U.S. patent application number 09/919097 was filed with the patent office on 2003-03-20 for process for manufacture of soluble highly branched polyamides, and at least partially aliphatic highly branched polyamides obtained therefrom.
This patent application is currently assigned to Eastman Kodak Company. Invention is credited to Wang, Jin-Shan.
Application Number | 20030055209 09/919097 |
Document ID | / |
Family ID | 25441505 |
Filed Date | 2003-03-20 |
United States Patent
Application |
20030055209 |
Kind Code |
A1 |
Wang, Jin-Shan |
March 20, 2003 |
PROCESS FOR MANUFACTURE OF SOLUBLE HIGHLY BRANCHED POLYAMIDES, AND
AT LEAST PARTIALLY ALIPHATIC HIGHLY BRANCHED POLYAMIDES OBTAINED
THEREFROM
Abstract
A process for the manufacture of soluble hyperbranched
polyamides is disclosed comprising the steps of combining
multifunctional monomer reactants comprising amine and carboxylic
acid functional groups in a reactor with water, and reacting amine
and carboxylic acid functional groups of the multi-functional
monomers at elevated temperature and pressure for a period of time
sufficient to form a highly branched polyamide. The present
invention advantageously provides a simple, practical, and
environmentally friendly process for the manufacture of soluble
hyperbranched polyamides comprising multifunctional in-chain and/or
end groups. The present invention also provides a process for the
manufacture of soluble hyperbranched polyamides from monomers with
a broad range of the ratio of functional amine groups to acid
groups. The invention is also directed towards soluble highly
branched polyamides which may be obtained by a process of the
invention, which comprise monomer units derived from
multifunctional amine or multifunctional acid functional group
containing aliphatic monomers.
Inventors: |
Wang, Jin-Shan; (Pittsford,
NY) |
Correspondence
Address: |
Paul A. Leipold
Patent Legal Staff
Eastman Kodak Company
343 State Street
Rochester
NY
14650-2201
US
|
Assignee: |
Eastman Kodak Company
|
Family ID: |
25441505 |
Appl. No.: |
09/919097 |
Filed: |
July 31, 2001 |
Current U.S.
Class: |
528/310 |
Current CPC
Class: |
C08G 69/28 20130101;
C08G 69/04 20130101; C08G 69/26 20130101; C08G 69/36 20130101; C08G
83/005 20130101 |
Class at
Publication: |
528/310 |
International
Class: |
C08G 069/08 |
Claims
What is claimed is:
1. A polymerization process for producing soluble hyperbranched
polyamides comprising (a) combining in a reactor water and
(a.sub.1) multi-functional di- or higher amine functional group
containing monomers represented by the following formula (I) and
multi-functional di- or higher carboxylic acid functional group
containing monomers represented by the following formula (III), or
a preformed salt of such di- or higher functional monomers, or
(a.sub.2) multi-functional branching monomers of the formula (III):
R.sup.1(NH.sub.2).sub.x (I) R.sup.2(COOH).sub.y (II)
A.sub.n-L-B.sub.m (III) where in formulas (I) and (II), R.sup.1 and
R.sup.2 are each independently a monomeric, oligomeric, or
polymeric compound nucleus, x and y are integers of at least 2,
without x and y being 2 at the same time, and in formula (III), one
of A and B represents an amine functional group, the other of A and
B represents a cerboxylic acid functional group, L represents a
monomeric, oligomeric, or polymeric compound nucleus linking group
between A and B, n is at least 1 and m at least 2, and wherein
multiple carboxylic acid functional groups of a multi-functional
monomer may be in anhydride form, and (b) reacting amine and
carboxylic acid functional groups of the multi-functional monomers
at a temperature of at least 100.degree. C. and a pressure of at
least 140 kPa, wherein polymerization proceeds by reaction of an
amine group of a first monomer unit with an acid group of a second
monomer unit to form a reaction product having an amide linkage
between the first and second monomer units and repetition of such
amidation reaction between additional amine groups and acid groups
of the multi-functional monomers and reaction products of the
multi-functional monomers for a period of time sufficient to form a
highly branched polyamide.
2. A process according to claim 1, wherein multi-functional
branching monomers of formula (m) are employed.
3. A process according to claim 2, wherein n is 1 and m is 2 or
3.
4. A process according to claim 3, wherein m is 2.
5. A process according to claim 2, wherein L comprises a further
substituted or unsubstituted straight or branched alkyl,
cycloalkyl, aryl or alkylaryl linking group moiety, or an
oligomeric or polymeric chain moiety.
6. A process according to claim 2 wherein L comprises a straight or
branched alkyl, cycloalkyl, aryl or alkylaryl moiety.
7. A process according to claim 2, wherein A represents an amino
group and B represents a carboxylic acid group.
8. A process according to claim 2 wherein B represents an amino
group and A represents a carboxylic acid group.
9. A process according to claim 1, wherein multi-functional di- or
higher amine functional group containing monomers of formula (I)
and multi-functional di- or higher carboxylic acid functional group
containing monomers of formula (II), wherein x and y are integers
from 2 and 4, without x and y being 2 at the same time, or a
preformed salt of such monomers, are employed.
