WO2017089099A1 - Process for the production of polyether ester block copolymers - Google Patents

Process for the production of polyether ester block copolymers Download PDF

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Publication number
WO2017089099A1
WO2017089099A1 PCT/EP2016/076775 EP2016076775W WO2017089099A1 WO 2017089099 A1 WO2017089099 A1 WO 2017089099A1 EP 2016076775 W EP2016076775 W EP 2016076775W WO 2017089099 A1 WO2017089099 A1 WO 2017089099A1
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Prior art keywords
polyether ester
carbon atoms
reactants
ester block
mixture
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PCT/EP2016/076775
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French (fr)
Inventor
Susanta MITRA
Suman Kumar SEN
Stephen D PASK
Abbas-Alli Ghudubhai Shaikh
Bander Al-Farhood
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Sabic Global Technologies B.V.
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Publication of WO2017089099A1 publication Critical patent/WO2017089099A1/en

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    • 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
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/66—Polyesters containing oxygen in the form of ether groups
    • C08G63/668—Polyesters containing oxygen in the form of ether groups derived from polycarboxylic acids and polyhydroxy compounds
    • C08G63/672—Dicarboxylic acids and dihydroxy compounds
    • 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
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/68—Polyesters containing atoms other than carbon, hydrogen and oxygen
    • C08G63/695—Polyesters containing atoms other than carbon, hydrogen and oxygen containing silicon
    • C08G63/6954—Polyesters containing atoms other than carbon, hydrogen and oxygen containing silicon derived from polxycarboxylic acids and polyhydroxy compounds
    • C08G63/6956—Dicarboxylic acids and dihydroxy compounds
    • 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
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/78—Preparation processes
    • C08G63/82—Preparation processes characterised by the catalyst used
    • C08G63/85—Germanium, tin, lead, arsenic, antimony, bismuth, titanium, zirconium, hafnium, vanadium, niobium, tantalum, or compounds thereof

Definitions

  • the present invention relates to a process for the production of polyether ester block copolymers with reduced undesired by-product formation and, polyether ester block copolymer produced using such process having a good balance of mechanical properties.
  • Polyether ester block copolymers are a class of thermoplastic materials exhibiting elastomeric properties. Primarily because of their easy processability coupled with good thermo- mechanical properties, polyether ester block copolymers have found wide ranges of applications in many industrial branches including but not limited to automotive components, sporting goods, hose, cable jacketing, seals, and shoe soles.
  • polycondensation processes such as melt polycondensation processes.
  • the polyether ester block copolymers according to the state of the art are commonly produced using diesters of dicarboxylic acids, such as dimethyl terephthalate (DMT) as one of the raw materials.
  • DMT dimethyl terephthalate
  • Such polyether ester block copolymers are for example described in US6670429.
  • Polyether ester block copolymers produced using such diesters of dicarboxylic acids may be produced in such way that they have a desirable balance of mechanical properties.
  • a disadvantage of the use of such diesters of dicarboxylic acids is that a quantity of an alcohol such as methanol is formed as a by-product. This is not desirable, as the alcohol that is produced has to be separated and further processed.
  • the formation of alcohol as a by-product in the production of polyether ester copolymers can be avoided by using dicarboxylic acids, such as terephthalic acid (TPA), instead of the diesters of dicarboxylic acids as raw material.
  • dicarboxylic acids such as terephthalic acid (TPA)
  • TPA terephthalic acid
  • the material properties such as the tensile properties of the polyether ester block copolymers produced using such dicarboxylic acids are inadequate for many purposes.
  • R1 and R2 each individually are a moiety comprising 2-10 carbon atoms.
  • R1 and R2 each individually may be a moiety comprising 2-4 carbon atoms.
  • R1 and R2 may each individually be a hydrocarbon moiety.
  • R1 and R2 may each individually be a branched or straight chain moiety.
  • R1 and R2 may be the same.
  • R1 and R2 may be different.
  • R1 and R2 may each individually be a hydrocarbon moiety,
  • R1 and R2 may each individually be a branched or straight chain moiety, and
  • R1 and R2 may be the same or different.
  • R1 and R2 may each individually be a moiety selected from an ethylene moiety, a propylene moiety, or a butylene moiety.
  • R1 and R2 may each individually be moieties selected from -CH2-CH2-,
  • R1 and R2 may be moieties selected from -CH2-CH2- or
  • both R1 and R2 may be -CH2-CH2-.
  • polyether ester block copolymers using such process eliminates the formation of undesired alcohol as a by-product.
  • the polyether ester block copolymers produced using such process show a good balance of mechanical properties, including a desirable tensile stress at 5% and 10% strain, a desirable tensile strength at break, and a desirable elongation at break.
  • the polyether ester block copolymers produced using such process show such good balance of mechanical properties at a relatively low molecular weight.
  • Such process allows for the production of polyether ester block copolymers having a good balance of mechanical properties in one single reaction operation rather than involving the addition of the reactants to the reactor in several separate stages
  • all reactants are fed to the process prior to the onset of the reaction.
  • the process may comprise all reactants to be fed to a reactor and subsequently the catalyst to be fed to the reactor.
  • the catalyst may be present in the polymerisation in quantities of for example 0.05-1 .00 % by weight, with regard to the weight of aromatic dicarboxylic acid comprising 6-12 carbon atoms present in the mixture of reactants.
  • such catalyst may for example be present in quantities ⁇ 0.05 % by weight, alternatively ⁇ 0.10 % by weight, alternatively ⁇ 0.15 % by weight, with regard to the total weight of the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms.
  • Such catalyst may for example be present in quantities ⁇ 1.00 % by weight, alternatively ⁇ 0.50 % by weight, alternatively ⁇ 0.30 % by weight, with regard to the total weight of the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms.
  • Such catalyst may for example be present in quantities ⁇ 0.05 % and ⁇ 1.00 % by weight, alternatively ⁇ 0.10 % and ⁇ 0.50 % by weight, alternatively ⁇ 0.15 % and ⁇ 0.30 % by weight, with regard to the total weight of the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms.
  • the presence of the catalyst in such quantities is understood to be beneficial in order for the polymerisation to result in a polyether ester block copolymer having a desired average molecular weight and desired tensile properties.
  • Use of a lower quantity of catalyst may result in an incomplete reaction, where the polyether ester block copolymer obtained does not have a desired average molecular weight and desired tensile properties; furthermore, the reaction will proceed at very slow reaction rates.
  • the use of a higher quantity of catalyst may result in the formation of undesired byproducts such as cyclic oligomers, where the polyether ester block copolymer obtained does not have desired tensile properties.
  • the use of a higher quantity of catalyst may result in undesirable effects during further processing of the obtained polymer due to the remaining reactivity of the catalyst present in the polymer.
  • the catalyst preferably is selected from bis(1 ,2-ethanediolato) titanium, bis(1 ,3- propanediolato) titanium, bis(1 ,2-propanediolato) titanium, bis(1 ,3-butanediolato) titanium, bis(2,3-butanediolato) titanium, or bis(1 ,3-butanediolato) titanium. More preferably, the catalyst is bis(1 ,2-ethanediolato) titanium.
