U.S. patent application number 17/374132 was filed with the patent office on 2021-11-04 for production of polyamide powders by ester aminolysis.
This patent application is currently assigned to Arkema France. The applicant listed for this patent is Arkema France. Invention is credited to Geoffroy CAMMAGE, Pierre NOGUES.
Application Number | 20210340338 17/374132 |
Document ID | / |
Family ID | 1000005710670 |
Filed Date | 2021-11-04 |
United States Patent
Application |
20210340338 |
Kind Code |
A1 |
NOGUES; Pierre ; et
al. |
November 4, 2021 |
PRODUCTION OF POLYAMIDE POWDERS BY ESTER AMINOLYSIS
Abstract
A method for producing a polycondensate powder dispersion,
wherein the method includes at least one step of polycondensation:
i) of at least one diester and at least one diamine, and/or ii) at
least one amino ester, while stirring, in a solvent that can
solubilize both the diamine and the diester and/or the amino ester
but not the polyamide that forms during the polycondensation, at a
temperature between 30.degree. C. and the boiling temperature of
the solvent, in order to produce a powder precipitate dispersed in
the solvent.
Inventors: |
NOGUES; Pierre; (Bernay,
FR) ; CAMMAGE; Geoffroy; (Rouen, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Arkema France |
Colombes |
|
FR |
|
|
Assignee: |
Arkema France
Colombes
FR
|
Family ID: |
1000005710670 |
Appl. No.: |
17/374132 |
Filed: |
July 13, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15539002 |
Jun 22, 2017 |
11066528 |
|
|
PCT/FR2015/053706 |
Dec 22, 2015 |
|
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17374132 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08G 69/04 20130101;
A61K 2800/10 20130101; A61Q 19/00 20130101; C08G 69/26 20130101;
C08G 69/02 20130101; A61K 8/88 20130101; A61K 8/022 20130101; C08J
2377/06 20130101; C08G 69/28 20130101; A61K 2800/412 20130101; C08J
3/14 20130101 |
International
Class: |
C08J 3/14 20060101
C08J003/14; C08G 69/28 20060101 C08G069/28; C08G 69/04 20060101
C08G069/04; C08G 69/26 20060101 C08G069/26; C08G 69/02 20060101
C08G069/02; A61K 8/02 20060101 A61K008/02; A61K 8/88 20060101
A61K008/88; A61Q 19/00 20060101 A61Q019/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 22, 2014 |
FR |
1463132 |
Claims
1. A polycondensate powder obtained from a process comprising a
polycondensation of: i) at least one diester and at least one
diamine, and/or ii) at least one amino ester wherein the
polycondensation is performed in a solvent that can dissolve both
the diamine and the diester and/or the amino ester, but not a
polyamide which forms during the polycondensation, such that a
polycondensate powder precipitate dispersed in the solvent is
obtained, wherein said at least one diester is of formula:
R.sub.1--(CH.sub.2).sub.m--R.sub.2, wherein m represents an integer
ranging from 0 to 36, and R.sub.1 and R.sub.2 represent identical
or different ester functions of general formula COOR.sub.3, wherein
R.sub.3 represents a saturated or unsaturated, linear or branched
alkyl chain of from 1 to 5 carbon atoms and/or
R.sub.1--(C.sub.6H.sub.4).sub.n--R.sub.2, wherein n represents an
integer ranging from 1 to 2, and R.sub.1 and R.sub.2 represent
identical or different ester functions of general formula
COOR.sub.3, wherein R.sub.3 represents a saturated or unsaturated,
linear or branched alkyl chain of from 1 to 5 carbon atoms; wherein
said at least one diamine is chosen from aliphatic diamines having
from 6 to 12 carbon atoms; and wherein said at least one amino
ester corresponds to the general formula
R.sub.5--(CH.sub.2).sub.p--R.sub.6, wherein p represents an integer
ranging from 0 to 36, R.sub.5 represents a primary or secondary
amine function, and R.sub.6 represents an ester function of general
formula COOR.sub.7, wherein R.sub.7 represents an alkyl chain of
from 1 to 5 carbon atoms.
2. The polycondensate powder of claim 1, wherein the polycondensate
powder comprises particles of free powder which have a spheroidal
shape, a D50 measured according to ISO standard 13320-1:1999
included within the range of from 1 to 200 .mu.m, and wherein the
powder further comprises traces of ester chain ends.
3. The polycondensate powder of claim 1, wherein the wherein the
powder further comprises from 0 to 50 mol % of a polycondensation
catalyst, relative to the number of moles of the
polycondensate.
4. The polycondensate powder of claim 3, wherein the
polycondensation catalyst is selected from the groups consisting of
sodium hydride, potassium hydride, sodium, sodium stearate,
ortho-phosphoric acid, stearic acid, ethanol, phenol, sodium
methoxide, sodium ethoxide, and mixtures thereof.
5. The polycondensate powder of claim 1, wherein the powder further
comprises traces of a polycondensation solvent.
6. The polycondensate powder of claim 5, wherein the
polycondensation solvent is selected from the group consisting of
linear alkanes, cycloaliphatic alkanes, halogenated solvents and
mixtures thereof.
7. The polycondensate powder of claim 1, wherein the powder further
comprises traces, relative to the total weight of the powder, of an
alcohol of formula R.sub.3OH and/or R.sub.7OH, wherein R.sub.3 and
R.sub.7 each represent an alkyl chain from 1 to 5 carbon atoms.
8. The polycondensate powder of claim 1, wherein the powder further
comprises a polycondensate that is an oligomer having a
number-average molar mass included in the range of from 300 g/mol
to 5000 g/mol.
9. The polycondensate powder of claim 1, wherein the powder further
comprises a polycondensate that is a polyamide having a
number-average molar mass of between 5000 and 30 000 g/mol.