10. A process according to claim 9, wherein one of x and y is 2 and
the other of x and y is 3.
11. A process according to claim 10, wherein x is 2 and y is 3.
12. A process according to claim 10, wherein y is 2 and x is 3.
13. A process according to claim 9, wherein the multifunctional
acid monomer comprises an anhydride group containing monomer.
14. A process according to claim 9, wherein the ratio of total
amine to acid groups of the multifunctional monomers is from 0.2 to
6.
15. A process according to claim 9, wherein the ratio of total
amine to acid groups of the multifunctional monomers is from 0.3 to
3.
16. A process according to claim 15, wherein the multifunctional
monomers employed in the process include at least one
multifunctional amine or multifunctional acid group containing
aliphatic monomer.
17. A process according to claim 9, wherein the multifunctional
monomers employed in the process include at least one
multifunctional amine or multifunctional acid group containing
aliphatic monomer.
18. A process according to claim 1, wherein the temperature
employed during polymerization is from 100 to 350.degree. C., and
the pressure varies from 140 kPa to 50.times.10.sup.3 kPa.
19. A process according to claim 18, wherein the temperature
employed during polymerization is from 150 to 280.degree. C.
20. A process according to claim 18, wherein the pressure varies
from 600 kPa to 7.times.10.sup.3 kPa
21. A process according to claim 1, wherein the temperature is from
100 to 350.degree. C. and the pressure from 140 kPa to
50.times.10.sup.3 kPa during a first stage of polymerization, and
further comprising heating solid polymer synthesized in such first
stage to higher temperature to facilitate further reaction and
obtain higher molecular weight polymer.
22. A process according to claim 1, wherein the content of water in
the reactor at the start of polymerization is from 0.1 to 99.9 wt %
in relation to total amount of solution.
23. A process according to claim 22, wherein the content of water
in the reactor at the start of polymerization is from 0.5 to 50 wt
%.
24. A process according to claim 22, wherein the content of water
in the reactor at the start of polymerization is from 1 to 30 wt
%.
25. A process according to claim 1, wherein the multifunctional
monomers employed in the process include at least one
multifunctional amine or multifunctional acid group containing
aliphatic monomer.
26. A soluble highly branched polyamide obtained from condensation
of multifunctional amine and multifunctional acid functional group
containing monomer reactants, wherein at least one of the
multifunctional amine and the multifunctional acid monomers is
aliphatic and the ratio of total amine functional groups to
carboxylic acid functional groups in the monomer reactants is from
0.3 to 3.
27. A soluble highly branched polyamide obtained from condensation
of multifunctional amine and multifunctional acid functional group
containing monomer reactants, wherein at least one of the
multifunctional amine and the multifunctional acid monomers is
aliphatic and the weight averaged molecular weight is above
1,000.
28. A soluble highly branched polyamide according to claim 27,
wherein the weight averaged molecular weight is above 2,000.
29. A soluble highly branched polyamide according to claim 27,
wherein the weight averaged molecular weight is above 4,000.
30. A soluble highly branched polyamide according to claim 27,
wherein the weight averaged molecular weight is above 6,000.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a process for the
manufacture of hyperbranched polymers, and polymers made by such
process. Specifically, the present invention relates to a practical
polymerization process for the manufacture of hyperbranched
polyamides in water, and hyperbranched polyamides made from such
process employing aliphatic multifunctional monomers and specific
ratios of amine to carboxylic acid groups.
BACKGROUND OF THE INVENTION
[0002] Polyamides represent one of the most important groups of
polymers with excellent heat and flame resistance and high tensile
strength and modulus. Branched polymers and copolymers have
attracted considerable attention over the past decades, since many
advanced materials with new or improved properties can be obtained
therefrom. The terms "hyperbranched" and "highly branched" used
herein with respect to branched polymers are intended to designate
polymers having a relatively high percentage of propagated
branching sites per number of polymerized monomer units, e.g. at
least one branching site per every ten monomer units, preferably at
least one branching site per every five monomer units and more
preferably at least one branching site per every three monomer
units. Highly branched polymers can be made by multi-step or one
step processes. Multi-step generation processes were exemplified by
Frechet in U.S. Pat. No. 5,041,516 and by Hult in U.S. Pat. No.
5,418,301. Both patents described that the highly branched polymers
known as dendrimer or "starburst polymer" were made through a
series of growth steps consisting of repeatedly reacting,
isolating, and purifying.
[0003] One-step process was first conceptualized by Flory (J. Am.
Chem. Soc., 74, p2718 (1952)) who demonstrated by theoretical
analysis that a highly branched and soluble polymers could be
formed from monomers comprising the structure AB.sub.2, where A and
B are reactive groups, by one-step condensation polymerization. In
contrast to the dendrimers, the polymer formed by AB.sub.2
polymerization is randomly branched. Most AB.sub.2 type monomers,
however, are not commercially available, and access to such
monomers accordingly involves synthetic efforts, which is
potentially problematic, especially on a large scale. To cope with
such problem, one-step process for formation of a highly branched
polymer may also use an A.sub.2+B.sub.3 approach. In
A.sub.2+B.sub.3 polymerization, di- and tri-functional monomers are
reacted together. For ideal A.sub.2+B.sub.3 polymerization,
intramolecular cyclization must be minimized as a competing and
chain terminating process during polymer propagation, all A groups
and all B groups should have near equal reactivity in both the
monomers as well as the growing polymers, and the A and B groups
should have exclusive reactivity with each other. In view of such
requirements, relatively few specific combinations of
A.sub.2+B.sub.3 polymerization schemes have been proposed.
