Sabic Innovative Plastics IP B.v.

Sabic Global Technologies B.v.

Shpp Global Technologies B.v.

Alvaro Carrillo

Hua Guo

Edward Norman Peters

Scott Michael Fisher

Alexey Kruglov

Gerardo Rocha-Galicia

Stephen M Farnell

Eylem Tarkin-Tas

Christina Louise Braidwood

Erik René Delsman

Gaurav Mediratta

Nitin Vilas Tople

Huseyin Tas

Stephan Moyses

Erik Rene Delsman

Satish Chandra Pandey

Farah Jean-Jacques Toublan

Prashant Kumar

Stephen Farnell

A poly(arylene ether) copolymer is the product of oxidative copolymerization of monomers including a monohydric phenol and a dihydric phenol of the formula wherein R, R, R, and Rare as defined herein. The poly(arylene ether) copolymer includes less than 0.1 weight percent of incorporated amine groups. A method of the manufacture of a poly(arylene ether) copolymer is also disclosed. A curable composition including the poly(arylene ether) copolymer and cured products derived therefrom are also described.

Poly(arylene ether) copolymer

An improved method of manufacture of a bisphenol comprises heating a monohydric phenol to a first temperature sufficient to melt the monohydric phenol; adding a carbonyl compound to 2.0-3.0 molar equivalents, based on the moles of carbonyl compound, of the monohydric phenol in the presence of catalytic amounts of an organosulfonic acid catalyst and a reaction promoter at a second temperature sufficient to maintain unreacted monohydric phenol in a molten state; increasing the temperature to a third temperature higher than the second temperature, and mixing for a time sufficient to produce the bisphenol in a yield of 80 to 100%, based on the amount of carbonyl compound; wherein mineral acids, Lewis acids, and ion exchange resins are not used. The method is applicable to the manufacture of 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane, a useful intermediate for the manufacture of bi-functional poly(phenylene ether)s.

Method of bisphenol manufacture

A poly(phenylene ether) copolymer comprises about 5 to 40 mole percent repeat units derived from 2-phenylphenol and 60 to about 95 mole percent repeat units derived from 2,6-dimethylphenol, wherein the poly(phenylene ether) copolymer has a weight average molecular weight of at least 8,000 atomic mass units, as measured by gel permeation chromatography. A method of preparing the poly(phenylene ether) copolymer, comprises oxidatively copolymerizing a monomer mixture comprising about 5 to 40 mole percent 2-phenylphenol and about 60 to about 95 mole percent 2,6-dimethylphenol in the presence of a solvent, molecular oxygen, and a polymerization catalyst comprising a metal ion and at least one amine ligand to form a solution of the poly(phenylene ether) copolymer in the solvent, wherein a ratio of total moles of 2-phenylphenol and 2,6-dimethylphenol to moles of metal ion is about 10:1 to about 1200:1.

Poly(phenylene ether) copolymer and method of making

A method of separating a poly(arylene ether) from a solvent includes treating a poly(arylene ether)-containing solution with a devolatilizing extruder to form an extruded composition, and cooling the extruded composition with a cooling device that does not immerse the extruded composition in water. The composition may be used to isolate a poly(arylene ether) from the solvent-containing reaction mixture in which it is prepared, or to remove solvent from a multi-component poly(arylene ether)-containing thermoplastic composition.

Method of separating a poly(arylene ether) composition from a solvent, and poly(arylene ether) composition prepared thereby

A composition is prepared by oxidative copolymerization of specific amounts of 2,6-dimethylphenol, 2,3,6-trimethylphenol, and a hydroxyaryl-terminated polysiloxane. The composition exhibits an increased heat resistance relative to a corresponding composition prepared by copolymerizing 2,6-dimethylphenol and hydroxyaryl-terminated polysiloxane, without 2,3,6-trimethylphenol. The composition is useful as a flame-retardant additive in polymer compositions that require high heat resistance.

