General Electric Company

Sabic Innovative Plastics IP B.v.

Other

David Michel Dardaris

James Manio Silva

Patrick Joseph McCloskey

Gary Charles Davis

Gary R Faler

Daniel Joseph Brunelle

Peter David Phelps

Joseph A King, Jr

Thomas Joseph Fyvie

Paul Dean Sybert

Tomoaki Shimoda

Theodorus L Hoeks

Paul William Buckley

Hiromi Ishida

Gregory Allen O'Neil

Kazushige Inoue

Alice M Colley

Pierre-Andre Bui

Pin-pin Wu

Monica M Marugan

Robert Russell Gallucci

James Alan Mahood

Eugene Pauling Boden

Jimmy Lynn Webb

James Franklin Hoover

Susan Adams Nye

Julia L Lee

Thomas L Evans

Luca P Fontana

Joseph Anthony Suriano

Donald G Legrand

Larry I Flowers

Eric Thomas Gohr

Kevin M Snow

Joshua James Stone

David Whalen

Henricus H Van Hout

Mahari Tjahjadi

Zhaohui Su

George T Seeger

Allen Wai-Yee Ko

Josef Gerardus Berndsen

Henricus H M Van Hout

Allen J Campbell

Adelbert Hermannus Groothuis

Colette Clarissa Knight

YeGang Lin

A method for preparing an aliphatic chloroformate comprising, introducing a mixture of at least one aliphatic hydroxyl compound, phosgene, at least one solvent, and optionally at least one organic base into a flow reactor to obtain a unidirectional flowing reaction mixture. The at least one aliphatic hydroxyl compound comprises at least one aliphatic hydroxyl group. The unidirectional flowing reaction mixture is maintained at a temperature between about 0&#xb0; C. and about 60&#xb0; C. to produce a single product stream comprising an aliphatic chloroformate.

Method for the prepration of aliphatic chloroformates

The present invention relates to an interfacial method of preparing ester-substituted diaryl carbonates. The method includes the steps of: forming a reaction mixture comprising phosgene, an ester-substituted phenol, an organic solvent, and a catalyst selected from the group consisting of a tertiary amine catalyst and a phase transfer catalyst, said reaction mixture having an organic phase and an aqueous phase, wherein said aqueous phase has a brine strength; allowing the reaction mixture to react wherein during the reaction, (i) the aqueous phase has a pH, and the pH is adjusted, if necessary, by the addition of an alkali metal hydroxide solution in amounts such that the pH is greater than or equal to 9.0 during at least some portion of the reaction, and (ii) the brine strength of the aqueous phase is adjusted, if necessary, by varying the concentration of the alkali metal hydroxide solution being added to maintain the pH such that the brine strength is between 15% and a saturated brine solution during at least some portion of the reaction: thereby forming an ester-substituted diaryl carbonate, wherein the reaction mixture is formed with less than 15% water of formulation, and wherein the brine strength is maintained at or above 15% and the pH is maintained at or above 9 for a sufficient portion of the process that the ester-substituted diaryl carbonate is formed with a conversion of at least 90% and a selectivity of at least 98%.

Method of preparing ester-substituted diaryl carbonates

The specification describes a continuous process for the preparation of monofunctional aromatic chloroformates (MAC) having the structure (I) wherein n is an integer from 1 to 5, and Rrepresents hydrogen, a branched or unbranched alkyl group having from 1&#x2013;15 carbon atoms, an aryl group which may be substituted or unsubstituted, a cycloaliphatic group which may be substituted or unsubstituted, or an arylalkyl group which may be substituted or unsubstituted.

Method and apparatus for preparing monofunctional aromatic chloroformates suitable for use as chainstopping agents

Siloxane bischloroformates are prepared in a continuous process by phosgenating siloxane bisphenols in a flow reactor using a substantial excess of phosgene and sodium hydroxide. While very high levels (&#x3e;95%) of conversion of the siloxane bisphenol to the corresponding siloxane bischloroformate are achieved using a flow reactor according to the method of the invention, only more modest conversion (&#x2dc;90%) of the siloxane bisphenol to the corresponding siloxane bischloroformate is attained when analogous batch processes are employed. The process holds promise for use in the manufacture of silicone-containing copolycarbonates which requires high purity siloxane bischloroformate intermediates.

Siloxane bischloroformates

Copolyorganosiloxanecarbonates are prepared by first preparing an oligomeric aromatic polycarbonate, such as an oligomeric bisphenol A polycarbonate, in the presence of a tertiary amine as the only catalyst species; contacting the oligomeric polycarbonate mixture with a polyorganosiloxane bis(aryl)chloroformate, such as the bischloroformate of hydroxy-terminated eugenol polydimethylsiloxane; and introducing phosgene and/or chain termination agent either continuously or in stages. A feature of the process is the presence of dihydroxyaromatic compound in only one charge, at the beginning. The products have excellent physical properties, including transparency.