[0004] With regard to the synthesis of hyperbranched polyamides
from AB.sub.2-type monomers, Kim reported the synthesis of
hyperbranched aromatic polyamides from sulfinyl amino acid chloride
derivatives in organic solvents (J. Am. Chem. Soc., 114, 4947
(1992)). U.S. Pat No. 5,514,764 disclosed preparation of
hyperbranched aromatic polyesters and polyamides by a one-step
process of polymerizing a monomer of the formula A-R-B.sub.2 where
R represents an aromatic moiety. U.S. Pat. No. 5,567,795 disclosed
synthesis of highly branched polymers in a single processing step
by using branching aromatic monomers and an end-capping monomer.
With regard to A.sub.2+B.sub.3 polymerization, Jikei et al
(Macromolecules, 32, 2061 (1999)), e.g., has reported synthesis of
hyperbranched aromatic polyamides from aromatic diamines and
trimesic acid. Copending, concurrently filed, commonly assigned
USSN ______ (Kodak Docket 82298) is directed towards the synthesis
of novel highly branched water soluble or dispersible polyamides
using, e.g., an A.sub.2+B.sub.3 or AB.sub.2 approach by
condensation polymerization of multifunctional monomer reactants
comprising amine and carboxylic acid functional groups, where in
order to obtain a water soluble or dispersible hyperbranched
polyamide, at least one of the multifunctional monomer unit
reactants contains an amine, phosphine, arsenine or sulfide group,
such that the highly branched polyamide contains in the backbone
thereof an N, P, As or S atom capable of forming an onium ion.
[0005] There are, however, disadvantages associated with the
polymerization processes described in the prior art for the
manufacture of hyperbranched polyamides. First, the use of organic
solvent is not environmentally friendly and practical. Second, as
shown previously by Jikei and others (Macromolecules, 32, 2061
(1999)), the A.sub.2+B.sub.3 polymerization of aromatic di-amine
(A.sub.2) and aromatic tri-carboxylic acid (B.sub.3) can result in
gelation within 10-20 min when the feed ratio of amino and carboxyl
groups was equal to 1. Moreover, even with the feed ratio of 2:3 of
amine to acid group in A.sub.2+B.sub.3 approach of Jikei, the
polymerization reaction employing solely aromatic monomers may only
lead to soluble materials under certain conditions such as at very
low concentration of monomer (<5 g/L).
[0006] The conventional process for manufacturing commercial linear
aliphatic polyamides is known as the "salt-strike" process. In this
process, aliphatic dicarboxylic acid monomer is admixed with
aliphatic diamine monomer in aqueous solution to form a salt. The
salt is fed into a reactor in which both temperature and pressure
are elevated. With the emission of water and volatile matter,
molten polymer is formed and discharged. The following limitations
may be associated with the described manufacture of linear
polyamides: (a) the molar ratio of diamine and diacid must be equal
to 1, or only low molecular weight material is obtained; (b) even
with the ratio of diamine and diacid being 1, post-polymerization
of pre-polymer at even higher temperature is often required in
order to get high molecular weight material; (c) the resultant
polymer chain usually only possesses limited NH.sub.2 and/or COOH
functionality (mostly not more than 2); and (d) high molecular
weight linear polyamides are generally characterized by poor
proccessability and solubility.
[0007] It would be desirable to provide a simple, practical, and
environmentally friendly process for the manufacture of soluble
hyperbranched polyamides with multifunctional groups. There is also
another need to develop a manufacturing process which will work
well with broader ranges of the ratio of amine groups to acidic
groups. It would be further desirable to provide soluble highly
branched polyamides obtained by condensation of multifunctional
amine and multifunctional acid monomers where at least one of the
multifunctional monomers is aliphatic, and where the ratio of total
amine functional groups to total acid functional groups of the
monomers is close to one.