10. A product comprising the powder as claimed in claim 1, wherein
the product is chosen from coatings, paints, anticorrosion
compositions, paper additives, powder agglomeration by
electromagnetic radiation-induced melting or sintering for
producing objects, electrophoresis gels, multilayer composite
materials, packaging, toys, products in the textile, automobile
and/or electronics industry, and cosmetic, pharmaceutical or
perfumery products.
11. A polycondensate powder obtained from a process comprising a
polycondensation of: i) at least one diester and at least one
diamine, and/or ii) at least one amino ester, the polycondensate
powder comprising particles of free powder which have a spheroidal
shape, a D50 measured according to ISO standard 13320-1:1999
included within the range of from 1 to 200 .mu.m, wherein the
powder further comprises 10 to 4000 meq/kg of ester chain ends
relative to the weight of polycondensate.
12. The polycondensate powder of claim 11, wherein the powder
further comprises at least one monomer chosen from the units: 2.9,
2.10, 4.6, 4.T, 6, 6.6, 6.9, 6.10, 6.12, 6.T, 9.2, 10.2, 10.10,
10.12, 10.T, 11, 12, 12.9, 12.10, 12.12, 12.T, and mixtures thereof
having alternating or block units.
13. The polycondensate powder of claim 11, wherein the powder
further comprises 10 to 10,000 ppm of solvent selected from linear
alkanes, cycloaliphatic alkanes, halogenated solvents and mixtures
thereof.
14. The polycondensate powder of claim 11, wherein the powder
further comprises from 0 to 50 mol % of a polycondensation catalyst
selected from the group consisting of sodium hydride, potassium
hydride, sodium, sodium stearate, ortho-phosphoric acid, stearic
acid, ethanol, phenol, sodium methoxide, sodium ethoxide, and
mixtures thereof.
15. The polycondensate powder of claim 11, wherein the powder
further comprises from 0.01% to 5% by weight of a monoalcohol of
formula R.sub.3OH and/or R.sub.7OH, wherein R.sub.3 and R.sub.7
each represent a saturated or unsaturated, linear or branched alkyl
chain of from 1 to 5 carbon atoms.
16. The polycondensate powder of claim 11, wherein the powder
further comprises a polycondensate that is an oligomer of
number-average molar mass included in the range of from 300 g/mol
to 5000 g/mol.
17. The polycondensate powder of claim 11, wherein the powder
further comprises a polycondensate that is a polyamide of
number-average molar mass of between 5000 and 30 000 g/mol.
18. The polycondensate powder of claim 11, wherein the powder
further comprises from 0.1% to 99.9% by weight of the particles and
from 0.1% to 99.9% by weight of a solvent, wherein the solvent is
selected from the group consisting of linear alkanes,
cycloaliphatic alkanes, halogenated solvents and mixtures
thereof.
19. The polycondensate powder of claim 11, wherein the particles
have a specific surface area measured according to a
Brunauer-Emmet-Teller method ranging from 1 to 20 m.sup.2/g.
20. A product comprising the powder as claimed in claim 11, wherein
the product is chosen from coatings, paints, anticorrosion
compositions, paper additives, powder agglomeration by
electromagnetic radiation-induced melting or sintering for
producing objects, electrophoresis gels, multilayer composite
materials, packaging, toys, products in the textile, automobile
and/or electronics industry, and cosmetic, pharmaceutical or
perfumery products.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional of U.S. application
Ser. No. 15/539,002, filed on Jun. 22, 2017, which is a U.S.
national stage of International Application No. PCT/FR2015/053706,
filed on Dec. 22, 2015, which claims the benefit of French
Application No. 1463132, filed on Dec. 22, 2014. The entire
contents of each of U.S. application Ser. No. 15/539,002,
International Application No. PCT/FR2015/053706, French Application
No. 1463132 are hereby incorporated herein by reference in their
entirety.
TECHNICAL FIELD
[0002] The present invention relates to the processes for
synthesizing polyamide (PA) powders from at least one diester and
at least one diamine and/or from at least one amino ester. The
present invention relates more particularly to a process for
producing polyamide powders by polycondensation. It also relates to
the polyamide that can be obtained by means of the process of the
invention, either in the form of a powder dispersion or in the form
of a free powder, and to the use thereof.
TECHNICAL BACKGROUND
[0003] Industrially, polyamides are prepared by polymerization,
either of at least one diamine and diacid pair, or of at least one
amino acid, or of a mixture of these two types of monomers. These
polyamides are used when they are in powder form, for specific
applications such as surface coatings, cosmetics and powder
agglomeration techniques by electromagnetic radiation-induced
melting or sintering for producing objects.
[0004] Patent document WO 2008/005415 describes a process for
synthesizing high-molecular-weight polyamide. This synthesis
consists of a polymerization in an extruder, at a very high
temperature of at least 300.degree. C., between monomers of diamine
and diacid type, or even diester type, although this technique is
not verified by examples in the case of the diester.
[0005] Patent document EP 0 515 553 describes a resin made up of
polyoxamides and copoly(amide-oxamide), synthesized by
polycondensation in the presence of di-n-butyl oxalate. The
polymerization is carried out in two successive steps: in a first
step, a prepolymerization is carried out in toluene, at ambient
temperature, so as to form a white precipitate, and then the
toluene is evaporated off. In a second step, the polymerization
continues at a temperature of 270.degree. C. The macromolecular and
oxygen-permeability properties of these polyoxamides and
copoly(amide-oxamide)s are described, but no mention is made of the
characteristics of the white precipitate obtained.
[0006] A problem noted in the context of the synthesis of
polyamides from ester is that of the side reactions which promote
in particular the appearance of N-alkylated amines. These unwanted
products disrupt the polycondensation and also the crystallization
of the polyamides.