  • the polyether ester block copolymers produced using the process of the present invention may for example comprise:
  • the polyether ester block copolymers produced using the process of the present invention may further comprise:
  • the polyether ester block copolymer may for example comprise ⁇ 49.5 % by weight, alternatively ⁇ 60.0 % by weight, alternatively ⁇ 70.0 % by weight, of hard block moieties (I), compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer may comprise ⁇ 89.5 % by weight, alternatively ⁇ 85.0 % by weight, alternatively ⁇ 80.0 % by weight, of hard block moieties (I), compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer may comprise ⁇ 49.5 and ⁇ 89.5 % by weight, alternatively ⁇ 60.0 and ⁇ 85.0 % by weight, alternatively ⁇ 70.0 and ⁇ 80.0 % by weight, of hard block moieties (I), compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer may for example comprise ⁇ 10.0 % by weight, alternatively ⁇ 15.0 % by weight, alternatively ⁇ 20.0 % by weight, of soft block moieties (II), compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer may comprise ⁇ 50.0 % by weight, alternatively ⁇ 40.0 % by weight, alternatively ⁇ 30.0 % by weight, of soft block moieties (II), compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer may comprise ⁇ 10.0 and ⁇ 50.0 % by weight, alternatively ⁇ 15.0 and ⁇ 40.0 % by weight, alternatively ⁇ 20.0 and ⁇ 30.0 % by weight, of soft block moieties (II).
  • the polyether ester block copolymer may for example comprise ⁇ 0.5 % by weight, alternatively ⁇ 1 .0 % by weight, alternatively ⁇ 1 .5 % by weight, of soft block moieties (III), compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer may comprise ⁇ 6.0 % by weight, alternatively ⁇ 5.0 % by weight, alternatively ⁇ 4.0 % by weight, alternatively ⁇ 3.0 % by weight, of soft block moieties (III), compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer may comprise ⁇ 0.5 and ⁇ 6.0 % by weight, alternatively ⁇ 0.5 and ⁇ 5.0 % by weight, alternatively ⁇ 0.5 and ⁇ 4.0 % by weight, alternatively ⁇ 1 .0 and ⁇ 3.0 % by weight, of soft block moieties (III), compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer may comprise ⁇ 0.5 and ⁇ 6.0 % by weight of soft block moieties (III) compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer may comprise ⁇ 0.5 and ⁇ 4.0 % by weight of soft block moieties (III) compared to the total weight of the polyether ester block copolymer.
  • the polyether ester block copolymer comprises hard block moieties (I), soft block moieties (II) and soft block moieties (III), the sum of the percentages of weights of (I), (II) and (III) is 100%. In the case where the polyether ester block copolymer does not comprise (III), the sum of the percentages of weights of (I) and (II) is 100 %.
  • the hard block moieties (I) as present in the polyether ester block copolymers of the present invention may for example comprise poly(alkylene arylate) moieties.
  • Such poly(alkylene arylate) moieties may for example be selected from poly(ethylene terephthalate), poly(butylene terephthalate), poly(propylene terephthalate), poly(ethylene naphthanoate), poly(propylene naphthanoate), poly(butylene naphthanoate), and/or poly(ethylene terephthalate)(butylene terephthalate).
  • the poly(alkylene arylate) moieties are poly(ethylene terephthalate), poly(butylene terephthalate) or poly(ethylene terephthalate)(butylene terephthalate).
  • the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms may for example be one or more selected from isophthalic acid, terephthalic acid, 1 ,4-naphthalene dicarboxylic acid, 1 ,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid,
  • the aromatic dicarboxylic acid comprising 6-12 carbon atoms may be one or more selected from terephthalic acid and/or isophthalic acid.
  • the aromatic dicarboxylic acid comprising 6-12 carbon atoms may be terephthalic acid.
  • the one or more aliphatic diol comprising 2-10 carbon atoms may for example be one or more selected from 1 ,2-ethanediol, 1 ,2-propanediol, 1 ,3-propanediol, 1 ,2-butanediol, 1 ,3- butanediol and/or 1 ,4-butanediol.
  • the one or more aliphatic diol comprising 2-10 carbon atoms is 1 ,4-butanediol.
  • the polyether ester block copolymer may be obtained by reacting a mixture of reactants comprising a first and a second aliphatic diol each having a different molecular composition.
  • the first and the second aliphatic diol may each be selected from 1 ,2-ethanediol, 1 ,2-propanediol, 1 ,3-propanediol, 1 ,2-butanediol, 1 ,3-butanediol and 1 ,4-butanediol.
  • the first aliphatic diol may be 1 ,2-ethanediol and the second aliphatic diol may be 1 ,4-butanediol.
  • the quantity of the first and the second aliphatic diol may for example be such that the ratio of the weight of the fraction of the hard blocks derived from the first aliphatic diol to the weight of the fraction of hard blocks derived from the second aliphatic diol is ⁇ 0.2 and ⁇ 2.0.
  • the one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms may for example be one or more selected from polyethyleneglycol, polypropyleneglycol and/or polytetramethyleneetherglycol, such as polyethyleneglycol.
  • the polyalkylene glycol may for example have a number average molecular weight M n as determined in accordance with ASTM D5296-1 1 of ⁇ 500 g/mol, alternatively ⁇ 1000 g/mol.
  • the polyalkylene glycol may for example have a number average molecular weight Mn of ⁇ 2500 g/mol, alternatively ⁇ 2000 g/mol.
  • the polyalkylene glycol may have a number average molecular weight M n of ⁇ 500 and ⁇ 2500 g/mol, alternatively ⁇ 1000 and ⁇ 2000 g/mol.
  • the hydroxy-terminated polysiloxane may for example be a polysiloxane according to the formula II:
  • R1 may be an alkyl moiety such as methyl, ethyl or propyl, for example methyl.
  • R2 may each individually be an alkyl moiety or a dialkyl ether moiety such as a dimethyl ether moiety, a diethyl ether moiety, a methyl ethyl ether moiety, or an ethyl propyl ether moiety.
  • each R2 may be an ethyl propyl ether moiety wherein the ethyl group of the ethyl propyl moiety is connected to the terminal hydroxyl-moiety of the hydroxy-terminated
  • n may be ⁇ 5 and ⁇ 30; n is the average number of recurring siloxane polymeric units.
  • the hydroxy-terminated polysiloxane may be a polysiloxane according to formula I wherein each R2 is an ethyl propyl ether moiety of which the ethyl moiety is connected to the terminal hydroxyl-moiety, each R1 is methyl, and n ⁇ 5 and ⁇ 30.
  • the one or more hydroxy-terminated polysiloxane may for example be a hydroxy- terminated polydimethyl siloxane or a copolymer thereof.
  • the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms is one or more selected from terephthalic acid, isophthalic acid, 1 ,4- naphthalenedicarboxylic acid, 1 ,5-naphthalenedicarboxylic acid, 2,6- naphthalenedicarboxylic acid, or combinations thereof; and/or the one or more aliphatic diol is one or more selected from 1 ,2-ethanediol, 1 ,2- propanediol, 1 ,3-propanediol, 1 ,2-butanediol, 1 ,3-butanediol, 1 ,4-butanediol or combinations thereof; and/or
  • the one or more polyalkylene glycol is selected from polyethyleneglycol, polypropyleneglycol, polytetramethyleneetherglycol, or combinations thereof; wherein the polymerisation takes in the presence of a catalyst having a structure according to formula I:
  • R1 and R2 each individually are a moiety comprising 2-10 carbon atoms.
  • the mixture of reactants may further comprise one or more hydroxy-terminated polysiloxane or a copolymer thereof.
  • Such hydroxy-terminated polysiloxane may be selected from hydroxy-terminated polydimethylsiloxanes.