SUMMARY OF THE INVENTION
[0008] In accordance with one embodiment of the invention, a
process for the manufacture of soluble hyperbranched polyamides is
disclosed comprising
[0009] (a) combining in a reactor water and (a.sub.1)
multi-functional di- or higher amine functional group containing
monomers represented by the following formula (I) and
multi-functional di- or higher carboxylic acid functional group
containing monomers represented by the following formula (II), or a
preformed salt of such di- or higher functional monomers, or
(a.sub.2) multi-functional branching monomers of the formula
(III):
R.sup.1(NH.sub.2).sub.x (I)
R.sup.2(COOH).sub.y (II)
A.sub.n-L-B.sub.m (III)
[0010] where in formulas (I) and (II), R.sup.1 and R.sup.2 are each
independently a monomeric, oligomeric, or polymeric compound
nucleus, x and y are integers of at least 2, preferably from 2 and
4, without x and y being 2 at the same time, and in formula (III),
one of A and B represents an amine functional group, the other of A
and B represents a carboxylic acid functional group, L represents a
monomeric, oligomeric, or polymeric compound nucleus linking group
between A and B, n is at least 1 and m at least 2, and preferably n
is 1 and m is 2 or 3, and wherein multiple carboxylic acid
functional groups of a multi-functional monomer may be in anhydride
form, and
[0011] (b) reacting amine and carboxylic acid functional groups of
the multi-functional monomers at a temperature of at least
100.degree. C. and a pressure of at least 140 kPa, wherein
polymerization proceeds by reaction of an amine group of a first
monomer unit with an acid group of a second monomer unit to form a
reaction product having an amide linkage between the first and
second monomer units and repetition of such amidation reaction
between additional amine groups and acid groups of the
multi-functional monomers and reaction products of the
multi-functional monomers for a period of time sufficient to form a
highly branched polyamide.
[0012] In accordance with another embodiment, the invention is also
directed towards soluble highly branched polyamides obtained from
condensation of multifunctional amine and multifunctional acid
functional group containing monomer reactants, wherein at least one
of the multifunctional amine and the multifunctional acid monomers
is aliphatic and the ratio of total amine functional groups to
carboxylic acid functional groups in the monomer reactants is from
0.3 to 3.
[0013] In accordance with a further embodiment, the invention is
also directed towards soluble highly branched polyamides obtained
from condensation of multifunctional amine and multifunctional acid
functional group containing monomer reactants, wherein at least one
of the multifunctional amine and the multifunctional acid monomers
is aliphatic and the weight averaged molecular weight is above
1,000.
[0014] The present invention advantageously provides a simple,
practical, and environmentally friendly process for the manufacture
of soluble hyperbranched polyamides comprising multifunctional
in-chain and/or end groups. The present invention also provides a
process for the manufacture of relatively high molecular weight
soluble hyperbranched polyamides from multifunctional aliphatic
monomers with a broad range of the ratio of functional amine groups
to acid groups, and uniquely enables the formation of at least
partially aliphatic polyamides wherein the ratio of total amine
functional groups to carboxylic acid functional groups in the
multifunctional monomer reactants is close to 1. Soluble
hyperbranched polyamides may be obtained with commercially
available materials and existing facility, of which the residual
terminal groups may be functionalized and chemically capped.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The process of the present invention comprises the steps of
combining multifunctional monomer reactants comprising amine and
carboxylic acid functional groups in a reactor with water, and
reacting amine and carboxylic acid functional groups of the
multi-functional monomers at elevated temperature and pressure for
a period of time sufficient to form a highly branched polyamide.
Polymerization proceeds by reaction of an amine group of a first
monomer unit with an acid group of a second monomer unit to form a
reaction product having an amide linkage between the first and
second monomer units and repetition of such midation reaction
between additional amine groups and acid groups of the
multi-functional monomers and reaction products of the
multi-functional monomers. The resulting highly branched polymer
may be discharged from the reactor, and precipitated and purified
according to conventional polymerization procedures, or the aqueous
polymer solution may be directly further used.
[0016] In accordance with one embodiment of the invention, the
multifunctional monomer reactants may comprise a combination of di-
or higher amine functional group containing monomers and di- or
higher carboxylic acid functional group containing monomers,
wherein at least one of the amine group or the acid group
containing monomers is a tri- or higher amine or acid functional
group containing monomer, or a preformed salt of such di- or higher
functional monomers. The polymerization process comprising
multifunctional monomers can be considered as A.sub.x+B.sub.y
hyperbranching polymerization where one of A.sub.x and B.sub.y
represents a multi-functional amine group containing monomer and
the other of A.sub.x and B.sub.y represents a multi-functional
carboxylic acid group containing monomer. There is no particular
requirement with regard to co-monomers of multifunctional amines
and multifunctional acids used in the present process of
manufacturing soluble hyperbranched polyamides, with the exceptions
that the number of functionalities x and y of the co-monomers are
each at least 2 with the functionality of at least one of the
co-monomers being 3 or more.
[0017] The compounds with multiple amine substitutes can be
represented by the following formula (I):
R.sup.1(NH.sub.2).sub.x (I)
[0018] and the multiple acids can be represented by the following
formula (II):
R.sup.2(COOH).sub.y (II)
[0019] wherein:
[0020] R.sup.1 and R.sup.2 are each independently a monomeric,
oligomeric, or polymeric compound nucleus, and x and y are integers
of at least 2, preferably between 2 and 4, without x and y being 2
at the same time. Each R.sup.1 and R.sup.2 compound nucleus may
comprise, e.g., a further substituted or unsubstituted straight or
branched alkyl, cycloalkyl, aryl or alkylaryl linking group moiety,
or an oligomeric or polymeric chain moiety, to which the functional
groups are attached.