[0007] It is also necessary to mention various processes for
producing polyamide powders known to those skilled in the art. Most
of these processes comprise two steps, with the polymerization
being carried out in a first step and the formation of the
particles, for example by milling, being carried out in a second
step.
[0008] Polyamide powders can be obtained for example by milling or
cryomilling of granules of polyamide having an initial mean
diameter of about 3 mm. Nevertheless, these mechanical
transformations by size reduction often result in particles of
irregular shape, having a wide particle size distribution and the
mean diameter of which is rarely less than 100 .mu.m.
[0009] It is also known practice to prepare polyamide powders by
dissolution in and then reprecipitation from a "good solvent" for
the polyamide. Since the solvents for polyamides at ambient
temperature are very corrosive, the choice of the "good solvent"
often involves an alcohol which dissolves the polyamide at high
temperature, which means that the work must be carried out under
pressure. The facilities must hold the pressure and the safety
conditions are strict.
[0010] Document EP 1 797 141 describes a technique for obtaining
thermoplastic polymer powder by means of a process of alloying with
a lost matrix. The incompatible blending of two polymers, in the
molten state, results in the formation of nodules of one polymer in
the other. The thermoplastic polymer powders are then recovered by
dissolving the water-soluble matrix in water. This process, carried
out in several steps, is thus of limited industrial interest.
[0011] Finally, it is known practice to obtain powders of polymer
such as polyamide by anionic precipitation polymerization of
lactams in solution. The polymerization is carried out in the
presence of the monomers, of a solvent for the monomers, of an
initiator, of a catalyst and of an activator and with stirring at a
temperature in the region of 100.degree. C. This process is
specific to polyamides and poly(ester-amide)s obtained from
monomers of lactam and lactone type. According to this process, it
is possible to obtain powders of micrometric size and of spheroidal
shape. However, it is not very flexible and allows only a slight
diversification of the nature of the powders according to the
desired final properties of the powder, by varying the nature of
the monomers, for example.
[0012] There is thus a need to develop an improved process for
producing polyamide powder, which can in particular be adapted to a
wider range of monomers, including those which are ester-based,
while at the same time preserving the fine control of the shape of
the particles obtained.
SUMMARY
[0013] The invention relates firstly to a process for producing a
polycondensate powder dispersion, characterized in that it
comprises at least one step of polycondensation:
[0014] i) of at least one diester and at least one diamine,
[0015] and/or
[0016] ii) of at least one amino ester,
with stirring, in a solvent that can dissolve both the diamine and
the diester and/or the amino ester, but not the polyamide which
forms during the polycondensation, at a temperature included in the
range of 30.degree. C. to the boiling point of said solvent, such
that a powder precipitate dispersed in the solvent is obtained.
[0017] According to one advantageous embodiment of the invention,
said process for producing powder also comprises a step of
separation of the solvent and of recovery of the powder.
[0018] Advantageously, the process of the invention is carried out
in the optional presence of a polycondensation catalyst, the
content of which is included in the range of from 0 to 50 mol %,
preferably from 0.01 mol % to 50 mol %, preferably from 0.01 mol %
to 30 mol %, preferably from 0.01 mol % to 20 mol %, relative to
the number of moles of all of the reagents. The term "all of the
reagents" is intended to mean the diamine.diester and/or amino
ester pair. The addition of catalyst above 30 mol %, or even
already above 20 mol %, generally has no more notable effect on the
reaction yield; a yield "ceiling" is then observed.
[0019] Advantageously in the invention, said at least one diester
is of formula R.sub.1--(CH.sub.2).sub.m--R.sub.2, wherein m
represents an integer ranging from 0 to 36, and R.sub.1 and R.sub.2
represent identical or different ester functions of general formula
COOR.sub.3, wherein R.sub.3 represents a saturated or unsaturated,
linear or branched alkyl chain of from 1 to 5 carbon atoms and/or
of formula R.sub.1--(C.sub.6H.sub.4).sub.n--R.sub.2, wherein n
represents an integer ranging from 1 to 2, and R.sub.1 and R.sub.2
represent identical or different ester functions of general formula
COOR.sub.3, wherein R.sub.3 represents a saturated or unsaturated,
linear or branched alkyl chain of from 1 to 5 carbon atoms.
[0020] According to one advantageous embodiment of the invention,
said at least one diester is chosen from methyl oxalate, ethyl
oxalate, propyl oxalate, butyl oxalate, dibutyl adipate, dibutyl
azelate, dimethyl sebacate, dibutyl suberate, dibutyl isophthalate,
dibutyl sebacate, dibutyl laurate, and mixtures thereof.
[0021] Advantageously, said at least one diamine is chosen from
aliphatic diamines having from 6 to 12 carbon atoms, said diamine
possibly being a saturated aryl and/or cyclic diamine.
[0022] Advantageously, said diamine is chosen from ethylenediamine,
hexamethylenediamine, piperazine, tetramethylenediamine,
octamethylenediamine, 1,9-diaminononane, decamethylenediamine,
dodecamethylenediamine, 1,5-diaminohexane,
2,2,4-trimethyl-1,6-diaminohexane, polyol diamines, isophorone
diamine (IPD), methyl pentamethylene diamine (MPDM),
bis(aminocyclohexyl)methane (BACM),
bis(3-methyl-4-aminocyclohexyl)methane (BMACM),
meta-xylylenediamine, bis-p-aminocyclohexylmethane and
trimethylhexamethylenediamine, and mixtures thereof.
[0023] Advantageously, said at least one amino ester is of formula
R.sub.5--(CH.sub.2).sub.p--R.sub.6, with p representing an integer
ranging from 0 to 36, R.sub.5 being a primary or secondary amine
function and R.sub.6 being an ester function of general formula
COOR.sub.7, R.sub.7 being a saturated or unsaturated, linear or
branched alkyl chain of from 1 to 5 carbon atoms.
