U.S. patent application number 09/916160 was filed with the patent office on 2003-03-13 for method for preparing copolyestercarbonates and articles therefrom.
This patent application is currently assigned to General Electric Company. Invention is credited to Brunelle, Daniel Joseph, O'Neil, Gregory Allen, Siclovan, Tiberiu Mircea, Suriano, Joseph Anthony, Webb, Jimmy Lynn.
Application Number | 20030050400 09/916160 |
Document ID | / |
Family ID | 25436791 |
Filed Date | 2003-03-13 |
United States Patent
Application |
20030050400 |
Kind Code |
A1 |
Suriano, Joseph Anthony ; et
al. |
March 13, 2003 |
METHOD FOR PREPARING COPOLYESTERCARBONATES AND ARTICLES
THEREFROM
Abstract
Block copolyestercarbonates substantially free of anhydride
linkages linking at least two mers of the polymer chain may be
prepared by a method which comprises the steps of: (A) preparing a
hydroxy-terminated polyester intermediate in a molten reaction
mixture comprising at least one 1,3-dihydroxybenzene moiety and at
least one aromatic dicarboxylic acid diarylester under
transesterification conditions, said polyester intermediate having
a degree of polymerization of at least 4; and (B) conducting a
reaction of said polyester intermediate with a carbonate precursor
in a two-phase system comprising an aqueous phase and a
water-immiscible organic solvent. Articles comprising the
copolyestercarbonates are another aspect of the invention.
Inventors: |
Suriano, Joseph Anthony;
(Clifton Park, NY) ; Siclovan, Tiberiu Mircea;
(Rexford, NY) ; O'Neil, Gregory Allen; (Clifton
Park, NY) ; Brunelle, Daniel Joseph; (Burnt Hills,
NY) ; Webb, Jimmy Lynn; (Ballston Lake, NY) |
Correspondence
Address: |
GENERAL ELECTRIC COMPANY
GLOBAL RESEARCH CENTER
PATENT DOCKET RM. 4A59
PO BOX 8, BLDG. K-1 ROSS
NISKAYUNA
NY
12309
US
|
Assignee: |
General Electric Company
|
Family ID: |
25436791 |
Appl. No.: |
09/916160 |
Filed: |
July 26, 2001 |
Current U.S.
Class: |
525/152 |
Current CPC
Class: |
C08G 63/64 20130101;
Y10T 428/31565 20150401 |
Class at
Publication: |
525/152 |
International
Class: |
C08L 001/00 |
Claims
What is claimed is:
1. A method for preparing a block copolyestercarbonate
substantially free of anhydride linkages linking at least two mers
of the polymer chain, which comprises the steps of: (A) preparing a
hydroxy-terminated polyester intermediate in a molten reaction
mixture comprising at least one 1,3-dihydroxybenzene moiety and at
least one aromatic dicarboxylic acid diarylester under
transesterification conditions, said polyester intermediate having
a degree of polymerization of at least 4; and (B) conducting a
reaction of said polyester intermediate with a carbonate precursor
in a two-phase system comprising an aqueous phase and a
water-immiscible organic solvent.
2. The method of claim 1 wherein at least one 1,3-dihydroxybenzene
moiety is selected from the group consisting of unsubstituted
resorcinol, 2-methyl resorcinol, and mixtures thereof.
3. The method of claim 2 wherein at least one 1,3-dihydroxybenzene
moiety is unsubstituted resorcinol.
4. The method of claim 1 wherein at least one aromatic dicarboxylic
acid diaryl ester is derived from a dicarboxylic acid selected from
the group consisting of isophthalic acid, terephthalic acid, and
naphthalene-2,6-dicarboxylic acid, and mixtures thereof.
5. The method of claim 4 wherein the aromatic dicarboxylic acid
diaryl ester comprises a mixture isophthalic acid diaryl ester and
terephthalic acid diaryl ester.
6. The method of claim 5 wherein the ratio of isophthalic acid
diaryl ester to terephthalic acid diaryl ester is about
0.2-5:1.
7. The method of claim 6 wherein the ratio of isophthalic acid
diaryl ester to terephthalic acid diaryl ester is about
0.8-2.5:1.
8. The method of claim 7 wherein the ratio of isophthalic acid
diaryl ester to terephthalic acid diaryl ester is about
1.01-1.5:1.
9. The method of claim 8 wherein the ratio of isophthalic acid
diaryl ester to terephthalic acid diaryl ester is about
1.02-1.2:1.
10. The method of claim 4 wherein at least one aromatic
dicarboxylic acid diaryl ester is derived from a monohydroxy
aromatic compound selected from the group consisting of an
unsubstituted monohydroxy aromatic compound and monohydroxy
aromatic compounds comprising at least one electron withdrawing
group ortho or para to the oxygen substituent of the monohydroxy
moiety.
11. The method of claim 10 wherein at least one aromatic
dicarboxylic acid diaryl ester is derived from a monohydroxy
aromatic compound selected from the group consisting of phenol,
o-carbomethoxyphenol, o-carbomethoxymethylphenol,
o-carboethoxyphenol, o-carbopropoxyphenol, o-chlorophenol,
o-carbophenylphenol, o-carbophenoxyphenol, o-carbobenzoxyphenol,
and o-nitrophenol.
12. The method of claim 10 wherein monohydroxy aromatic compound is
recovered from the reaction mixture.
13. The method of claim 4 further comprising at least one aliphatic
dicarboxylic acid diaryl ester.
14. The method of claim 13 wherein an aliphatic dicarboxylic acid
diaryl ester comprises at least one dicarboxylic acid selected from
the group consisting of a C.sub.3-20 straight chain alkylene
dicarboxylic acid, a C.sub.3-20 branched alkylene dicarboxylic
acid, C.sub.4-20 cycloalkylene dicarboxylic acid, and a C.sub.4-20
bicycloalkylene dicarboxylic acid.
15. The method of claim 14 wherein an aliphatic dicarboxylic acid
diaryl ester comprises at least one alkylene dicarboxylic acid
selected from the group consisting of sebacic acid,
cyclohexane-1,4-dicarboxylic acid, and mixtures thereof.
16. The method of claim 13 wherein at least one alkylene
dicarboxylic acid diaryl ester is derived from a monohydroxy
aromatic compound selected from the group consisting of an
unsubstituted monohydroxy aromatic compound and monohydroxy
aromatic compounds comprising at least one electron withdrawing
group ortho or para to the oxygen substituent of the monohydroxy
moiety.
17. The method of claim 16 wherein at least one alkylene
dicarboxylic acid diaryl ester is derived from a monohydroxy
aromatic compound selected from the group consisting of phenol,
o-carbomethoxyphenol, o-carbomethoxymethylphenol,
o-carboethoxyphenol, o-carbopropoxyphenol, o-chlorophenol,
o-carbophenylphenol, o-carbophenoxyphenol, o-carbobenzoxyphenol,
and o-nitrophenol.
18. The method of claim 16 wherein monohydroxy aromatic compound is
recovered from the reaction mixture.
19. The method of claim 1 wherein the molar ratio of
1,3-dihydroxybenzene moiety to dicarboxylic acid diester in step
(A) is in the range of about 1.01-1.90:1.
20. The method of claim 19 wherein the molar ratio of
1,3-dihydroxybenzene moiety to dicarboxylic acid diester in step
(A) is in the range of about 1.01-1.25:1.
21. The method of claim 1 wherein step (A) further comprises a
catalyst.
22. The method of claim 21 wherein a catalyst is present at a total
level of about 10.sup.-8 moles to about 0.1 moles per mole of
dicarboxylic acid diester compound.
23. The method of claim 21 wherein the catalyst comprises at least
one member selected from the group consisting of
nitrogen-containing basic compounds, phosphorus-containing basic
compounds, alkali metal compounds, alkaline earth metal compounds,
a boric acid and a boric ester.
24. The method of claim 21 wherein the catalyst comprises at least
two members selected from the group consisting of
nitrogen-containing basic compounds, phosphorus-containing basic
compounds, alkali metal compounds, alkaline earth metal compounds,
a boric acid and a boric ester.
25. The method of claim 1 wherein the polyester intermediate is
recovered from the reaction mixture of step (A).
26. The method of claim 1 wherein the polyester intermediate
comprises phenolic hydroxy end-groups at a level in a range of
between about 500 ppm and about 20,000 ppm.
27. The method of claim 26 wherein the polyester intermediate
comprises phenolic hydroxy end-groups at a level in a range of
between about 1500 ppm and about 9700 ppm.
28. The method of claim 1 wherein the polyester intermediate has a
weight average molecular weight of at least about 900.
29. The method of claim 28 wherein the polyester intermediate has a
weight average molecular weight in a range of between about 900 and
about 20,000.
30. The method of claim 1 wherein the polyester intermediate shows
decrease in molecular weight of less than about 20% upon heating
said polyester at a temperature of about 280-290.degree. C. for
five minutes.
31. The method of claim 30 wherein the polyester intermediate shows
decrease in molecular weight of less than about 10% upon heating
said polyester at a temperature of about 280-290.degree. C. for
five minutes.
32. The method of claim 1 wherein the carbonate precursor is
phosgene and the two-phase system further comprises an acid
acceptor.
33. The method of claim 32 wherein the two-phase system further
comprises at least one catalyst.
34. The method of claim 32 wherein the pH in step (B) is maintained
in the range of about 4-9 for the initial part and increased to
about 10-13 during the latter part of said reaction.
35. The method of claim 32 wherein the reaction in step (B) is
conducted in the presence of at least one organic dihydroxy
compound different from the hydroxy-terminated polyester
intermediate.
36. The method of claim 35 wherein at least one organic dihydroxy
compound is the same as at least one 1,3-dihydroxybenzene moiety in
step (A).
37. The method of claim 36 wherein at least one organic dihydroxy
compound is unsubstituted resorcinol.
38. The method of claim 35 wherein at least one organic dihydroxy
compound is different from any 1,3-dihydroxybenzene moiety in step
(A).
39. The method of claim 38 wherein at least one organic dihydroxy
compound is bisphenol A.
40. The method of claim 35 wherein at least one polycarbonate
homopolymer is prepared in the presence of or simultaneously with
the copolyestercarbonate.
41. The method of claim 40 wherein at least one organic dihydroxy
compound is bisphenol A.
42. The method of claim 35 wherein the reaction in step (B) is
conducted in the presence of a mixture of organic dihydroxy
compounds, at least one of which is the same as and at least one of
which is different from any 1,3-dihydroxybenzene moiety in step
(A).
43. The method of claim 42 wherein the mixture of organic dihydroxy
compounds consists of unsubstituted resorcinol and bisphenol A.
44. The method of claim 1 wherein step (B) is conducted in the
presence of at least one mono-phenolic compound as
chain-stopper.
45. The method of claim 1 wherein the copolyestercarbonate is
recovered from the reaction mixture.
46. The method of claim 1 wherein the copolyestercarbonate shows
decrease in molecular weight of less than about 20% upon heating
said copolyestercarbonate at a temperature of about 280-290.degree.
C. for five minutes.
47. The method of claim 46 wherein the copolyestercarbonate shows
decrease in molecular weight of less than about 10% upon heating
said copolyestercarbonate at a temperature of about 280-290.degree.
C. for five minutes.
48. The method of claim 1 wherein the copolyestercarbonate has
polyester blocks with degree of polymerization of at least about
10
49. The method of claim 1 wherein the copolyestercarbonate has
polyester blocks with degree of polymerization of at least about
20.
50. The method of claim 1 wherein the copolyestercarbonate has
polyester blocks with degree of polymerization in a range of
between about 30 and about 150.
51. The method of claim 1 wherein the copolyestercarbonate has
polycarbonate blocks with degree of polymerization of at least
about 1.
52. The method of claim 1 wherein the copolyestercarbonate has
polycarbonate blocks with degree of polymerization of at least
about 3.
53. The method of claim 1 wherein the copolyestercarbonate has
polycarbonate blocks with degree of polymerization of at least
about 10.
54. The method of claim 1 wherein the copolyestercarbonate has
polycarbonate blocks with degree of polymerization in a range of
between about 20 and about 200.
55. A method for preparing a block copolyestercarbonate
substantially free of anhydride linkages linking at least two mers
of the polymer chain, which comprises the steps of: (A) preparing a
hydroxy-terminated polyester intermediate in a molten reaction
mixture comprising at least one 1,3-dihydroxybenzene moiety and at
least one aromatic dicarboxylic acid diarylester under
transesterification conditions, said polyester intermediate having
a degree of polymerization in a range of between about 4 and about
150; recovering the copolyestercarbonate from the reaction mixture;
and (B) conducting a reaction of said polyester intermediate with
phosgene in a two-phase system comprising an aqueous phase, a
water-immiscible organic solvent, an acid acceptor, and at least
one catalyst; and isolating the copolyestercarbonate, said
copolyestercarbonate showing decrease in molecular weight of less
than about 10% upon heating said copolyestercarbonate at a
temperature of about 280-290.degree. C. for five minutes.
56. The method of claim 55 wherein step (B) is conducted in the
presence of at least one mono-phenolic compound as
chain-stopper.
57. A method for preparing a block copolyestercarbonate
substantially free of anhydride linkages linking at least two mers
of the polymer chain, which comprises the steps of: (A) preparing a
hydroxy-terminated polyester intermediate in a molten reaction
mixture comprising at least one 1,3-dihydroxybenzene moiety and at
least one aromatic dicarboxylic acid diarylester under
transesterification conditions, said polyester intermediate having
a degree of polymerization in a range of between about 4 and about
150; recovering the copolyestercarbonate from the reaction mixture;
and (B) conducting a reaction of said polyester intermediate with a
carbonate precursor in the presence of at least one organic
dihydroxy compound different from the hydroxy-terminated polyester
intermediate in a two-phase system comprising an aqueous phase, a
water-immiscible organic solvent, an acid acceptor, and at least
one catalyst; and isolating the copolyestercarbonate, said
copolyestercarbonate having a degree of polymerization in the
carbonate blocks in a range of between about 1 and about 200; and
showing decrease in molecular weight of less than about 10% upon
heating said copolyestercarbonate at a temperature of about
280-290.degree. C. for five minutes.
58. The method of claim 57 wherein at least one organic dihydroxy
compound is bisphenol A.
59. The method of claim 57 wherein at least one organic dihydroxy
compound is unsubstituted resorcinol.
60. The method of claim 57 wherein step (B) is conducted in the
presence of at least one mono-phenolic compound as
chain-stopper.
61. The method of claim 57 wherein at least one polycarbonate
homopolymer is prepared in the presence of or simultaneously with
the copolyestercarbonate.
62. A multilayer article comprising: a substrate layer comprising
at least one thermoplastic polymer, thermoset polymer, cellulosic
material, glass, or metal, and at least one coating layer thereon,
said coating layer comprising the copolyestercarbonate of claim
1.
63. The article of claim 62 wherein the substrate comprises at
least one homo- or copolymeric aliphatic olefin or functionalized
olefin polymer, polycarbonate, polyester or addition polymer of an
alkenylaromatic compound
64. The article of claim 63 wherein the substrate comprises at
least one polyethylene, polypropylene, bisphenol A homo- or
copolycarbonate, poly(alkylene terephthalate), or ABS or ASA
copolymer.
65. The article of claim 62 wherein the coating layer further
comprises at least one colorant.
66. The article of claim 62 wherein the coating layer further
comprises at least one stabilizer additive selected from the group
consisting of phosphorous acid, a UV absorber, a hindered phenol,
and a phosphite.
67. The article of claim 62 wherein the substrate contains at least
one of fillers and colorants.
68. The article of claim 62 further comprising an intermediate
layer disposed between said coating and substrate layers.
69. The article of claim 68 wherein the intermediate layer contains
at least one of fillers and colorants.
70. The article of claim 62 which is an aircraft, automotive,
truck, military vehicle, military aircraft, military water-borne
vehicle, scooter, or motorcycle exterior or interior component,
panel, quarter panel, rocker panel, trim, fender, door, decklid,
trunklid, hood, bonnet, roof, bumper, fascia, grill, mirror
housing, pillar applique, cladding, body side molding, wheel cover,
hubcap, door handle, spoiler, window frame, headlamp bezel,
headlamp, tail lamp, tail lamp housing, tail lamp bezel, license
plate enclosure, roof rack, or running board; an enclosure,
housing, panel, part, or trim for an outdoor vehicle or device, an
electrical or telecommunication device, network interface device,
outdoor furniture, aircraft, boat or marine equipment, outboard
motor, depth finder, personal water-craft, jet-ski, pool, spa,
hot-tub, step, step covering, automatic teller machine (ATM), lawn
or garden tractor, lawn mower, tool, sporting equipment, toy,
snowmobile, recreational vehicle, golf course marker, or playground
equipment; an enclosure, housing, panel, part, or trim for a
computer, desk-top computer, portable computer, lap-top computer,
palm-held computer, monitor, printer, keyboard, FAX machine,
copier, telephone, mobile phone, phone bezel, radio sender, radio
receiver, meter, antenna, light fixture, lighting appliance,
transformer, or air conditioner; an article used in building or
construction, glazing, roofing, window, window trim, floor, wall
panel, door, door trim, countertop, decorative window furnishing or
treatment; a treated glass cover for a picture, painting, poster,
or display item; a protected graphic; an outdoor or indoor sign;
optical lens; ophthalmic lens; corrective ophthalmic lens;
implantable ophthalmic lens; an article made from a plastic-wood
combination; a utility pit cover; shoe lace; cladding or seating
for public transportation; cladding or seating for trains, subways,
or buses; cladding for satellite dishes; coated helmet or personal
protective equipment; coated synthetic or natural textiles; coated
photographic film or photographic print; coated painted article;
coated dyed article; coated fluorescent article; or coated foam
article.