[0021] In a preferred embodiment, one of the multifunctional amines
and multifunctional acids is di-functional (i.e., one of x and y is
2 in Formula I and II), and the other is tri- or tetra-functional
(i.e., the other of x and y is 3 or 4 in Formula I and II). In a
particularly preferred embodiment, one of the multifunctional
amines and multifunctional acids is di-functional, and the other is
tri-functional. In a particular embodiment, the present invention
may employ anhydride group containing monomers as multifunctional
acid monomers. With regard to anhydride group containing monomers,
each anhydride group is considered as supplying two functional acid
groups in the present process.
[0022] A particular embodiment of the invention is directed towards
soluble highly branched aliphatic or partially aliphatic polyamides
obtained from condensation of multifunctional amine and
multifunctional acid functional group containing monomer reactants,
wherein at least one of the multifunctional amine and the
multifunctional acid monomers is aliphatic (i.e., non-aromatic) and
the ratio of total amine functional groups to carboxylic acid
functional groups in the monomer reactants is from 0.3 to 3.
Condensation of multifunctional aliphatic monomers to form soluble
highly branched polyamides in organic solution has been found to be
particularly problematic, especially where the ratio of amine
groups to carboxylic acid groups of the multifunctional monomer
reactants is close to one (e.g., between 0.3 and 3). The process of
the invention advantageously enables the preparation of unique
aliphatic and partially aliphatic highly branched polyamides.
[0023] Examples of multifunctional arnines which may be used in the
present invention include but are not limited to:
tris(2-aminoethyl) amine, tris(2-aminopropyl)amine, diaminohexane,
ethylenediamine, diethylenetriamine, p-phenylene diamine,
4,4'-oxydianiline, Jeffamines, and amino-substituted
polydimethylsiloxanes.
[0024] Examples of multifunctional acids which may be used in the
present invention include but are not limited to: succinic acid,
adipic acid, 1,4-cyclohexyl dicarboxylic acid, tall oil fatty
acids, sebacic acid, dodecanedioic acid, dimer acids, C-19
dicarboxylic acid, C-21 dicarboxylic acid, nitrilotriacetic acid,
trimesic acid, phthalic acid, isophthalic acid, terephthalic
acid.
[0025] Examples of multifunctional acids in anhydride form which
may be used in the present invention include but are not limited to
succinic anhydride, (cis-/trans-) 1,2-cyclohexanedicarboxylic
anhydride, 1,2,4,5-benzenetetracarboxylic dianhydride,
1,2,3,4-cyclopentane-tetra-ca- rboxylic dianhydride.
[0026] In another particular embodiment of the present invention, a
pre-formed salt or an admixture of multifunctional amine,
multifunctional acid or anhydride may be employed. The said
pre-formed salt may be made in-situ or made separately. The salt
made separately may be either purified prior to polymerization in
accordance with the invention, or used in the form of a crude
solution prepared in water.
[0027] In accordance with a further embodiment of the invention,
the multifunctional monomer reactants may comprise multi-functional
branching monomers of the formula (III):
A.sub.n-L-B.sub.m (III)
[0028] where one of A and B represents an amine functional group,
the other of A and B represents a carboxylic acid functional group,
L represents a linking group between A and B, and n is at least 1
and m at least 2. L may be any monomeric, oligomeric, or polymeric
compound nucleus, such as a further substituted or unsubstituted
straight or branched alkyl, cycloalkyl, aryl or alkylaryl linking
group moiety, or an oligomeric or polymeric chain moiety, and n
preferably represents 1 and m preferably represents 2 or 3, and
most preferably 2. Multifunctional A.sub.n-L-B.sub.m branching
monomers may themselves be commercially available, or may be
prepared from commercially available starting materials using
conventional reaction procedures. Multifunctional branching
monomers may be pre-formed and isolated prior to subsequent
reaction, or may be prepared in-situ in the formation of a highly
branched polyamide in accordance with the invention. As in the case
of A.sub.x+B.sub.y type hyperbranching polymerization as described
above, multiple carboxylic acid functional groups of a
multi-functional branching monomer may be in anhydride form.
[0029] Examples of multifunctional branching monomers for use in
accordance with the invention include but are not limited to:
2,3-diaminoproponic acid, 2,5-diaminopentanoic acid, 1-Lysine
hydrate.
[0030] As disclosed in copending, concurrently filed, commonly
assigned USSN ______ (Kodak Docket 82298), the disclosure of which
is hereby incorporated by reference, a highly branched water
soluble or dispersible polyamide may be obtained using an
A.sub.2+B.sub.3 or AB.sub.2 approach by condensation polymerization
of multifunctional monomer reactants comprising amine cad
carboxylic acid functional groups, where in order to obtain a water
soluble or dispersible hyperbranched polyamide, at least one of the
multifunctional monomer unit reactants contains an amine,
phosphine, arsenine or sulfide group, such that the highly branched
polyamide contains in the backbone thereof an N, P, As or S atom
capable of forming an onium ion. The present invention may be
advantageously employed for formation of such water soluble or
dispersible polyamides.