  • the mixture of reactants comprises:
  • the mixture of reactants may comprise ⁇ 10.0 and ⁇ 50.0 wt%, alternatively ⁇ 20.0 and ⁇ 45.0 wt%, alternatively ⁇ 30.0 and ⁇ 40.0 wt%, of one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms, with regard to the total weight of the mixture of reactants.
  • the mixture or reactants may comprise ⁇ 10.0 and ⁇ 60.0 wt%, alternatively ⁇ 30.0 and ⁇ 55.0, alternatively ⁇ 40.0 and ⁇ 55.0 wt% of one or more aliphatic diol comprising 2-10 carbon atoms, with regard to the total weight of the mixture of reactants.
  • the mixture of reactants may comprise ⁇ 5.0 and ⁇ 60.0 wt%, alternatively ⁇ 10.0 and ⁇ 40.0 wt%, alternatively ⁇ 10.0 and ⁇ 20.0 wt% of one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms, with regard to the total weight of the mixture of reactants.
  • the process for production of polyether ester block copolymers according to the present invention may for example be a polycondensation process.
  • Such polycondensation process may be performed in one single reactor or in multiple reactors, such as in multiple reactors arranged in series.
  • the process is performed in a single reactor.
  • the process may be a batch process or a continuous process.
  • the process may be a melt process in which the reactants are present in the molten state.
  • the process may comprise two reaction steps. Such process comprising two reaction steps may comprise a first and a second step, wherein the first step precedes the second step.
  • an esterification reaction takes place in the first step, and a transesterification takes place in the second step.
  • a mixture of reactants comprising one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms, one or more aliphatic diol comprising 2-10 carbon atoms, and one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms is introduced into a reactor.
  • a quantity of the reactants having hydroxyl-functional groups may react with a quantity of the reactants having carboxylic acid functional groups.
  • the reactants having hydroxyl-functional groups include the aliphatic diol, the polyalkylene glycol and the hydroxy-terminated polysiloxane.
  • the reactants having carboxylic acid functional groups include the aromatic dicarboxylic acid.
  • Carboxylic acid functional groups of the aromatic dicarboxylic acid may react with the hydroxyl-functional groups of the aliphatic diol, the polyalkylene glycol and/or the hydroxy-terminated polysiloxane to form ester moieties.
  • Such first step may for example be operated at atmospheric pressure.
  • the catalyst is introduced during the first step.
  • the polyether ester block copolymers may be formed by
  • the second step may for example be operated at a pressure below atmospheric pressure, for example at pressures ⁇ 0.01 mbar and ⁇ 200 mbar, alternatively ⁇ 0.01 mbar and ⁇ 100 mbar.
  • the second step may for example comprise two or more stages, in which in the first stage the pressure may for example be kept at ⁇ 1 mbar and ⁇ 200 mbar, alternatively ⁇ 1 mbar and ⁇ 100 mbar, and in which in a second stage the pressure may for example be further reduced to ⁇ 0.01 mbar and ⁇ 1 mbar, alternatively ⁇ 0.01 mbar and ⁇ 0.1 mbar.
  • the first step and the second step may be performed in a single reactor.
  • the process comprises a first step and a subsequent second reaction step, wherein the first step is operated at atmospheric pressure under removal of water and the subsequent second step is operated at a pressure ⁇ 0.01 mbar and ⁇ 200 mbar.
  • the catalyst is preferably introduced to the process in the first step.
  • the process comprises the steps of:
  • the present invention relates to a process for the production of polyether ester block copolymers wherein the process comprises reacting a mixture of reactants comprising:
  • polyalkylene glycol is 100%
  • reaction takes in the presence of 0.05 - 1.00 %wt of a catalyst with regard to the weight of the aromatic dicarboxylic acid, the catalyst being bis(1 ,2-ethanediolato) titanium; wherein the process comprises the steps of
  • the present invention further relates to polyether ester block copolymers obtained using the process according to the invention. Furthermore, the invention relates to articles produced using such polyether ester block copolymer.
  • a mixture of reactants comprising:
  • polycondensation was performed in the same reactor.
  • the reactor pressure was reduced from atmospheric pressure to 100 mbar over a period of 90 minutes.
  • the reactor pressure was further reduced to below 0.1 mbar over a period of 45 minutes, and the reaction temperature was increased to 250 °C over a period of 20 minutes.
  • the reaction mixture was kept under constant stirring at 250 °C at a pressure of below 0.1 mbar for a period of 2.0 hours.
  • the resulting polyether ester block copolymer was forced from the reactor by applying nitrogen pressure.
  • a polyether ester block copolymer A comprising 78 wt% of poly(butylene terephthalate)-based hard blocks, 20.0 wt% of polyethyleneglycol-based soft blocks and 2.0 wt% polydimethylsiloxane-based soft blocks with regard to the total weight of the polyether ester block copolymer was obtained.
  • a mixture of reactants comprising:
  • polycondensation was performed in the same reactor.
  • the reactor pressure was reduced from atmospheric pressure to 100 mbar over a period of 90 minutes.
  • the reactor pressure was further reduced to below 0.1 mbar over a period of 45 minutes, and the reaction temperature was increased to 250 °C over a period of 20 minutes.
  • the reaction mixture was kept under constant stirring at 250 °C at a pressure of below 0.1 mbar for a period of 2.0 hours.
  • the resulting polyether ester block copolymer was forced from the reactor by applying nitrogen pressure.
  • a polyether ester block copolymer B comprising 78 wt% of poly(butylene terephthalate)-based hard blocks, 20.0 wt% of polyethyleneglycol-based soft blocks and 2.0 wt% polydimethylsiloxane-based soft blocks with regard to the total weight of the polyether ester block copolymer was obtained.
  • Experiment C comparative
  • a mixture of reactants comprising:
  • polycondensation was performed in the same reactor.
  • the reactor pressure was reduced from atmospheric pressure to 100 mbar over a period of 90 minutes. Then the reactor pressure was further reduced to below 0.1 mbar over a period of 30 minutes.
  • the reaction mixture was kept under constant stirring at 250 °C at a pressure of below 0.1 mbar for a period of 2.0 hours. Finally the resulting polyether ester block copolymer was forced from the reactor by applying nitrogen pressure.
  • a polyether ester block copolymer C comprising 78 wt% of poly(butylene terephthalate)-based hard blocks, 20.0 wt% of polyethyleneglycol-based soft blocks and 2.0 wt% polydimethylsiloxane-based soft blocks with regard to the total weight of the polyether ester block copolymer was obtained.
  • a mixture of reactants comprising:
  • the dimethyl terephthalate was transesterified with the 1 ,4-butanediol, polyethyleneglycol and dihydroxy terminated polydimethylsiloxane.
  • a quantity of methanol was produced which was distilled out from the reaction mixture under nitrogen atmosphere.
  • polycondensation was performed in the same reactor.
  • the reactor pressure was reduced from atmospheric pressure to 100 mbar over a period of 90 minutes and the temperature further increased to 240 °C over a period of 45 minutes. Then the reactor pressure was further reduced to below 0.1 mbar over a period of 30 minutes, and the reaction temperature was increased to 250 °C.
  • the reaction mixture was kept under constant stirring at 250 °C at a pressure of below 0.1 mbar for a period of 2.0 hours. Finally the resulting polyether ester block copolymer was forced from the reactor by applying nitrogen pressure.
  • a polyether ester block copolymer D comprising 78 wt% of poly(butylene terephthalate )-based hard blocks, 20.0 wt% of polytetramethylene ether glycol-based soft blocks and 2.0 wt%
  • polydimethylsiloxane-based soft blocks with regard to the total weight of the polyether ester block copolymer was obtained.