[0024] Advantageously, said polycondensation catalyst is chosen
from sodium hydride, potassium hydride, sodium, sodium stearate,
ortho-phosphoric acid, stearic acid, ethanol, phenol, sodium
methoxide, sodium ethoxide, and mixtures thereof.
[0025] Advantageously, said solvent is chosen from linear alkanes,
cycloaliphatic alkanes, halogenated solvents and mixtures thereof,
the solvent preferably having a boiling point above the
polymerization temperature included in the range of from 30.degree.
C. to 180.degree. C., preferably in the range of from 30.degree. C.
to 150.degree. C., preferably from 30 to 100.degree. C., and
preferably in the region of 100.degree. C. Furthermore, it is
preferred to use one (or more) solvent(s) that is (are) liquid at
ambient temperature (temperature included in the range of from 15
to 25.degree. C.).
[0026] Advantageously, said polycondensation is characterized by a
simultaneous precipitation in the form of powders of the
polycondensate.
[0027] Advantageously, said stirring is at a speed included in the
range of from 1 to 2000 rpm, preferably carried out by means of a
paddle stirring system, even more preferentially by means of a
paddle and counter-paddle stirring system.
[0028] The invention also relates to a polyamide that can be
obtained according to the process described above.
[0029] Advantageously, said polycondensate powder comprises
particles of free powder which have a spheroidal shape, a D50
measured according to ISO standard 13320-1:1999 included in the
range of from 1 to 200 .mu.m, and which comprise traces of ester
chain ends, preferably 10 to 4000 meq/kg of ester chain ends,
relative to the weight of polycondensate.
[0030] Advantageously, the polycondensate comprises at least one
monomer chosen from the units: 2.9, 2.10, 4.6, 4.T, 6, 6.6, 6.9,
6.10, 6.12, 6.T, 9.2, 10.2, 10.10, 10.12, 10.T, 11, 12, 12.9,
12.10, 12.12, 12.T, and mixtures thereof having alternating or
block units. In this embodiment, T is terephthalic acid.
[0031] Advantageously, the powder exhibits traces of the solvent
used for the dispersion, preferably from 10 to 10 000 ppm of
solvent.
[0032] Advantageously, traces of a polycondensation catalyst are
found, preferably from 0 to 50 mol %, preferably from 0.01 mol % to
30 mol %, preferably from 0.01 mol % to 20 mol %, relative to the
number of moles of polycondensate.
[0033] Advantageously, traces of monoalcohol, preferably from 0.01%
to 5% by weight, relative to the total weight of the powder, of
alcohol of formula R.sub.3OH and/or R.sub.7OH, wherein R.sub.3 and
R.sub.7 each represent a saturated or unsaturated, linear or
branched alkyl chain of from 1 to 5 carbon atoms, are found.
[0034] Advantageously, said polycondensate is an oligomer of
number-average molar mass included in the range of from 300 g/mol
to 5000 g/mol.
[0035] Advantageously, said polycondensate is a polyamide of
number-average molar mass of between 5000 and 30,000 g/mol,
preferably included in the range of from 8000 to 15 000 g/mol.
[0036] Advantageously, the polyamide powder is used in coatings,
paints, anticorrosion compositions, paper additives, powder
agglomeration techniques by electromagnetic radiation-induced
melting or sintering for producing objects, electrophoresis gels,
multilayer composite materials, the packaging, toy, textile,
automobile and/or electronics industry, and in cosmetic,
pharmaceutical or perfumery products.
[0037] Advantageously, said oligomer powder is used as an ester
and/or amine reactive synthon in polymer chain extension reactions,
either alone or as an additive in powder agglomeration techniques
by electromagnetic radiation-induced melting or sintering for
producing objects, as a polyamide reinforcement or as an organic
filler for composite materials.
[0038] The invention also relates to a powder dispersion
comprising: [0039] from 0.1% to 99.9% by weight, preferably from
0.1% to 30% by weight, of powder particles in accordance with the
invention, [0040] from 0.1% to 99.9% by weight, preferably from 70%
to 99.9% by weight, of solvent in accordance with the invention,
relative to the total weight of the dispersion.
[0041] The invention can also be included in a cosmetic and/or
perfumery composition.
Advantageously, said cosmetic and/or perfumery composition
comprises: [0042] from 0.1% to 99.9%, preferably from 0.1% to 30%
by weight, of powder particles according to the invention, [0043]
from 0.1% to 99.9%, preferably from 70% to 99.9% by weight, of a
medium that is acceptable in cosmetics and/or in perfumery,
relative to the total weight of the composition. Advantageously,
said composition is a colored, noncolored or transparent product
chosen from the following products: [0044] makeup products for the
human face and body, such as a foundation, tinted cream, loose or
compact powder, eyeshadow, mascara, eyeliner or lipstick, [0045]
care products for the human face and body, such as a cream, milk,
lotion, mask, exfoliation product, cleansing and/or makeup-removal
products, deodorants, antiperspirants, shaving products or
hair-removal products, [0046] hair products, such as shampoos, hair
shaping products, hairstyle maintaining products, antidandruff
products, anti-hair loss products, products to counteract dryness
of the hair, hair dyes or bleaching products, [0047] perfumery
products, such as a fragrance, milk, cream or loose or compact
powder which is fragranced.
[0048] Since ester chemistry is experiencing a growing development,
an increasing number of commercial products are proposed,
increasing the advantage of the present invention. Another
advantage of the present invention is that of carrying out the
synthesis of polyamide powder at temperatures below that of the
prior art. This results in energy savings and a positive impact on
the environment.