71. A method for preparing a multilayer article which comprises
applying at least one thermally stable coating layer to a second
layer, said second layer comprising at least one thermoplastic
polymer, thermoset polymer, cellulosic material, glass, or metal,
and said coating layer comprising the copolyestercarbonate of claim
1.
72. The method of claim 71 wherein the substrate comprises at least
one homo- or copolymeric aliphatic olefin or functionalized olefin
polymer, polycarbonate, polyester or addition polymer of an
alkenylaromatic compound.
73. The method of claim 72 wherein the substrate comprises at least
one polyethylene, polypropylene, bisphenol A homo- or
copolycarbonate, poly(alkylene terephthalate), or ABS or ASA
copolymer.
74. The method of claim 71 wherein the coating layer further
comprises at least one colorant.
75. The method of claim 71 wherein the coating layer further
comprises at least one stabilizer additive selected from the group
consisting of phosphorous acid, a UV absorber, a hindered phenol,
and a phosphite.
76. The method of claim 71 wherein the substrate contains at least
one of fillers and colorants.
77. The method of claim 71 further comprising an intermediate layer
disposed between said coating and substrate layers.
78. The method of claim 77 wherein the intermediate layer contains
at least one of fillers and colorants.
79. The method of claim 71 wherein said multilayer article is
further applied to a substrate layer.
80. The method of claim 79 wherein the substrate layer comprises at
least one homo- or copolymeric aliphatic olefin or functionalized
olefin polymer, polycarbonate, polyester or addition polymer of an
alkenylaromatic compound.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to a method for preparation of
thermally stable copolyestercarbonates comprising polyester chain
members derived from at least one 1,3-dihydroxybenzene and at least
one aromatic dicarboxylic acid. The invention also relates to
articles made from thermally stable copolyestercarbonates.
[0002] Various resinous articles comprising polymers have a problem
of long term color instability. In many cases this instability is
seen as yellowing of the polymer, detracting from the article's
attractiveness and also transparency when the polymer was initially
transparent. Loss of gloss can also be an undesirable long term
phenomenon in a resinous article.
[0003] Yellowing of polymers is often caused by the action of
ultraviolet radiation, and such yellowing is frequently designated
"photoyellowing". Numerous means for suppressing photoyellowing
have been employed and proposed. Many of these involve
incorporation in the polymer of ultraviolet absorbing compounds
(UVA's). For the most part, UVA's are low molecular weight
compounds, which must be employed at relatively low levels,
typically up to 1% by weight, to avoid degradation of the physical
properties of the polymer such as impact strength and high
temperature properties as reflected in heat distortion
temperature.
[0004] One way of protecting a resinous article against
photoyellowing and loss of gloss is to apply a coating of a
weatherable second polymer, the term "weatherable" as used herein
signifying resistance to such phenomena. Coatings made from
polyesters containing chain members derived from at least one
1,3-dihydroxybenzene derivative and at least one aromatic
dicarboxylic acid (sometimes referred to hereinafter as resorcinol
arylate polyesters) often possess good weatherability properties.
The arylate moieties typically comprise isophthalate,
terephthalate, or especially mixtures of iso- and terephthalate
units. Resorcinol arylate polyesters comprising mixtures of
isophthalate and terephthalate chain members typically have good
weatherability properties and may provide protection against
photoyellowing when coated over a resinous substrate.
[0005] The good weatherability properties of polyesters comprising
resorcinol arylate units is believed to arise in large part from
the screening effect said polymers may provide to ultraviolet (UV)
light. On exposure to UV light polymers comprising resorcinol
arylate chain members may undergo photochemical Fries rearrangement
converting at least a portion of the polymer from polyester chain
members to o-hydroxybenzophenone-type chain members. The
o-hydroxybenzophenone-type chain members act to screen further UV
light and protect UV-sensitive components in a resorcinol
arylate-containing composition. The good weatherability properties
of polymers comprising resorcinol arylate chain members make them
especially useful in blends and also in multilayer articles in
which said polymers may act as a protecting layer for more
sensitive substrate components.
[0006] Polyesters containing resorcinol arylate chain members have
been prepared by an interfacial method. The interfacial method
comprises a solvent mixture containing water and at least one
organic solvent substantially immiscible with water. According to
U.S. Pat. No. 3,460,961 and Eareckson, Journal of Polymer Science,
vol. XL, pp. 399-406 (1959), preparation of resorcinol arylate
polyesters with a mixture of iso- and terephthalate chain members
is performed by an interfacial method in water and a
water-immiscible solvent such as chloroform or methylene chloride
using 1:1 stoichiometric ratio of resorcinol to either iso- or
terephthaloyl dichloride, or a mixture thereof, in the presence of
aqueous sodium hydroxide. The resorcinol is combined with the
aqueous sodium hydroxide before addition of acid chlorides, and the
reaction is run at pH which is initially high but which decreases
as the reaction proceeds. The molecular weight of the polymers is
not controlled. The method provides polymer with very high weight
average molecular weight (Mw) and low hydroxy end-group
concentration, making the polymer unsuitable for some applications.
Furthermore, the polymer has poor thermal stability and loses
molecular weight upon thermal treatment.
[0007] Block copolyestercarbonates comprising resorcinol arylate
chain members in combination with carbonate chain members are
disclosed in commonly owned, co-pending application Ser. No.
09/416,529, filed Oct. 12, 1999. These copolymers have excellent
weatherability and are compatible with polycarbonates in blends. In
one embodiment these block copolyestercarbonates are prepared by a
method which comprises the steps of: (A) preparing a
hydroxy-terminated polyester intermediate having a degree of
polymerization of at least 4 by the reaction of at least one
1,3-dihydroxybenzene moiety with at least one aromatic dicarboxylic
acid dichloride under alkaline conditions; and (B) conducting a
reaction of said polyester intermediate with a carbonate precursor.
The polyester intermediate is synthesized by an interfacial method
employing in one embodiment resorcinol, isophthaloyl dichloride,
terephthaloyl dichloride, water and methylene chloride, which is
often the organic solvent of choice.
[0008] The polyester intermediate comprises hydroxy end-groups
suitable for growing polycarbonate chains in a subsequent reaction
step with a carbonate precursor, and optional second dihydroxy
compound. However, formation of hydroxy terminated, low molecular
weight resorcinol arylate polyester oligomers (for example, with
degree of polymerization of about 5-20) is quite difficult when
typical procedures are followed. This is believed to be due to high
water solubility and very low methylene chloride solubility of
resorcinol as compared to other dihydric phenol monomers.
Conventional methods of producing resorcinol arylate polyester
oligomers lead to very high molecular weight polyesters, even when
a large excess of resorcinol is employed. In addition such
polyesters typically exhibit thermal instability, which is believed
to be due to the presence of anhydride linkages in the polyester
chains. Control of oligomer molecular weight and polymer terminal
groups in resorcinol arylate polyester oligomers can be achieved to
some extent by the use of phase transfer catalysts, as disclosed in
commonly owned, copending application Ser. No. 09/368,706, filed
Aug. 5, 1999. Unfortunately, several issues with the use of phase
transfer catalysts in large scale operations exist. Emulsions can
be encountered during work-up and washing steps using centrifugal
separators, and the presence of phase transfer catalysts can
accelerate polymer hydrolysis during work-up or cause problems with
recycle brine streams. Thus, it would be desirable to obtain
hydroxy-terminated, thermally stable, low molecular weight
polyester oligomers comprising 1,3-dihydroxybenzene moieties via an
alternative process.
[0009] A method previously disclosed for the formation of high
molecular weight (as opposed to low molecular weight) polyesters
comprising arylate structural units is a melt process wherein the
polymerization reaction is a transesterification or redistribution
reaction of diphenylphthalates and a dihydric phenol, such as is
described in GB 924,607. In order to shift the reaction equilibrium
to the product polyester and thus increase molecular weight, the
phenol by-product is continuously removed from the reaction
mixture, typically under reduced pressure. The molecular weight
build in the melt process typically takes place in two or more
steps in a cascade of reactors with subsequently higher
temperatures and higher vacuum to remove the phenol from an
increasingly more viscous polymer.
[0010] Japanese Kokai 56/133,332 describes copolyestercarbonates
"having a highly alternating orientation" rather than a block
structure. They are prepared by a 2-step process in which the first
step is preparation of a hydroxy-terminated polyester oligomer
having a degree of polymerization of only 1-2 and made by an
interfacial process in the presence of methylene chloride. The
second step is treatment of said oligomer in an interfacial process
with a carbonate precursor such as phosgene to afford a final
product having essentially alternating polyester and polycarbonate
linkages; i.e., the degree of polymerization of the carbonate
blocks is also about 1-2. These copolyestercarbonates are alleged
to have excellent heat resistance, solvent resistance and
moldability. No details of their weatherability are provided.
[0011] It remains of interest, therefore, to develop a method for
preparing thermally stable block copolyestercarbonates comprising
resorcinol arylate chain members through preparation in a first
step of low molecular weight hydroxy-terminated polyester oligomers
comprising 1,3-dihydroxybenzene moieties. The polyester oligomers
desirably have controlled molecular weight, high thermal stability,
and low color. There is also a particular need for weatherable,
solvent resistant articles comprising block copolyestercarbonates,
which are capable of use for such varied purposes as body parts for
outdoor vehicles and devices (OVAD) such as automobiles.
SUMMARY OF THE INVENTION
[0012] The present inventors have discovered a method to prepare
block copolyestercarbonates comprising resorcinol arylate polyester
chain members which provides polymer in thermally stable form with
controlled molecular weight without the need to employ an
interfacial method for polyester oligomer preparation.
[0013] In one of its embodiments the present invention provides a
method for preparing a block copolyestercarbonate substantially
free of anhydride linkages linking at least two mers of the polymer
chain, which comprises the steps of:
[0014] (A) preparing a hydroxy-terminated polyester intermediate in
a molten reaction mixture comprising at least one
1,3-dihydroxybenzene moiety and at least one aromatic dicarboxylic
acid diarylester under transesterification conditions, said
polyester intermediate having a degree of polymerization of at
least 4; and
[0015] (B) conducting a reaction of said polyester intermediate
with a carbonate precursor in a two-phase system comprising an
aqueous phase and a water-immiscible organic solvent.
[0016] Various other features, aspects, and advantages of the
present invention will become more apparent with reference to the
following description and appended claims.
DETAILED DESCRIPTION
[0017] In one embodiment the present invention comprises a two
step, melt-interfacial method for preparing thermally stable block
copolyestercarbonates comprising resorcinol arylate polyester chain
members which derive their thermal stability in large part from
being substantially free of anhydride linkages in the polymer
chains. Thermal stability within the context of the present
invention refers to resistance of a polymer to molecular weight
degradation under thermal conditions. Thus, a polymer with poor
thermal stability shows significant molecular weight degradation
under thermal conditions, such as during extrusion, molding,
thermoforming, hot-pressing, and like conditions. Molecular weight
degradation may also be manifest through color formation and/or in
the degradation of other properties such as weatherability, gloss,
mechanical properties, and/or thermal properties. Molecular weight
degradation can also cause significant variation in processing
conditions as the melt viscosity changes.
[0018] In one embodiment block copolyestercarbonates of the present
invention comprise alternating polycarbonate and polyester blocks.
Within the context of the invention "alternating polycarbonate and
polyester blocks" means that the copolyestercarbonates comprise at
least one polycarbonate block and at least one polyester block.
[0019] In a particular embodiment block copolyestercarbonates
comprise structural units of the formula (I): 1
[0020] wherein each R.sup.1 is independently halogen or C.sub.1-12
alkyl, p is 0-3, each R.sup.2 is independently a divalent organic
radical, m is at least 1 and n is at least about 4. In one
embodiment n is at least about 10, in another embodiment n is at
least about 20, in another embodiment n is at least about 30, in
another embodiment n is in a range of between about 4 and about
150, in another embodiment n is in a range of between about 10 and
about 150, in another embodiment n is in a range of between about
20 and about 150, and in still another embodiment n is in a range
of between about 30 and about 150. In one embodiment m is at least
about 3, in another embodiment m is at least about 10; in another
embodiment m is at least about 20; in another embodiment m is in a
range of between about 1 and about 200; in another embodiment m is
in a range of between about 3 and about 200; in another embodiment
m is in a range of between about 10 and about 200; and in still
another embodiment m is in a range of between about 20 and about
200. In some embodiments m is between about 20 and 50.
[0021] The ester blocks comprise structural units derived from
1,3-dihydroxybenzene moieties which may be unsubstituted or
substituted. Alkyl substituents, if present, are exemplified by
straight-chain, branched, or cyclic alkyl groups, and are most
often located in the ortho position to both oxygen atoms although
other ring locations are contemplated. Suitable C.sub.1-12 alkyl
groups comprise methyl, ethyl, n-propyl, isopropyl, butyl,
iso-butyl, t-butyl, hexyl, cyclohexyl, nonyl, decyl, and
aryl-substituted alkyl, such as benzyl. In one embodiment a
suitable C.sub.1-12 alkyl group is methyl. Suitable halogen
substituents comprise bromo, chloro, and fluoro.
1,3-Dihydroxybenzene moieties containing a mixture of alkyl and
halogen substituents are also suitable. The value for p may be 0-3;
in one embodiment the value for p is 0-2, and in another embodiment
the value for p is 0-1. One example of a suitable
1,3-dihydroxybenzene moiety is 2-methylresorcinol. In some
embodiments the 1,3-dihydroxybenzene moiety is unsubstituted
resorcinol in which p is zero. Polymers containing mixtures of
1,3-dihydroxybenzene moieties, such as a mixture of unsubstituted
resorcinol with 2-methylresorcinol are also contemplated.
[0022] The ester blocks also comprise structural units derived from
dicarboxylic acid moieties which are bound to structural units
derived from 1,3-dihydroxybenzene moieties. Structural units
derived from dicarboxylic acid moieties may comprise monocyclic
aromatic moieties. In some embodiments monocyclic aromatic moieties
comprise phenyl and further comprise isophthalate or terephthalate,
or their alkyl, halogen or chlorine-substituted derivatives wherein
said optional substituents are as defined for 1,3-dihydroxybenzene
moieties. Structural units derived from dicarboxylic acid moieties
may also comprise polycyclic aromatic moieties. In some embodiments
polycyclic aromatic moieties comprise fused polycyclic aromatic
moieties such as naphthyl, linked polycyclic aromatic moieties such
as biaryls or biphenyl, or moieties of the formula
--Ar--Y.sup.1--Ar--, wherein Ar is an aromatic moiety and Y.sup.1
is C.sub.1-10 alkylene, haloalkylene, --O--, --S--, --SO--,
--SO.sub.2--, --CO--, --(R.sup.3)P(.dbd.O)--, or --(R.sup.3)N--,
wherein R.sup.3 comprises alkyl, haloalkyl, aryl, haloaryl,
alkaryl, haloalkaryl, aralkyl, haloaralkyl, cycloalkyl, or
halocycloalkyl. In some particular embodiments polycyclic aromatic
moieties comprise biphenyl-4,4'-dicarboxy- late,
diphenylether-4,4'-dicarboxylate,
diphenylsulfone-4,4'-dicarboxylate- ,
diphenylketone-4,4'-dicarboxylate,
diphenylsulfide-4,4'-dicarboxylate,
diphenylmethane-4,4'-dicarboxylate,
diphenyldichloromethane-4,4'-dicarbox- ylate, or
naphthalenedicarboxylate, such as naphthalene-2,6-dicarboxylate and
naphthalene-2,7-dicarboxylate; or alkyl-, halogen- or
chlorine-substituted derivatives of said polycyclic moieties,
wherein said optional substituents are as defined for
1,3-dihydroxybenzene moieties. In some embodiments dicarboxylic
acid moieties comprise mixtures of any of the foregoing monocyclic
and/or polycyclic aromatic dicarboxylates. In one embodiment the
aromatic dicarboxylic acid moieties comprise isophthalate and/or
terephthalate. Either or both of said latter moieties may be
present. For the most part, both are present in a molar ratio of
isophthalate to terephthalate in the range of about 0.2-5.0:1. In
some embodiments when the isophthalate to terephthalate ratio is
greater than about 4.0:1, then unacceptable levels of cyclic
oligomer may form. In other embodiments when the isophthalate to
terephthalate ratio is less than about 0.25:1, then unacceptable
levels of insoluble polymer may form. In one embodiment the molar
ratio of isophthalate to terephthalate is about 0.4-2.5:1, and in
another embodiment about 0.67-1.5:1.