  • Polyether ester block copolymer E was a material of the grade Hytrel ® 6356, obtainable from Dupont, which was used for comparative purposes.
  • ASTM D638-10 relates to a standard test method for tensile properties of plastics.
  • Determination of properties was performed at room temperature using samples of 2 mm thickness and a head speed of 50 mm/min. Samples were conditioned at 50% relative humidity at 23°C for 48 hrs prior to testing.
  • the weight average molecular weight M w of the polyether ester block copolymers was determined ASTM D5296-1 1 using a Shimadzu Class VP LC10 AD.
  • ASTM D5296-1 1 relates to a standard test method for molecular weight averages and molecular weight distribution of polystyrene by high performance size-exclusion chromatography. In the present invention, this standard has been used for determination of the molecular weight of the polyether ester block copolymers.

Abstract

The present invention relates to a process for the production of polyether ester block copolymers wherein the process comprises reacting a mixture of reactants comprising: • one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms; • one or more aliphatic diol comprising 2-10 carbon atoms; and • one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms; wherein the reaction takes in the presence of a catalyst having a structure according to formula (I); wherein R1 and R2 each individually are a moiety comprising 2-10 carbon atoms. The production of polyether ester block copolymers using such process eliminates the formation of undesired alcohol as a by-product. The polyether ester block copolymers produced using such process show a good balance of mechanical properties. Such process allows for the production of polyether ester block copolymers having a good balance of mechanical properties in a single reaction rather than involving the addition of the reactants to the reactor in several separate feeds.

Description

Process for the production of polyether ester block copolymers
The present invention relates to a process for the production of polyether ester block copolymers with reduced undesired by-product formation and, polyether ester block copolymer produced using such process having a good balance of mechanical properties.
Polyether ester block copolymers are a class of thermoplastic materials exhibiting elastomeric properties. Primarily because of their easy processability coupled with good thermo- mechanical properties, polyether ester block copolymers have found wide ranges of applications in many industrial branches including but not limited to automotive components, sporting goods, hose, cable jacketing, seals, and shoe soles.
The production of polyether ester block copolymers commonly takes place via
polycondensation processes such as melt polycondensation processes. The polyether ester block copolymers according to the state of the art are commonly produced using diesters of dicarboxylic acids, such as dimethyl terephthalate (DMT) as one of the raw materials. Such polyether ester block copolymers are for example described in US6670429.
Polyether ester block copolymers produced using such diesters of dicarboxylic acids may be produced in such way that they have a desirable balance of mechanical properties. However, a disadvantage of the use of such diesters of dicarboxylic acids is that a quantity of an alcohol such as methanol is formed as a by-product. This is not desirable, as the alcohol that is produced has to be separated and further processed.
The formation of alcohol as a by-product in the production of polyether ester copolymers can be avoided by using dicarboxylic acids, such as terephthalic acid (TPA), instead of the diesters of dicarboxylic acids as raw material. However, the material properties such as the tensile properties of the polyether ester block copolymers produced using such dicarboxylic acids are inadequate for many purposes.
For that reason, there is a need for development of a process for the production of polyether ester block copolymers using dicarboxylic acids as raw material, wherein the polyether ester block copolymers produced show a good balance of mechanical properties.
This has now been achieved according to the present invention by a process for the production of polyether ester block copolymers wherein the process comprises reacting a mixture of reactants comprising:
• one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms;
• one or more aliphatic diol comprising 2-10 carbon atoms; and • one or more polyalkylene glycol having a polymeric structure comprising
alkylene oxide units having 2-10 carbon atoms;
wherein the reaction takes in the presence of a catalyst having a structure according to formula I:
O 0
/ \ / \
Rl Ti R2
\ / \ /
O 0
Formula I
wherein R1 and R2 each individually are a moiety comprising 2-10 carbon atoms.
Alternatively, R1 and R2 each individually may be a moiety comprising 2-4 carbon atoms.
R1 and R2 may each individually be a hydrocarbon moiety. R1 and R2 may each individually be a branched or straight chain moiety. R1 and R2 may be the same. R1 and R2 may be different. R1 and R2 may each individually be a hydrocarbon moiety, R1 and R2 may each individually be a branched or straight chain moiety, and R1 and R2 may be the same or different.
For example, R1 and R2 may each individually be a moiety selected from an ethylene moiety, a propylene moiety, or a butylene moiety.
For example, R1 and R2 may each individually be moieties selected from -CH2-CH2-,
Figure imgf000003_0001
For example, both R1 and R2 may be moieties selected from -CH2-CH2- or
-CH2-CH2-CH2-. For example, both R1 and R2 may be -CH2-CH2-.
The production of polyether ester block copolymers using such process eliminates the formation of undesired alcohol as a by-product. The polyether ester block copolymers produced using such process show a good balance of mechanical properties, including a desirable tensile stress at 5% and 10% strain, a desirable tensile strength at break, and a desirable elongation at break. Furthermore, the polyether ester block copolymers produced using such process show such good balance of mechanical properties at a relatively low molecular weight. Such process allows for the production of polyether ester block copolymers having a good balance of mechanical properties in one single reaction operation rather than involving the addition of the reactants to the reactor in several separate stages
In a preferred embodiment of the invention, all reactants are fed to the process prior to the onset of the reaction. For example, the process may comprise all reactants to be fed to a reactor and subsequently the catalyst to be fed to the reactor.
The catalyst may be present in the polymerisation in quantities of for example 0.05-1 .00 % by weight, with regard to the weight of aromatic dicarboxylic acid comprising 6-12 carbon atoms present in the mixture of reactants. Alternatively, such catalyst may for example be present in quantities≥ 0.05 % by weight, alternatively≥ 0.10 % by weight, alternatively≥ 0.15 % by weight, with regard to the total weight of the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms. Such catalyst may for example be present in quantities < 1.00 % by weight, alternatively < 0.50 % by weight, alternatively < 0.30 % by weight, with regard to the total weight of the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms.
Such catalyst may for example be present in quantities≥ 0.05 % and < 1.00 % by weight, alternatively≥ 0.10 % and < 0.50 % by weight, alternatively≥ 0.15 % and < 0.30 % by weight, with regard to the total weight of the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms.
The presence of the catalyst in such quantities is understood to be beneficial in order for the polymerisation to result in a polyether ester block copolymer having a desired average molecular weight and desired tensile properties. Use of a lower quantity of catalyst may result in an incomplete reaction, where the polyether ester block copolymer obtained does not have a desired average molecular weight and desired tensile properties; furthermore, the reaction will proceed at very slow reaction rates. The use of a higher quantity of catalyst may result in the formation of undesired byproducts such as cyclic oligomers, where the polyether ester block copolymer obtained does not have desired tensile properties. Furthermore, the use of a higher quantity of catalyst may result in undesirable effects during further processing of the obtained polymer due to the remaining reactivity of the catalyst present in the polymer.
The catalyst preferably is selected from bis(1 ,2-ethanediolato) titanium, bis(1 ,3- propanediolato) titanium, bis(1 ,2-propanediolato) titanium, bis(1 ,3-butanediolato) titanium, bis(2,3-butanediolato) titanium, or bis(1 ,3-butanediolato) titanium. More preferably, the catalyst is bis(1 ,2-ethanediolato) titanium. The polyether ester block copolymers produced using the process of the present invention may for example comprise:
(I) hard block moieties formed by reacting one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms with one or more aliphatic diol comprising 2-10 carbon atoms;
(II) soft block moieties formed by reacting one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms with one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms. Alternatively, the polyether ester block copolymers produced using the process of the present invention may further comprise:
(III) soft block moieties formed by reacting one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms with one or more hydroxy-terminated polysiloxane or a copolymer thereof.
