixing kneader used according to the invention has the advantage that the residence time can be substantially longer than in the extruder.
• the degassing is much easier and more widely possible, so that the gaseous polycondensation products can be discharged in a simple manner.
• the inventive shear rate can be adjusted more easily in the mixing kneader.
• the process according to the invention can be carried out as a batch process or as a continuous process.
• the process is carried out continuously, wherein preferably continuously operated biaxial mixing kneaders are used, as they are available for example as LIST TCF or BUSS SMS.
• the combination of mixing kneader, degree of filling and shear rate makes it possible according to the invention to achieve high molecular weights of the aromatic polyethersulfones without the product suffering from discoloration.
• a large number of different aromatic polyethersulfones can be prepared in which one or more dichlorodiphenylsulfone components are reacted with one or more bisphenol components as monomers.
• aromatic groups of the polyethersulfones also referred to as arylene groups, may be the same or different and independently of one another represent an aromatic radical having 6 to 18 carbon atoms.
• Suitable arylene groups are phenylene, bisphenylene, terphenylene, 1, 5-naphthylene, 1, 6-naphthylene, 1, 5-anthrylene, 9,10-anthrylene or 2,6-anthrylene. Of these, preferred are 1,4-phenylene and 4,4'-biphenylene. Preferably, these aromatic radicals are not substituted. However, they can carry one or more substituents. Suitable substituents are, for example, alkyl, arylalkyl, aryl, nitro, cyano or alkoxy groups and heteroaromatics such as pyridine and halogen atoms.
• the preferred substituents include alkyl radicals having up to 10 carbon atoms such as methyl, ethyl, i-propyl, n-hexyl, i-hexyl, Ci to Cio alkoxy such as methoxy, ethoxy, n-propoxy, n-butoxy, aryl radicals with up to 20 carbon atoms, such as phenyl or naphthyl, as well as fluorine and chlorine.
• Polyarylene ether sulfones which can be used according to the invention can be synthesized from recurring units of the formula I. wherein
• t and q are independently 0, 1, 2 or 3,
• R a and R b are each independently a hydrogen atom or a C 1 -C 12 alkyl group, and R c and R d independently of one another each represent a hydrogen atom or a C 1 -C 12 -alkyl-,
• Ci2-alkoxy or C6-Ci8-aryl group stand,
• R c and R d are optionally substituted independently of one another by fluorine and / or chlorine atoms or, if appropriate together with the carbon atom to which they are attached, form a C 3 -C 12 -cycloalkyl group which is optionally substituted by one or more carbon atoms C6 alkyl groups, provided that at least one of the groups T, Q and Z is -SO2- and, when t and q are 0, Z is -SO2-,
• Ar and Ar 1 independently of one another are C 6 -C 18 -arylene groups, these being optionally substituted by C 1 -C 12 -alkyl, C 6 -C 18 -aryl, C 1 -C 12 -alkoxy groups or halogen atoms.
• aromatic polyethersulfones preferably have at least one of the following structural units:
• dichlorodiphenylsulfone components and bisphenol components used as monomers are derived from these structures.
• dichlorodiphenylsulfone and dihydroxydiphenylsulfone are used for the preparation of polyethersulfones.
• Such products are available, for example under the name Ultrason ® E from BASF SE.
• the mixing kneader is equipped with a reflux condenser to condense evaporating monomers and the condensed monomers are returned to the mixing kneader, it is possible to work with equimolar amounts of the two monomer components, or with slight deviations therefrom.
• the process according to the invention can be carried out at any suitable temperatures, provided that the monomers are present in the melt.
• the reaction is carried out at a temperature in the range of 250 to 350 ° C.
• the reaction is preferably carried out without pressure, wherein in the polycondensation resulting low molecular weight condensation products are discharged in gaseous form.
• the alkali metal carbonate which is preferably potassium carbonate
• the alkali metal carbonate can be introduced as a separate component in the mixing kneader. However, it can also be used premixed with at least one of the monomers.
• the condensation of bisphenols with Dihalogenbenzol-16en first bisphenol and alkali metal carbonate can be reacted, the product is then polycondensed in the mixing kneader with the DihalogenbenzolENS. It is also possible to mix it into the dihalobenzene compound.
• the alkali carbonate is predispersed in at least one of the monomer components, preferably in the halogen-containing monomer due to its reactivity with the phenolic groups and the formation of salts.
• the metered addition can also be carried out in solid form by gravimetric dosing or by a lateral entry screw.
• a lateral entry screw When entering through the hood of the mixing kneader, it must be ensured that there is no blockage by solids.