[0023] In another embodiment ester blocks of block
copolyestercarbonates comprise structural units derived from
1,3-dihydroxybenzene moieties in combination with structural units
derived from alkylene dicarboxylic acid, alkylene diol, or alkylene
alpha-hydroxy-omega-carboxylic acid moieties. In some embodiments
these alkylene structural units are termed "soft-block" segments.
The term soft-block as used herein, indicates that at least some
segments of the ester blocks are made from non-aromatic monomer
units. Such non-aromatic monomer units are known in certain
embodiments to impart flexibility to the soft-block-containing
polymers. In some embodiments the ester blocks comprise those
comprising structural units of formulas (II), (III), and (IV):
2
[0024] wherein R.sup.1 and p are as previously defined; Z is an
aromatic radical; R.sup.4 is an aliphatic group; and R.sup.5 and
R.sup.6 each independently represent 3
[0025] or --CH.sub.2--O--,
[0026] wherein formula (W) in one embodiment contributes from about
1 to about 45 mole percent to the ester linkages of the polyester
block. In another embodiment formula (IV) contributes from about 5
to about 40 mole percent, and in still another embodiment about 5
to about 20 mole percent to the ester linkages of the polyester
block. Another embodiment provides a composition wherein R.sup.4
comprises a C.sub.3-20 straight chain alkylene, C.sub.3-20 branched
alkylene, or C.sub.4-20 cyclo- or bicycloalkylene group. Another
embodiment provides a composition wherein R.sup.4 comprises a
C.sub.3-14 straight chain alkylene, or C.sub.5-6 cycloalkylene, and
still another embodiment provides a composition wherein R.sup.4
represents C.sub.3-10 straight-chain alkylene or
C.sub.6-cycloalkylene. Formula (III) represents an aromatic
dicarboxylic acid residue. The divalent aromatic radical Z in
formula (III) may be derived from at least one divalent monocyclic
or polycyclic dicarboxylic acid moiety as defined hereinabove; in
some embodiments the divalent aromatic radical Z in formula (III)
may be comprise at least one of 1,3-phenylene, 1,4-phenylene, or
2,6-naphthylene. In some embodiments Z comprises at least about 40
mole percent 1,3-phenylene. In some embodiments of copolyesters
containing soft-block chain members p in formula (II) is zero.
[0027] In some embodiments of the invention ester blocks of block
copolyestercarbonates comprise from about 1 to about 45 mole %
sebacate or cyclohexane-1,4-dicarboxylate units. In a particular
embodiment ester blocks comprise resorcinol isophthalate and
resorcinol sebacate units in molar ratio between 8.5:1.5 and
9.5:0.5.
[0028] In the polycarbonate blocks, each R2 is independently an
organic radical derived from a dihydroxy compound. In some
embodiments at least about 60 percent of the total number of R2
groups in the polymer are aromatic organic radicals and the balance
thereof are aliphatic, alicyclic, or aromatic radicals. Suitable R2
radicals comprise m-phenylene, p-phenylene, 4,4'-biphenylene,
4,4'-bi(3,5-dimethyl)-phenyle- ne, 2,2-bis(4-phenylene)propane and
similar radicals such as those which correspond to the
dihydroxy-substituted aromatic hydrocarbons disclosed by name or
formula (generic or specific) in U.S. Pat. No. 4,217,438.
[0029] In various embodiments of the invention suitable
dihydroxy-substituted aromatic hydrocarbons also comprise
4,4'-(3,3,5-trimethylcyclohexylidene)diphenol;
1,1-bis(4-hydroxy-3-methyl- phenyl)cyclohexane;
2,2-bis(4-hydroxyphenyl)propane (commonly known as bisphenol-A);
2,2-bis(4-hydroxy-3,5-dimethylphenyl)propane;
2,2-bis(4-hydroxy-3-methylphenyl)propane;
2,2-bis(4-hydroxy-3-ethylphenyl- )propane;
2,2-bis(4-hydroxy-3-isopropylphenyl)propane;
2,4'-dihydroxydiphenylmethane; bis(2-hydroxyphenyl)methane;
bis(4-hydroxy-phenyl)methane; bis(4-hydroxy-5-nitrophenyl)methane;
bis(4-hydroxy-2,6-dimethyl-3-methoxyphenyl)methane;
1,1-bis(4-hydroxyphenyl)ethane;
1,1-bis(4-hydroxy-2-chlorophenyl)ethane;
2,2-bis(3-phenyl-4-hydroxyphenyl)-propane;
bis(4-hydroxyphenyl)cyclohexyl- methane;
2,2-bis(4-hydroxyphenyl)-1-phenylpropane; hydroquinone, resorcinol;
C.sub.1-3 alkyl-substituted resorcinols.
[0030] Suitable dihydroxy-substituted aromatic hydrocarbons also
comprise those containing indane structural units such as
represented by the formula (V), which compound is
3-(4-hydroxyphenyl)-1,1,3-trimethylindan-5- -ol, and by the formula
(VI), which compound is 1-(4-hydroxyphenyl)-1,3,3--
trimethylindan-5-ol: 4
[0031] Also included among suitable dihydroxy-substituted aromatic
hydrocarbons are the
2,2,2',2'-tetrahydro-1,1'-spirobi[1H-indene]diols having formula
(VII): 5
[0032] wherein each R.sup.7 is independently selected from
monovalent hydrocarbon radicals and halogen radicals; each R.sup.8,
R.sup.9, R.sup.10, and R.sup.11 is independently C.sub.1-6 alkyl;
each R.sup.12 and R.sup.13 is independently H or C.sub.1-6 alkyl;
and each n is independently selected from positive integers having
a value of from 0 to 3 inclusive. In one embodiment a
2,2,2',2'-tetrahydro-1,1'-spirobi[1H-ind- ene]-diol is
2,2,2',2'-tetrahydro-3 ,3,3',3'-tetramethyl-1,1'-spirobi[1H-i-
ndene]-6,6'-diol.
[0033] In some embodiments each R.sup.2 is an aromatic organic
radical and in other embodiments a radical of the formula
(VIII):
A.sup.1-Y.sup.2-A.sup.2--, (VIII)
[0034] wherein each A.sup.1 and A.sup.2 is a monocyclic divalent
aryl radical and Y.sup.2 is a bridging radical in which one or two
carbon atoms separate A.sup.1 and A.sup.2. The free valence bonds
in formula (VIII) are usually in the meta or para positions of
A.sup.1 and A.sup.2 in relation to Y.sup.2. Compounds in which
R.sup.2 has formula (VIII) 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.
[0035] In formula (VIII), A.sup.1 and A.sup.2 typically represent
unsubstituted phenylene or substituted derivatives thereof,
illustrative substituents (one or more) being alkyl, alkenyl, and
halogen (particularly bromine). In one embodiment A.sup.1 and
A.sup.2 are unsubstituted phenylene radicals. In another embodiment
both A.sup.1 and A.sup.2 are p-phenylene, although both may be o-
or m-phenylene or one o- or m-phenylene and the other
p-phenylene.
[0036] The bridging radical, Y.sup.2 is one in which one or two
atoms, separate A.sup.1 from A.sup.2. In one embodiment one atom
separates A.sup.1 from A.sup.2. Illustrative, non-limiting radicals
of this type are --C.dbd.O, --O--, --S--, --SO-- or --SO.sub.2--,
methylene, cyclohexylmethylene, 2-[2.2.1]-bicycloheptyl methylene,
ethylene, isopropylidene, neopentylidene, cyclohexylidene,
cyclopentadecylidene, cyclododecylidene, and adamantylidene.
[0037] In one embodiment Y.sup.2 is a gem-alkylene radicals. Also
included, however, are unsaturated radicals. In a particular
embodiment the bisphenol is 2,2-bis(4-hydroxy-phenyl)propane
(hereinafter referred to as bisphenol A or BPA), in which Y.sup.2
is isopropylidene and A.sup.1 and A.sup.2 are each p-phenylene.
[0038] Depending upon whether or not any unreacted
1,3-dihydroxybenzene moiety is present in the reaction mixture as
described hereinafter, R.sup.2 in the polycarbonate blocks may
consist of or at least partially comprise a radical derived from a
1,3-dihydroxybenzene moiety. Therefore, in one embodiment of the
present invention the copolyestercarbonates comprise polycarbonate
blocks with R.sup.2 radicals derived from a dihydroxy compound
identical to at least one 1,3-dihydroxybenzene moiety in the
polyester blocks. In another embodiment the copolyestercarbonates
comprise polycarbonate blocks with R.sup.2 radicals derived from a
dihydroxy compound different from any 1,3-dihydroxybenzene moiety
in the polyester blocks. In yet another embodiment the
copolyestercarbonates comprise polycarbonate blocks containing a
mixture of R.sup.2 radicals derived from dihydroxy compounds at
least one of which is the same as and at least one of which is
different from any 1,3-dihydroxybenzene moiety in the polyester
blocks. When a mixture of R.sup.2 radicals derived from dihydroxy
compounds is present, then the molar ratio of dihydroxy compounds
identical to those present in the polyester blocks to those
dihydroxy compounds different from those present in the polyester
blocks is typically about 1:999 to 999:1. In some embodiments the
copolyestercarbonates comprise polycarbonate blocks containing a
mixture of R.sup.2 radicals derived from at least two of
unsubstituted resorcinol, a substituted resorcinol, and bisphenol
A.
[0039] Diblock, triblock, and multiblock copolyestercarbonates are
encompassed in the present invention. The chemical linkages between
blocks comprising polyester chain members and blocks comprising
polycarbonate chain members typically comprise a carbonate linkage
between a diphenol residue of a polyester moiety and a
--C.dbd.O)--O-- moiety of a polycarbonate moiety, although other
types of linkages such as ester and/or anhydride are also possible.
A typical carbonate linkage between said blocks is shown in formula
(IX), wherein R.sup.1 and p are as previously defined: 6
[0040] In one embodiment the copolyestercarbonate is substantially
comprised of a diblock copolymer with a carbonate linkage between a
polyester block and a polycarbonate block. In another embodiment
the copolyestercarbonate is substantially comprised of a triblock
carbonate-ester-carbonate copolymer with carbonate linkages between
the polyester block and polycarbonate end-blocks.
Copolyestercarbonates with at least one carbonate linkage between a
polyester block and a polycarbonate block are typically prepared
from polyester oligomers comprising at least one
1,3-dihydroxybenzene and whose chains contain in one embodiment at
least one and in other embodiments at least two hydroxy-terminal
sites (hereinafter sometimes referred to as hydroxy-terminated
polyester intermediate).
[0041] In another embodiment the copolyestercarbonate comprises
polyester blocks linked by carbonate linkages as shown in the
representative structure of formula (X): 7
[0042] wherein R.sup.1, p, and n are as previously defined, Ar is
an aromatic moiety, and the polyester structural units are as
described for formula I. In some embodiments Ar comprises a
hydroxyphenol residue derived from a 1,3-dihydroxybenzene moiety or
an aryloxycarboxyphenyl residue derived from an aromatic
dicarboxylic acid diarylester. Copolyestercarbonates comprising
formula (X) may arise from reaction of hydroxy-terminated polyester
intermediate with a carbonate precursor in the substantial absence
of any dihydroxy compound different from the hydroxy-terminated
polyester intermediate.
[0043] In the copolyestercarbonates of the present invention the
distribution of the blocks may be such as to provide a copolymer
having any desired weight proportion of polyester blocks in
relation to polycarbonate blocks. In one embodiment the copolymers
contain about 10-99% by weight polyester blocks.
[0044] In step (A) of the method of the invention for the
preparation of block copolyestercarbonates, an oligomeric polyester
intermediate is prepared by a transesterification reaction in the
melt by combining at least one 1,3-dihydroxybenzene moiety with at
least one diester of a dicarboxylic acid. In one embodiment the
molar ratio of 1,3-dihydroxybenzene moiety to dicarboxylic acid
diester is greater than 1:1; in another embodiment in the range of
between about 1.01:1 and about 1.90:1, in another embodiment in the
range of between about 1.01:1 and about 1.25:1, and in still
another embodiment in a range of between about 1.1:1 and about
1.2:1.
[0045] In various embodiments 1,3-dihydroxybenzene moieties may
comprise those defined hereinabove. In particular embodiments
illustrative examples of 1,3-dihydroxybenzene moieties may comprise
unsubstituted resorcinol or an alkyl- and/or halo-substituted
resorcinol or mixtures of the foregoing.
[0046] In various embodiments dicarboxylic acid diesters may
comprise precursors for structural units derived from dicarboxylic
acid moieties as defined hereinabove. In one embodiment
dicarboxylic acid diesters are diaryl esters derived from a
dicarboxylic acid and a monohydroxy aromatic compound, wherein
aromatic moieties are monocyclic or polycyclic aromatic moieties as
defined herein. In particular embodiments illustrative examples of
dicarboxylic acid diaryl esters may comprise monocyclic aromatic
dicarboxylic acid diaryl esters such as diaryl isophthalate, diaryl
terephthalate, or their halogen or chlorine-substituted
derivatives; or polycyclic aromatic dicarboxylic acid diaryl esters
such as fused polycyclic aromatic dicarboxylic acid diaryl esters
including naphthalene diaryl ester; linked polycyclic aromatic
moieties including biaryl diaryl esters or biphenyl diaryl ester,
or moieties of the formula Ar'O--Ar--Y.sup.1--Ar--OAr', wherein Ar
and Ar' are independently aromatic moieties as defined herein and
Y.sup.1 is C.sub.1-10 alkylene, haloalkylene, --O--, --S--, --SO--,
--SO.sub.2--, --CO--, --(R.sup.3)P(.dbd.O)--, or --(R.sup.3)N--,
wherein R.sup.3 comprises alkyl, haloalkyl, aryl, haloaryl,
alkaryl, haloalkaryl, aralkyl, haloaralkyl, cycloalkyl, or
halocycloalkyl. In some particular embodiments polycyclic aromatic
dicarboxylic acid diaryl esters comprise
biphenyl-4,4'-diaryldicarboxylate,
diphenylether-4,4'-diaryldicarboxylate- ,
diphenylsulfone-4,4'-diaryldicarboxylate,
diphenylketone-4,4'-diaryldica- rboxylate,
diphenylsulfide-4,4'-diaryldicarboxylate,
diphenylmethane-4,4'-diaryldicarboxylate,
diphenyldichloromethane-4,4'-di- aryldicarboxylate, or naphthalene
diaryldicarboxylate, such as naphthalene-2,6-diaryldicarboxylate
and naphthalene-2,7-diaryldicarboxyla- te; or halogen or
chlorine-substituted derivatives of said polycyclic aromatic
dicarboxylic acid diaryl esters. In other embodiments dicarboxylic
acid diesters comprise alkylene dicarboxylic acid diesters, and in
a particular embodiment alkylene dicarboxylic acid diaryl esters,
wherein alkylene groups comprise in various embodiments C.sub.3-20
straight chain alkylene, C.sub.3-20 branched alkylene, or
C.sub.4-20 cyclo- or bicycloalkylene group
[0047] In some embodiments dicarboxylic acid diesters comprise
mixtures of any combination of the foregoing alkylene, monocyclic
and polycyclic aromatic dicarboxylic acid diaryl esters in amounts
to provide proportions of structural units as described
hereinabove. In various embodiments diaryl esters comprise diphenyl
esters and are derived from phenol. In some embodiments aromatic
dicarboxylic acid diaryl esters comprise diphenyl isophthalate,
diphenyl terephthalate, or mixtures thereof. Either or both of
isophthalate and terephthalate moieties may be present. In other
embodiments diaryl esters comprise those derived from monohydroxy
aromatic compounds comprising at least one electron withdrawing
group ortho, meta, or para to the oxygen substituent of the
monohydroxy moiety. In another embodiment diaryl esters comprise
those derived from monohydroxy aromatic compounds comprising at
least one electron withdrawing group ortho or para to the oxygen
substituent of the monohydroxy moiety. In another embodiment diaryl
esters comprise those derived from monohydroxy aromatic compounds
comprising at least one electron withdrawing group ortho or para to
the oxygen substituent of the monohydroxy moiety selected from the
group consisting of carboalkoxy, carboaryloxy, carboaryl, halo,
cyano, and nitro, and mixtures thereof. In another embodiment
diaryl esters comprise those derived from monohydroxy aromatic
compounds selected from the group consisting of
o-carbomethoxyphenol, o-carbomethoxymethylphenol,
o-carboethoxyphenol, o-carbopropoxyphenol, o-chlorophenol,
o-carbophenylphenol, o-carbophenoxyphenol, o-carbobenzoxyphenol,
and o-nitrophenol.