[0049] The present invention makes it possible to overcome several
drawbacks of the prior art. It more particularly provides a process
for producing polyamide from at least one diester and at least one
diamine and/or at least one amino ester, in which the polyamide
powder obtained has advantageous characteristics and is notably
easy to synthesize. The process makes it possible to carry out, at
low temperature (temperature below 200.degree. C.) and in a
dispersed medium, the production of polyamide powder having a
controlled particle size, a spheroidal morphology and a surface
porosity.
[0050] This type of reaction for a diamine/diacid pair cannot be
carried out by those skilled in the art under these conditions
because of the non-reactivity of the diamine/diacid pair under the
conditions specific to the precipitation polymerization process.
The applicant has discovered that, surprisingly, the precipitation
polymerization process can be used according to the invention, by
virtue of the reactivity of diesters with diamines. Indeed, the
ester aminolysis reaction makes it possible to use a precipitation
polymerization process normally reserved for the anionic
polymerization of lactams in solution. The polycondensation of at
least one diester and at least one diamine and/or at least one
amino ester gives excellent results in a reaction carried out
according to the invention. It is advantageous to note that the
presence of an initiator and of an activator usually required in
such reactions is not required in the present invention.
Advantageously, the reaction according to the invention is thus
carried out much more simply than with lactams, in temperature
ranges around 100.degree. C. and with stirring.
DETAILED DESCRIPTION OF EMBODIMENTS
[0051] The invention is now described in greater detail and in a
non-limiting manner in the description which follows.
[0052] Unless otherwise indicated, the proportions or percentages
indicated are by weight.
[0053] For the purposes of the invention, the term "polycondensate"
is intended to mean both an oligomer and/or a polyamide obtained by
polycondensation.
[0054] For the purposes of the invention, the term "polyamide" is
intended to mean the products of condensation of amino esters
and/or diesters with diamines and, as a general rule, any polymer
formed by units linked to one another by amide groups.
[0055] For the purposes of the invention, the term "oligomer" is
intended to mean a chemical molecule consisting of one to four
monomers.
[0056] For the purposes of the invention, the term "monomer" is
intended to mean a repeating unit of the oligomer or of the
polyamide. The case where a repeating unit consists of the
combination of a diester with a diamine is particular. It is
considered that it is the combination of a diamine and of a
diester, that is to say the diamine.diester pair (in equimolar
amount), which corresponds to the monomer. This is explained by the
fact that, individually, the diester or the diamine is just one
structural unit, which is not sufficient on its own to form a
polymer.
[0057] The invention envisions producing a polycondensate powder
from at least one diester and at least one diamine, and/or at least
one amino ester, as defined above.
[0058] According to one particular embodiment of the invention, a
single diamine diester pair is used, so as to form a
homopolyamide.
[0059] According to one preferred embodiment of the invention, two
or more diamine diester pairs are used, so as to form a copolyamide
(CoPA).
[0060] According to another particular embodiment, a single amino
ester having a single index n is used so as to form a
homopolyamide.
[0061] According to an even more preferred embodiment, two or more
amino esters having different indices n are used, so as to form a
CoPA.
[0062] According to the process of the invention, introduced for
example into a reactor are the monomer(s) included in the range of
from 20% to 75%, preferably 30%, by weight of at least one diester
and at least one diamine and/or of at least one amino ester, in a
dispersion solvent, relative to the total weight of dispersion. The
solvent may comprise in particular one or more of the following
compounds: linear alkanes, cycloaliphatic alkanes, halogenated
solvents and mixtures thereof. The solvent preferably comprises a
solvent of Shellsol type. The term "solvent of Shellsol type" is
intended to mean a solvent consisting of a hydrocarbon
fraction.
[0063] It is also possible to introduce into the medium a
polycondensation catalyst, the content of which is included in the
range of from 0 to 50 mol %, preferably from 0.01 mol % to 50 mol
%, preferably from 0.01 mol % to 30 mol %, preferably from 0.01 mol
% to 20 mol %, relative to the number of moles of all of the
reagents. The use of a catalyst has an advantageous effect on the
control of the polymerization and on the precipitation of the
powders. According to one advantageous embodiment of the process of
the invention, an acid catalysis and a basic catalysis can
alternatively be used. Preferably, a basic catalysis, preferably
comprising sodium methoxide, is used.
[0064] The reaction temperature is included in the range of from
30.degree. C. to the boiling point of the solvent, preferably from
50.degree. C. to 120.degree. C., preferably from 80.degree. C. to
110.degree. C., preferably equal to 100.degree. C.
[0065] Stirring is applied to the reaction medium, preferably
included in the range of from 1 to 2000 rpm, preferably 150 rpm,
preferably 310 rpm. This stirring can be carried out by any system
sufficient to bring about the dispersion of the PA powders in the
solvent, including by shear.
[0066] According to one advantageous embodiment of the invention,
the stirring is carried out by means of a paddle stirring system,
preferably by means of a paddle and counter-paddle stirring
system.
[0067] This step lasts for example at least one hour, or at least
two hours, or at least three hours, or at least four hours, or at
least five hours.
[0068] The temperature is preferably constant. Alternatively, this
temperature can vary for example in a monotone or cyclic manner or
in steps. A temperature increase phase can be provided for at the
beginning of the process or before. Preferably, said phase lasts
less than 30 minutes, or less than 20 minutes, or less than 15
minutes, or less than 10 minutes.
[0069] The ester aminolysis results, according to the process of
the invention, in the formation of a polycondensate. According to
the invention, the ester aminolysis, by reaction of at least one
diamine and at least one diester and/or of at least one amino
ester, leads directly to the synthesis of polycondensate.