[0031] In the case of using anhydride group containing
multifunctional monomers, a hybrid approach comprising both
A.sub.xB.sub.y and A.sub.x+B.sub.y type hyperbranching
polymerization may be employed, since a variety of monomers are
formed through reacting amine and anhydride depending upon the
experimental conditions employed. For example, the mixture of
triamine 1 and mono-anhydride 2 may yield the following different
kinds of monomers wherein the content of each monomer is strongly
dependent of the molar ratio of tramine to mono-anhydride, the
method of preparation, and other experimental factors: 1
[0032] The present process yield hyperbranched polyamide having at
least one branched center with one branch site and at least one
amide linkage along its backbone. One or more structural modifiers
may additionally be fed to the reactor together with the
multifunctional monomer(s) to modify the chemical structure or
architecture of the final polymers may be modified by adding
suitable mono- or multi-functional modifiers. Also, other
functional or special groups may be introduced by adding mono- or
multifunctional agents. Highly branched polyamides may be prepared
in accordance with the invention employing a pure single
A.sub.n-L-B.sub.m type branching monomer compound in a
"self-condensation" reaction, A.sub.x and B.sub.y multifunctional
monomers in a co-condensation reaction, or a mixture of a variety
of branching monomers or branching monomers and non-branching
monomers may be employed to achieve a combination of
self-condensation and co-condensation.
[0033] Hyperbranched polyamides may be obtained which have
number-average molecular weights of from 100 to 10.sup.8 and
polydispersity (the ratio of weight-average molecular weight to
number-average molecular weight) from 1.01 to 200.
[0034] The temperature and pressure of polymerization, as well as
the ratio of amine to acid (or anhydride) groups of the monomers
and the amount of water employed in the process of the present
invention, are factors which can control the molecular weight, the
nature and number of functional groups, the branching degree, and
other structural features of the resulting hyperbranched
polyamides.
[0035] In a preferred embodiment, the temperature employed during
polymerization is from 100 to 350.degree. C., more preferably 150
to 280.degree. C., and the pressure varies from 140 kPa to
50.times.10.sup.3 kPa, preferably from 600 to 7.times.10.sup.3 kPa.
It is an advantage of the invention that polymerization of
relatively high molecular weight highly branched polyamides can be
obtained in a single polymerization step at such only moderately
elevated temperatures. Optionally, solid polymer synthesized at
such temperatures can be heated to even higher temperature in order
to facilitate further reaction and obtain higher molecular weight
poly mer.
[0036] In a preferred embodiment, the ratio of amine to acid groups
(including acid functional groups of any anhydride groups) varies
from 0.1 to 10, more preferably 0.2 to 6, most preferably 0.3 to 3.
It is an advantage of the invention that relatively high molecular
weight highly branched polymers can be obtained which are still
soluble (i.e., without gelation), even where functional group
ratios are close to 1. Water is required for conversion of
multi-functional monomers to soluble hyperbranched polyamide
without gelation in accordance with the process of the invention.
In a preferred embodiment, the content of water may be from 0.1 to
99.9 wt % in relative to total amount of reaction solution, more
preferably 0.5 to 50 wt %, most preferably 1 to 30 wt %.
[0037] The present process is conducted preferably in the absence
of a catalyst. However, any catalysts that can facilitate the
polymerization and enhance the degree of the control of the
molecular weight, the nature and number of functional groups, the
branching degree, and other structural features of the
hyperbranched polyamide can be optionally used.
[0038] The hyperbranched polyamides obtained by the present
invention can be made through batch process, semi-batch process,
continuous process, and the like. Many of these processes have been
well documented. The polymerization reactor preferably may be of
the type typically used in the synthesis of linear polyamides, for
example a stainless steel autoclave.
[0039] The reaction time required to complete polymerization varies
depending upon the specific polymerization system and experimental
conditions employed. In a typical embodiment, the polymerization
time will be from 0.1 to 100 hours, more typically 0.5 to 5 hours.
Combinatorial chemistry and experimental design can be used in the
present invention to explore and optimize the experimental
conditions.
[0040] The final polymers can be purified with known processes such
as precipitation, extraction, and the like. Polymers can be used in
the forms of solid particle, solution, dispersion, and the like.
Since the hyperbranched polyamides made from the present invention
comprise either NH.sub.2 or COOH or both of NH.sub.2 and COOH
functional end groups, the modification of NH.sub.2 and COOH groups
through conventional reactions may yield hyperbranched polyamides
with a variety of functional means and with more complex
structure/architecture.
[0041] The polymers and copolymers prepared in the present
invention can be used in a variety of applications such as
plastics, elastomers, fibers, engineering resins, coatings, paints,
adhesives, asphalt modifiers, detergents, diagnostic agents and
supports, dispersants, emulsifiers, rheology modifiers, viscosity
modifiers, in ink and imaging compositions, as leather and cements,
lubricants, surfactant, as paper additives, as intermediates for
chain extensions such as polyurethanes, as additives in inkjet,
printing, optical storage, photography, photoresist, and coloration
of polymer, as water treatment chemicals, cosmetics, hair products,
personal care products, polymeric dyes, polymeric couplers,
polymeric developers, antistatic agents, in food and beverage
packaging, pharmaceuticals, carriers for drug and biological
materials, slow release agent formulations, crosslinking agents,
foams, deodorants, porosity control agents, complexing and
chelating agents, carriers for chiral resolution agents, catalysts,
carriers for gene transfection, for encapsulation, as light
harvesting materials, as non-linear optical materials, to form
super macromolecular assemble.