[0048] Step (A) of the method may be conducted in the presence of
at least one catalyst. Suitable catalysts comprise those known to
effect transesterification reactions. In various embodiments
catalysts comprise acidic, neutral, or basic catalysts, such
classifications often being based on the reaction of a conventional
acid-base indicator and the catalyst when the latter is dissolved
in a polar ionizing solvent such as water. In one embodiment a
basic catalyst is employed. Suitable basic catalysts comprise the
alkali metals, examples of which comprise lithium, sodium,
potassium, rubidium, and cesium; and their corresponding
carbonates, hydroxides, hydrides, borohydrides, phenates,
bisphenates, (that is, salt of a bisphenol); carboxylates such as
acetate or benzoate; fluorides; and oxides. Group II and III
elements can also be used in place of the alkali metals of the
foregoing classes of compounds such as metals and compounds of
calcium, magnesium and aluminum. Other bases comprise trialkyl or
triaryl tin hydroxides, acetates, phenates, and the like. In
particular embodiments examples of catalysts comprise lithium,
sodium, potassium, rubidium, and cesium metals; lithium hydride,
aluminum tri-isopropoxide and triphenyl tin hydroxide.
[0049] In other embodiments catalysts comprise metal oxides, metal
acetates, titanium, and tin compounds. Suitable metal oxides
comprise antimony trioxide, germanium oxide, arsenic trioxide, lead
oxide, magnesium oxide, and zinc oxide. Suitable metal acetates
comprise cobalt acetate, zinc acetate, cadmium acetate and
manganese acetate. Suitable titanium compounds comprise the
titanates such as tetrabutyl titanate and tetraisopropyl titanate.
Suitable tin compounds comprise dibutyl tin oxide, dibutyl tin
methoxide and dibutyl tin dilaurate.
[0050] In other particular embodiments illustrative examples of
catalysts comprise at least one nitrogen-containing basic compound,
phosphorus-containing basic compound, alkali metal compound,
alkaline earth metal compound, or a boric acid or boric ester.
Mixtures of such catalysts may also be employed.
[0051] In various embodiments nitrogen-containing basic compounds
comprise alkyl-, aryl- or alkaryl quaternary ammonium hydroxides
such as tetramethylammonium hydroxide, tetraethylammonium
hydroxide, tetrabutylammonium hydroxide and trimethylbenzylammonium
hydroxide; tertiary amines represented by R.sub.3N (wherein R is
alkyl or aryl or a mixture thereof) such as trimethylamine,
triethylamine, dimethylbenzylamine and triphenylamine; secondary
amines represented by R.sub.2NH (wherein R is as defined above);
primary amines represented by RNH.sub.2 (wherein R is as defined
above); ammonia; or basic salts such as tetramethylammonium
borohydride, tetrabutylammonium borohydride, tetrabutylammonium
tetraphenyl borate, tetramethylammonium tetraphenyl borate, and
hexaalkylguanidinium salts and alpha,omega-bis(pentaalkylguan-
idinium)alkane salts, comprising hexaethylguanidinium halides,
alpha,omega-bis(pentaalkylguanidinium)alkane halides, and
hexaethylguanidinium chloride. In various embodiments
phosphorus-containing basic compounds comprise quaternary
phosphonium hydroxides and quaternary phosphonium carboxylates,
such as tetrabutylphosphonium acetate.
[0052] In various embodiments alkali metal compounds comprise
sodium hydroxide, potassium hydroxide, lithium hydroxide, sodium
hydrogencarbonate, potassium hydrogencarbonate, lithium
hydrogencarbonate, sodium carbonate, potassium carbonate, lithium
carbonate, sodium acetate, potassium acetate, lithium acetate,
sodium stearate, potassium stearate, lithium stearate, sodium
borohydride, potassium borohydride, lithium borohydride, sodium
borophenylate, sodium benzoate, potassium benzoate, lithium
benzoate, disodium hydrogenphosphate, dipotassium
hydrogenphosphate, dilithium hydrogenphosphate, disodium salt of
bisphenol A, dipotassium salt of bisphenol A, dilithium salt of
bisphenol A, sodium phenylate, potassium phenylate, and lithium
phenylate.
[0053] In various embodiments alkaline earth metal compounds
comprise calcium hydroxide, barium hydroxide, magnesium hydroxide,
strontium hydroxide, calcium hydrogencarbonate, barium
hydrogencarbonate, magnesium hydrogencarbonate, strontium
hydrogencarbonate, calcium carbonate, barium carbonate, magnesium
carbonate, strontium carbonate, calcium acetate, barium acetate,
magnesium acetate, strontium acetate, calcium stearate, barium
stearate, magnesium stearate and strontium stearate.
[0054] In various embodiments boric acid or boric acid ester
compounds comprise boric acid and boric acid esters represented by
the general formula B(OR).sub.n(OH).sub.3-n (wherein R is alkyl or
aryl, and n is 1, 2 or 3), and boric acid esters comprising
trimethyl borate, triethyl borate, tributyl borate, trihexyl
borate, triheptyl borate, triphenyl borate, tritolyl borate and
trinaphthyl borate.
[0055] Catalyst may be present in one embodiment at a total level
of about 10.sup.-8 moles to about 0.1 moles, in another embodiment
at a total level of about 10.sup.-8 moles to about 0.06 moles, in
another embodiment at a total level of about 10.sup.-8 moles to
about 0.02 moles, in another embodiment at a total level of about
10.sup.-7 moles to about 0.02 moles, in another embodiment at a
total level of about 10.sup.-6 moles to about 0.02 moles, in
another embodiment at a total level of about 10.sup.-5 moles to
about 0.02 moles, in another embodiment at a total level of about
10.sup.-4 moles to about 0.02 moles, and in still another
embodiment at a total level of about 10.sup.-3 moles to about 0.02
moles, in all cases per mole of dicarboxylic acid diester
compound.
[0056] In various embodiments the amount of the nitrogen containing
basic compound employed is in one embodiment from about 10.sup.-6
moles to about 10.sup.-1 moles and in another embodiment from about
10.sup.-5 moles to about 10.sup.-2 moles, in all cases per mole of
dicarboxylic acid diester compound. The amount of the alkali metal
or alkaline earth metal compound employed is in one embodiment from
about 10.sup.-8 moles to about 10.sup.-3 moles, in another
embodiment from about 10.sup.-7 moles to about 10.sup.-4 moles, and
in still another embodiment from about 10.sup.-7 moles to about
10.sup.-2 moles, in all cases per mole of dicarboxylic acid diester
compound. The amount of the boric acid or boric acid ester is in
one embodiment from about 10.sup.-8 moles to about 10.sup.-1 moles,
in another embodiment from about 10.sup.-7 moles to about 10.sup.-2
moles, and in still another embodiment from about 10.sup.-6 moles
to about 10.sup.-4 moles, in all cases per mole of dicarboxylic
acid diester compound.
[0057] Prior to its introduction into a reaction mixture, a
catalyst may be in liquid form, for example in the case of solid
catalysts through melting or through dissolution in a liquid or
normally solid, low melting solvent. In various embodiments
solvents comprise phenol and substituted phenols. Substituted
phenols which can be used comprise those comprising at least one
substituent R, wherein R comprises alkyl of 1 to 10 carbon atoms,
alkoxy of 1 to 10 carbon atoms, aryl of 6 to 10 carbon atoms,
chloro, bromo or mixtures thereof. Illustrative examples of
solvents comprise o-benzyl-phenol, o-bromophenol, m-bromophenol,
m-chlorophenol, p-chlorophenol, 2,4-dibromophenol,
2,6-dichlorophenol, 3,5-dimethoxyphenol, o-ethoxyphenol,
m-ethyl-phenol, p-ethylphenol, o-isopropylphenol, m-methoxyphenol,
m-propylphenol, p-propylphenol, and the like. In other embodiments
solvents may be of the ether type, for example, tetrahydrofuran and
the various glymes, for example, ethylene glycol dimethylether and
the like. Liquid phosphites such as triphenyl phosphite and
tris(nonylphenyl)phosphite, and phosphates such as trimethyl or
triethyl phosphate are also useful in diluents. In one embodiment
any solvent or diluent used with a catalyst corresponds to a
monohydroxy aromatic compound comprising a dicarboxylic acid
diester as defined hereinabove. In a particular embodiment any
solvent or diluent used with a catalyst corresponds to the
monohydroxy aromatic compound comprising the dicarboxylic acid
diester reactant. In another particular embodiment phenol comprises
the solvent for the normally solid catalysts. Combinations of
catalysts and combinations of solvents may also be used. In various
embodiments when a basic catalyst is employed, the catalyst may be
introduced concurrently with the aforementioned molten reactants to
the polymerization to avoid heating the reactants in the presence
of the catalyst prior to onset of the transesterification.
[0058] Methods for synthesizing polyesters by a transesterification
reaction in the melt, typically in the presence of at least one
catalyst, are well known in the art, and are described in many
references, illustrative examples of which include U.S. Pat. Nos.
3,395,119; 3,399,170; 4,108,834; 4,137,278; 4,255,555; 4,278,785;
4,283,523; 4,319,017; 4,661,580; 4,680,371; 4,725,647; 4,782,131;
and 4,957,996; European Patent Application No. 0035897; British
Patent Nos. GB 924,607 and GB 2,085,458; and Japanese Patent
Application Nos. 02169623; 02169624; 02169625; and 58038721.
[0059] Any transesterification reaction in the melt to prepare
polyester oligomers may be performed in one or more stages.
Transesterification reactions may be performed in batch,
continuous, or semi-continuous mode. Temperatures for
transesterification reactions are those sufficient to effect
reaction and are in one embodiment above about 80.degree. C., in
another embodiment in a range between about 100.degree. C. and
about 400.degree. C., in another embodiment in a range between
about 150.degree. C. and about 320.degree. C., and in still another
embodiment in a range between about 180.degree. C. and about
260.degree. C. In some embodiments transesterification reactions
may be performed under reduced pressure to aid removal of
monohydroxy aromatic compound derived from dicarboxylic acid
diester. In various embodiments pressure may be reduced in steps.
In various embodiments provision is made for recovery and recycle
of monohydroxy aromatic compound using art-recognized methods.
Depending upon various factors such as the boiling point of any
1,3-dihydroxybenzene moiety included as reactant, provision may
also be made for recovery and recycle of any 1,3-dihydroxybenzene
compound removed along with monohydroxy compound. Recovery and
recycle of any 1,3-dihydroxybenzene compound may be performed using
art-recognized methods. In any recovery and recycle method any
1,3-dihydroxybenzene compound may be separated from monohydroxy
aromatic compound or utilized jointly therewith.
[0060] In various embodiments when a catalyst is employed, the
catalyst may be introduced concurrently with the aforementioned
molten reactants to the polymerization to avoid heating the
reactants in the presence of the catalyst prior to onset of the
transesterification. In other embodiments catalyst may be
introduced in one or more portions. The reaction mixtures may
optionally comprise stabilizers, added for example to reduce any
color formation. Stabilizers include those known in the art for
polyester formation by transesterification reaction in the melt. In
various embodiments the transesterification reaction is performed
under an inert atmosphere. In other embodiments one or more of the
ingredients comprising the reaction mixture are dried before use.
Any polyester oligomer may be isolated before use in step (B) or
reacted directly in step (B) without isolation. In one embodiment
polyester intermediate is isolated by solidification, optionally
with one or more steps of increasing surface area of the solid, or
solvent-washing or trituration.
[0061] Polyester oligomer intermediates from step (A) may have
varying molecular weights, as well as varying ratios of hydroxy
end-groups to phenyl ester end-groups. In various embodiments
complete conversion to hydroxy terminated oligomers is possible and
a chain stopper may be added in step (B) of the process to generate
copolyestercarbonates of desired molecular weight. In other
embodiments a low ratio of hydroxy end-groups to phenyl ester
end-groups may be targeted in the first step, thus lowering the
time and pressure requirements for the reaction as well as
eliminating the need to add chain stopper in step (B).
[0062] Polyester oligomer intermediates from step (A) typically
have weight average molecular weight (vs. polystyrene standards) in
one embodiment of at least about 900, in another embodiment of at
least about 2400, and in still another embodiment of at least about
4800. In other embodiments said oligomers have weight average
molecular weights in a range of between about 900 and about 20,000,
in still other embodiments in a range of between about 900 to about
15,000, in still other embodiments in a range of between about 900
to about 8,000, in still other embodiments in a range of between
about 900 to about 6,000, and in still other embodiments in a range
of between about 900 to about 5,000. In other embodiments said
oligomers have weight average molecular weights in a range of
between about 10,000 to about 40,000, and in still other
embodiments about 15,000 to about 32,000. Said intermediates often
have carboxylic acid end-groups in one embodiment at a level in a
range of between about 30 ppm and about 15,000 ppm, in another
embodiment at a level in a range of between about 30 ppm and about
5000 ppm, in another embodiment at a level in a range of between
about 300 ppm and about 5000 ppm, and in still another embodiment
at a level in a range of between about 300 ppm and about 1500 ppm.
Said intermediates often have phenolic hydroxy end-groups at a
level in a range in one embodiment of between about 2 ppm and about
37,000 ppm, in another embodiment of between about 500 ppm and
about 20,000 ppm, in another embodiment of between about 1000 ppm
and about 14,000 ppm, in still another embodiment of between about
1500 ppm and about 11,000 ppm, and in still another embodiment of
between about 1500 ppm and about 9700 ppm. Carboxylic acid
end-groups may be present through hydrolysis of ester groups under
the reaction conditions and as adventitious acid groups present in
dicarboxylic acid diester starting material.
[0063] In step (B) of the method a polyester oligomer is combined
and reacted with reactants comprising a carbonate precursor. In one
embodiment of step (B) of the method the carbonate precursor is
phosgene. When phosgene is employed, this step may be conducted
according to art-recognized interfacial procedures (i.e., in a
two-phase water-organic solvent system) employing in various
embodiments a suitable interfacial polymerization catalyst and an
acid acceptor, typically an alkaline reagent, which in one
embodiment is sodium hydroxide. Optionally one or both of a
branching agent and a chain termination agent such as are described
below may be present. At least one catalyst may be present in the
two-phase system of step (B). Catalysts for polycarbonate synthesis
by interfacial methods are well-known in the art and many examples
are suitable for use. In one embodiment a catalyst comprises
triethylamine. In one embodiment to suppress scrambling of the
block copolymer, the pH is maintained at a relatively low level,
typically in the range of about 4-9, for the initial part of the
phosgenation reaction; it may be increased to about 10-13 during
the latter part of said reaction.
[0064] In one embodiment step (B) is conducted in the absence of
any organic dihydroxy compound different from hydroxy-terminated
polyester intermediate. In another embodiment step (B) is conducted
in the presence of at least one organic dihydroxy compound
different from hydroxy-terminated polyester intermediate. In
various embodiments said organic dihydroxy compound has the formula
HO--R.sup.2--OH, wherein R.sup.2 is as previously defined.
Therefore, in one embodiment the method of the present invention
comprises conducting the reaction of step (B) in the presence of at
least one organic dihydroxy compound of the formula HO--R.sup.2--OH
identical to at least one 1,3-dihydroxybenzene moiety in the
polyester blocks prepared in step (A). In another embodiment the
method comprises conducting the reaction of step (B) in the
presence of at least one organic dihydroxy compound of the formula
HO--R.sup.2--OH different from any 1,3-dihydroxybenzene moiety in
the polyester blocks prepared in step (A). In yet another
embodiment the method comprises conducting the reaction of step (B)
in the presence of a mixture of organic dihydroxy compounds of the
formula HO--R.sup.2--OH at least one of which is the same as and at
least one of which is different from any 1,3-dihydroxybenzene
moiety in the polyester blocks. In still another embodiment the
method comprises conducting the reaction of step (B) in the
presence of a mixture of two organic dihydroxy compounds of the
formula HO--R.sup.2--OH one of which is the same as and one of
which is different from any 1,3-dihydroxybenzene moiety in the
polyester blocks. When a mixture of dihydroxy compounds is present,
then the molar ratio of dihydroxy compounds identical to those
present in the polyester blocks to those dihydroxy compounds
different from those present in the polyester blocks is typically
about 1:999 to 999:1. In some embodiments the method comprises
conducting the reaction of step (B) in the presence of a mixture of
dihydroxy compounds comprising at least two of unsubstituted
resorcinol, a substituted resorcinol, and bisphenol A. In another
embodiment the method comprises conducting the reaction of step (B)
in the presence of bisphenol A. In another embodiment the method
comprises conducting the reaction of step (B) in the presence of
unsubstituted resorcinol.