[0070] Parasitic reactions can theoretically be observed, such as a
cyclization of the diester, an intramolecular cyclization, an
intermolecular cyclization or an N,N'-dimethylation. The alkylation
of the amines by the esters, originating from the competition of
the acyl-alkyl groups (N-alkylation), leads to the interruption of
the formation of the polyamide, since there is permanent formation
of nonreactive chain ends. Without being bound by any theory, the
inventors think that, by virtue of the process according to the
invention, only the last reaction is possible at low temperature
(temperature below 200.degree. C.), all the other reactions being
linked to a high temperature (greater than or equal to 200.degree.
C.). The lower the reaction temperature, the less the N-alkylation
occurs. Advantageously, the process according to the invention
makes it possible to reduce or even prevent the parasitic
reactions.
[0071] Simultaneously with the polycondensation, a dispersion of
powder in the solvent forms. The reaction medium opacifies, marking
the start of the formation of a powder, preferably after one
hour.
[0072] The powder dispersion can be stored in this state or else
the powder can be separated from the dispersion solvent and
recovered. Preferably, the polycondensate is thus recovered in
powder form.
[0073] Where appropriate, the separation step can be carried out
according to any liquid-solid separation techniques, preferably by
solvent evaporation.
[0074] Various additives can also be introduced into the medium, in
particular organic fillers, such as PA, or mineral fillers, such as
silica; and/or surfactants.
[0075] Advantageously, an organic or mineral filler, preferably
silica, is added to the reaction medium to assist with the
precipitation by making it possible to control the size
distribution of the particles. Use may be made of a 5 .mu.m
hydrophilic silica (Sipernat 320DS), but use is preferably made of
a hydrophobic silica consisting of agglomerates which are smaller
than one micrometer in size (Aerosil R972). The addition of silica
has an advantageous effect on the size of the polycondensate
powder. In the absence of such a filler, the powder tends to form
agglomerates which coalesce, and in this case it proves to be
difficult, or even impossible, to control the size distribution of
the particles, and thus to obtain a powder with a D50 of less than
100 m, or even a D50 of less than 200 m.
[0076] Advantageously, various types of surfactants can be added to
the reaction medium. These surfactants make it possible to
stabilize the growing particles in the reaction medium. They may
for example be sodium stearate or butanol, preferably butanol.
[0077] The number-average molar mass of the polyamide obtained can
be determined by size exclusion chromatography, using
hexafluoroisopropanol (HFIP) as solvent and eluent, and a
refractometric detection. The number-average molar mass of the
polyamide obtained can also be determined by NMR (nuclear magnetic
resonance), or else by quantitative determination of the chain
ends. NMR is preferably used to determine the number-average molar
mass.
[0078] The characteristics of the powders of polyamide, which is
the subject of the invention, are in particular: [0079] the mean
particle diameter of from 1 to 200 .mu.m, preferably from 1 to 100
.mu.m, even more advantageously from 5 to 60 .mu.m; [0080] the
narrow particle size distribution by volume. The particle size
distribution by volume of the powders is determined according to
the usual techniques, for example using a Coulter LS 230 particle
size analyzer, according to ISO standard 13320-1:1999. On the basis
of the particle size distribution by volume, it is possible to
determine the volume mean diameter ("D50") and also the particle
size dispersion (standard deviation) which measures the width of
the distribution. It is one of the advantages of the process
described that it makes it possible to obtain a tight or narrow
(dispersion) particle size distribution by volume; [0081] the
spheroidal shape of the particles, that is to say in the shape of a
spheroid, which has a shape similar to that of a sphere; [0082] the
particle surface porosity, measured by the apparent specific
surface area (also called SSA). The particles of the invention have
an SSA measured according to the BET method ranging from 1 to 20
m.sup.2/g, preferably from 2 to 10 m.sup.2/g, preferably from 3 to
6 m.sup.2/g. The BET (Brunauer-Emmet-Teller) method is a method
known to those skilled in the art. It is in particular described in
The journal of the American Chemical Society, vol. 60, page 309,
February 1938, and corresponds to international standard ISO
5794/1. The specific surface area measured according to the BET
method corresponds to the total specific surface area, that is to
say that it includes the surface area formed by the pores.
EXAMPLES
[0083] The following examples illustrate the invention without
limiting it.
Example 1--Precipitation Polymerization of a PA 6.10
[0084] A dibutyl sebacate/hexamethylenediamine reaction mixture is
prepared in a 1:1 weight ratio. The reaction mixture is introduced
into a glass reactor in an amount of 30% by weight in Shellsol.
Sodium methanolate is added to the reaction medium in an amount of
17 mol % relative to one of the monomers. The reaction is carried
out with stirring at 150 rpm and heated up to a temperature of
100.degree. C. The reaction time is 7 hours.
[0085] The medium is then filtered so as to recover the PA 6.10
powder, and then the powder is washed with ethanol, and then with
water and finally oven-dried at 75.degree. C. The powder is
analyzed by .sup.1H NMR and DSC.
[0086] The total yield by weight is 72%. This yield by weight is
calculated by calculating the ratio of the weight of powder
obtained after washing and drying to the weight of powder
theoretically expected at the end of reaction.
[0087] The PA 6.10 powder obtained has a molar mass of
approximately 1200 g/mol.
[0088] The PA 6.10 powder obtained has a melting point (M.sub.p)
equal to 201.degree. C. and a viscosity of 0.23 (according to
Arkema method: 0.5 g/dl in metacresol at 25.degree. C.).
[0089] The D50 of the powder is then measured according to ISO
standard 13320-1:1999. The mean diameter of the powder particles
obtained is 80 .mu.m.