Poly(phenylene ether)-polysiloxane composition and method

A thermoplastic composition that includes a poly(arylene ether)-polysiloxane block copolymer is prepared by a method that includes oxidatively copolymerizing a monohydric phenol and a hydroxyaryl-terminated polysiloxane. The oxidative polymerization includes a monohydric phenol addition period characterized by a first temperature, a build period following the addition period and characterized by a second temperature greater than the first temperature, and a temperature ramp period between the addition period and the build period. During the temperature ramp period, the temperature is increased at an average rate of about 0.01 to about 0.35&#xb0; C. per minute, which improves the efficiency with which the hydroxyaryl-terminated polysiloxane is incorporated into the poly(arylene ether)-polysiloxane block copolymer.

Poly(arylene ether)-polysiloxane composition and method

A method of purifying a capped poly(phenylene ether) includes mixing a poly(phenylene ether) capping reaction mixture comprising a capped poly(phenylene ether), a capping agent, a capping byproduct, a capping catalyst, and a poly(phenylene ether) solvent, and first washing solvents comprising a C1-C4 alkanol and water to form a first liquid phase comprising the capped poly(phenylene ether) and poly(phenylene ether) solvent, and a second liquid phase comprising C1-C4 alkanol and water; and separating the first liquid phase from the second liquid phase. Capped poly(phenylene ether) having reduced levels of residual capping agent, capping byproduct, and capping catalyst is produced from poly(phenylene ether) capping reaction mixtures by this method.

Poly(phenylene ether) process

A poly(2,6-dimethyl-1,4-phenylene ether) prepared using a morpholine-containing polymerization catalyst has a monomodal molecular weight distribution with a reduced content of very high molecular weight species. It also exhibits increased morpholine incorporation in the high molecular weight fraction. Compared to commercially available poly(2,6-dimethyl-1,4-phenylene ether) prepared using a di-n-butylamine-containing polymerization catalyst, the poly(2,6-dimethyl-1,4-phenylene ether) of the invention exhibits reduced odor. Compared to other poly(2,6-dimethyl-1,4-phenylene ether) prepared using a morpholine-containing polymerization catalyst, the poly(2,6-dimethyl-1,4-phenylene ether) of the invention exhibits improved molecular weight build during compounding and improved compatibilization with polyamides.

Morpholine-substituted poly(arylene ether) and method for the preparation thereof

A thermoplastic composition includes a poly(arylene ether) and a poly(arylene ether)-polysiloxane block copolymer. The thermoplastic composition is prepared by a method that includes oxidatively copolymerizing a monohydric phenol and a hydroxyaryl-terminated polysiloxane. The method is simpler than prior methods of preparing poly(arylene ether)-polysiloxane block copolymers by linking pre-formed poly(arylene ether) and polysiloxane blocks. The method is also produces greater incorporation of polysiloxane into the poly(arylene ether)-polysiloxane block copolymer than prior methods of copolymerizing monohydric phenols and hydroxyaryl-terminated polysiloxane.

A poly(arylene ether) copolymer is the product of oxidative copolymerization of monomers including a monohydric phenol and a dihydric phenol. It has an intrinsic viscosity of about 0.04 to about 0.15 deciliter per gram and, on average, about 1.8 to about 2 hydroxyl groups per molecule. The poly(arylene ether) copolymer is enriched in low molecular weight copolymer chains and copolymer chains that include a terminal unit derived from the dihydric phenol.

Capped poly(arylene ether)s are prepared by a method that includes reacting a poly(arylene ether) with a capping agent to form a capping reaction mixture, washing the capping reaction mixture with a concentrated basic aqueous solution, and isolating the capped poly(arylene ether) by a total isolation method. The washing method is effective for removal of capping-related impurities, and surprisingly does not result in decomposition of the capped poly(arylene ether).

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Delmar, NY, United States of America

Alvaro Carrillo