[0065] At least one organic dihydroxy compound different from
hydroxy-terminated polyester intermediate may be introduced into
the reaction mixture of step (B) through any convenient method of
combination. In one embodiment at least one organic dihydroxy
compound may be present as unreacted 1,3-dihydroxybenzene moiety
from step (A). In another embodiment at least one organic dihydroxy
compound may be added following step (A), before or during reaction
with carbonate precursor in step (B). In another embodiment at
least one organic dihydroxy compound is present as unreacted
1,3-dihydroxybenzene moiety from step (A) and at least one organic
dihydroxy compound may be added following step (A), before or
during reaction with carbonate precursor in step (B). Any dihydroxy
compound added following step (A), before or during reaction with
carbonate precursor in step (B), may be the same as or different
from any 1,3-dihydroxybenzene moiety present initially in step (A).
In a particular embodiment at least one organic dihydroxy compound
comprises at least one unsubstituted resorcinol or substituted
resorcinol from step (A) and at least one dihydroxy compound added
following step (A) different from unsubstituted resorcinol or
substituted resorcinol. In some embodiments a molar excess of
resorcinol (relative to total moles dicarboxylic acid diester
present) is employed in step (A), in which case there may be some
unreacted resorcinol remaining, and bisphenol A is added before or
during reaction with carbonate precursor in step (B). The amount of
any 1,3-dihydroxybenzene moiety remaining unreacted from step (A)
is in one embodiment less than about 15 mole %, in another
embodiment less than about 10 mole %, and in another embodiment
less than about 5 mole % of the 1,3-dihydroxybenzene moiety
initially present in step (A). In another embodiment the amount of
1,3-dihydroxybenzene moiety remaining unreacted from step (A) is
less than about 2 mole % of the 1,3-dihydroxybenzene moiety
initially present in step (A).
[0066] The amount of any dihydroxy compound added following step
(A) may be that required to provide at least one polycarbonate
block with a desired degree of polymerization. In one embodiment
the amount of any dihydroxy compound added following step (A) is
such that the a polycarbonate block has a degree of polymerization
of at least 1, in another at least about 3, in another embodiment
at least about 10 and in still another embodiment in a range of
about 20-200. In some embodiments the amount of any dihydroxy
compound added following step (A) is such that a polycarbonate
block has a degree of polymerization between about 20 and 50.
[0067] At least one chain-stopper (also referred to sometimes
hereinafter as capping agent) may also be present in step (B), and
said chain-stopper may be incorporated into the structures of
copolyestercarbonates of the invention. A chain-stopper may
comprise at least one mono-phenolic compound. In some embodiments
at least one chain-stopper may be present in quantities of about
0.05 to about 10 mole %, based on total dihydroxy compounds used in
step (B), or, when no additional dihydroxy compound is used in step
(B), based on total dihydroxy compounds used in step (A).
[0068] Suitable mono-phenolic compounds as chain-stoppers include
monocyclic phenols, such as phenol, C.sub.1-C.sub.22
alkyl-substituted phenols, p-cumyl-phenol, p-tertiary-butyl phenol,
hydroxy diphenyl; monoethers of diphenols, such as p-methoxyphenol.
Alkyl-substituted phenols include those with branched chain alkyl
substituents having 8 to 9 carbon atoms, preferably in which about
47 to 89% of the hydrogen atoms are part of methyl groups as
described in U.S. Pat. No. 4,334,053. For some embodiments the use
of a mono-phenolic UV screener as capping agent is preferred. Such
compounds include 4-substituted-2-hydroxybenzophenones and their
derivatives, aryl salicylates, monoesters of diphenols, such as
resorcinol monobenzoate, 2-(2-hydroxyaryl)-benzotriazoles and their
derivatives, 2-(2-hydroxyaryl)-1,3,5-triazines and their
derivatives, and like compounds. Especially preferred mono-phenolic
chain-stoppers are phenol, p-cumylphenol, and resorcinol
monobenzoate.
[0069] Suitable mono-carboxylic acid chlorides as chain-stoppers
include monocyclic, mono-carboxylic acid chlorides, such as benzoyl
chloride, C.sub.1-C.sub.22 alkyl-substituted benzoyl chloride,
toluoyl chloride, halogen-substituted benzoyl chloride,
bromobenzoyl chloride, cinnamoyl chloride, 4-nadimidobenzoyl
chloride, and mixtures thereof; polycyclic, mono-carboxylic acid
chlorides, such as trimellitic anhydride chloride, and naphthoyl
chloride; and mixtures of monocyclic and polycyclic mono-carboxylic
acid chlorides. The chlorides of aliphatic monocarboxylic acids
with up to 22 carbon atoms are also suitable. Functionalized
chlorides of aliphatic monocarboxylic acids, such as acryloyl
chloride and methacryloyl chloride, are also suitable. Suitable
mono-chloroformates include monocyclic, mono-chloroformates, such
as phenyl chloroformate, alkyl-substituted phenyl chloroformate,
p-cumyl phenyl chloroformate, toluene chloroformate, and mixtures
thereof.
[0070] In another embodiment the method of the invention may
encompass the inclusion of at least one branching agent in either
or both of step (A) and step (B). Said branching agent may be
incorporated into the structures of the copolyestercarbonates of
the invention. Suitable branching agents comprise trifunctional or
higher functional carboxylic acid esters and/or trifunctional or
higher functional phenolic compounds. Such branching agents, if
included, can preferably be used in quantities of 0.005 to 1 mole
%, based on dicarboxylic acid diesters present in step (A) or on
total dihydroxy compound present in step (B), respectively.
Illustrative examples of suitable branching agents comprise
trifunctional or higher carboxylic acid esters, such as trimesic
acid triarylester, cyanuric acid triarylester,
3,3',4,4'-benzophenone tetracarboxylic acid tetraarylester,
1,4,5,8-naphthalene tetracarboxylic acid tetraarylester or
pyromellitic acid tetraarylester, and trifunctional or higher
phenols, such as phloroglucinol,
4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)-2-hepten- e,
4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)-heptane,
1,3,5-tri-(4-hydroxyphenyl)-benzene,
1,1,1-tri-(4-hydroxyphenyl)-ethane, tri-(4-hydroxyphenyl)-phenyl
methane, 2,2-bis-[4,4-bis-(4-hydroxyphenyl)-- cyclohexyl]-propane,
2,4-bis-(4-hydroxyphenylisopropyl)-phenol,
tetra-(4-hydroxyphenyl)-methane,
2,6-bis-(2-hydroxy-5-methylbenzyl)-4-met- hyl phenol,
2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)-propane,
tetra-(4-[4-hydroxyphenylisopropyl]-phenoxy)-methane,
1,4-bis-[(4,4-dihydroxytri-phenyl)methyl]-benzene. In some
embodiments triarylesters are triphenylesters.
[0071] Following completion of both reactions, the block
copolyestercarbonate may be used in solution or transferred by any
convenient procedure to some other solvent for use. In some
embodiments the copolyestercarbonate is recovered and isolated from
solution by conventional procedures. These procedures may comprise,
for example, at least one of anti-solvent precipitation, washing,
drying and devolatilization-pelletization via extrusion.
[0072] The block copolyestercarbonates of this invention are
polymers having excellent physical properties. Their light
transmitting properties may be similar to those of polycarbonates.
Thus, they are often substantially transparent and may often be
employed as substitutes for polycarbonates in the fabrication of
transparent sheet material when improved weatherability is
mandated.
[0073] Block copolyestercarbonates made by the method of the
present invention have in one embodiment less than about 500 ppm,
in another embodiment less than about 100 ppm, in another
embodiment less than about 50 ppm, in another embodiment less than
about 20 ppm, in another embodiment less than about 10 ppm, and in
still another embodiment less than about 5 ppm phenolic end-groups.
In yet another embodiment phenolic end-groups in block
copolyestercarbonates of the invention are essentially undetectable
using standard analytical methods. Said copolymers contain in one
embodiment less than about 100 ppm, in another embodiment less than
about 50 ppm, in another embodiment less than about 25 ppm, and in
another embodiment less than about 10 ppm free 1,3-dihydroxybenzene
moiety. The copolymers have in one embodiment less than about 1000
ppm, in another embodiment less than about 500 ppm, in another
embodiment less than about 200 ppm, in another embodiment less than
about 100 ppm, in another embodiment less than about 50 ppm, in
another embodiment less than about 10 ppm, and in still another
embodiment less than about 5 ppm carboxylic acid end-groups. In yet
another embodiment carboxylic acid end-groups in block
copolyestercarbonates of the invention are essentially undetectable
using standard analytical methods. The concentration of carboxylic
acid end-groups in the copolyestercarbonates is in one embodiment
less than that present in the polyester intermediate from step (A).
Any carboxylic acid end-groups in said polyester intermediate may
react with carbonate precursor in step (B). For example, when
phosgene is the carbonate precursor, carboxylic acid groups may
react to form carboxylic acid chlorides which may then react with
any phenolic groups present.
[0074] In another of its embodiments the present invention
comprises methods for making thermally stable oligomeric polyester
intermediates and block copolyestercarbonates. In the present
context thermally stable means that the polymers show decrease in
molecular weight in one embodiment of less than about 20%, in
another embodiment of less than about 10%, and in another
embodiment of less than about 5% upon heating said polymers at a
temperature of about 280-290.degree. C. for five minutes. Although
the scope of the invention is not intended to be limited by theory,
it is believed that thermal stability may be related to the
presence or absence of anhydride linkages. The presence of
anhydride linkages may also result in lowered hydrolytic stability
in the polyester intermediates and copolyestercarbonates. Typical
anhydride linkages are illustrated in Formula (XI). 8
[0075] Such anhydride linkages link at least two mers in a polymer
chain and may arise through combination of two isophthalate or
terephthalate moieties or mixtures thereof, although it is to be
understood that anhydride linkages may arise through combination of
any suitable similar dicarboxylic acid residues or mixtures of
suitable dissimilar dicarboxylic acid residues present in a
reaction mixture. The presence of anhydride linkages may result in
thermal molecular weight loss outside the range cited hereinabove.
In some embodiments either or both of polyester intermediates and
copolyestercarbonates are substantially free of anhydride linkages.
Substantially free of anhydride linkages in the present context
means that a polymer has thermal molecular weight loss within the
range cited hereinabove. Anhydride linkages may also be detected by
means known to those skilled in the art such as by .sup.13C nuclear
magnetic resonance spectroscopy (NMR). After thermal processing
(for example, extrusion and/or molding), the molecular weight of
copolyestercarbonate containing anhydride linkages often decreases,
and the anhydride NMR resonances typically decrease. Anhydride
linkages may also be detected by reaction of polymer with a
nucleophile, such as a secondary amine. For example, polyester
intermediate or copolyestercarbonate may be dissolved in a
convenient solvent, such as methylene chloride, and treated with a
secondary amine, such as dibutylamine or diisobutylamine, for
several minutes at ambient temperature. Comparison of the starting
polymer molecular weight to that after amine treatment typically
shows a decrease in molecular weight which may be correlated with
the corresponding decrease observed under typical thermal
processing conditions. Although the invention is not meant to be
limited by theory, it is believed that nucleophiles, such as
secondary amine and phenolic, attack anhydride linkages (as opposed
to ester linkages) selectively under the reaction conditions. The
decrease in molecular weight upon reaction with amine nucleophile
is therefore an indication of the presence of anhydride
functionality in the polymer.
[0076] In one of its embodiments the present invention comprises
the copolyestercarbonates as described. In some embodiments of
methods of making said copolyestercarbonates there may be present
following step (B) some polyester intermediate from step (A) which
is not covalently bound to a carbonate moiety. For example there
may be present a polyester intermediate possessing end-groups which
may not be reactive with carbonate precursor. Illustrative examples
of end-groups comprise carboxylic acid, carboxylic acid ester,
carboxylic acid chloride or end-capped species without any
functional group. Therefore, in another of its embodiments the
present invention comprises the said copolyestercarbonates in
combination with polyester homopolymer containing structural units
comprising those of the polyester blocks in the
copolyestercarbonate, said polyester homopolymer being made in step
(A) of the same process as said copolyestercarbonate. When it is
desired to isolate substantially pure copolyestercarbonate, then
the level of said polyester homopolymer present in
copolyestercarbonate is in one embodiment less than about 20 wt. %,
in another embodiment less than about 10 wt. % and in still another
embodiment less than about 4 wt. % of copolyestercarbonate. In some
embodiments the level of said polyester homopolymer is less than
about 1 wt. % of copolyestercarbonate isolated substantially pure.
When it is desired to prepare a blend of copolyestercarbonate with
polyester homopolymer through synthesis in steps A and B, then in
some embodiments proportions of the copolyestercarbonates in such
blends comprise up to about 80 wt. % of the composition.
[0077] When an organic dihydroxy compound different from the
1,3-dihydroxybenzene moiety of step (A) is present in step (B),
then some portion of said dihydroxy compound may undergo
transesterification with ester blocks in both copolyestercarbonate
and in any polyester homopolymer that might be present, depending
upon reaction parameters such as pH and temperature. Therefore, in
another of its embodiments the present invention comprises the said
copolyestercarbonates in combination with polyester copolymer with
structural units comprising 1,3-dihydroxybenzene moieties from step
(A) and any organic dihydroxy compound added for step (B), both in
combination with aromatic dicarboxylic acid moieties as described,
said polyester copolymer being derived from the synthesis process.
The level of said polyester copolymer present in
copolyestercarbonate is in one embodiment less than about 20 wt. %,
in another embodiment less than about 5 wt. % and in still another
embodiment less than about 2 wt. % of copolyestercarbonate. In
another embodiment the level of said polyester copolymer is less
than about 1 wt. % of copolyestercarbonate.
[0078] In yet another of its embodiments the present invention
comprises copolyestercarbonates in which a portion of the ester
blocks have undergone transesterification with and incorporation of
some portion of organic dihydroxy compound added in step (B) as
described above. For example, in one embodiment
copolyestercarbonates may be produced in which an organic dihydroxy
compound such as bisphenol A is incorporated into a portion of the
ester blocks, either before, during, or after carbonate block
formation with hydroxy-terminated polyester intermediate. The level
of said organic dihydroxy compound added in step (B) incorporated
into said ester blocks is in one embodiment less than about 20 wt.
%, in another embodiment less than about 5 wt. % and in still
another embodiment less than about 2 wt. % of copolyestercarbonate.
In another embodiment the level of incorporation of said organic
dihydroxy compound added in step (B) into said ester blocks is less
than about 1 wt. % of copolyestercarbonate.
[0079] When step (B) is performed in the presence of at least one
organic dihydroxy compound different from hydroxy-terminated
polyester intermediate produced in step (A), then polycarbonate
homopolymer may be formed which is not covalently bound to
polyester intermediate. Therefore, in another of its embodiments
the present invention comprises the said copolyestercarbonates in
combination with polycarbonate homopolymer containing structural
units comprising those of the polycarbonate blocks in the
copolyestercarbonate, said polycarbonate homopolymer being made in
step (B) of the same process as said copolyestercarbonate. When it
is desired to isolate substantially pure copolyestercarbonate, then
the level of said polycarbonate homopolymer present in
copolyestercarbonate is in one embodiment less than about 20 wt. %,
in another embodiment less than about 10 wt. % and in still another
embodiment less than about 4 wt. % of copolyestercarbonate. In
another embodiment the level of said polycarbonate homopolymer is
less than about 2 wt. % of copolyestercarbonate isolated
substantially pure. When it is desired to prepare a blend of
copolyestercarbonate with at least one polycarbonate homopolymer
through synthesis in steps A and B, then at least one polycarbonate
homopolymer in the blends may be prepared essentially
simultaneously with carbonate block formation in the
copolyestercarbonate in step (B). Alternatively, at least one
polycarbonate homopolymer in the blends may be prepared after the
block copolyestercarbonate formation is at least partially or
essentially complete, for example, in one option, through addition
of more organic dihydroxy compound, carbonate precursor, and chain
stopper. The proportions of the copolyestercarbonates in such
blends are determined chiefly by the resulting proportions of ester
blocks, which are believed to comprise the active
weatherability-improving entities, typical proportions providing in
various embodiments about 10-50% by weight of ester blocks in the
blend. Typically blends of copolyestercarbonate with up to about 95
wt. % polycarbonate homopolymer may be prepared, if desired,
through synthesis in steps A and B. In a particular embodiment
blends of copolyestercarbonate comprising bisphenol A carbonate
blocks may be prepared along with bisphenol A polycarbonate
homopolymer through synthesis in step (A) and step (B) in the
presence of phosgene.