The polyether ester block copolymer may for example comprise≥ 49.5 % by weight, alternatively≥ 60.0 % by weight, alternatively≥ 70.0 % by weight, of hard block moieties (I), compared to the total weight of the polyether ester block copolymer. For example, the polyether ester block copolymer may comprise < 89.5 % by weight, alternatively < 85.0 % by weight, alternatively < 80.0 % by weight, of hard block moieties (I), compared to the total weight of the polyether ester block copolymer. For example, the polyether ester block copolymer may comprise≥ 49.5 and < 89.5 % by weight, alternatively≥ 60.0 and < 85.0 % by weight, alternatively≥ 70.0 and < 80.0 % by weight, of hard block moieties (I), compared to the total weight of the polyether ester block copolymer.
The polyether ester block copolymer may for example comprise≥ 10.0 % by weight, alternatively≥ 15.0 % by weight, alternatively≥ 20.0 % by weight, of soft block moieties (II), compared to the total weight of the polyether ester block copolymer. For example, the polyether ester block copolymer may comprise < 50.0 % by weight, alternatively < 40.0 % by weight, alternatively < 30.0 % by weight, of soft block moieties (II), compared to the total weight of the polyether ester block copolymer. For example, the polyether ester block copolymer may comprise≥ 10.0 and < 50.0 % by weight, alternatively≥ 15.0 and < 40.0 % by weight, alternatively≥ 20.0 and < 30.0 % by weight, of soft block moieties (II). The polyether ester block copolymer may for example comprise≥ 0.5 % by weight, alternatively≥ 1 .0 % by weight, alternatively≥ 1 .5 % by weight, of soft block moieties (III), compared to the total weight of the polyether ester block copolymer. For example, the polyether ester block copolymer may comprise < 6.0 % by weight, alternatively < 5.0 % by weight, alternatively < 4.0 % by weight, alternatively < 3.0 % by weight, of soft block moieties (III), compared to the total weight of the polyether ester block copolymer. For example, the polyether ester block copolymer may comprise≥ 0.5 and < 6.0 % by weight, alternatively≥ 0.5 and < 5.0 % by weight, alternatively≥ 0.5 and < 4.0 % by weight, alternatively≥ 1 .0 and < 3.0 % by weight, of soft block moieties (III), compared to the total weight of the polyether ester block copolymer.
For example, the polyether ester block copolymer may comprise≥ 0.5 and < 6.0 % by weight of soft block moieties (III) compared to the total weight of the polyether ester block copolymer. In another embodiment, the polyether ester block copolymer may comprise≥ 0.5 and < 4.0 % by weight of soft block moieties (III) compared to the total weight of the polyether ester block copolymer.
In the case where the polyether ester block copolymer comprises hard block moieties (I), soft block moieties (II) and soft block moieties (III), the sum of the percentages of weights of (I), (II) and (III) is 100%. In the case where the polyether ester block copolymer does not comprise (III), the sum of the percentages of weights of (I) and (II) is 100 %.
The hard block moieties (I) as present in the polyether ester block copolymers of the present invention may for example comprise poly(alkylene arylate) moieties. Such poly(alkylene arylate) moieties may for example be selected from poly(ethylene terephthalate), poly(butylene terephthalate), poly(propylene terephthalate), poly(ethylene naphthanoate), poly(propylene naphthanoate), poly(butylene naphthanoate), and/or poly(ethylene terephthalate)(butylene terephthalate). Preferably, the poly(alkylene arylate) moieties are poly(ethylene terephthalate), poly(butylene terephthalate) or poly(ethylene terephthalate)(butylene terephthalate).
The one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms may for example be one or more selected from isophthalic acid, terephthalic acid, 1 ,4-naphthalene dicarboxylic acid, 1 ,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, For example, the aromatic dicarboxylic acid comprising 6-12 carbon atoms may be one or more selected from terephthalic acid and/or isophthalic acid. For example, the aromatic dicarboxylic acid comprising 6-12 carbon atoms may be terephthalic acid.
The one or more aliphatic diol comprising 2-10 carbon atoms may for example be one or more selected from 1 ,2-ethanediol, 1 ,2-propanediol, 1 ,3-propanediol, 1 ,2-butanediol, 1 ,3- butanediol and/or 1 ,4-butanediol. Preferably, the one or more aliphatic diol comprising 2-10 carbon atoms is 1 ,4-butanediol.
The polyether ester block copolymer may be obtained by reacting a mixture of reactants comprising a first and a second aliphatic diol each having a different molecular composition. The first and the second aliphatic diol may each be selected from 1 ,2-ethanediol, 1 ,2-propanediol, 1 ,3-propanediol, 1 ,2-butanediol, 1 ,3-butanediol and 1 ,4-butanediol. For example, the first aliphatic diol may be 1 ,2-ethanediol and the second aliphatic diol may be 1 ,4-butanediol. The quantity of the first and the second aliphatic diol may for example be such that the ratio of the weight of the fraction of the hard blocks derived from the first aliphatic diol to the weight of the fraction of hard blocks derived from the second aliphatic diol is≥ 0.2 and < 2.0.
The one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms may for example be one or more selected from polyethyleneglycol, polypropyleneglycol and/or polytetramethyleneetherglycol, such as polyethyleneglycol. The polyalkylene glycol may for example have a number average molecular weight Mn as determined in accordance with ASTM D5296-1 1 of≥ 500 g/mol, alternatively≥ 1000 g/mol. The polyalkylene glycol may for example have a number average molecular weight Mn of < 2500 g/mol, alternatively < 2000 g/mol. For example, the polyalkylene glycol may have a number average molecular weight Mn of≥ 500 and < 2500 g/mol, alternatively≥ 1000 and < 2000 g/mol.
The hydroxy-terminated polysiloxane may for example be a polysiloxane according to the formula II:
Rl
I
HO—— R2—— O— f l.- St— O 4 J- η R2— OH
I
Rl
Formula II
Wherein R1 may be an alkyl moiety such as methyl, ethyl or propyl, for example methyl.
R2 may each individually be an alkyl moiety or a dialkyl ether moiety such as a dimethyl ether moiety, a diethyl ether moiety, a methyl ethyl ether moiety, or an ethyl propyl ether moiety. For example, each R2 may be an ethyl propyl ether moiety wherein the ethyl group of the ethyl propyl moiety is connected to the terminal hydroxyl-moiety of the hydroxy-terminated
polysiloxane.
n may be≥ 5 and < 30; n is the average number of recurring siloxane polymeric units.
For example, the hydroxy-terminated polysiloxane may be a polysiloxane according to formula I wherein each R2 is an ethyl propyl ether moiety of which the ethyl moiety is connected to the terminal hydroxyl-moiety, each R1 is methyl, and n≥ 5 and < 30.
The one or more hydroxy-terminated polysiloxane may for example be a hydroxy- terminated polydimethyl siloxane or a copolymer thereof.