• a minimum diameter of the hood of 150 mm is advantageous, as well as a short discharge path of the solid powder perpendicular to the kneading bars.
• the monomers can also be granulated to adjust their flow behavior.
• the monomers and alkali carbonate in powder form must be introduced into the side entry screw and introduced through it into the mixing kneader.
• the degree of filling in the mixing kneader can be controlled by the operation of a discharge screw, which removes product according to the entry in the mixing kneader.
• the reaction time in the mixing kneader can be freely selected depending on the desired molecular weight of the aromatic polyethersulfone.
• the reaction time in the mixing kneader is preferably from 1 to 3.5 hours, particularly preferably from 1.5 to 3 hours.
• the amount of dichlorodiphenyl sulfone should typically be increased by about 4 to 6 mol%, since this compound evaporates more readily than the dihydroxydiphenylsulfone component because of its vapor pressure of about 100 mbar at a temperature of 300 ° C.
• the invention also relates to aromatic polyethersulfones obtainable by the process described above.
• aromatic polyethersulfones preferably have a number average molecular weight of above 10,000, with the number average molecular weight preferably ranging from 10,000 to 26,000.
• the polydispersity is preferably 2 to 7.5, particularly preferably 2.4 to 3.2 for biphenol-based products, and more preferably 3 to 7.5 for DHDPS-based products.
• PESU Polyethersulfone
• DCDPS dichlorodiphenylsulfone
• DHDPS dihydroxydiphenylsulfone
• the mixing kneader is heated by means of a thermostat, whereby only heating of the outer wall is possible.
• the three starting substances are introduced into the reactor as solid powders. After purging with argon, the reactor is heated to the reaction temperature, kept for the required reaction time at this temperature and then cooled.
• the motor of the mixing kneader typically moves with one
• Example 1 shows the experimental conditions and results for the preparation of polyethersulfone.
• the batch cycle time t c is given in addition to reaction temperature, rotor speed, monomer amounts and molar ratio.
• the product was mechanically discharged from the mixing kneader, ground to a particle size of about 2 mm and washed twice with water for three hours at 80 ° C. This allowed about 80% by weight of the by-produced potassium chloride to be removed. Due to the residual content of potassium chloride, the certain viscosity number VN is lower compared to a pure polymer.
• the molecular weights were determined by GPC methods. Table 1
• the degree of filling of the mixing kneader was 0.22 in these examples.
• the rotation speed of 20 revolutions per minute corresponds to a shear rate of 100 s _1 .
• the speed of rotation of the mixer was varied in Comparative Experiments V50 and V51, with both rotor standstill and high rotational speed resulting in molecular weight reduction. Without sufficient rotation, the formation of new interfaces between gas phase and melt is absent, so that the condensation products of water and carbon dioxide can not be sufficiently dissipated. If the rotational speed was too high, the shear stress of the melt was increased by a factor of ten. The color of the product was much darker compared to Example 5. In addition, gel particle formation occurred.
• VN [ml / g] 55.6 61, 1 44.1 56.1 36.6 60.3 35.9 62.2
• the monomers DCDPS, DHDPS and K 2 C0 3 are premixed in the apparatus shown schematically in Fig. 1 in the molar compositions shown in Table 5 and in the solid feed of the gravimetric feeder.
• the feedstocks are continuously fed into the screw feeder (feeder screw) according to the set throughput and from there into the kneader.
• the stuffing screw is cooled, so that the starting materials are still in solid form.
• the feedstocks DCDPS and DHDPS are melted and begin to react with the potash. This forms the polymer and the by-products H 2 0, C0 2 and KCl.
• the gaseous components H 2 0 and C0 2 are degassed (off gases) and leave the reaction chamber via the exhaust pipe.
• Part of the monomer DCDPS sublimates into the gas phase and is carried along with it and is condensed out of a condensing condenser and returns to the process space.
• the feeds are mixed by the rotating kneader and polymerize while being transported in the axial direction through the kneader.
• a discharge screw At the outlet of the kneader there is a discharge screw, which discharges the present polymer melt (product), which still contains KCl, out of the mixing kneader.
• a melt pump behind the discharge screw a melt pump can be switched, with which the discharged amount can be dosed, and a string or underwater granulation can be connected.
• the speeds (in min "1 ) correspond to the following shear rates (in s " 1 )

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• Chemical & Material Sciences (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Medicinal Chemistry (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Polyethers (AREA)
• Polymers With Sulfur, Phosphorus Or Metals In The Main Chain (AREA)

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• 2013
  • 2013-09-03 JP JP2015529064A patent/JP2015526579A/ja active Pending
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• 2019
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