[0080] In some embodiments when step (B) is performed in the
presence of at least one organic dihydroxy compound different from
hydroxy-terminated polyester intermediate produced in step (A),
then a new polyester homopolymer may be formed through reaction,
for example, of some portion of said organic dihydroxy compound
with any aromatic dicarboxylic acid species present in the reaction
mixture. In some embodiments aromatic dicarboxylic acids may be
present in the reaction mixture of step (A), for example through
adventitious hydrolysis of aromatic dicarboxylic acid diester or as
impurities initially present in aromatic dicarboxylic acid diester.
In one embodiment said aromatic dicarboxylic acids may be converted
to the corresponding dicarboxylic acid dichlorides through reaction
with phosgene in step (B). Therefore, in another of its embodiments
the present invention comprises the said copolyestercarbonates in
combination with polyester homopolymer containing structural units
comprising organic dihydroxy compound added in step (B) in
combination with aromatic dicarboxylic acid moieties as described,
said polyester homopolymer being made in the same process as said
copolyestercarbonate. The level of said polyester homopolymer
present in copolyestercarbonate is in one embodiment less than
about 12 wt. %, in another embodiment less than about 6 wt. % and
in still another embodiment less than about 4 wt. % of
copolyestercarbonate. In another embodiment the level of said
polyester homopolymer is less than about 2 wt. % of
copolyestercarbonate. In an illustrative embodiment bisphenol A
polyester derived from bisphenol A added in step (B) may be present
in the copolyestercarbonates of the invention.
[0081] It is believed that the weatherability and certain other
beneficial properties of the copolyestercarbonates of the invention
are attributable, at least in part, to the occurrence of thermally
or photochemically induced Fries rearrangement of arylate blocks to
yield o-hydroxybenzophenone moieties or analogs thereof which serve
as stabilizers to UV radiation. More particularly, at least a
portion of arylate polyester chain members can rearrange to yield
chain members with at least one hydroxy group ortho to at least one
ketone group. Such rearranged chain members are typically
o-hydroxybenzophenone-type chain members comprising one or more of
the following structural moieties of formulas (XII)-(XIV): 9
[0082] wherein R.sup.1 and p are as previously defined. Thus, in
one of its embodiments the present invention comprises compositions
containing copolyestercarbonates containing structural units
comprising those shown in formula (XV) wherein R.sup.1, R.sup.2, p,
m, and n are as previously defined: 10
[0083] It is also contemplated to introduce moieties of the types
illustrated in formulas (XII), (XIII), and (XIV) via synthesis and
polymerization of appropriate monomers in copolyestercarbonates. In
one embodiment the present invention provides copolyestercarbonates
comprising structural units represented by formulas (XVI) and
(XVII): 11
[0084] wherein R.sup.1 and p are as previously defined and wherein
the molar ratio of structural units represented by formula (XVI) to
structural units represented by formula (XVII) ranges from about
99:1 to about 1:1, and preferably from about 99:1 to about 80:20.
Although iso- and terephthalate units are illustrated in formulas
(XVI) and (XVII), the dicarboxylic acid residues in the ester
blocks may be derived from any suitable dicarboxylic acid residue,
as defined hereinabove, or mixture of suitable dicarboxylic acid
residues. In various embodiments p in both formulas (XVI) and
(XVII) is zero and the ester blocks comprise dicarboxylic acid
residues derived from a mixture of iso- and terephthalic acid
residues, wherein the molar ratio of isophthalate to terephthalate
is about 0.25-4.0:1, preferably about 0.4-2.5:1, and more
preferably about 0.67-1.5:1.
[0085] The copolyestercarbonates may be employed in blends with
other polymers, especially condensation polymers such as
polycarbonates, polyesters, copolyestercarbonates, polyarylates,
polyetherimides, polyphenylene ethers; and addition polymers. The
polycarbonates in blend compositions of the invention are, for the
most part, similar in molecular structure to the carbonate blocks
of the copolyestercarbonate as described hereinabove, with
illustrative examples being bisphenol A homo- and copolycarbonates.
Polyesters are illustrated by poly(alkylene dicarboxylates),
especially poly(ethylene terephthalate) (hereinafter sometimes
designated "PET"), poly(1,4-butylene terephthalate) (hereinafter
sometimes designated "PBT"), poly(trimethylene terephthalate)
(hereinafter sometimes designated "PTT"), poly(ethylene
naphthalate) (hereinafter sometimes designated "PEN"),
poly(1,4-butylene naphthalate) (hereinafter sometimes designated
"PBN"), poly(cyclohexanedimethanol terephthalate) (hereinafter
sometimes designated "PCT"), poly(cyclohexanedimethanol-co-ethylene
terephthalate) (hereinafter sometimes designated "PETG"), and
poly(1,4-cyclohexanedimeth- yl-1,4-cyclohexanedicarboxylate)
(hereinafter sometimes designated "PCCD"), and especially
poly(alkylene arenedioates), with poly(ethylene terephthalate) and
poly(1,4-butylene terephthalate) being preferred.
[0086] Polyarylates that may be employed in blends comprise those
known in the art. They often comprise structural units derived from
aromatic dihydroxy compounds and aromatic dicarboxylic acid
compounds described herein as suitable for preparation of
polycarbonates, polyesters, and copolyestercarbonates. In various
embodiments polyarylates comprise those with structural units
comprising the 1,3-dihydroxybenzene moiety present in the ester
blocks of the copolyestercarbonates, those with structural units
comprising any organic dihydroxy compound added in the carbonate
block formation step in synthesis of said copolyestercarbonates,
and those with structural units comprising both of the
aforementioned dihydroxy moieties. In illustrative embodiments
polyarylates comprise terephthalate and/or isophthalate structural
units in combination with one or more of unsubstituted resorcinol,
substituted resorcinol, and bisphenol A. The polyetherimide resins
are generically known compounds whose preparation and properties
are described in numerous publications and U.S. patents, and
include those available from General Electric Plastics under the
tradename ULTEM.
[0087] Suitable addition polymers comprise homopolymers and
copolymers, especially homopolymers of alkenylaromatic compounds,
such as polystyrene, including syndiotactic polystyrene, and
copolymers of alkenylaromatic compounds with ethylenically
unsaturated nitrites, such as acrylonitrile and methacrylonitrile;
dienes, such as butadiene and isoprene; and/or acrylic monomers,
such as ethyl acrylate. These latter copolymers comprise the ABS
(acrylonitrile-butadiene-styrene) and ASA
(acrylonitrile-styrene-alkyl acrylate) copolymers. Suitable
addition polymers also comprise acrylic polymers such as those of
(meth)acrylamides or of alkyl (meth)acrylates such as poly(methyl
methacrylate) ("PMMA"), wherein the nomenclature "meth(acryl . . .
)" indicates that both acryl and methacryl polymers are
designated.
[0088] Proportions of the block copolyestercarbonates in such
blends are determined chiefly by the resulting proportions of ester
blocks, which comprise the active weatherability-improving
entities, typical proportions providing about 10-50% by weight of
ester blocks in the blend. By reason of some degree of
incompatibility between the block copolyestercarbonates of the
invention and the various polymers in which they may be
incorporated, said blends are often not transparent. However,
transparent blends may often be prepared, if desired, by adjusting
the length of the ester blocks in the block copolyestercarbonates.
The other properties of said blends are excellent.
[0089] The blend compositions of the invention may be prepared by
such conventional operations as solvent blending or melt blending
as by an extrusion process. They may additionally contain
art-recognized additives including, but not limited to, impact
modifiers, UV screeners, UV absorbers, flame retardants,
stabilizers, color stabilizers, heat stabilizers, ester interchange
inhibitors, flow aids and mold release agents. The blends may
contain fillers such as glass fibers, glass fiber fabric, chopped
glass, knit glass fiber fabric, glass spheres, KEVLAR fiber,
polyphenylene sulfide fiber, woven basalt fiber fabric, silicates,
zeolites, titanium dioxide, stone powder, carbon fibers, carbon
black, graphite, calcium carbonate, talc, mica, lithopone, zinc
oxide, zirconium silicate, iron oxides, diatomaceous earth, calcium
carbonate, magnesium oxide, chromic oxide, zirconium oxide,
aluminum oxide, crushed quartz, talc, clay, kaolin, asbestos,
cellulose, wood flour, cork, cotton and synthetic textile fibers,
especially reinforcing fillers such as glass fibers and carbon
fibers, as well as colorants such as metal flakes, glass flakes and
beads, ceramic particles, other polymer particles, dyes and
pigments which may be organic, inorganic or organometallic. In
addition It is intended that the blend compositions comprise simple
physical blends and any reaction products thereof, for example, as
illustrated by polyester-polycarbonate transesterification
products.
[0090] The present invention also comprises articles comprising
copolyestercarbonates made by methods disclosed herein. Such
articles generally display resistance to weathering due to the
presence of said copolyestercarbonates. In some embodiments such
articles may be monolithic, composite, or multilayer. In various
embodiments articles comprise those consisting essentially of
copolyestercarbonate optionally containing art-recognized additives
as described herein. In other embodiments articles comprise those
consisting essentially of copolyestercarbonate in a blend with at
least one other thermoplastic resin optionally containing
art-recognized additives as described herein.
[0091] In a particular embodiment the present invention comprises
multilayer articles comprising a substrate layer comprising at
least one thermoplastic polymer, thermoset polymer, cellulosic
material, glass, ceramic, or metal, and at least one coating layer
thereon, said coating layer comprising at least one
copolyestercarbonate comprising structural units derived from at
least one 1,3-dihydroxybenzene moiety and at least one aromatic
dicarboxylic acid moiety, and prepared by methods embodied in the
present invention. In the present context a multilayer article is
one containing at least two layers. In various embodiments a
coating layer comprises at least one thermally stable
copolyestercarbonate comprising resorcinol arylate polyester chain
members substantially free of anhydride linkages linking at least
two mers of the polymer chain. Optionally, the multilayer articles
may further comprise an interlayer, for example an adhesive
interlayer (sometimes known as a tie-layer), between any substrate
layer and any thermally stable polymer coating layer. Multilayer
articles of the invention comprise those which comprise a substrate
layer and a coating layer of said thermally stable polymer; those
which comprise a substrate layer with a coating layer of said
thermally stable polymer on each side of said substrate layer; and
those which comprise a substrate layer and at least one coating
layer of said thermally stable polymer with at least one interlayer
between a substrate layer and a coating layer. Any interlayer may
be transparent, translucent, or opaque, and/or may contain an
additive, for example a colorant or decorative material such as
metal flake. If desired, an overlayer may be included over the
coating layer of thermally stable polymer, for example to provide
abrasion or scratch resistance. The substrate layer, coating layer
of thermally stable polymer, and any interlayers or overcoating
layers are preferably in contiguous superposed contact with one
another.
[0092] Within the context of the present invention it should be
understood that any coating layer comprising a thermally stable
polymer comprising resorcinol arylate polyester chain members may
also comprise polymer comprising o-hydroxy-benzophenone or
analogous chain members resulting from Fries rearrangement of said
resorcinol arylate polyester chain members, for example after
exposure of said coating layer to UV-light. Typically, a
preponderance of polymer comprising o-hydroxy-benzophenone or
analogous chain members will be on that side or sides of said
coating layer exposed to UV-light and will overlay in a contiguous
superposed layer or layers that polymer comprising unrearranged
resorcinol arylate polyester chain members. If it is worn away or
otherwise removed, polymer comprising o-hydroxybenzophenone or
analogous chain members is capable of regenerating or renewing
itself from the resorcinol arylate-containing layer or layers, thus
providing continuous protection for any UV-light sensitive
layers.
[0093] Coating layers and any intermediate layers may optionally
contain art-recognized additives, illustrative examples of which
comprise color stabilizing additives, heat stabilizers, UV
screeners, and auxiliary UV absorbers. For example, illustrative UV
absorbers comprise hydroxybenzophenones, hydroxybenzotriazoles,
hydroxybenzotriazines, cyanoacrylates, oxanilides, and
benzoxazinones. Illustrative UV absorbers also comprise nano-size
inorganic materials such as titanium oxide, cerium oxide, and zinc
oxide, all with particle size less than about 100 nanometers.
Illustrative examples of stabilizer additives also comprise
carbodiimides, such as bis-(2,6-diisopropylphenyl)carbodiimide and
polycarbodiimides; hindered amine light stabilizers; hindered
phenols; phosphites and phosphorous acid. Such stabilizer additives
are known in the art and are disclosed in standard reference works
such as "Plastics Additives Handbook", 5th edition, edited by H.
Zweifel, Hanser Publishers. In some embodiments mixtures of
stabilizer additives are particularly effective, especially
mixtures of the abovementioned stabilizer additives.
[0094] The amount of any stabilizer additive employed is in one
embodiment in a range between about 0.0005 wt. % and 10 wt. %, in
another embodiment in a range between about 0.001 wt. % and about
10 wt. %, in another embodiment in a range between about 0.04 wt. %
and about 8 wt. %, in another embodiment in a range between about
0.01 wt. % and about 6 wt. %, in another embodiment in a range
between about 0.2 wt. % and about 5 wt. %, in another embodiment in
a range between about 0.5 wt. % and about 5 wt. %, and in still
another embodiment in a range between about 1 wt. % and about 5 wt.
% based on the weight of copolyestercarbonate in a coating layer. A
stabilizer additive may be combined with coating layer using known
methods. In one embodiment stabilizer additive is at least
partially dissolved in a solution with components of a coating
layer, and a film of coating layer comprising stabilizer additive
is solvent cast. In another embodiment stabilizer additive is at
least partially dissolved in a solution and impregnated from said
solution into solid or at least partially solid coating layer. In
still another embodiment stabilizer additive is combined with
coating layer in a melt method such as co-extrusion. If desired,
the stabilizer additive may be combined with coating layer in the
form of a solution of stabilizer additive, for example in water or
organic solvent. In one embodiment an aqueous solution of
phosphorous acid is employed as stabilizer additive.
[0095] It is also within the scope of the invention for other
polymers to be present which are miscible in at least some
proportions with a polymer coating layer comprising at least one
thermally stable copolyestercarbonate comprising structural units
derived from at least one 1,3-dihydroxybenzene moiety and at least
one aromatic dicarboxylic acid moiety. Illustrative examples of at
least partially miscible polymers comprise polyetherimide and
polyesters such as PBT, PET, PTT, PEN, PBN, PETG, PCCD, and
bisphenol A polyarylate. Preferably, the coating layer polymer
consists essentially of thermally stable resorcinol arylate
copolyestercarbonates, optionally containing art-recognized
additives.
[0096] The material of the substrate layer in the articles of this
invention may be at least one thermoplastic polymer, whether
addition or condensation prepared. Thermoplastic polymers comprise
polycarbonates, particularly aromatic polycarbonates, polyacetals,
polyarylene ethers, polyphenylene ethers, polyarylene sulfides,
polyphenylene sulfides, polysulfones, polyimides, polyamideimides,
polyetherimides, polyetherketones, polyaryletherketones,
polyetheretherketones, polyetherketoneketones, polyamides,
polyesters, liquid crystalline polyesters, polyetheresters,
polyetheramides, polyesteramides, and polyestercarbonates (other
than those employed for the coating layer, as defined herein).
Polycarbonates and polyesters are frequently preferred. A substrate
layer may additionally contain art-recognized additives including,
but not limited to, colorants, pigments, dyes, impact modifiers,
stabilizers, color stabilizers, heat stabilizers, UV screeners, UV
absorbers, flame retardants, fillers, flow aids, ester interchange
inhibitors, and mold release agents.
[0097] Suitable polycarbonates (hereinafter sometimes designated
"PC") comprise polycarbonates comprising structural units of the
types described for organic carbonate blocks in
copolyestercarbonates of the invention. In various embodiments
polycarbonates are bisphenol A homo- and copolycarbonates. In one
embodiment the weight average molecular weight of the initial
polycarbonate ranges from about 5,000 to about 100,000, and in
another embodiment from about 25,000 to about 65,000.
[0098] The polycarbonate substrate may also be a
copolyestercarbonate (other than that copolyestercarbonate employed
for the coating layer as defined hereinafter). Such copolymers
typically comprise, in addition to the organic carbonate units,
ester units such as isophthalate and/or terephthalate. The
copolyestercarbonates which find use in the instant invention and
the methods for their preparation are well known in the art as
disclosed in, for example, U.S. Pat. Nos. 3,030,331; 3,169,121;
3,207,814; 4,156,069; 4,194,038; 4,238,596; 4,238,597; 4,487,896;
and 4,506,065.