TABLE-US-00001 TABLE 1 .sup.1H NMR analysis of example 1 Molar
ratio Ex. 1 Secondary amide 76.12% Ester 3.79% Acid 5.76% Primary
amine 11.60% Alcohol 2.72%
[0090] The NMR analyses clearly show the production of a polyamide
from a diester and from a diamine.
Tests: Influence of the Catalyst Concentration and of the
Temperature Profile on the Synthesis Yield by Weight
[0091] Tests were carried out by varying the catalyst
concentration. The conditions used are identical to those of
example 1. The results are presented in the following table (the
higher the yield by weight, the more efficient the reaction).
TABLE-US-00002 TABLE 2 Influence of the catalyst concentration on
the yield Test Catalyst [mol %] Yield by weight 1 17 72% 2 9 20% 3
40 72%
[0092] According to the yields by weight obtained under the
conditions of example 1, it is possible to conclude that there is
an optimal loading of sodium methanolate (reaction catalyst):
approximately 17 mol %. Indeed, with less catalyst (9 mol %), the
reaction gives a lower yield by weight; and with more catalyst (40
mol %), there is no improvement observed compared to 17 mol %.
[0093] Tests were carried out by varying the reaction temperature.
The results are presented in the following table (the higher the
yield by weight, the more efficient the reaction).
TABLE-US-00003 TABLE 3 Influence of the thermal profile on the
action of the sodium methanolate Precipitation Catalyst yield Test
[%] Thermal profile by weight 1 17 100.degree. C. over the 72%
course of 7 h 4 17 100.degree. C. over the 72% course of 15 h 5 17
80.degree. C. over the 52% course of 15 h 6 17 120.degree. C. over
the 13% course of 7 h
[0094] According to the yields by weight obtained, it is possible
to conclude that there is an optimal synthesis temperature:
100.degree. C. Indeed, it appears that, with a lower temperature
(80.degree. C.) or a higher temperature (120.degree. C.), the
reaction is less efficient.
[0095] Tests were carried out by varying the stirring speed of the
reaction medium. The results are presented in the following table
(the higher the yield by weight, the more efficient the
reaction).
TABLE-US-00004 TABLE 4 Influence of the stirring speed on the
particle size Test Stirring speed [rpm] Mean diameter [.mu.m] 1 150
100 7 310 80
[0096] The stirring speed has a direct effect on the size of the
polycondensate powder particles; the faster the stirring, the
smaller the particles.
Example 2--Oil/Water Emulsion of the Polycondensate Powder
According to the Invention
[0097] A formulation A for a cosmetic cream, of the oil-in-water
type, having the following composition by weight is prepared:
[0098] Water: 83.44%. [0099] Chlorphenesin: 0.28%. [0100] Xanthan
gum: 0.2%. [0101] Hydroxyethyl acrylate and copolymer of sodium
acryloyldimethyl taurate: 0.5%. [0102] Arachidyl alcohol and
behenyl alcohol and arachidyl glucoside: 3.0%. [0103]
Caprylic/capric triglycerides: 5.0%. [0104] Cyclohexasiloxane:
1.0%. [0105] Phenoxyethanol and ethylhexylglycerol: 0.5%. [0106]
Antioxidant: 0.08%. [0107] Glycerol: 3.0%. [0108] Composition
according to the invention: 3.0%.
[0109] A formulation B for a pressed cosmetic powder for smoothing
out imperfections, having the following composition by weight, is
prepared: [0110] Octyldodecyl xyloside: 5.0%. [0111] Isostearyl
isostearate: 3.0%. [0112] Talc: 44.7%. [0113] Mica: 30.0%. [0114]
Talc and disodium stearoyl glutamate/aluminum hydroxide: 5.0%.
[0115] Cellulose: 5.0%. [0116] Salicylic acid: 0.2%. [0117]
Pigments: 2.1%. [0118] Composition according to the invention:
5.0%.
[0119] In the two formulations above, the composition according to
the invention is produced from particles of copolyamide 6/12.
[0120] The particles have a volume-mean diameter D50 of 10
.mu.m.
The composition has a pH included in the range of from 5 to 9, for
example of 7.5.
Embodiments
[0121] 1. A process for producing a polycondensate powder
dispersion, characterized in that it comprises at least one step of
polycondensation: i) of at least one diester and at least one
diamine, and/or ii) of at least one amino ester, with stirring, in
a solvent that can dissolve both the diamine and the diester and/or
the amino ester, but not the polyamide which forms during the
polycondensation, at a temperature included in the range of from
30.degree. C. to the boiling point of said solvent, such that a
powder precipitate dispersed in the solvent is obtained. [0122] 2.
The process for producing a powder dispersion as in embodiment 1,
characterized in that it also comprises a step of separation of the
solvent and of recovery of the powder. [0123] 3. The process as in
either one of embodiments 1 and 2, wherein said polycondensation is
carried out in the presence of a polycondensation catalyst, the
content of which is included in the range of from 0.01 mol % to 50
mol %, preferably from 0.01 mol % to 30 mol %, relative to the
number of moles of all of the reagents. [0124] 4. The process as in
any one of embodiments 1 to 3, wherein said at least one diester is
of formula: R.sub.1--(CH.sub.2).sub.m--R.sub.2, wherein m
represents an integer ranging from 0 to 36, and R.sub.1 and R.sub.2
represent identical or different ester functions of general formula
COOR.sub.3, wherein R.sub.3 represents a saturated or unsaturated,
linear or branched alkyl chain of from 1 to 5 carbon atoms and/or
R.sub.1--(C.sub.6H.sub.4).sub.n--R.sub.2, wherein n represents an
integer ranging from 1 to 2, and R.sub.1 and R.sub.2 represent
identical or different ester functions of general formula
COOR.sub.3, wherein R.sub.3 represents a saturated or unsaturated,
linear or branched alkyl chain of from 1 to 5 carbon atoms. [0125]
5. The process as in any one of embodiments 1 to 4, wherein said at
least one primary or secondary diamine is chosen from aliphatic
diamines having from 6 to 12 carbon atoms, said diamine possibly
being a saturated aryl or cyclic diamine. [0126] 6. The process as
in any one of embodiments 1 to 5, wherein said at least one amino
ester corresponds to the general formula
R.sub.5--(CH.sub.2).sub.p--R.sub.6, wherein p represents an integer
ranging from 0 to 36, R.sub.5 represents a primary or secondary
amine function, and R.sub.6 represents an ester function of general
formula COOR.sub.7, wherein R.sub.7 represents an alkyl chain of
from 1 to 5 carbon atoms. [0127] 7. The process as in any one of
embodiments 3 to 6, wherein the polycondensation catalyst is chosen
from sodium hydride, potassium hydride, sodium, sodium stearate,
ortho-phosphoric acid, stearic acid, ethanol, phenol, sodium
methoxide, sodium ethoxide, and mixtures thereof. [0128] 8. The
process as in any one of the preceding embodiments, wherein the
solvent is chosen from linear alkanes, cycloaliphatic alkanes,
halogenated solvents and mixtures thereof, the solvent preferably
having a boiling point included in the range of from 30.degree. C.