EXAMPLES
[0042] The invention can be better appreciated by reference to the
following specific embodiments.
Examples 1-2
Hyperbranching Polymerization of tris(2-aminoethyl)amine (A.sub.3)
and 1,4-cyclohexanedicarboxylic acid (B.sub.2) in water
[0043] A typical example of making hyperbranched polyamides from
hyperbranching polymerization of tris(2-aminoethyl)amine (A.sub.3)
and 1,4-cyclohexanedicarboxylic acid (B.sub.2) in water is
described as follows:
[0044] Example 1: To a three-neck round flask equipped with a
stirring bar and water condenser, 117 grams (0.6838 mol) of
1,4-cyclohexanedicarboxyli- c acid, 100 grams (0.6838 mol) of
tris(2-aminoethyl)amine, and 440 ml of deionized water were added.
The solution was heated at 60.degree. C. for three hours. The salt
solution obtained was concentrated to contain ca. 65 wt % solid (35
wt % water) and then added to a 1 liter stainless steel autoclave.
Polymerization was carried out, at 235.degree. C. and ca.
3.3.times.10.sup.3 kPa (416-480 psi) for 3 hours. The polymer was
precipitated twice from cold acetone and dried at room temperature
under vacuum for 24 hours.
[0045] Example 2: The general process of Example 1 was repeated,
except for changing the molar ratio of reactants to obtain a
different ratio of reactive NH.sub.2 and COOH groups.
[0046] Table 1 summarizes the results for hyperbranching
polymerization of tris(2-aminoethyl)amine (A.sub.3) and
1,4-cyclohexanedicarboxylic acid (B.sub.2).
1 TABLE 1 Solubility.sup.d No [A]/[B].sup.a Yield.sup.b, Tg,
.degree. C. M.sub.w,SEC.sup.c Water Methanol Acetone 1 3/2 72% 130
.about.20K S S N 2 3/1 30% 65 S S N .sup.amolar ratio of reactive
NH.sub.2 and COOH groups; .sup.bbased on total amount of monomers
used, insoluble materials <1% in all cases;
.sup.cweight-averaged molecular weight was measured by means of
size exclusive chromatography; .sup.dS: soluble; N: insoluble.
Comparative Examples 3-5.
Hyperbranching Polymerization of tris(2-aminoethyl)amine (A.sub.3)
and 1,4-cyclohexanedicarboxylic acid (B.sub.2) in organic
solvents
[0047] A typical example of making hyperbranched polyamides from
hyperbranching polymerization of tris(2-aminoethyl)amine (A.sub.3)
and 1,4-cyclohexanedicarboxylic acid (B.sub.2) in organic solvent
is described as follows:
[0048] Example 3: All reactants, tris(2-aminoethyl)amine (44grams),
1,4-cyclohexanedicarboxylic acid (17 gram), pyridine (35grams),
N-methylpyrolidinone (396 grams) and triphenyl phosphate (93
grams), were charged into a 1L three-neck round bottom flask along
with a stir bar. The solution was stirred at 80.degree. C. in a
nitrogen atmosphere for three hours. The product was precipitated
in 2L of cold ether, collected via suction filtration and dried in
the vacuum oven.
[0049] Examples 4 and 5: The general process of Example 3 was
repeated, except for changing the molar ratio of reactants to
obtain a different ratio of reactive NH.sub.2 and COOH groups.
[0050] Table 2 shows the polymerization results.
2TABLE 2 No [A]/[B] [M].sub.o.sup.a [P(OPh).sub.3]/[NH.sub.2] T, hr
Yield Tg, .degree. C. 3 9/2 3.25% 1/3 3 30% 83 4 3/1 3.25% 1/3 3 c
5 3/2 3.25% 1/3 3 c .sup.ainitial monomer concentration in solvent,
g/ml; .sup.bbased on total amount of monomers used; .sup.conly
trace amount of soluble materials were collected and significant
amount of insoluble material were obtained.
[0051] While hyperbranching polymerization of
tris(2-aminoethyl)amine (A.sub.3) and 1,4-cyclohexanedicarboxylic
acid (B.sub.2) in organic solvents and in the presence of
condensation agent worked with relatively high molar ratio of
amines to acid group in monomers in Comparative Example 3,
Comparative Examples 4 and 5 demonstrate that polymerization of
monomers with functional group ratios closer to one did not result
in successful polymerization as was attained in Examples 1 and
2.
Example 6-17
Hyperbranching Polymerization of tris(2-aminoethyl)amine (A.sub.3)
and succinic acid (B.sub.2) in water
[0052] A variety of experimental conditions as designated in Table
3 were employed for the polymerization of tris(2-aminoethyl)amine
(A.sub.3) and succinic acid (B.sub.2) in water. The general
procedure employed was otherwise generally the same as in Example
1, except for using succinic acid instead of
1,4-cyclohexanedicarboxylic acid as B.sub.2 monomer. The
polymerization results are summarized in Table 3.