[0099] Polyester substrates comprise poly(alkylene dicarboxylates),
especially poly(ethylene terephthalate), poly(1,4-butylene
terephthalate), poly(trimethylene terephthalate), poly(ethylene
naphthalate), poly(butylene naphthalate),
poly(cyclohexanedimethanol terephthalate),
poly(cyclohexanedimethanol-co-ethylene terephthalate), and
poly(1,4-cyclohexanedimethyl-1,4-cyclohexanedicarboxylate). Also
included are polyarylates, illustrative examples of which comprise
those comprising structural units derived from bisphenol A,
terephthalic acid, and isophthalic acid.
[0100] Suitable addition polymer substrates comprise homo- and
copolymeric aliphatic olefin polymers and functionalized olefin
polymers (which are homopolymers and copolymers comprising
structural units derived from either aliphatic olefins or
functionalized olefins or both), and their alloys or blends.
Illustrative examples comprise polyethylene, polypropylene,
thermoplastic polyolefin (sometimes referred to in the art as
"TPO"), poly(vinyl chloride), poly(vinyl chloride-co-vinylidene
chloride), poly(vinyl fluoride), poly(vinylidene fluoride),
poly(vinyl acetate), poly(vinyl alcohol), poly(vinyl butyral),
poly(acrylonitrile), acrylic polymers such as those of
(meth)acrylamides or of alkyl (meth)acrylates such as poly(methyl
methacrylate) (sometimes referred to as "PMMA"), and polymers of
alkenylaromatic compounds such as polystyrenes, including
syndiotactic polystyrene. The preferred addition polymers for many
purposes are polystyrenes and especially the so-called ABS and ASA
copolymers, which may contain thermoplastic, non-elastomeric
styrene-acrylonitrile side chains grafted on an elastomeric base
polymer of butadiene and alkyl acrylate, respectively.
[0101] Blends of any of the foregoing polymers may also be employed
as substrates. Typical blends comprise those comprising PC/ABS,
PC/ASA, PC/PBT, PC/PET, PC/polyetherimide, PC/polysulfone,
polyester/polyetherimide, PMMA/acrylic rubber, polyphenylene
ether/polystyrene, polyphenylene ether/polyamide or polyphenylene
ether/polyester. Although the substrate layer may incorporate other
thermoplastic polymers, the above-described polycarbonates and/or
addition polymers still more preferably constitute the major
proportion thereof.
[0102] The substrate layer in the multilayer articles of this
invention may also comprise at least one of any thermoset polymer.
Suitable thermoset polymer substrates comprise those derived from
epoxys, cyanate esters, unsaturated polyesters, diallylphthalate,
acrylics, alkyds, phenol-formaldehyde, novolacs, resoles,
bismaleimides, PMR resins, melamine-formaldehyde,
urea-formaldehyde, benzocyclobutanes, hydroxymethylfurans, and
isocyanates. In one embodiment of the invention the thermoset
polymer substrate comprises a RIM material. In one embodiment of
the invention the thermoset polymer substrate further comprises at
least one thermoplastic polymer, such as, but not limited to,
polyphenylene ether, polyphenylene sulfide, polysulfone,
polyetherimide, or polyester. Said thermoplastic polymer is
typically combined with thermoset monomer mixture before curing of
said thermoset.
[0103] In one embodiment of the invention a thermoplastic or
thermoset substrate layer also incorporates at least one filler
and/or pigment. Illustrative extending and reinforcing fillers, and
pigments comprise silicates, zeolites, titanium dioxide, stone
powder, glass fibers or spheres, carbon fibers, carbon black,
graphite, calcium carbonate, talc, mica, lithopone, zinc oxide,
zirconium silicate, iron oxides, diatomaceous earth, calcium
carbonate, magnesium oxide, chromic oxide, zirconium oxide,
aluminum oxide, crushed quartz, calcined clay, talc, kaolin,
asbestos, cellulose, wood flour, cork, cotton and synthetic textile
fibers, especially reinforcing fillers such as glass fibers, carbon
fibers, and metal fibers, as well as colorants such as metal
flakes, glass flakes and beads, ceramic particles, other polymer
particles, dyes and pigments which may be organic, inorganic or
organometallic. In another embodiment the invention encompasses
multilayer articles comprising a filled thermoset substrate layer
such as a sheet-molding compound (SMC).
[0104] The substrate layer may also comprise at least one
cellulosic material including, but not limited to, wood, paper,
cardboard, fiber board, particle board, plywood, construction
paper, Kraft paper, cellulose nitrate, cellulose acetate butyrate,
and like cellulosic-containing materials. The invention also
encompasses blends of at least one cellulosic material and either
at least one thermoset polymer (particularly an adhesive thermoset
polymer), or at least one thermoplastic polymer (particularly a
recycled thermoplastic polymer, such as PET or polycarbonate), or a
mixture of at least one thermoset polymer and at least one
thermoplastic polymer.
[0105] Multilayer articles encompassed by the invention also
comprise those comprising at least one glass layer. Typically any
glass layer is a substrate layer, although multilayer articles
comprising a thermally stable polymer coating layer interposed
between a glass layer and a substrate layer are also contemplated.
Depending upon the nature of coating and glass layers, at least one
adhesive interlayer may be beneficially employed between any glass
layer and any thermally stable polymer coating layer. The adhesive
interlayer may be transparent, opaque or translucent. For many
applications it is preferred that the interlayer be optically
transparent in nature and generally have a transmission of greater
than about 60% and a haze value less than about 3% with no
objectionable color.
[0106] Metal articles exposed to UV-light may exhibit tarnishing
and other detrimental phenomena. In another embodiment the
invention encompasses multilayer articles comprising at least one
metal layer as substrate layer. Representative metal substrates
comprise those comprising brass, aluminum, magnesium, chrome, iron,
steel, copper, and other metals or alloys or articles containing
them, which may require protection from UV-light or other weather
phenomena. Depending upon the nature of coating and metal layers,
at least one adhesive interlayer may be beneficially employed
between any metal layer and any thermally stable polymer coating
layer.
[0107] Another aspect of the invention is a method for preparing a
multilayer article which comprises applying at least one thermally
stable coating layer to a second layer, said second layer
comprising at least one thermoplastic polymer, thermoset polymer,
cellulosic material, glass, or metal, and said coating layer
comprising at least one copolyestercarbonate comprising structural
units derived from at least one 1,3-dihydroxybenzene moiety and at
least one aromatic dicarboxylic acid moiety, the polymer being
substantially free of anhydride linkages linking at least two mers
of the polymer chain.
[0108] In one embodiment of the invention, at least one thermally
stable coating layer is applied to a second layer, which may be the
substrate layer or at least one intermediate layer ultimately to be
disposed between the coating and substrate layers. An intermediate
layer may comprise any of the materials suitable for use as the
substrate or coating layer, and may further contain fillers and
colorants such as described hereinabove. When necessary, it may be
specifically chosen so as to provide good adhesion between
substrate and coating layers. Colorants of the previously described
types may also be present in the coating layer.
[0109] In one embodiment application of at least one coating layer
may be performed by solvent-casting. In another embodiment
application of said coating layer comprises fabrication of a
separate sheet thereof followed by application of the coating layer
sheet to the second layer, or by simultaneous production of both
layers, typically in a melt process. Thus, there may be employed
such methods as thermoforming, compression molding, co-injection
molding, coextrusion, overmolding, blow molding, multi-shot
injection molding and placement of a film of the coating layer
material on the surface of the second layer followed by adhesion of
the two layers, typically in an injection molding apparatus; e.g.,
in-mold decoration, or in a hot-press. These operations may be
conducted under art-recognized conditions.
[0110] It is also within the scope of the invention to apply a
structure comprising the coating layer and the second layer to a
third, substrate layer, which may be, for example, of a
thermoplastic, thermoset, metal, or cellulosic material similar or
identical to that of the second layer but different from that of
the coating layer. This may be achieved, for example, by charging
an injection mold with the structure comprising the coating layer
and the second layer and injecting the substrate sheet material
behind it. By this method, in-mold decoration and the like are
possible. Both sides of the substrate layer may receive the other
layers, though it is usually preferred to apply them to only one
side.
[0111] The thicknesses of the various layers in multilayer articles
of this invention are most often as follows:
[0112] substrate--at least about 125.mu. (microns), or at least
about 250.mu., or at least about 400.mu.,
[0113] coating--about 2-2,500, or about 10-250 or about
50-175.mu.,
[0114] second material, if any--about 2-2,500, or about 10-250, or
about 50-175.mu.,
[0115] total--at least about 125.mu., or at least about 250.mu., or
at least about 400.mu..
[0116] The articles of this invention are typically characterized
by the usual beneficial properties of the substrate layer, in
addition to weatherability as may be evidenced by such properties
as improved initial gloss, improved initial color, improved
resistance to ultraviolet radiation and maintenance of gloss,
improved impact strength, and resistance to organic solvents
encountered in their final applications. Depending upon such
factors as the coating layer/substrate combination, the multilayer
articles may possess recycling capability, which makes it possible
to employ the regrind material as a substrate for further
production of articles of the invention.
[0117] Multilayer articles which can be made which comprise
copolyestercarbonates of the invention comprise those involving
outdoor use and storage and hence requiring resistance to
weathering. Illustrative applications comprise aircraft,
automotive, truck, military vehicle (including automotive,
aircraft, and water-borne vehicles), and motorcycle exterior and
interior components, including panels, quarter panels, rocker
panels, trim, fenders, doors, decklids, trunklids, hoods, bonnets,
roofs, bumpers, fascia, grilles, mirror housings, pillar appliques,
cladding, body side moldings, wheel covers, hubcaps, door handles,
spoilers, window frames, headlamp bezels, headlamps, tail lamps,
tail lamp housings, tail lamp bezels, license plate enclosures,
roof racks, and running boards; enclosures, housings, panels, and
parts for outdoor vehicles and devices; enclosures for electrical
and telecommunication devices; outdoor furniture; boats and marine
equipment, including trim, enclosures, and housings; outboard motor
housings; depth finder housings, personal water-craft; jet-skis;
pools; spas; hot-tubs; steps; step coverings; building and
construction applications such as glazing, roofs, windows, floors,
decorative window furnishings or treatments; treated glass covers
for pictures, paintings, posters, and like display items; optical
lenses; ophthalmic lenses; corrective ophthalmic lenses;
implantable ophthalmic lenses; wall panels, and doors; protected
graphics; outdoor and indoor signs; enclosures, housings, panels,
and parts for automatic teller machines (ATM); enclosures,
housings, panels, and parts for lawn and garden tractors, lawn
mowers, and tools, including lawn and garden tools; window and door
trim; sports equipment and toys; enclosures, housings, panels, and
parts for snowmobiles; recreational vehicle panels and components;
playground equipment; articles made from plastic-wood combinations;
golf course markers; utility pit covers; computer housings;
desk-top computer housings; portable computer housings; lap-top
computer housings; palm-held computer housings; monitor housings;
printer housings; keyboards; FAX machine housings; copier housings;
telephone housings; mobile phone housings; radio sender housings;
radio receiver housings; light fixtures; lighting appliances;
network interface device housings; transformer housings; air
conditioner housings; cladding or seating for public
transportation; cladding or seating for trains, subways, or buses;
meter housings; antenna housings; cladding for satellite dishes;
coated helmets and personal protective equipment; coated synthetic
or natural textiles; coated photographic film and photographic
prints; coated painted articles; coated dyed articles; coated
fluorescent articles; coated foam articles; and like applications.
The invention further contemplates additional fabrication
operations on said articles, such as, but not limited to, molding,
in-mold decoration, baking in a paint oven, lamination, and/or
thermoforming.
[0118] Without further elaboration, it is believed that one skilled
in the art can, using the description herein, utilize the present
invention to its fullest extent. The following examples are
included to provide additional guidance to those skilled in the art
in practicing the claimed invention. The examples provided are
merely representative of the work that contributes to the teaching
of the present application. Accordingly, these examples are not
intended to limit the invention, as defined in the appended claims,
in any manner.
[0119] Molecular weights were determined in chloroform by gel
permeation chromatography (GPC) relative to polystyrene and are
reported as weight average (M.sub.w) or number average
(M.sub.n).
EXAMPLE 1
[0120] Into a glass reactor equipped with a stir shaft, Dean Stark
trap with Vigreux column and vacuum attachment was charged
resorcinol (3.03 g, 0.0275 moles), diphenylisophthalate (3.98 g,
0.0125 moles), diphenylterephthalate (3.98 g, 0.0125 moles),
lithium hydroxide (2.2 milligrams [mg]), and tetramethylammonium
hydroxide (10 microliters of 25 wt % solution). A nitrogen
atmosphere was established (3 vacuum purges) and slow stirring
begun. The reactor was lowered into a salt bath controlled at about
200.degree. C. After 15 minutes the pressure was reduced to 100
Torr. This pressure and temperature were maintained for 45 minutes
during which time about 1 mL of phenol was collected. The pressure
was then lowered to 50 Torr and maintained for 60 minutes,
collecting an additional 1 mL of phenol. The temperature was then
raised to 220.degree. C. and after 60 minutes an additional 1.2 mL
of phenol was obtained. For the next 30 minutes the reactor was
held at 220.degree. C. and 25 Torr. Finally, the temperature
increased to 240.degree. C. and full vacuum applied for 45 minutes,
the final amount of phenol being about 3.5 mL (80% of theory). The
viscous amber colored material was poured onto an aluminum pan,
yielding 4.5 grams. GPC analysis indicated a Mw of 8,026. The Tg of
this material was 112.degree. C. A similar reaction was conducted
yielding 4.06 g of polyester oligomers with a Mw of 8,327 and a Tg
of 115.degree. C.
[0121] Into a 5-neck Morton round bottomed flask equipped with a pH
electrode, phosgene addition tube, condenser, caustic addition
port, and a stirring shaft was charged polyester oligomers (7.0 g
obtained by combining the two polyester materials above), methylene
chloride (100 mL) deionized water (100 mL), and triethylamine (200
microliters). The pH of the reaction mixture was taken to 9 and
phosgene added (1.5 g, 0.5 g/min). The pH was maintained at 9 for
the entire phosgenation. The reaction mixture was separated, the
organic phase washed with hydrochloric acid (1N), hydrochloric acid
(0.1N) and twice with water, and the polymer was isolated by
precipitation in hot water. The Mw of the isolated material was
13,202.
EXAMPLE 2
[0122] Into a glass reactor equipped with a stir shaft, Dean Stark
trap with Vigreux column and vacuum attachment was charged
resorcinol (3.03 g, 0.0275 moles), diphenylisophthalate (3.98 g,
0.0125 moles), diphenylterephthalate (3.98 g, 0.0125 moles),
lithium hydroxide (2.2 mg), and tetramethylammonium hydroxide (10
microliters of 25 wt % solution). A nitrogen atmosphere was
established (3 vacuum purges) and slow stirring begun. The reactor
was lowered into a salt bath controlled at about 200.degree. C.
After 15 minutes the pressure was reduced to 100 Torr. This
pressure and temperature were maintained for 45 minutes during
which time about 2.2 mL of phenol was collected. The pressure was
then lowered to 50 Torr and maintained for 30 minutes, collecting
an additional 0.8 mL of phenol. The temperature was then raised to
220.degree. C. and after 30 minutes a cumulative total of about 3.2
mL of phenol had been obtained. For the next 30 minutes the reactor
was held at 220.degree. C. and 25 Torr, then 240.degree. C. and 25
Torr for 30 minutes. Finally, the temperature held at 240.degree.
C. and full vacuum applied for 60 minutes, the final amount of
phenol being about 3.8 mL (86% of theory). The viscous amber
colored material was poured onto an aluminum pan, yielding 3.1
grams. An additional 2.6 g was chipped out of the reactor after
cooling. GPC analysis indicated a Mw of 9,891. The Tg of this
material was 118.degree. C.
[0123] Into a 5-neck Morton round bottomed flask equipped with a pH
electrode, phosgene addition tube, condenser, caustic addition
port, and a stirring shaft was charged polyester oligomers (5.8 g),
bisphenol A (3.8 g, 0.016 moles), methylene chloride (100 mL),
deionized water (100 mL), and triethylamine (200 microliters). The
pH of the reaction mixture was taken to 10 and phosgene added (3.4
g, 0.75 g/min). The pH was maintained at 10 for the entire
phosgenation. The reaction mixture was separated, the organic phase
washed with hydrochloric acid (1N), hydrochloric acid (0.1N) and
twice with water, and the polymer was isolated by precipitation in
hot water. The Mw of the isolated material was 24,513.
EXAMPLE 3
[0124] Into a glass reactor equipped with a stir shaft, Dean Stark
trap with Vigreux column and vacuum attachment was charged
resorcinol (3.03 g, 0.0275 moles), diphenylisophthalate (3.98 g,
0.0125 moles), diphenylterephthalate (3.98 g, 0.0125 moles),
lithium hydroxide (3.5 mg), and tetramethylammonium hydroxide (10
microliters of 25 wt % solution). A nitrogen atmosphere was
established (3 vacuum purges) and slow stirring began. The reactor
was lowered into a salt bath controlled at about 200.degree. C.