The present invention in one preferred embodiment relates to a process for the production of polyether ester block copolymers by reacting a mixture of reactants wherein:
the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms is one or more selected from terephthalic acid, isophthalic acid, 1 ,4- naphthalenedicarboxylic acid, 1 ,5-naphthalenedicarboxylic acid, 2,6- naphthalenedicarboxylic acid, or combinations thereof; and/or the one or more aliphatic diol is one or more selected from 1 ,2-ethanediol, 1 ,2- propanediol, 1 ,3-propanediol, 1 ,2-butanediol, 1 ,3-butanediol, 1 ,4-butanediol or combinations thereof; and/or
the one or more polyalkylene glycol is selected from polyethyleneglycol, polypropyleneglycol, polytetramethyleneetherglycol, or combinations thereof; wherein the polymerisation takes in the presence of a catalyst having a structure according to formula I:
O 0
/ \ / \
Rl Tt R2
\ / \ /
O 0
Formula I
wherein R1 and R2 each individually are a moiety comprising 2-10 carbon atoms. The mixture of reactants may further comprise one or more hydroxy-terminated polysiloxane or a copolymer thereof. Such hydroxy-terminated polysiloxane may be selected from hydroxy-terminated polydimethylsiloxanes.
Preferably, the mixture of reactants comprises:
• ≥ 10.0 and < 50.0 wt% of one or more aromatic dicarboxylic acid comprising 6- 12 carbon atoms; and/or
• ≥ 10.0 and < 60.0 wt% of one or more aliphatic diol comprising 2-10 carbon atoms; and/or
• ≥ 5.0 and < 60.0 wt% of one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms
with regard to the total weight of the mixture of reactants; wherein the sum of the %wt of the aromatic dicarboxylic acid, the aliphatic diol and the polyalkylene glycol is 100%.
For example the mixture of reactants may comprise≥ 10.0 and < 50.0 wt%, alternatively≥ 20.0 and < 45.0 wt%, alternatively≥ 30.0 and < 40.0 wt%, of one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms, with regard to the total weight of the mixture of reactants. The mixture or reactants may comprise≥ 10.0 and < 60.0 wt%, alternatively≥ 30.0 and < 55.0, alternatively≥ 40.0 and < 55.0 wt% of one or more aliphatic diol comprising 2-10 carbon atoms, with regard to the total weight of the mixture of reactants. The mixture of reactants may comprise≥ 5.0 and < 60.0 wt%, alternatively≥ 10.0 and < 40.0 wt%, alternatively≥ 10.0 and < 20.0 wt% of one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms, with regard to the total weight of the mixture of reactants.
The process for production of polyether ester block copolymers according to the present invention may for example be a polycondensation process. Such polycondensation process may be performed in one single reactor or in multiple reactors, such as in multiple reactors arranged in series. Preferably, the process is performed in a single reactor.
The process may be a batch process or a continuous process. The process may be a melt process in which the reactants are present in the molten state. The process may comprise two reaction steps. Such process comprising two reaction steps may comprise a first and a second step, wherein the first step precedes the second step. In the case where the polycondensation takes place in a process comprising a first step and a second step, an esterification reaction takes place in the first step, and a transesterification takes place in the second step.
In that first step, a mixture of reactants comprising one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms, one or more aliphatic diol comprising 2-10 carbon atoms, and one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms is introduced into a reactor. In that first step, a quantity of the reactants having hydroxyl-functional groups may react with a quantity of the reactants having carboxylic acid functional groups. The reactants having hydroxyl-functional groups include the aliphatic diol, the polyalkylene glycol and the hydroxy-terminated polysiloxane. The reactants having carboxylic acid functional groups include the aromatic dicarboxylic acid. Carboxylic acid functional groups of the aromatic dicarboxylic acid may react with the hydroxyl-functional groups of the aliphatic diol, the polyalkylene glycol and/or the hydroxy-terminated polysiloxane to form ester moieties.
Such first step may for example be operated at atmospheric pressure. The catalyst is introduced during the first step.
In the second step, the polyether ester block copolymers may be formed by
transesterification of the reaction mixture obtained from the first step. The second step may for example be operated at a pressure below atmospheric pressure, for example at pressures≥ 0.01 mbar and < 200 mbar, alternatively≥ 0.01 mbar and < 100 mbar. The second step may for example comprise two or more stages, in which in the first stage the pressure may for example be kept at≥ 1 mbar and < 200 mbar, alternatively≥1 mbar and < 100 mbar, and in which in a second stage the pressure may for example be further reduced to≥ 0.01 mbar and < 1 mbar, alternatively≥ 0.01 mbar and < 0.1 mbar. The first step and the second step may be performed in a single reactor.
Preferably, the process comprises a first step and a subsequent second reaction step, wherein the first step is operated at atmospheric pressure under removal of water and the subsequent second step is operated at a pressure≥ 0.01 mbar and < 200 mbar.
The catalyst is preferably introduced to the process in the first step. In a further preferred embodiment, the process comprises the steps of:
1 ) introducing the mixture of reactants and the catalyst to a reactor;
2) reacting the mixture of reactants at a temperature of≥ 180°C and < 300°C, alternatively≥ 190°C and < 300°C, at atmospheric pressure under removal of water; 3) further reacting at a temperature of≥ 220°C and < 300°C, alternatively≥ 230°C and < 300°C at a pressure of≥ 0.01 mbar and < 200 mbar, alternatively≥ 0.01 mbar and < 100 mbar; and
4) removing the produced polyether ester copolymer from the reactor;
wherein the steps 1 -4 are performed in that order.
In a most preferred form, the present invention relates to a process for the production of polyether ester block copolymers wherein the process comprises reacting a mixture of reactants comprising:
• 20.0 - 50.0 wt% of one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms, wherein the aromatic carboxylic acid is terephthalic acid;
• 40.0 - 60.0 wt% of one or more aliphatic diol comprising 2-10 carbon atoms, wherein the aliphatic diol is 1 ,4-butanediol; and
• 5.0 - 25.0 wt% of one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms, wherein the polyalkylene glycol is polyethyleneglycol;
with regard to the total weight of the mixture of reactants; wherein the sum of the %wt of the aromatic dicarboxylic acid, the aliphatic diol and the
polyalkylene glycol is 100%;
wherein the reaction takes in the presence of 0.05 - 1.00 %wt of a catalyst with regard to the weight of the aromatic dicarboxylic acid, the catalyst being bis(1 ,2-ethanediolato) titanium; wherein the process comprises the steps of
1 ) introducing the mixture of reactants and the catalyst to a reactor;
2) reacting the mixture of reactants at a temperature of≥ 180°C and < 300°C, alternatively≥ 190°C and < 300°C, at atmospheric pressure under removal of water;
3) further reacting at a temperature of≥ 220°C and < 300°C, alternatively≥ 230°C and < 300°C at a pressure of≥ 0.01 mbar and < 200 mbar, alternatively≥ 0.01 mbar and < 100 mbar; and
4) removing the produced polyether ester copolymer from the reactor;
wherein the steps 1 -4 are performed in that order. The present invention further relates to polyether ester block copolymers obtained using the process according to the invention. Furthermore, the invention relates to articles produced using such polyether ester block copolymer.
The invention will now be illustrated by the following non-limiting examples.