to 180.degree. C. [0129] 9. The process as in any one of the
preceding embodiments, wherein the polycondensation is
characterized by a simultaneous precipitation in the form of
polycondensate powders. [0130] 10. The process as in one of the
preceding embodiments, wherein the stirring is at a speed included
in the range of from 1 to 2000 rpm, preferably carried out by means
of a paddle stirring system, even more preferably by means of a
paddle and counter-paddle stirring system. [0131] 11. A
polycondensate powder which can be obtained according to the
process of any one of embodiments 1 to 10, characterized in that it
comprises particles of free powder which have a spheroidal shape, a
D50 measured according to ISO standard 13320-1:1999 included in the
range of from 1 to 200 .mu.m, and which comprise traces of ester
chain ends, preferably 10 to 4000 meq/kg of ester chain ends,
relative to the weight of polycondensate. [0132] 12. The powder as
in embodiment 11, characterized in that it comprises from 0 to 50
mol %, preferably from 0.01 mol % to 30 mol %, preferably from 0.01
mol % to 20 mol %, of a polycondensation catalyst, relative to the
number of moles of polycondensate. [0133] 13. The powder as in
either one of embodiments 11 and 12, characterized in that it
comprises traces of a polycondensation solvent as defined in either
one of embodiments 1 and 8, preferably from 10 to 10 000 ppm of
polycondensation solvent. [0134] 14. The powder as in any one of
embodiments 11 to 13, characterized in that it comprises traces,
preferably from 0.01% to 5% by weight, relative to the total weight
of the powder, of alcohol of formula R.sub.3OH and/or R.sub.7OH,
wherein R.sub.3 and R.sub.7 each represent an alkyl chain from 1 to
5 carbon atoms. [0135] 15. The powder as in any one of embodiments
11 to 14, characterized in that the polycondensate is an oligomer
having a number-average molar mass included in the range of from
300 g/mol to 5000 g/mol. [0136] 16. The powder as in any one of
embodiments 11 to 15, characterized in that the polycondensate is a
polyamide having a number-average molar mass of between 5000 and 30
000 g/mol, preferably included in the range of from 8000 to 15 000
g/mol. [0137] 17. The use of powder as in any one of embodiments 11
to 16, in coatings, paints, anticorrosion compositions, paper
additives, powder agglomeration by electromagnetic
radiation-induced melting or sintering for producing objects,
electrophoresis gels, multilayer composite materials, packaging,
toys, the textile, automobile and/or electronics industry, and in
cosmetic, pharmaceutical or perfumery products. [0138] 18. The use
of oligomer powder as in embodiment 15, as an ester and/or amine
reactive synthon in polymer chain extension reactions, either alone
or as an additive for powder agglomeration by electromagnetic
radiation-induced melting or sintering for producing objects or as
a polyamide reinforcement. [0139] 19. An oligomer or polymer powder
dispersion obtained according to the process of any one of
embodiments 1 to 10, characterized in that it comprises: [0140]
from 0.1% to 99.9% by weight, preferably from 0.1% to 30% by
weight, of particles of powder in accordance with any one of
embodiments 11 to 16; and [0141] from 0.1% to 99.9% by weight,
preferably from 70% to 99.9% by weight, of solvent in accordance
with either one of embodiments 1 and 8, relative to the total
weight of the dispersion. [0142] 20. A cosmetic and/or perfumery
composition, characterized in that it comprises: [0143] from 0.1%
to 99.9%, preferably from 0.1% to 30% by weight, of particles of
powder as defined in any one of embodiments 11 to 16, and [0144]
from 0.1% to 99.9%, preferably from 70% to 99.9% by weight, of a
medium which is acceptable in cosmetics and/or in perfumery,
relative to the total weight of the composition. [0145] 21. The
composition as in embodiment 20, said composition being a colored,
noncolored or transparent product chosen from the following
products: [0146] makeup products for the human face and body, such
as a foundation, tinted cream, loose or compact powder, eyeshadow,
mascara, eyeliner or lipstick; [0147] care products for the human
face and body, such as a cream, milk, lotion, mask, exfoliation
product, cleansing and/or makeup-removal products, deodorants,
antiperspirants, shaving products or hair-removal products; [0148]
hair products, such as shampoos, hair shaping products, hairstyle
maintaining products, antidandruff products, anti-hair loss
products, products for counteracting dryness of the hair, hair dyes
or bleaching products; [0149] perfumery products, such as a
fragrance, milk, cream or loose or compact powder which is
fragranced.
* * * * *