3TABLE 3 No [A]/[B] H.sub.2O % T, .degree. C. Time, h P.sup.a, kPa
Yield Tg, .degree. C. M.sub.w,SEC 6 3/1 34 235 3.5 2758 71% 34 7
3/2 35 235 3.5 2758 47% 53 8 3/4 33 235 3.5 2758 60% 50 9 3/2 35
215 3.5 690 92% 61 10 3/2 5 210 3.5 620 83% 48 12,000 11.sup.b 3/2
<0.5 200 3.5 <140 Gel 12 3/2 30 250 3.5 2896 93% 58 3,800 13
3/2 30 280 3.5 3999 93% 67 4,800 14 1/1 30 250 3.5 2689 90% 68
11,800 15 1/1 30 280 3.5 4482 63% 52 2,000 16 1/1 30 210 3.5 690
80% 82 6,900 17 1/1 30 250 15 2758 65% .sup.apolymerization
pressure; .sup.bcomparison
[0053] The above results show that soluble (non-gelled) highly
branched polyamides of relatively high molecular weight (e,g, above
1,000, above 2,000, above 4,000, and more preferably above 6,000)
may be obtained from processes in accordance with the invention
employing multifunctional monomers with a variety of amine to
carboxylic acid functional group molar ratios.
Example 18
Hyperbranching Polymerization of L-Lysine (AB.sub.2 monomer)
[0054] An admixture of 13.5 grams of L-lysine and 8 grams of
deionized water was added to a 50 ml stainless steel autoclave.
Polymerization was carried out at 250.degree. C. and under 2689 kPa
(390 psi) for 3 hours. The resulting polymer was precipitated twice
from cold acetone and dried at room temperature under vacuum for 24
hours with 90% yield.
Example 19
Hyperbranching Polymerization of tris(2-antinoethyl)amine (A.sub.3)
and suceinic anhydride B.sub.2) in water
[0055] 8.88 grams of tris(2-aminoethyl)amine (A.sub.3) was charged
into a round bottom flask containing 35 ml of ethanol and a stir
bar. After cooling down the solution with a dry ice/acetone bath, a
succinic anhydride THF solution (6.07 grams of monomer in 20 ml of
TJF) was slowly added over a 30 min period of time. The solution
was then allowed to stir at room temperature for two hours and the
solvents were removed by rotory evaporation. Polymerization of a
monomer solution comprising the dry powder as prepared above and
7.7 ml of deionized water at 250.degree. C. and under 2827 kPa (410
psi) for 3.5 hours gave rise to hyperbranched polyamides with 85%
yield. The polymer is soluble in water and methanol, but not in
acetone.
Example 20
Hyperbranching Polymerization of diaminohexane (A.sub.2) and
1,2,3,4-cyclopentane-tetra-carboxylic dianhydride (B.sub.4) in
water
[0056] 10.5 grams of diaminohexane (A.sub.2) was charged into a
round bottom flask containing 35 ml of ethanol and a stir bar.
After cooling down the solution with a dry ice/acetone bath, a
1,2,3,4-cyclopentane-tet- ra-carboxylic dianhydride THF solution
(6.33 grams monomer in 15 ml of TBF) was slowly added over ca, 30
min period of time. The solution was then allowed to stir at room
temperature for two hours and the solvents were removed by rotory
evaporation. Polymerization of a monomer solution comprising the
dry powder as prepared above and 7.4 ml of deionized water at
250.degree. C. and under 3172 kPa (460 psi) for 3.5 hours gave rise
to white powder hyperbranched polyamides with 82% yield. The
polymer is soluble in acidic water, and has a Tg of 65.degree.
C.
Example 21
Hyperbranching Polymerization of 1,4-diaminobutane (A.sub.2) and
trinesic acid (B.sub.3) in water
[0057] A 40% salt solution in water was first prepared by heating a
mixture of diaminobutane (A.sub.2, 4.4grams) and trimesic acid
(B.sub.3, 10.5 grams) in 10 ml of water at 60.degree. C. for 2
hours. Polymerization of the monomer salt solution prepared above
was carried out at 250.degree. C. and under 3172 kPa (460 psi) for
3.5. The polymer was precipitated from cold acetone with 90%
yield.
Example 22
Preparation of hyperbranched polyamide with fully dendritic
units
[0058] A mixture of 2.30 grams of polymer obtained from Example 14
and 7.40 grams of 2-dodecen-1-yl succinic anhydride in 30ml of
methylsulfoxide was stirred at room temperature for 4 hours. The
final polymer was precipitated from acetone and dried under vacuum
overnight. Both NMR and MS spectra confirmed a complete
transformation of --NH.sub.2 groups to --NH--C(O)-- units. The
solubility of the polymers before and after modification was also
different: the parent polymer was soluble in both acidic and basic
water, while the modified polymer was only dispersible in basic
water.
[0059] The invention has been described in detail with particular
reference to certain preferred embodiments thereof, but it will be
understood that variations and modifications can be effected within
the spirit and scope of the invention.
* * * * *