Method for preparation of copolyorganosiloxanecarbonates of high clarity

Silicone-containing copolycarbonates possessing relatively long siloxane chains and yet having low haze values and hence transparency are prepared by reacting a siloxane bischloroformate with a hydroxy-terminated polycarbonate oligomer to afford a silicone-containing polycarbonate intermediate which is then reacted with a bisphenol, phosgene and a chainstopper under interfacial reaction conditions to afford a product silicone-containing copolycarbonate. The product silicone-containing copolycarbonates have lower haze values than similarly constituted copolycarbonates prepared by other methods.

Method of preparing transparent silicone-containing copolycarbonates

Thermally stable block copolyestercarbonates comprising chain members derived from at least one dihydroxy-substituted aromatic hydrocarbon moiety and at least one aromatic dicarboxylic acid moiety, said polymer being substantially free of anhydride linkages linking at least two mers of the polyester chain segments, are prepared by a method comprising the steps of: (a) preparing a hydroxy-terminated polyester intermediate comprising structural units derived from at least one dihydroxy-substituted aromatic hydrocarbon moiety and at least one aromatic dicarboxylic acid moiety; and (b) conducting a reaction of the polyester intermediate with phosgene in a reaction mixture comprising water, a substantially water-immiscible organic solvent, and a base, wherein base and phosgene are added simultaneously to the reaction mixture at a substantially constant molar ratio of base to phosgene for a time period of at least about 60% of the total amount of phosgene added.

Method for copolyestercarbonate synthesis

A new method of converting oligomeric chloroformates to high molecular weight polycarbonate is presented. By carefully controlling the relative concentrations and amounts of hydroxyl and chloroformate groups present in the oligomeric polycarbonate, the method of the invention provides for the efficient preparation of polycarbonate while minimizing phosgene usage. The product polycarbonates prepared by the method of the invention are fully capped with no additional phosgene required beyond that needed to prepare the oligomeric chloroformate starting material. The method of the present invention provides polycarbonates having non-detectable levels (<5 ppm) of aromatic hydroxyl endgroups, low polydispersity, and low levels of residual monomer and endcap, thereby obviating the need for monomer and endcap recycle.

Method of making polycarbonate

Siloxane bischloroformates are prepared in a continuous process by phosgenating siloxane bisphenols in a flow reactor using a substantial excess of phosgene and sodium hydroxide. While very high levels (>95%) of conversion of the siloxane bisphenol to the corresponding siloxane bischloroformate are achieved using a flow reactor according to the method of the invention, only more modest conversion (&tilde;90%) of the siloxane bisphenol to the corresponding siloxane bischloroformate is attained when analogous batch processes are employed. The process holds promise for use in the manufacture of silicone-containing copolycarbonates which requires high purity siloxane bischloroformate intermediates.

Thermally stable polymers comprising chain members derived from at least one 1,3-dihydroxybenzene moiety and at least one aromatic dicarboxylic acid moiety, said polymer being substantially free of anhydride linkages linking at least two mers of the polymer chain, are prepared using an interfacial method comprising the steps of: (a) combining at least one 1,3-dihydroxybenzene moiety and at least one catalyst in a mixture of water and at least one organic solvent substantially immiscible with water; (b) adding to the mixture from (a) a controlled stoichiometric ratio of at least one acid chloride and at least one base while maintaining the pH between about 4 and about 8.5, and (c) adjusting the pH of the reaction mixture to a value in the range of about 7 and about 9 following complete addition of acid chloride, and stirring the reaction mixture for a time sufficient to destroy any anhydride linkages in the polymer chain.

Thermally stable polymers, method of preparation, and articles made therefrom

In a continuous flow reactor one or more bisphenols is converted by the action of phosgene and aqueous base into a mixture of mono- and bisphenol chloroformates which are then treated with a catalyst, additional aqueous caustic and a monophenol to afford endcapped polycarbonates. At relatively high levels of added monophenol endcapped polycarbonate oligomers are obtained. The method is especially suited for the continuous preparation of endcapped oligomers of tetrabromobisphenol A polycarbonate. The method is characterized by efficient use of phosgene, and conversion of chloroformate groups to carbonate linkages aided by trialkylamine catalysts bearing at least one methyl group on nitrogen, such as N,N-dimethylbutylamine (DMBA).

Continuous preparation of polycarbonate

This invention relates to a process and apparatus for the continuous preparation of mono and bis-chloroformate products of halogenated dihydroxy compounds by an interfacial process. The mono and bis-chloroformate products may optionally be converted to capped oligomers.

Method for the continuous preparation of chloroformate products of halogenated dihdroxy compounds

Increasing the endcap level to a level greater than about 90% for Optical Quality (OQ) Melt Polycarbonate significantly reduces the as-molded static charge for injection molded parts for Optical Disc applications. The use of resins with higher endcap levels in combination with antistatic additives provides a highly robust formulation suitable for even the most demanding emerging formats as Digital Versatile Disc (DVD) and in all commercial Optical media molding machines. Thus, optical quality polycarbonates are prepared by performing a base-catalyzed polymerization of a diaryl carbonate and a dihydric phenol under conditions effective to produce a polycarbonate product having an endcap level of 90% or greater.

Optical quality polycarbonates with reduced static charge and method for making same

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Ballston Spa, NY, United States of America

David Michel Dardaris