After 15 minutes the pressure was reduced to 100 Torr. This
pressure and temperature were maintained for 45 minutes during
which time about 2.2 mL of phenol was collected. The pressure was
then lowered to 50 Torr and maintained for 30 minutes, collecting
an additional 0.8 mL of phenol. The temperature was then raised to
220.degree. C. and after 30 minutes the cumulative total of phenol
was about 3.3 ML. For the next 30 minutes the reactor was held at
220.degree. C. and 25 Torr, then 240.degree. C. and 25 Torr for 30
minutes. Finally, the temperature held at 240.degree. C. and full
vacuum applied for 60 minutes, the final amount of phenol collected
being about 4.1 mL (93% of theory). The viscous amber colored
material was poured onto an aluminum pan, yielding 4.9 grams. GPC
analysis indicated a Mw of 14,400.
[0125] Into a 5-neck Morton round bottomed flask equipped with a pH
electrode, phosgene addition tube, condenser, caustic addition
port, and a stirring shaft was charged polyester oligomers (4.75
g), bisphenol A (3.01 g, 0.0132 moles), methylene chloride (100
mL), deionized water (100 mL), and triethylamine (200 microliters).
The pH of the reaction mixture was taken to 10 and phosgene added
(3.0 g, 0.75 g/min). The pH was maintained at 10 for the entire
phosgenation. The reaction mixture was separated, the organic phase
washed with hydrochloric acid (1N), hydrochloric acid (0.1N) and
twice with water, and the polymer was isolated by precipitation in
hot water. The Mw of the isolated material was 35,861.
EXAMPLE 4
[0126] Into a glass reactor equipped with a stir shaft, Dean Stark
trap with Vigreux column and vacuum attachment was charged
resorcinol (3.66 g, 0.0332 moles), diphenylisophthalate (3.98 g,
0.0125 moles), diphenylterephthalate (3.98 g, 0.0125 moles), sodium
hydroxide (2.65 microliters of 25 wt % solution), and
tetrabutylphosphonium acetate (20 microliters of 40 wt % solution).
A nitrogen atmosphere was established (3 vacuum purges) and slow
stirring begun. The reactor was lowered into a salt bath controlled
at about 200.degree. C. After 15 minutes the pressure was reduced
to 100 Torr. This pressure and temperature were maintained for 165
minutes during which time about 3.3 mL of phenol was collected. The
pressure was then lowered to 75 Torr and maintained for 60 minutes,
collecting an additional 0.2 mL of phenol. The temperature was then
raised to 220.degree. C. and after 60 minutes a cumulative total of
about 3.7 mL of phenol had been obtained. For the next 60 minutes
the reactor was held at 240.degree. C. and 75 Torr, then
240.degree. C. and 50 Torr for 60 minutes. Finally, the temperature
held at 240.degree. C. and full vacuum applied for 90 minutes, the
final amount of phenol being about 4.3 mL (98% of theory). The
viscous amber colored material was poured onto an aluminum pan,
yielding 4.2 grams. An additional 1.6 g was chipped out of the
reactor after cooling. GPC analysis indicated a Mw of 5,511.
[0127] Into a 5-neck Morton round bottomed flask equipped with a pH
electrode, phosgene addition tube, condenser, caustic addition
port, and a stirring shaft was charged polyester oligomers (5.7 g),
bisphenol A (1.5 g, 0.006 moles), phenol (0.08 g, 0.00085 moles),
methylene chloride (100 mL), deionized water (25 mL), and
triethylamine (50 microliters). The pH of the reaction mixture was
taken to 10 and phosgene added (1.2 g, 0.4 g/min). The pH was
maintained at 10 for the entire phosgenation. The reaction mixture
was separated, the organic phase washed with hydrochloric acid
(1N), hydrochloric acid (0.1N) and twice with water, and the
polymer was isolated by precipitation in hot water. The Mw of the
isolated material was 32,158.
EXAMPLE 5
[0128] Into a glass reactor equipped with a stir shaft, Dean Stark
trap with Vigreux column and vacuum attachment was charged
resorcinol (3.03 g, 0.0275 moles), diphenylisophthalate (3.98 g,
0.0125 moles), diphenylterephthalate (3.98 g, 0.0125 moles), sodium
hydroxide (2.65 microliters of 25 wt % solution), and
tetrabutylphosphonium acetate (20 microliters of 40 wt % solution).
A nitrogen atmosphere was established (3 vacuum purges) and slow
stirring began. The reactor was lowered into a salt bath controlled
at about 200.degree. C. After 15 minutes the pressure was reduced
to 100 Torr. This pressure and temperature were maintained for 165
minutes during which time about 2.6 mL of phenol was collected. The
pressure was then lowered to 75 Torr and maintained for 60 minutes,
collecting an additional 0.1 mL of phenol. The temperature was then
raised to 220.degree. C. and after 60 minutes a cumulative total of
about 3.0 mL of phenol had been obtained. For the next 60 minutes
the reactor was held at 240.degree. C. and 75 Torr, then
240.degree. C. and 50 Torr for 60 minutes. Finally, the temperature
held at 240.degree. C. and full vacuum applied for 40 minutes, the
final amount of phenol being about 4.2 mL (95% of theory). The
viscous amber colored material was poured onto an aluminum pan,
yielding 3.84 grams. An additional 1.9 g was chipped out of the
reactor after cooling. GPC analysis indicated a Mw of 11,080.
[0129] Into a 5-neck Morton round bottomed flask equipped with a pH
electrode, phosgene addition tube, condenser, caustic addition
port, and a stirring shaft was charged polyester oligomers (5.7 g),
bisphenol A (1.5 g, 0.006 moles), phenol (0.056 g, 0.00059 moles),
methylene chloride (100 mL), deionized water (25 mL), and
triethylamine (50 microliters). The pH of the reaction mixture was
taken to 10 and phosgene added (1.2 g, 0.4 g/min). The pH was
maintained at 10 for the entire phosgenation. The reaction mixture
was separated, the organic phase washed with hydrochloric acid
(1N), hydrochloric acid (0.1N) and twice with water, and the
polymer was isolated by precipitation in hot water. The Mw of the
isolated material was 19,219.
EXAMPLE 6
[0130] Into a glass reactor equipped with a stir shaft, Dean Stark
trap with Vigreux column and vacuum attachment was charged
resorcinol (5.5 g, 0.05 moles), diphenylisophthalate (3.98 g,
0.0125 moles), diphenylterephthalate (3.98 g, 0.0125 moles), sodium
hydroxide (2.65 microliters of 25 wt % solution), and
tetrabutylphosphonium acetate (20 microliters of 40 wt % solution).
A nitrogen atmosphere was established (3 vacuum purges) and slow
stirring began. The reactor was lowered into a salt bath controlled
at 200.degree. C. After 15 minutes the pressure was reduced to 100
Torr. This pressure and temperature were maintained for 165 minutes
during which time a cumulative total of about 3.6 mL of phenol was
collected. The temperature was then raised to 220.degree. C. and
after 120 minutes a cumulative total of 3.9 mL of phenol had been
obtained. Finally, the temperature held at 240.degree. C. and the
vacuum lowered to 50 Torr for 60 minutes, the final amount of
phenol being about 4.1 mL (93% of theory). The fluid amber colored
material was poured onto an aluminum pan, yielding 7.62 grams. GPC
analysis indicated a Mw of 1,306.
[0131] Into a 5-neck Morton round bottomed flask equipped with a pH
electrode, phosgene addition tube, condenser, caustic addition
port, and a stirring shaft was charged polyester oligomers (7.0 g),
bisphenol A (1.5 g, 0.006 moles), phenol (0.08 g, 0.00085 moles),
methylene chloride (100 mL), deionized water (25 mL), and
triethylamine (50 microliters). The pH of the reaction mixture was
taken to 10 and phosgene added (2 g, 0.4 g/min). The pH was
maintained at 10 for the entire phosgenation. The reaction mixture
was separated, the organic phase washed with hydrochloric acid
(1N), hydrochloric acid (0.1N) and twice with water, and the
polymer was isolated by precipitation in hot water. The Mw of the
isolated material was 52,325.
EXAMPLE 7
[0132] Into a glass reactor equipped with a stir shaft, Dean Stark
trap with Vigreux column and vacuum attachment was charged
resorcinol (3.66 g, 0.0332 moles), diphenylisophthalate (3.98 g,
0.0125 moles), diphenylterephthalate (3.98 g, 0.0125 moles), sodium
hydroxide (2.65 microliters of 25 wt % solution), and
tetrabutylphosphonium acetate (20 microliters of 40 wt % solution).
A nitrogen atmosphere was established (3 vacuum purges) and slow
stirring begun. The reactor was lowered into a salt bath controlled
at about 200.degree. C. After 15 minutes, the pressure was reduced
to 100 Torr. This pressure and temperature were maintained for 165
minutes during which time about 3.1 mL of phenol was collected. The
temperature was then raised to 240.degree. C. and the pressure
lowered to 75 Torr, and after 120 minutes a cumulative total of 3.9
mL of phenol had been obtained. The temperature was held at
240.degree. C. and the vacuum lowered to 50 Torr for 60 minutes,
and finally full vacuum for 30 minutes. The final amount of phenol
being about 4.2 mL (95% of theory). The fluid amber colored
material was poured onto an aluminum pan, yielding 4.98 grams. GPC
analysis indicated a Mw of 5,209.
[0133] Into a 5-neck Morton round bottomed flask equipped with a pH
electrode, phosgene addition tube, condenser, caustic addition
port, and a stirring shaft was charged polyester oligomers (4.9 g),
bisphenol A (1.17 g, 0.005 moles), methylene chloride (100 mL),
deionized water (25 mL), and triethylamine (50 microliters). The pH
of the reaction mixture was taken to 10 and phosgene added (1.2 g,
0.4 g/min). The pH was maintained at 10 for the entire
phosgenation. The reaction mixture was separated, the organic phase
washed with hydrochloric acid (1N), hydrochloric acid (0.1N) and
twice with water, and the polymer was isolated by precipitation in
hot water. The Mw of the isolated material was 50,637.
EXAMPLE 8
[0134] Into a glass reactor equipped with a stir shaft, Dean Stark
trap with Vigreux column and vacuum attachment was charged
resorcinol (3.03 g, 0.0275 moles), diphenylisophthalate (3.98 g,
0.0125 moles), diphenylterephthalate (3.98 g, 0.0125 moles), sodium
hydroxide (2.65 microliters of 25 wt % solution), and
tetrabutylphosphonium acetate (20 microliters of 40 wt % solution).
A nitrogen atmosphere was established (3 vacuum purges) and slow
stirring begun. The reactor was lowered into a salt bath controlled
at about 200.degree. C. After 25 minutes the pressure was reduced
to 100 Torr. This pressure and temperature were maintained for 105
minutes during which time about 2.8 mL of phenol was collected. The
pressure was lowered to 75 Torr and maintained at this temperature
and pressure for 60 minutes. The temperature was then raised to
240.degree. C. and after 120 minutes a cumulative total of 3.6 mL
of phenol had been obtained. Finally, the pressure was lowered to
50 Torr for an hour and full vacuum for 60 minutes, the final
amount of phenol collected being about 4.1 mL (93% of theory). The
fluid amber colored material was poured onto an aluminum pan,
yielding 5.22 grams. GPC analysis indicated a Mw of 7,541.
[0135] Into a 5-neck Morton round bottomed flask equipped with a pH
electrode, phosgene addition tube, condenser, caustic addition
port, and a stirring shaft was charged polyester oligomers (5.15
g), bisphenol A (1.4 g, 0.006 moles), methylene chloride (100 mL),
deionized water (25 mL), and triethylamine (50 microliters). The pH
of the reaction mixture was taken to 10 and phosgene added (1.2 g,
0.4 g/min). The pH was maintained at 10 for the entire
phosgenation. The reaction mixture was separated, the organic phase
washed with hydrochloric acid (1N), hydrochloric acid (0.1N) and
twice with water, and the polymer was isolated by precipitation in
hot water. The Mw of the isolated material was 21,328.
CONTROL EXAMPLE 8
[0136] A polyester intermediate derived from resorcinol with a 1:1
mixture of iso- and terephthaloyl dichlorides was prepared in a
blender according to the interfacial method of U.S. Pat. No.
3,460,961. The isolated polymer had weight average molecular weight
of about 289,000. The procedure was repeated with methylene
chloride as organic solvent with addition of 4 mole % chain-stopper
(phenol), resulting in polymer with weight average molecular weight
of about 51,000. The latter polyester intermediate was used to
prepare a resorcinol arylate-containing block copolyestercarbonate
with 50% by weight carbonate blocks through interfacial reaction
with phosgene, bisphenol A, and p-cumyl phenol capping agent.
Extrusion of the copolyestercarbonate gave amber pellets. The
copolymer had initial Mw of 75,900 and Mw after extrusion of 64,500
(85% retention). A separate sample of material was treated with
diisobutylamine in solution; the Mw of the recovered material was
73,000 (96% retention).
[0137] The molecular weight values for polyester oligomer and
copolyestercarbonate product are summarized in Table 1, along with
% excess resorcinol added and % phenol removed in polyester
oligomer formation step (A), and % phenol added in
copolyestercarbonate formation step (B).
1TABLE 1 % mol % total Final copolymer Mw % excess phenol added mol
% polymer % Mw % example oligomer resorcinol removed phenol phenol
Mw loss* ester/carbonate 1 8,175 10 80 0 20 13,202 0.2 100/0 2
9,891 10 86 0 8.3 24,513 0.3 60/40 3 14,400 10 93 0 4.2 35,861 1.4
60/40 4 5,511 32 98 2.8 4.7 32,158 0.9 80/20 5 11,080 10 95 2 5.7
19,219 1.9 80/20 6 1,306 100 93 3.4 7 52,325 0.5 83/17 7 5,209 32
95 0 3.6 50,637 1.6 80/20 8 7,541 10 93 0 5.3 21,328 0.3 80/20 *by
diisobutylamine test
[0138] The copolyestercarbonates of Table 1 showed essentially no
molecular weight loss in the diisobutylamine test, indicating that
no anhydride was present. The diisobutylamine test was also run on
selected polyester oligomer samples; essentially no molecular
weight loss was observed.
EXAMPLE 9
[0139] To a 100 mL 3-neck flask equipped with a mechanical stirrer,
nitrogen inlet and reflux condenser with Dean-Stark apparatus were
added bis(o-chlorophenyl)-isophthalate (30.97 g, 80 mmol),
bis(o-chlorophenyl)sebacate (8.46 g, 20 mmol), freshly distilled
resorcinol (11.01 g, 100 mmol) and tetramethylammonium
tetraphenylborate (50.4 mg, 100 ppm wt). The flask was blanketed
with dry nitrogen and the contents maintained at 250.degree. C. for
one hour, during which time vigorous distillation of chlorophenol
occurred. The temperature was then gradually raised to 280.degree.
C. over a period of three hours while passing a slow stream of
nitrogen through. The molten polymer was quickly poured onto a
TEFLON coated metal sheet to give a translucent light amber colored
material. GPC analysis indicated a Mw of 4,000. The polyester
oligomer was suitable for use in preparation of
copolyestercarbonates.
EXAMPLE 10
[0140] To a melt polycondensation reactor equipped with mechanical
stirrer, nitrogen inlet and reflux condenser with Dean-Stark
apparatus were added bis(methylsalicyl)isophthalate (8.688 g, 20
mmol), resorcinol (2.202 g, 20 mmol) and lithium hydroxide (1.4 mg,
128 ppm wt.). The mixture was heated under argon at 220.degree. C.
Within 5 minutes a white suspension formed. After 30 minutes, 4.2
ml of methyl salicylate (81% conversion) distilled under
application of slight vacuum. High vacuum was applied at one hour
reaction time. No oligomer sublimation was noticed. The mixture was
reacted at 250.degree. C. for one more hour, then cooled to
150.degree. C. under argon and quickly stranded out of the reactor
at this temperature to give a transparent, almost colorless
polymer. GPC analysis indicated a Mw of 15,000. The polyester
oligomer was suitable for use in preparation of
copolyestercarbonates.
[0141] While the invention has been illustrated and described in
typical embodiments, it is not intended to be limited to the
details shown, since various modifications and substitutions can be
made without departing in any way from the spirit of the present
invention. As such, further modifications and equivalents of the
invention herein disclosed may occur to persons skilled in the art
using no more than routine experimentation, and all such
modifications and equivalents are believed to be within the spirit
and scope of the invention as defined by the following claims. All
patents cited herein are incorporated herein by reference.
* * * * *