Preparation of polyether ester block copolymers
Experiment A
A mixture of reactants comprising:
• 682 g terephthalic acid as dicarboxylic acid;
• 1064 g 1 ,4-butanediol as alkane diol;
· 228 g polyethyleneglycol having Mn of 1500 as polyalkylene glycol; and
• 34.4 g dihydroxy terminated polydimethylsiloxane (Baysilone OF-OH 702E, obtained from Momentive Performance Materials of India) as polysiloxane.
was charged into a dried reactor pre-heated to 200 °C under nitrogen atmosphere. Subsequently, an amount of 0.15 weight % of titanium (IV) glycolate (CAS Reg. Nr. 310-92-9) with regard to the weight of terephthalic acid in the mixture of reactants was added as catalyst. The mixture of reactants was heated from 200 °C to 240 °C over a period of 30 minutes and kept under constant stirring for another 2.0 hours. During this step, the terephthalic acid was esterified with the 1 ,4-butanediol, polyethyleneglycol and dihydroxy terminated
polydimethylsiloxane. During the reaction, a quantity of water was produced which was distilled off from the reaction mixture.
In the second step, polycondensation was performed in the same reactor. The reactor pressure was reduced from atmospheric pressure to 100 mbar over a period of 90 minutes. Then the reactor pressure was further reduced to below 0.1 mbar over a period of 45 minutes, and the reaction temperature was increased to 250 °C over a period of 20 minutes. The reaction mixture was kept under constant stirring at 250 °C at a pressure of below 0.1 mbar for a period of 2.0 hours. Finally the resulting polyether ester block copolymer was forced from the reactor by applying nitrogen pressure. A polyether ester block copolymer A comprising 78 wt% of poly(butylene terephthalate)-based hard blocks, 20.0 wt% of polyethyleneglycol-based soft blocks and 2.0 wt% polydimethylsiloxane-based soft blocks with regard to the total weight of the polyether ester block copolymer was obtained.
Experiment B (comparative)
A mixture of reactants comprising:
• 341 g terephthalic acid as dicarboxylic acid;
• 532 g 1 ,4-butanediol as alkane diol;
• 1 14 g polyethyleneglycol having Mn of 1500 as polyalkylene glycol; and
• 17.2 g dihydroxy terminated polydimethylsiloxane (Baysilone OF-OH 702E, obtained from Momentive Performance Materials of India) as polysiloxane.
was charged into a dried reactor pre-heated to 200 °C under nitrogen atmosphere. Subsequently, an amount of 0.15 weight % of titanium (IV) tetraisopropoxide (CAS Reg. Nr. 546-68-9) with regard to the weight of terephthalic acid in the mixture of reactants was added as catalyst. The mixture of reactants was heated from 200 °C to 240 °C over a period of 30 minutes and kept under constant stirring for another 2.0 hours. During this step, the terephthalic acid was esterified with the 1 ,4-butanediol, polyethyleneglycol and dihydroxy terminated polydimethylsiloxane. During the reaction, a quantity of water was produced which was distilled off from the reaction mixture.
In the second step, polycondensation was performed in the same reactor. The reactor pressure was reduced from atmospheric pressure to 100 mbar over a period of 90 minutes. Then the reactor pressure was further reduced to below 0.1 mbar over a period of 45 minutes, and the reaction temperature was increased to 250 °C over a period of 20 minutes. The reaction mixture was kept under constant stirring at 250 °C at a pressure of below 0.1 mbar for a period of 2.0 hours. Finally the resulting polyether ester block copolymer was forced from the reactor by applying nitrogen pressure. A polyether ester block copolymer B comprising 78 wt% of poly(butylene terephthalate)-based hard blocks, 20.0 wt% of polyethyleneglycol-based soft blocks and 2.0 wt% polydimethylsiloxane-based soft blocks with regard to the total weight of the polyether ester block copolymer was obtained. Experiment C (comparative)
A mixture of reactants comprising:
• 681 g terephthalic acid as dicarboxylic acid; and
• 1064 g 1 ,4-butanediol as alkane diol; was charged into a dried reactor pre-heated to 200 °C under nitrogen atmosphere.
Subsequently, an amount of 0.075 weight % of titanium (IV) tetraisopropoxide (CAS Reg. Nr. 546-68-9) with regard to the weight of terephthalic acid in the mixture of reactants was added as catalyst. The mixture of reactants was heated from 200 °C to 240 °C over a period of 30 minutes and kept under constant stirring for another 1.5 hours. During this step, the terephthalic acid was esterified with the 1 ,4-butanediol. During the reaction, a quantity of water was produced which was distilled off from the reaction mixture. The reactor pressure was reduced to 700 mbar over a period of 10 minutes and the reaction mixture was kept for 20 minutes at a pressure of 700 mbar and 240 °C to further remove water.
Subsequently, the reactor pressure was brought back to atmospheric pressure and
• 228 g polyethyleneglycol having Mn of 1500 as polyalkylene glycol; and
• 34.4 g dihydroxy terminated polydimethylsiloxane (Baysilone OF-OH 702E,
obtained from Momentive Performance Materials of India) as polysiloxane.
were charged along with an amount of 0.075 weight % of titanium (IV) tetraisopropoxide (CAS Reg. Nr. 546-68-9) with regard to the weight of terephthalic acid as catalyst into the reactor. The reaction temperature was increased to 250 °C in next 5 minutes. The reaction mixture was left under constant stirring for next 10 minutes. During this step, the reaction mixture from the first stage was transesterified with the polyethyleneglycol and dihydroxy terminated polydimethylsiloxane.
In the second step, polycondensation was performed in the same reactor. The reactor pressure was reduced from atmospheric pressure to 100 mbar over a period of 90 minutes. Then the reactor pressure was further reduced to below 0.1 mbar over a period of 30 minutes. The reaction mixture was kept under constant stirring at 250 °C at a pressure of below 0.1 mbar for a period of 2.0 hours. Finally the resulting polyether ester block copolymer was forced from the reactor by applying nitrogen pressure. A polyether ester block copolymer C comprising 78 wt% of poly(butylene terephthalate)-based hard blocks, 20.0 wt% of polyethyleneglycol-based soft blocks and 2.0 wt% polydimethylsiloxane-based soft blocks with regard to the total weight of the polyether ester block copolymer was obtained.
Experiment D (comparative)
A mixture of reactants comprising:
• 796 g dimethyl terephthalate as dicarboxylic acid diester;
• 532 g 1 ,4-butanediol as alkane diol; • 228 g polyethyleneglycol having Mn of 1500 as polyether glycol; and
• 34.4 g dihydroxy terminated polydimethylsiloxane (Baysilone OF-OH 702E) as polysiloxane.
was charged into a dried reactor pre-heated to 120 °C under nitrogen atmosphere. The mixture of reactants was heated from 120 °C to 170 °C under constant stirring during 20 minutes. Subsequently, an amount of 0.15 weight % of titanium (IV) tetraisopropoxide (CAS Reg. Nr. 546-68-9) with regard to the weight of dimethyl terephthalate in the mixture of reactants was added as catalyst. The reaction temperature was then increased to 220 °C over a period of 2.0 hours. The reaction mixture was then kept at 220 °C for 30 minutes. During this step, the dimethyl terephthalate was transesterified with the 1 ,4-butanediol, polyethyleneglycol and dihydroxy terminated polydimethylsiloxane. During the reaction, a quantity of methanol was produced which was distilled out from the reaction mixture under nitrogen atmosphere.
In the second step, polycondensation was performed in the same reactor. The reactor pressure was reduced from atmospheric pressure to 100 mbar over a period of 90 minutes and the temperature further increased to 240 °C over a period of 45 minutes. Then the reactor pressure was further reduced to below 0.1 mbar over a period of 30 minutes, and the reaction temperature was increased to 250 °C. The reaction mixture was kept under constant stirring at 250 °C at a pressure of below 0.1 mbar for a period of 2.0 hours. Finally the resulting polyether ester block copolymer was forced from the reactor by applying nitrogen pressure. A polyether ester block copolymer D comprising 78 wt% of poly(butylene terephthalate )-based hard blocks, 20.0 wt% of polytetramethylene ether glycol-based soft blocks and 2.0 wt%
polydimethylsiloxane-based soft blocks with regard to the total weight of the polyether ester block copolymer was obtained.
Determination of properties of polyether ester block copolymers
Tensile properties of polyether ester block copolymers A through D as prepared above as well as of comparative polyether ester block copolymer E were determined in accordance with ASTM D638-10 on type V specimens using a Zwick/Roell Z010 universal tensile testing machine.
Polyether ester block copolymer E was a material of the grade Hytrel® 6356, obtainable from Dupont, which was used for comparative purposes. ASTM D638-10 relates to a standard test method for tensile properties of plastics.
Determination of properties was performed at room temperature using samples of 2 mm thickness and a head speed of 50 mm/min. Samples were conditioned at 50% relative humidity at 23°C for 48 hrs prior to testing.
The weight average molecular weight Mw of the polyether ester block copolymers was determined ASTM D5296-1 1 using a Shimadzu Class VP LC10 AD. ASTM D5296-1 1 relates to a standard test method for molecular weight averages and molecular weight distribution of polystyrene by high performance size-exclusion chromatography. In the present invention, this standard has been used for determination of the molecular weight of the polyether ester block copolymers.
The values for the properties of the tested samples are presented in table I.
Table I
Figure imgf000016_0001
* due to very broad molecular weight distribution peak, no meaningful Mw obtainable.
The properties of the polyether ester block copolymers A through E as presented in table I demonstrate the effects of the process of the present invention:
• Comparing the properties of polyether ester block copolymer A with B clearly shows that the process of the present invention in which an aromatic dicarboxylic acid and a catalyst according to formula I is used allows for the production of a polyether ester block copolymer having improved mechanical properties compared to a polyether ester block copolymer prepared using an aromatic dicarboxylic acid and a catalyst according to the state of the art such as titanium tetraisopropoxide; • Comparing the properties of polyether ester block copolymer A with C clearly shows that if using a catalyst according to the state of the art such as titanium tetraisopropoxide, in order to obtain a polyether ester block copolymer having the desired mechanical properties, the reaction is to be performed by split addition of the reactants rather than in a single reaction as with the present invention
• Comparing the properties of polyether ester block copolymer A with D clearly shows that the process of the present invention in which an aromatic dicarboxylic acid and a catalyst according to formula I is used allows for the production of a polyether ester block copolymer having the desired mechanical properties without having the disadvantage of the formation of an alcohol such as methanol as by-product;
• Comparing the properties of polyether ester block copolymer A with E clearly shows that the process of the present invention allows for the production of a polyether ester block copolymer having the desired mechanical properties at a lower weight average molecular weight Mw compared with polyether ester block copolymers according to the state of the art.

Claims

Claims
1 . Process for the production of polyether ester block copolymers wherein the process
comprises reacting a mixture of reactants comprising:
• one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms;
• one or more aliphatic diol comprising 2-10 carbon atoms; and
• one or more polyalkylene glycol having a polymeric structure comprising
alkylene oxide units having 2-10 carbon atoms;
wherein the reaction takes in the presence of a catalyst having a structure according to formula I:
O 0
/ \ / \
l Ti R2
\ / \ /
O 0
Formula I
wherein R1 and R2 each individually are a moiety comprising 2-10 carbon atoms.
2. Process according to claim 1 wherein the all reactants are fed to the process prior to the onset of the reaction.
3. Process according to any one of the claims 1-2 wherein the catalyst is added to the
reaction in quantities of≥ 0.05 wt% and < 1.00 wt% with regard to the weight of the aromatic dicarboxylic acid present in the mixture of reactants.
4. Process according to any one of the claims 1-3 wherein the catalyst is selected from bis(1 , 2-ethanediolato) titanium, bis(1 ,3-propanediolato) titanium, bis(1 ,2-propanediolato) titanium, bis(1 ,3-butanediolato) titanium, bis(2,3-butanediolato) titanium, bis(1 ,3- butanediolato) titanium.
5. Process according to any one of the claims 1-4 wherein:
• the one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms is one or more selected from terephthalic acid, isophthalic acid, 1 ,4- naphthalenedicarboxylic acid, 1 ,5-naphthalenedicarboxylic acid, 2,6- naphthalenedicarboxylic acid, or combinations thereof; and/or
• the one or more aliphatic diol is one or more selected from 1 ,2-ethanediol, 1 ,2- propanediol, 1 ,3-propanediol, 1 ,2-butanediol, 1 ,3-butanediol, 1 ,4-butanediol or combinations thereof; and/or
• the one or more polyalkylene glycol is one or more selected from
polyethyleneglycol, polypropyleneglycol, polytetramethyleneetherglycol, or combinations thereof.
Process according to any one of the claims 1-5 wherein the mixture of reactants further comprises a hydroxy-terminated polysiloxane or a copolymer thereof.
Process according to any one of the claims 1-6 wherein the mixture of reactants comprises:
• 10.0 - 50.0 wt% of one or more aromatic dicarboxylic acid comprising 6-12 carbon atoms; and/or
• 10.0 - 60.0 wt% of one or more aliphatic diol comprising 2-10 carbon atoms; and/or
• 5.0 - 60.0 wt% of one or more polyalkylene glycol having a polymeric structure comprising alkylene oxide units having 2-10 carbon atoms;
with regard to the total weight of the mixture of reactants; wherein the sum of the %wt of the aromatic dicarboxylic acid, the aliphatic diol and the polyalkylene glycol is 100%.
Process according to any one of claims 1 -7 wherein the process is performed in a single reactor.
Process according to any one of claims 1 -8 comprising a first step and a subsequent second step, wherein:
• the first step is operated at atmospheric pressure under removal of water;
• the subsequent second step is operated at a pressure≥ 0.01 mbar and < 200 mbar. Process according to claim 9 wherein the catalyst is introduced to the process in the first step.
Process according to any one of claims 9-10 wherein the process comprises the steps:
1 ) introducing the mixture of reactants and the catalyst to a reactor;
2) reacting the mixture of reactants at a temperature of≥ 180°C and < 300°C at atmospheric pressure under removal of water;
3) further reacting at a temperature of≥ 220°C and < 300°C at a pressure of≥ 0.01 mbar and < 200 mbar; and
4) removing the produced polyether ester copolymer from the reactor;
wherein the steps 1 -4 are performed in that order.
Polyether ester block copolymer obtained from or obtainable by the process according to any one of the claims 1-1 1 .
Article produced using the polyether ester block copolymer obtained from or obtainable by the process according to any one of claims 1 -1 1 or using the polyether ester block copolymer of claim 12.
PCT/EP2016/076775 2015-11-27 2016-11-07 Process for the production of polyether ester block copolymers WO2017089099A1 (en)

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CN111100277A (en) * 2018-10-25 2020-05-05 中国石油化工股份有限公司 Modified polyether ester for engineering plastic base material and preparation method thereof
CN115785409A (en) * 2022-11-22 2023-03-14 中国石油化工股份有限公司 Titanium catalyst and preparation method thereof

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CN111100277A (en) * 2018-10-25 2020-05-05 中国石油化工股份有限公司 Modified polyether ester for engineering plastic base material and preparation method thereof
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